SUZUKI URESGRIS SERVICE MANUALFOREWORD The SUZUKI DR650R/S was designed to offer superior performance through lightweight design, four stroke-power, engine counter-balancers, coo!- ing system and link type suspension. This service manual has been produced primarily for experienced mechanics whose job is to in- spect, adjust, repair and service SUZUKI vehicles. Apprentice mechanics and “do it yourself” me- chanics will also find this manual to be an extreme- ly useful guicle, The DR65OR/S, manufactured to standard speci fications, is the main subject matter of this manual. However, the DR65OR/S machines distributed in your country might differ in minor respects from the standard-specification and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. This manual contains up-to-date information at the time of its issue. Later made modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any. SUZUKI MOTOR CORPORATION Motorcycle Department Overseas Service Division © COPYRIGHT SUZUKI MOTOR CORPORATION 1992 GENERAL INFORMATION 7 PERIODIC MAINTENANCE AND E 7 TUNE-UP PROCEDURES ENGINE Ei FUEL AND LUBRICATION SYSTEM 4 ELECTRICAL SYSTEM Gi CHASSIS I a SERVICING INFORMATION 7 DR650RP/SP ('93-MODEL) a DR650RER/SER (’94-MODEL) E : J DR650RES/SES (’95-MODEL) 170VIEW OF DR650RN/DR650SN LEFT SIDE RIGHT SIDE ~Difference between photographs and actual motorcycles depends on markets,eet zyme Lae CONTENTS: /1 SERIAL NUMBER LOCATIONS: +++-0+-0-000000000ceeeeveeeeeees DoD FUEL AND OIL RECOMMENDATIONS: --++++00+00000000000000290 7 BREAK-IN PROCEDURES. -- . oa sere 2 SPECIAL MATERIALS: . 1-3 PRECAUTIONS AND GENERAL INSTRUCTIONS: «+ +--+----+- 1-5 INFORMATION LABELS: +++----+++-- ++ fittteeeeees 1-6 COUNTRY OR AREA+ 000000000000 ceeeeeeeeeteteetettteneeees 1-6 SPECIFICATIONS ---+- +--+ +> vee aaa 1-711 GENERAL INFORMATION SERIAL NUMBER LOCATIONS The frame serial number or V.ILN. (Vehicle Identification Number) @ is stamped on the steering head pipe. The engine serial number @ is located on the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL For U.S.A. model 1, Use only unleaded gasoline of at least 87 pump octane (25™) method or 91 octane or higher rated by research method. 2.SUZUKI recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Buty! Ether) is permitted, 4. Use of blended gasoline/alcohol fuel is permitted provided ‘that it contains not more than 10% ethanol. Gasoline/ alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol free unleaded gasoline. 6. Failure to follow these guideline could possibly void appli- cable warranty coverage. Check with your fuel supplier to be sure that the fuel you intend to use meets the require- ments listed above. For CANADA model Use only unleaded gasoline of at least 87 pump octane (BM) method or 91 octane or higher rated by the Research Method. For other models Gasoline used should be graded 85 — 95 octane (Research Method) or higher. An unleaded gasoline is recommended.GENERAL INFORMATION 1.2 ENGINE OIL For U.S.A. model SUZUK! recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the | | mutricrane API (American Petroleum Institute) classification system. The viscosity rating is SAE 10W/40. If an SAE 10W/40 motor oil is not available, select an alternate according to the right chart. For other models Be sure that the engine oil you use comes under API classifica- tion of SE or SF and that its viscosity rating is SAE 10W/40. If SAE 10W/40 motor oil is not available, select the oil viscosity according to the right chart. FRONT FORK OIL Use fork oil # 10. 