2004 service data 01e - serviceinfo mc info/2004_service data_manual.pdf · among the 2004 suzuki...

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04

STROKE

SE

RV

ICE

DA

TA

K4

9 9 5 6 3 - 0 1 0 4 0 - 0 1 E

FOREWORDAmong the 2004 SUZUKI motorcycles and vehicles with 4 & 2 stroke engines, many new modelshave been added, and even in the previous models many refinements have been made.

This service data manual gives service data for 2004 models of SUZUKI 4 & 2 stroke engine motorcy-cles and vehicles. These data have been prepared for experienced mechanics who inspect, adjust,repair and service SUZUKI motorcycles. For the methods of measurement and adjustment for theindividual data, refer to the service manual for the particular model.

This data manual contains data which are up-to-data at the time it is issued. News of later modifica-tions will be provided to the national distributors through service bulletins, etc., so if you have anyinquiry, please contact your distributor.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2004

SAMPLE

CONTENTS

4 STROKEAN250 ....................................................................................................... 1AN400 ....................................................................................................... 3AN650 ....................................................................................................... 5AN650A .................................................................................................... 7DL650 ...................................................................................................... 9DL1000 .....................................................................................................12DR200SE (E-03, 28, 33) ...........................................................................14DR200SE (E-06, 24) .................................................................................16DR650SE ..................................................................................................18DR-Z110 ...................................................................................................20DR-Z125/L ................................................................................................22DR-Z250 (E-03, 28, 33) ............................................................................24DR-Z250 (E-24) ........................................................................................26DR-Z400/E (E-01, 03, 28, 33) ...................................................................28DR-Z400E (E-24) ......................................................................................30DR-Z400S .................................................................................................32GS125T ....................................................................................................34GS500/U/F/FU ..........................................................................................36GSF600/U/Z/ZU ........................................................................................38GSF600S/SU ............................................................................................40GSF1200/Z ...............................................................................................42GSF1200S ................................................................................................45GSX600F ..................................................................................................47GSX750F ..................................................................................................50GSX1300R/RZ/RUD/RUF .........................................................................52GSX1400/UD ............................................................................................55GSX-R600/UE/UF .....................................................................................57GSX-R750/UF ...........................................................................................60GSX-R1000 ..............................................................................................62GZ125/U ...................................................................................................65GZ250 .......................................................................................................67LS650 .......................................................................................................69LT-160/F160 .............................................................................................71LT-A400/F ................................................................................................73LT-A500F .................................................................................................75LT-F250 ....................................................................................................77LT-F300F ..................................................................................................79LT-F400F ..................................................................................................81LT-F500F ..................................................................................................83LT-V700F ..................................................................................................85LT-Z250 ....................................................................................................87LT-Z400 ....................................................................................................89RM-Z250 ...................................................................................................91RV125 .......................................................................................................93SD110/S ...................................................................................................94SV650/S/SU/U ..........................................................................................96SV1000/UD/UF .........................................................................................98SV1000SD/SF ........................................................................................101UH125 .....................................................................................................103UH150 .....................................................................................................105VL125/U ..................................................................................................106VL250 .....................................................................................................108VL800/Z ..................................................................................................109

SAMPLE

CONTENTS

VL1500 .................................................................................................. 111VS800GL ............................................................................................... 113VS1400GLP ........................................................................................... 116VZ800 .................................................................................................... 118VZ1600 .................................................................................................. 121

2 STROKEA100X/XS .............................................................................................. 124AY50 ...................................................................................................... 125AY50W ................................................................................................... 126JR50 ...................................................................................................... 128JR80 ...................................................................................................... 129LT50 ....................................................................................................... 130LT80 ....................................................................................................... 131LT-A50 ................................................................................................... 132RM60 ..................................................................................................... 133RM65 ..................................................................................................... 134RM85/L .................................................................................................. 135RM100 ................................................................................................... 137RM125 ................................................................................................... 138RM250 ................................................................................................... 139

PLE

SAM

COUNTRY AND AREA CODE

These may be some differences amoung models depending on specifications. If the service data dif-fer, it is noted there by using the following codes.The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY OR AREA CODE COUNTRY OR AREAE-01 General E-28, P-28 Canada

E-02, P-02 U. K. P-31 PhilippinesE-03 P-03 U. S. A. (Except for California) E-33, P-33 California (U. S. A)

E-06 South Africa P-37 BrazilP-09 Colombia P-42 Pakistan

E-13 Southeast Asia P-43 Saudi ArabiaE-17 P-17 Sweden P-51 Korea

E-19, P-19 E. U. E-54, P-54 IsuraelP-21 Belgium E-71, P-71 Mexico

E-24, P-24 Australia

NOTE:These service data are current as of APRIL 2004, and they are subject to change withoutnotice.