99000-99044.10G: SUZUKI Fork oil + 10 BRAKE FLUID ‘Specification and classification: DOT 4 99000-23110: SUZUKI Brake fluid WARNING: * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicon-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken trom old or used or unsealed containers. * Never re-use brake fluid left over from a previous servicing, which has been stored for a long period, BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. ‘© Keep to these break-in engine speed limits. Initial 800 km (500 miles): Below 3 000 r/min Up to 1.600 km (1 000 miles): Below 5 000 r/min Over 1.600 km (1000 miles): Below 7 500 r/min * Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 7 500 r/min at any time,3 GENERAL INFORMATION SPECIAL MATERIALS The materials listed below are needed for maintenance work on this motorcycle and should be kept on hand for ready use, These items supplement such standard materials as cleaning fluids, lubricant, emery cloth and the like, How to use them and where to use them are described in the text of this manual. MATERIAL | PART PAGE For USA. model For other models © Throtle orp 22 © Speedometer gear box 22 {Brake pedal shaft 22 © Oilseais 3.35 © Oring 346,53 © Front and rer whee! hub 22 bearing 62.19 © Steering stem bearingand | 22 ste! balls 6-14.17 © Shock absorber lower besring | 6:28, 23 SUZUKISUPER GREASE “A” | sUZUKIsUPER GREASE a” | ° SuMloneverbexings dust” | 628,38 98000-25030 99000-26010 | # Swingarm bearings | 622,23 | _ = oa © Caliper axle | 8 C2 eS “ | | | | 3 So | suzucisiticone Grease | suzUKt sILIcone GREASE | 99000-25100 99000-25100 | | Vaive stems | 320 > ‘© Piston pin | 347 © Camshett journals and cams | 351 LZ. |S Rocker arm shafts | 314 & | © Decompression shaft | 314 | © countrhattanddriveare | 331 gees SUZUKI MOLY PASTE SUZUKI MOLY PASTE | | 99000-25140 99000-25140 ‘© Ovlinder head cover [24 | 351 | © Mogneto lead wire grommet | 342 é 1 Mating surface offeft and | 3:39 a @ right halves of crankcase ‘© Neutral lead wire grommet | 3:37 SUZUKI BOND NO. 12078 SUZUKI BOND NO. 12078 | 9910431140 9900031140 | ‘© Crankcate bearing retainer 334 | screws \ © Gearshift cam stopper bolt | 3:38 Gearshift cam quide/paw! 339 lifter sorews and nuts ‘© Engine oll pump securing a2 | ‘© Noutral switch ead protector | 3:57 | «© Aircleaner mounting bolts THREAD LOCK "1342" | THREAD Lock "1342" Front footrest bolt 99000-32060 :99000:32060 © Front forkdamper rod bolt | 6412GENERAL INFORMATION 1.4 MATERIAL, ] r PART | Pace For US.A. model For other models & © Kick starter pawl guide/ | 328 stopper ID ai ‘THREAD LOCK SUPER THREAD LOCK SUPER "19338" "13338" ‘99000-32020 ‘99000-32020 _ oe ‘© Muffler mounting bolts | 34 © Gearshift arm stopper 3-40 © Cam sprocket bolts | 381 ‘© Balancer chain guide screws 340 © 2nd drive gear 3:33 | © Air cleaner mounting bolts | | THREAD LOCK SUPER “1303” | THREAD LOCK SUPER "1303" 99000-32030 ‘99000-32030 © Magneto rotor bolt 3.42 THREAD LOCK SUPER “1303” | THREAD LOCK SUPER “1305” 99000-32030 ‘99000-32100 © Brake dise bolt et 619 THREAD LOCK SUPER "1360" | THREAD LOCK SUPER "1360" 99000-32130 99000-32130 (© Front and rear brake 12 243 SUZUKI BRAKE FLUID SUZUKI BRAKE FLUID 99000-23110 (0.5L) 99000-23110 (0.5L)1.5 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycle. 1D Do not run engine indoors with little or no ventilation. 1 Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circli the circlip over the shaft. After installing a circlip, always insure that i , care must be taken not to expand the end gap larger than required to slip completely seated in its groove and securely fitted. 1 Tighten bolts and nuts from the ones of larger diameter to those of smaller diameter, and from inside to ‘outside diagonally, to the specified tightening torque. 11 Use special tools where specified. C1 Use specified genuine parts and recommended oils. | When more than 2 persons perform work together, pay attention to the safety of each other. 1 After the reassembly, check parts for tightness and operation. C Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING ....... The personal safety of the rider or bystanders may be involve Disregarding this information could result in personal injury. CAUTION ....... These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. «This provides special information to make maintenance easier or important instruc- tions clearer. NOTE REPLACEMENT PARTS When you replace any parts, use only genuine SUZUKI replace- ment parts, or their equivalent, Genuine SUZUKI parts are high quality parts which are designed and built specifically for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.GENERAL INFORMATION 1.6 INFORMATION LABELS ‘Vacuum hose piping diagram label (For E-3 model) 1D plate (For E-28 modell 1 plate (For €-28 model) 10 mm Information label (For E-03, E-33 models) Fuel caution label (For E-02, E:24 models) Noise label (For E-03, FUEL FILLER CAP tomm — Tireair pressure label jp | COUNTRY OR AREA Sree E02: U.K. £-22: Germany E03: U.S.A E.24: Australia E.04: France E.25: Netherlands E-15: Finland £.28: Canada E-16: Norway E.34: Italy E-17: Sweden £.39: Austria E-18: Switzerland E.53: Spain E-21: Belgium4-7 GENERAL INFORMATION SPECIFICATIONS ELECTRICAL Ignition type ....... SUZUKI “PEI” DIMENSIONS AND DRY MASS Ignition timing . 0° B.T.D.C. Below 2 200 Overall length 2.395 mm (94.3 in) r/min and 28° B.T.D.C. (For Sweden, Switzerland Above 4 300 r/min and Germany) Spark plug ......... NGK DP9EA-9 or NIPPON 2.305 mm (90.7 in} DENSO X27EP-U9 (For others) (For Kraly and U.S.A.) Overall width. ....... 870 mm (34.3 in) NGK DPR9EA‘9 or Overall height . 1.270 mm (50.0 in) NIPPON DENSO X27EPR- Wheelbase + 1.515 mm (59.6 in) U9 (For others) Seat height... £890 mm (35.0 in) Battery .. <2. 12V10.8kC (3 Ah)/10 HR Ground clearance .... 260 mm (10.2 in) Generator... Three-phase A.C. generator Dry mass. . 154 kg (340 Ibs) Fuse 2.0.0.2 .ee2.+ 20A (Main) 1A (Turn signal) 10A (Headlight H) ENGINE 10A (Headlight L) Type. ....s....2++. Fourstroke, air-cooled, oHc Mumba of ene Fromaopenton.... Teale Bore ......... =. 95.0 mm (3.740 in) ms damped . Stroke ............ 90.4 mm (3.559 in) 7 — Te Piston displacement .. 640 cm? (39.0 cu. in) ai . reaper ep Compression ratio ... 9.721 et er are oa , reload fully Carburetor . MIKUNI BST40SS, single ern ert Air cleaner ......... Polyurethane foam element pileeoe Stuer systems... Priwary Kick Storing angle... 45" (ght & Left) Lubrication system... Wet sump = REL ae aon Turning radius ...... 2.4m (7.9 ft) Front brake ........ Disc Rear brake ......... Disc TRANSMISSION Front tire size....... 90/90-21 54S Clutch Wet multi-plate type Rear tire size * 120/90-17 64s Transmission ....... S-speed constant mesh Gearshift pattern... 1-down, 4-up Primary reduction... 2.200 (66/30) CAPACITIES reduction ...... 2.625 (42/16) Fuel tank Gear ratios, Low .... 2.416 (29/12) including reserve ... 17 L (4.8/3.7 US/Imp gal) 2nd... 1.625 (26/16) reserve... 3,51. (0.9/0.8 US/Imp gal) 3rd... 1.263 (24/19) Engine oil, oil change . 2 000 ml (2.1/1.8 US/ 4th... 1,000 (21/21) imp at) Top .... 0.826 (19/28) with filter change .. 2 150 ml (2.3/1.9 US/ Drivechain ......,.. TAKASAGO RK520SO Imp qt) orDAIDOD.I.D.520VC-, overhaul ......... 2 600 ml (2.7/2.3 US/ 114 links Imp at) Front fork oll ....... 536 ml (18.1/18.9 US/ Imp 02) ‘These specifications are subject to change without notice.