SAMPLE

1

AN250

1/7 E-02, 19, 24, 38, 71

VALVE + VALVE GUIDE Unit: mm

CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMITValve diam. IN. 28.3 —

EX. 25.0 —Tappet clearance (when cold) IN. 0.08 – 0.13 —

EX. 0.17 – 0.22 —Valve guide to valve stem clear-ance

IN. 0.10 – 0.37 —EX. 0.30 – 0.57 —

Valve guide I.D. IN. & EX. 5.000 – 5.012 —Valve stem O.D. IN. 4.975 – 4.990 —

EX. 4.955 – 4.970 —Valve stem deflection IN. & EX. — 0.35Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 1.7Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length IN. & EX. — 38.8Valve spring tension

IN. & EX.182 – 210 N

(18.2 – 21.0 kgf)at length 31.5 mm

—

ITEM STANDARD LIMITCam height IN. 33.430 – 33.477 33.130

EX. 33.500 – 33.547 33.200Camshaft journal oil clearance 22 0.032 – 0.066 0.15

17.5 0.028 – 0.059 0.15Camshaft journal holder I.D. 22 22.012 – 22.025 —

17.5 17.512 – 17.525 —Camshaft journal O.D. 22 21.959 – 21.980 —

17.5 17.466 – 17.484 —Camshaft runout — 0.10Rocker arm shaft I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —Cylinder head distortion — 0.05

2/7 E-02, 19, 24, 38, 71

CYLINDER + PISTON + PISTON RING Unit: mm

CONROD + CRANKSHAFT Unit: mm

OIL PUMP

CLUTCH Unit: mm

ITEM STANDARD LIMITCompression pressure 1250 – 1650 kPa

(12.5 – 16.5 kgf/cm2)1050 kPa

(10.5 kgf/cm2)Piston to cylinder clearance 0.04 – 0.05 0.120Cylinder bore 73.000 – 73.015 73.090Piston diam. 72.955 – 72.970

Measure at 15 mm from the skirtend. 72.880

Cylinder distortion — 0.05Piston ring free end gap 1st R 9.3 7.4

2nd R 7.2 5.7Piston ring end gap 1st 0.10 – 0.30 0.5

2nd 0.35 – 0.50 1.0Piston ring to groove clearance 1st — 0.18

2nd — 0.15Piston ring groove width 1st 1.01 – 1.04 —

2nd 1.01 – 1.04 —Oil 2.01 – 2.03 —

Piston ring thickness 1st 0.97 – 0.99 —2nd 0.97 – 0.99 —

Piston pin bore 19.002 – 19.008 19.030Piston pin O.D. 18.996 – 19.000 19.980

ITEM STANDARD LIMITConrod small end I.D. 19.006 – 19.014 19.04Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.75 1.0Conrod big end width 21.95 – 22.00 ----Width between crankshaft webs 59.9 – 60.1 ----Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pressure (at 60°C) Above 80 kPa (0.8 kgf/cm2)

Below160 kPa (1.6 kgf/cm2)at 3 000 r/min

—

ITEM STANDARD LIMITClutch wheel I.D. 135.0 – 135.2 135.5Clutch shoe thickness 3.0 2.0Engagement r/min 2500 – 3100 rpm —Lock-up r/min 4400 – 5400 rpm —LE
P
3/7 E-02, 19, 24, 38, 71

TRANSMISSION Unit: mm Except ratio

INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR

FI SENSORS

ITEM STANDARD LIMITPrimary reduction ratio 1.000 —Reduction ratio 2.417 – 0.836 —Secondary reduction 2.750 —Final reduction ratio 2.933 —Drive V-belt width 22.6 21.6Movable driven face spring free length 150 142.5

Movable drive face roller O.D. 23.72 – 23.88 —

ITEM SPECIFICATION NOTEInjector resistance 10 – 18 Ω at 20 °C —Fuel pump discharge amount 35 ml and more

For 10 sec, at 300 kPa (3.0 kgf/cm2) —

Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm2) —

ITEM SPECIFICATION NOTECKP sensor resistance 180 – 280 ΩCKP sensor peak voltage 4.5 V and more (When cranking) : G, : BIIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.6 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 0.6 kΩ

Opened Approx. 3.8 kΩTP sensor output voltage Closed Approx. 0.6 V

Opened Approx. 3.8 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 1.14 kΩ at 40 °CIAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 1.14 kΩ at 40 °CTO sensor resistance 19.1 – 19.7 kΩTO sensor output voltage Normal 1.3 V and less