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE- 27 PERIODIC MAINTENANCE CHART: 27 GB LUBRICATION POINTS: 22 MAINTENANCE AND TUNE-UP PROCEDURES: --- +--+ +++ ++ 23 CYLINDER HEAD BOLTS AND NUTS, EXHAUST PIPE NUTS AND MUFFLER CONNECTIONS: «+++ +--+ ++-+++++-2- 3 AIR CLEANER ELEMENT: 25 VALVE CLEARANCE: +--+ +++ 000000000 0eee eee e cent entrees 26 DE-COMPRESSION LEVER: -- ce ad SPARK PLUGS: +0220 000c00ccceeeccesee eects eetenersenees 27 FUEL LINE: + 28 FUEL COCK STRAINER: «+--+ +0000 0000000000 . 28 ENGINE OIL AND OIL FILTER: ++ +--+ ++-+ 000000020 00eee secon 29 CARBURETOR: «00-00 002200cccccececeeeeeeeteeeeenessaeees 2-10 211 2-12 2-12 2-14 2-16 SPARK ARRESTER (Only for CANADA) 2-16 STEERING: 2:17 FRONT FORK:+ +0 020000000 00ecvecee cece eeceteceeneeteneeees 217 REAR SUSPENSION. ------- 217 CHASSIS BOLTS AND NUTS: «+++ +++ 000000000 00eeeereeeee 2-1824 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART INTERVAL: km 1000 | 6000 | 12000 | 18000 | 24.000 BY COMET SE OS SO SEO mites 600 | 4000 | 7500 | 11000 | 15.000 MONTHS WHICHEVER COMES FIRST | months ~[-12 | 24 [36 | ae Cylinder head bolts and nuts, exhaust pipe nuts _ tT lo r 1 and muffler connections | Air cleaner element "Clean every 3.000 km (2 000 miles) De-compression lever fr 1 1 1 1 Valve clearance 1 I 1 1 1 Spark plugs [= 1 R 1 R —t ft 1 \ \ Fuel line Replace every four years. Fuel cock strainer _ = = c = Engine oil _ _ _ R | Carburetor idle rpm | Balancer chain c R R R R Engine oil filter R = R = R 1 1 1 1 i 1 1 I \ 1 Clutch _ 1 \ i \ Drive chain Clean and lubricate every 1 000 km (600 miles) Brakes - 1 ! 1 I t i 1 1 ' Brake hoses — {ii | 4 | po _ Replace every four years. 1 1 To \ i Brake fluid Change every two years. Tires = 1 [4 i i Clean every 6 000 km (4 000 miles). kan Spark arrester Only for Canada Steering t SI Front fork = = i 1 Rear suspension = = i Chassis bolts and nuts 1 | Tt T T al-|-|- NOTE: I: Inspect and adjust, clean, lubricate or replace as necessary. R: Replace T: Tighten C: CleanPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 22 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part. Major oiling points are indicated below. Drive chain Side stand pivot Throttle cable [Throttle grip holder and brake lever holder De-comp, cable [Brake pedal pivor . Motor oil . Grease NOTE: * Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motor- cycle has been operated under wet or rainy conditions. If the spray is unavailable, use either motor oil or grease. * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.2.3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES: MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. CYLINDER HEAD BOLTS AND NUTS, EXHAUST PIPE NUTS AND MUFFLER CONNECTIONS er Ti Every 6 000 km (4 000 miles, 12 months) | CYLINDER HEAD # Remove the frame covers, seat and fuel tank. ‘© Disconnect the spark plug caps. Disconnect the de-comp. cable. ‘* Remove the upper side of engine mounting bolts. (Refer to page 3:3.) ‘Remove the cylinder head cover. (Refer to page 36.) © First loosen and retighten the four bolts (D, and two nuts @ to the specified torque with a torque wrench sequentially in diagonally, when the engine is cold. Tightening torque @: 35 — 40 N-m (3.5 — 4.0 kg-m, 26.5 — 29.0 lb-ft) @: 23 — 27 Nm (2.3 — 2.7 kgm, 16.5 ~ 19.5 Ib-ft) © After firmly tightening the cylinder head bolts and nuts, tighten the two cylinder base nuts @ to the specified torque. Tightening torque @: 7 — 11 Nem (0.7 — 1.1 kg-m, 5.0 — 8.0 Ib-ft) © When installing the cylinder head cover, apply SUZUKI BOND NO. 12078 to the mating surface. (Refer to page 351)PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4 EXHAUST PIPE AND MUFFLER © Tighten the exhaust pipe nuts ®, muffler connection bolt ® and muffler mounting bolts @ to the specified corque. Tightening torque @: 23 — 28 N-m (2.3 — 2.8 kg-m, 16.5 — 20.0 lb-ft) @: 23 — 28 N-m (2.3 — 2.8 kg-m, 16.5 — 20.0 lb-ft) ©: 23 — 28 N-m (2.3 — 2.8 kg-m, 16.5 — 20.0 lb-ft)28 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER ELEMENT | Clean Every 3 000 km (2 000 miles) If the air cleaner is clogged with dust, intake resistance will be increased with @ resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. © Remove the left frame cover. ‘© Remove the air cleaner case cover by removing screws © Remove the air cleaner element by removing bolt @ © Remove the polyurethane foam element @ from the ele- ment frame @. * Fill a washing pan of a proper size with non-flammable cleaning solvent. Immerse the element in the cleaning sol- vent and wash it clean. ‘© Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands ‘© Immerse the element in motor oil, and squeeze the oil out of the element leaving it slightly wet with oil. NOTE: Do not twist or wring the element because it will tear or the individual cells of the element will be damaged. CAUTIOI Inspect the element carefully for rips, torn seams, etc. If any damage is noted, replace the element. ‘© Reinstall the cleaned or new cleaner element in the reverse order of removal. CAUTION: If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this compo- nent! Non-flammable cleaning we ) SAE yow/40 | Aye®ERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 28 VALVE CLEARANCE Inspect Initial 1000 km (600 miles, 2 months) and Every 6 000 km (4.000 miles, 12 months) Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. At ‘the distances indicated above, check and adjust the clearance to the specification. Valve clearance specifications: 0.08 — 0.13 mm (IN. and EX.) (0.003 — 0.005 in) ‘The procedure for adjusting the valve clearance is as follows: NOTE: Valve clearance is to be checked when the engine is cold. Bath intake and exhaust valves must be checked and adjusted when the piston is at Top-Dead~Center (TDC) on the com- pression stroke. ‘¢ Remove the frame covers, seat and fuel tank. © Remove the spark plug and valve inspection caps, intake and exhaust. ‘* Remove the valve tir cap. ‘* Turn the crankshaft counterclockwise with the box wrench to set the piston at T.D.C. on the compression stroke. (Turn the crankshaft until the “"T'" line @ on the magneto rotor is aligned with the center of hole on the magneto cover.) © Insert the thickness gauge into the clearance between the valve stem end and the adjusting screw on the rocker arm. inspection plug and magneto cover (09900-20803: Thickness gauge © If clearance is off the specification, bring it into the specified range with the screwdriver. © Securely tighten the lock nut after adjustment is completed, CAUTION: Both right and left valve clearances, should be as closely set as po: «Reinstall the spark plug, valve inspection caps, valve timing inspection plug and magneto cover cap.2:7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES DE-COMPRESSION LEVER Inspect Initial 2 000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) Incorrect adjustment of the lever clearance may result in starting difficulties or engine damage, Check the lever clear- ance and if necessary, adjust as follows © After adjusting the valve clearance, loosen bath lock nuts ® on the cable adjuster @). © Locate the adjuster @) to provide the specified lever clear- ance (A) as shown in the figure. © Tighten both fock nuts @ De-compression lever clearance ®): 1—2 mm (0.04 — 0.08 in) SPARK PLUGS. Inspect Every 6 000 km (4 000 miles, 12 months) and Replace Every 12 000 km (7 500 miles, 24 months) The plug gap is adjusted to 0.8 — 0.9 mm (0.03 — 0.04 in) The gap is correctly adjusted with a thickness gauge. When carbon is deposited on the spark plug, remove the carbon by Using a tool with a pointed end. If the