Leaning 3.8 V and moreInjector voltage Battery voltageIgnition coil primary peak voltage 150 V and more (when cranking) : W

: GroundPAIR solenoid valve resistance 20 – 24 Ω at 20 °C

SAM

4/7 E-02, 19, 24, 38, 71

THROTTLE BODY

THERMOSTAT + RADIATOR + FAN + COOLANT

ELECTRICAL Unit: mm

ITEMSPECIFICATION

E-02, 19, 71, 24 E38ID No. 14G0 14G1Bore size 31.2 mm ←Fast idle r/min 1600 – 2000 r/min ←Idle r/min 1500 ± 100 r/min ←Idle air screw opening 2 and 1/8 turns out ←IAC valve resistance Approx. 3 – 9 Ω at 20 – 24 °C ←Throttle cable play 2.0 – 4.0 mm ←

ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature Approx.88 °C —

Thermostat valve lift Over 3.0 mm at 95 °C —Engine coolant temperature sensor resistance

20 °C Approx. 2.58 kΩ40 °C Approx. 1.14 kΩ —80 °C Approx. 0.28 kΩ

100 °C Approx. 0.16 kΩ —Radiator cap valve opening pres-sure

107.9 – 137.3 kPa(1.1 – 1.4 kgf/cm2) —

Cooling fan thermo-switch operat-ing temperature

ON 93 – 103 °C —OFF 87 – 97 °C —

Engine coolant type Use an anti-freeze/coolant compatible with alumi-num radiator, mixed with distilled water only, at theratio of 50:50.

—

Engine coolant including reserve Reserve tank side Approx. 250 ml —

Engine side Approx. 1300 ml —

ITEM STANDARD/SPECIFICATION NOTESpark plug Type NGK: CR7E

DENSO: U22ESR-NGap 0.6 – 0.7

Spark performance 8.0 mm and over at 1 atm.CKP sensor resistance 180 – 288 Ω G-BICKP sensor peak voltage 4.5 V and more : G, : BIIgnition coil resistance Primary 3 – 5 Ω

Secondary 17 – 30 kΩIgnition coil primary peak voltage 150 V and more : W

: GroundGenerator coil resistance Charging 0.2 – 0.6 Ω Y – YGenerator no-load voltage(When cold) 55 V and more at 5 000 r/min

Generator Max. output Approx. 375 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/min

2

5/7 E-02, 19, 24, 38, 71

WATTAGE Unit: W

ITEM STANDARD/SPECIFICATION NOTEStarter relay resistance 3 – 6 ΩBattery Type

designation FT12A-BS

Capasity 12 V 36 kC (10 Ah) /10 HRFuse size Head-

lightHI 15 ALO 15 A

Meter 10 AIgnition 10 A

Turn signal 15 APower source 10 A

Main 30 A

ITEMSTANDARD/SPECIFICATION

E-02, 19, 71 E-24 E-38Headlight HI 35 × 2 ← ←

LO 35 × 2 ← ←Parking or position light 5Brake light/Taillight 21/5 × 2 ← 21 × 2Taillight 5Turn signal light 21 × 4 ← ←License light 5 ← ←Instrument panel light 1.7 × 3 ← ←Oil change indicator light 1.7 ← ←FI indicator light 1.7 ← ←Brake lock indicator light 1.7 ← ←High beam indicator light 1.7 ← ←Turn signal indicator light 1.7 × 2 ← ←Trunk light 5 ← ←

6/7 E-02, 19, 24, 38, 71

BRAKE + WHEEL Unit: mm

SUSPENSION Unit: mm

TIRE

ITEM STANDARD LIMITBrake disc thickness Front 4.5 ± 0.2 4.0

Rear 5.5 ± 0.2 5.0Brake disc runout — 0.30Master cylinder bore Front 11.000 – 11.043 —

Rear 14.000 – 14.043 —Master cylinder piston diameter Front 10.957 – 10.984 —

Rear 13.957 – 13.984 —Brake caliper cylinder bore Front 33.960 – 34.010/22.650 – 22.700 —

Rear 25.400 – 25.450 —Brake caliper piston diameter Front 33.878 – 33.928/22.568 – 22.618 —

Rear 25.318 – 25.368 —Wheel rim runout Axial — 2.0

Radial — 2.0Wheel axle runout Front — 0.25

Rear — 0.25Wheel rim size Front 13M/C × MT3.00 —

Rear 13M/C × MT3.50 —

ITEM STANDARD LIMITFront fork stroke 100 —Front fork spring free length 330.4 324Front fork oil type SUZUKI FORK OIL G-10 (#10) —Front fork oil capacily (each leg) 284 ml —Front fork oil level 96 —Rear wheel travel 100 —Rear shock absorber spring adjuster 3rd —