electrode is extremely worn or burnt, replace the plug. Also replace the plug if it has ‘a broken insulator, damaged thread, etc. NGK DP9EA‘9 or DPR9EA or NIPPON DENSO X27EP-U9 or X27EPR-U9 as listed in the table should be used as the standard plug. However, the heat range of the plug should be selected to meet the requirements of speed, actual load, fuel, etc. {f the plugs need to be replaced, it is recommended that the standard plugs listed in the table be selected. Remove the plugs and inspect the insulators. Proper heat range would be indicated if all insulators are light brown in color. If they are blackened by carbon, they should be replaced by a hat type NGK DP8EA-9 or DPRBEA-9 or NIPPON DENSO X24EP-U9 or X24EPR-U9. NOTE: To check the spark plugs, first make sure that the fuel tank contains unleaded gasoline, and after a test ride if the plugs are either sooty with carbon or burnt white, replace them. ZA cwoe-29mm | 0.03 — 0.04 in) IPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2.8 CAUTION: Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result. NIPPON | NK Merce REMARKS If the standard plug is apt to DPBEAS | X24EP-U9 | get wet, replace it with this hot type plug DP9EAS | X27EP-U9_| Standard “RI type spark plug T NGK InEON REMARKS DENSO If the standard plug is apt to DPREEA® | X24EPR-U9 | get wet, replace it with this | hot type plug. DPR9EAS | X27EPR-U9 | Standard NOTE: “R’" type spark plug is installed for some specifications, “R”” type spark plug has a resister located at the center electrode to prevent radio noise. FUEL LINE | inspect Initial 1.000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months) Replace Every 4 years FUEL COCK STRAINER Clean Every 12 000 km (7 500 miles, 24 months) Refer to page 4-1 for removal procedure.2.9 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE OIL AND OIL FILTER [ENGINE OIL] [Replace (Change) Initial 1 000 km (600 miles,2 months) and Every 6 000 km (4.000 miles, 12 months) [OIL FILTER] Replace Initial 1 000km (600 miles, 2 months) and Every 12 000 km (7 500 miles, 24 months) The oil should be changed while the engine is warm. Oil filter replacement at the above intervals should be done together with engine oil change. '* Keep the motorcycle upright, supported by jack or wooden block. ‘* Place an oil pan below the engine and remove the engine oil drain plug @ and oil filler cap @ to drain engine oil. ‘* Remove the oil filter cap by removing the three bolts @). ‘* Remove the oil filter @ and install the new one. ‘* Replace the oil filter cap and tighten the bolts @) securely. NOTE: Before installing the oil filter and oil filter cap, check to be sure that the spring ®) and new O-rings (® and @) are installed correctly. ‘© Tighten the oil drain plug @ securely, and pour fresh oil through the oil filler. The engine will hold about 2 150 ml of oil. Use an API classification of SE or SF oil with SAE 10W/40 viscosity. * Start up the engine and allow it to run for several minutes at idling speed. ‘* Turn off the engine and wait about five minutes, then check the oil level through the inspection window @. If the level is below mark “F’”, add oil to that level. NECESSARY AMOUNT OF ENGINE OIL Oil change: 2 000 ml (2.1/1.8 US/Imp qt) Filter change — : 2 150 ml (2.3/1.9 US/Imp qt) Overhaul engine : 2 600 mi (2.7/2.3 US/Imp at)}ODIC MAINTENANCE AND TUNE-UP PROCEDURES CARBURETOR les, 2 months) and Inspect Initial 1.000 km (600 Every 6 000 km (4 0( | THROTTLE CABLE ADJUSTMENT A twin throttle cable system is used in this motorcycle. Cable © Is for pulling and cable @) is for returning, To adjust the cable play, adjust the returning cable first and then adjust the pulling cable, Returning cable play The returning cable should be adjusted to have a thread length ® of 2 — 3 mm (0.08 — 0.12 in) as shown in the Fig, If the adjustment is necessary, adjust the thread length in the follow- ing way: * Loosen lock nuts (). © Move the adjuster @) to obtain the thread length @ of 2 — 3mm (0.08 ~ 0.12 in} © Tighten the lock nuts @) securely, Pulling cable play The pulling cable should be adjusted to have a cable play @ of 0.5 — 1.0 mm (0.02 ~ 0.04 in) as shown in the Fig. If the adjustment is necessary, adjust the cable play in the following way: Turn the handlebar all the way to the left. © Loosen the lock nuts (8), @) ‘© Turn the adjuster 7) or move the adjuster @) to obtain the cable play ©) of 0.5 — 1.0 mm (0.02 ~ 0.04 in). ‘Tighten the lock nuts (@), ©) securely. WARNING: After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically. IDLE RPM ADJUSTMENT. NOTE: Make this adjustment when the engine is warm. © Connect a tachometer. * Start up the engine and set its speed at anywhere between 1400 and 1 600 r/min by turning the throttle stop screw (®). ‘© Turn in or out the pilot screw within 1/2 turn from the standard setting, and set it when the engine speed is at the highest possible level. # After previous adjustment, recheck the idling speed and adjust to between 1400 and 1 600 r/min with throttle stop screw if necessary. Continued on next page—2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES Engine idle speed: 1400 + 100 r/min 1500+ 50 +/min 1500 * 100 r/min + for Canada for Switzerland for the Others BALANCER CHAIN {Inspect Initial 1 000 km (600 miles, 2 months) and | Every 6 000 km (4 000 miles, 12 months) The balancer chain is maintained at the proper tension by a manually adjusted tensioner. To prevent chain noise, the ten- sioner must be adjusted at the intervals listed above. The pro- cedure for adjusting the balancer chain tensioner is as follows: ‘¢ Remove the engine under cover and gearshift lever. © Drain engine oil ¢ Remove the engine sprocket cover and magneto cover. (Refer to page 35.) © Turn the crankshaft counterclockwise with a box wrench to set the piston at T.D.C. on the compression stroke, ‘¢ More turn the crankshaft until the center (D of protrusion (trigger pole) on the magneto rotor is aligned with the align- ing mark @) on the crankcase. © Loosen the lock nut @) and stopper bolt), and then loosen the chain tensioner bolts (),@)) © Torque the front driven sprocket (2) with the torque wrench by applying the 10 N:m (1.0 kgm, 7.0 Ib-ft) while holding the crankshaft with a tool as shewn in Fig. This will allow @ spring to pull the ch up any chain slack. ‘ Tighten the chain tensioner bolts ((),@) to the specified torque. Tightening torque: 15 — 20 N-m {bolts 3), (1.5 — 2.0 kg-m, 11.0 — 14.5 tb-fe) tensioner, taking NOTE: _ When tightening the chain tensioner bolts, tighten the bolt 6) first and bolt @ last. Tighten the stopper bolt @ and lock nut @ NOTE: When adjusting the balancer chain ten- sioner, change the oil at the same time. CAUTION: To prevent oil leakage, do not use the old magneto cover gasket.PERIODIC MAINTENANCE AND TUNE.UP PROCEDURES 2-12 CLUTCH Inspect Initial 1.000 km (600 miles, 2 months) and Every 6 000 km (4.000 miles, 12 months) ‘© Loosen the lock nut () and turn the adjuster @) fully in. © Loosen the clutch cable adjuster lock nuts @) and slide the cable adjuster @ to provide the specified clutch lever play Clutch lever play (A) : 10 — 15 mm (0.4 — 0.6 in) Tighten the lock nuts ((D and @)) while holding the adjuster in position, NOTE: Minor adjustment can be made by the adjuster 2) after loosen- jing the lock nut (@). At the same intervals, lubricate the clutch cable with motor oil. DRIVE CHAIN Inspect Initial 1.000 km (600 miles, 2 months) and Every 6 000 km (4 000 miles, 12 months} Clean and Lubricate Every 1.000 km (600 miles) Visually inspect the drive chain for the listed below possible defects. (Lift the rear wheel and place a jack or block under the engine, and turn the rear wheel slowly by hand with the transmission in NEUTRAL.) * Loose pins * Damaged rollers * Dry or rusted links * Kinked or binding links Excessive wear * Missing O-rings If any defects are found, the drive chain must be replaced.2-43 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CHECKING Pull out the cotter pin (For Canada and U.S.A.) © Loosen the axle nut Tense the drive chain fully by turning the right and left chain adjusters 2). © Count out 21 pins (20 pitches) on the chain and measure the distance between the two points, If the distance exceeds the service limit, the chain must be replaced. Service Limit: 319.4 mm (12.87 in) ADJUSTING '* Place the motorcycle on its side-stand for accurate adjust: ment. © Turn both chain adjusters (@) until the chain has 20 — 40 mm (0.8 — 1.6 in) of slack at the middle between engine and rear sprockets. The number () on both chain adjusters must be at the same number to ensure that the front and rear wheels are correctly aligned. Drive chain slack: 20 — 40 mm (0.8 — 1.6 in) © After adjusting the drive chain, tighten the axle nut © to the specified torque. Always use a new cotter pin (For Canada and U.S.A.). Tightening torque: 50 — 80 N-m {5.0 — 8.0 kg-m, 36.0 — 58.0 Ib-ft) CLEANING AND LUBRICATING © Wash the drive chain with kerosene. If the chain tends to rust faster, the intervals must be shortened. CAUTION: Do not use trichlene, gasoline or any similar fluids: These fluids have too great a dissolving power for this chain and, what is more important, can damage the O-rings (or seals) confining the grease in the bush-to-pin clearance. Remember, high durability comes from the presence of grease in that clearance. © After washing and drying the chain, oil it with a heavy- weight motor oil CAUTIOI Do not use any oil sold commercially as “drive chain oil”. Such oil too can damage the O-rings (or seals). The standard drive chain is DAIDO D.I.D. 520VC-5 or TAKASAGO RK520SO. SUZUKI recommends that this stan- dard drive chain be used for the replacement.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 214 BRAKES Inspect Initial 1.000 km (600 miles, 2 months) and Every 6 000 km (4.000 miles, 12 months) Replace hoses Every 4 years Replace (Change) fluid Every 2 years BRAKE FLUID LEVEL Keep the motorcycle upright and place the handlebar straight. ‘© Check the brake fluid level by observing the upper (only for rear brake) and lower (both front and rear brake) limit lines on the brake fluid reservoirs. ‘© When the level is below the lower limit line, replenish with brake fluid that meets the following specification. Specification and classification: DOT 4 99000-23110: SUZUKI BRAKE FLUID WARNING: The brake system of this motorcycle is filled with a glycol- based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for a long period, WARNING: Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hose for cracks and hose joints for cracks and oil leakage before riding. BRAKE PADS Wearing condition of brake pads can be checked by observ- ing the limit line @ (front brake) and groove ©) (rear brake) marked on the pad. When the wear exceeds the limit mark, replace the pads with new ones. (Refer to pages 6-6 and 6-25.) BRAKE PEDAL HEIGHT ‘© Loosen the lock nut @) and rotate the push rod @ to locate brake pedal 5 mm below the top face of the footrest. # Retighten the lock nut @ to secure the push rod @ in the proper position Brake pedal height (4) : 5 mm (0.2 in)