ITEM STANDARD LIMITCold inflation tire pres-sure

Solo ridingFront 175 kPa

(1.75 kgf/cm2) —

Rear 200 kPa(2.00 kgf/cm2) —

Dual ridingFront 175 kPa

(1.75 kgf/cm2) —


Tire size Front 110/90-13M/C 55P —Rear 130/70-13M/C 63P —

Tire type Front BRIDGESTONE HOOP B03G —Rear — —

Tire tread depth(Recommended depth)

Front — 1.6 mmRear — 2.0 mmLE

P

7/7 E-02, 19, 24, 38, 71

FUEL + OILITEM SPECIFICATION NOTE

Fuel type Gasoline used should be graded 91 octane orhigher. An unleaded gasoline is recommended.

Fuel tank capacity Including reserve 15.0 L

Fuel meter red zone Approx. 3.0 L

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Oil change 1.9 L

Filter change 2.0 LOverhaul 2.3 L

Transmission oil capacity Oil change 190 mlOverhaul 200 ml

SAM

3

AN400

1/8 E-02, 03, 19, 28, 33, 54

VALVE + VALVE GUIDE Unit: mm (in)

ITEM STANDARD LIMITValve diam. IN. 30.6

(1.20) ––

EX. 27.0(1.06) ––

Tappet clearance (when cold) IN. 0.08 – 0.13(0.003 – 0.005) ––

EX. 0.17 – 0.22(0.007 – 0.009) ––

Valve guide to valve stem clear-ance IN. 0.10 – 0.37

(0.004 – 0.015) ––

EX. 0.30 – 0.57(0.012 – 0.022) ––

Valve guide I.D. IN. & EX. 5.000 – 5.012(0.1969 – 0.1973) ––

Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) ––

EX. 4.955 – 4.970(0.1951 – 0.1957) ––

Valve stem deflection IN. & EX. –– 0.35(0.014)

Valve stem runout IN. & EX. –– 0.05(0.002)

Valve head thickness IN. & EX. –– 0.5(0.02)

Valve stem end length IN. & EX. –– 1.7(0.07)

Valve seat width IN. & EX. 0.9 – 1.1(0.035 – 0.043) ––

Valve head radial runout IN. & EX. –– 0.03(0.001)

Valve spring free length IN. & EX. –– 38.8(1.53)

Valve spring tension IN. & EX.

182 – 210 N(18.2 – 21.0 kgf, 40.1 – 46.3 lbs)

at length 31.5 mm (1.24 in)––

2/8 E-02, 03, 19, 28, 33, 54

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMITCam height IN. 33.430 – 33.477

(1.316 – 1.318)33.130(1.304)

EX. 33.300 – 33.347(1.311 – 1.313)

33.000(1.299)

Camshaft journal oil clearance22 0.032 – 0.066

(0.001 – 0.003)0.15

(0.006)

17.5 0.028 – 0.059(0.001 – 0.002)

0.15(0.006)

Camshaft journal holder I.D.22 22.012 – 22.025

(0.8666 – 0.8671) ––

17.5 17.512 – 17.525(0.689 – 0.690) ––

Camshaft journal O.D.22 21.959 – 21.980

(0.8645 – 0.8654) ––

17.5 17.466 – 17.484(0.6876 – 0.6883) ––

Camshaft runout –– 0.10(0.004)

Rocker arm shaft I.D. IN. & EX. 12.000 – 12.018(0.472 – 0.473) ––

Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984(0.471 – 0.472) ––

Cylinder head distortion –– 0.05(0.002)

ITEM STANDARD LIMITCompression pressure 860 – 900 kPa

(8.6 – 9.0 kgf/cm², 122 – 128 psi)616 kPa

(6.16 kgf/cm²,88 psi)

Piston to cylinder clearance 0.045 – 0.055(0.0018 – 0.0022)

0.120(0.005)

Cylinder bore 83.000 – 83.015(3.2677 – 3.2683)

83.085(3.271)

Piston diam. 82.950 – 82.965 (3.2657 – 3.2663)Measure at 15 mm (0.6 in) from the skirtend.

82.880(3.263)

Cylinder distortion –– 0.05(0.002)

Piston ring free end gap 1st R Approx. 11.3 (0.44) 9.0(0.35)

2nd R Approx. 7.7 (0.30) 6.2(0.24)

Piston ring end gap 1st 0.20 – 0.35(0.008 – 0.014)

0.70(0.03)

2nd 0.35 – 0.50(0.014 – 0.020)

1.0(0.04)

Piston ring to groove clearance 1st –– 0.18(0.007)

2nd –– 0.15(0.006)LE

P

3/8 E-02, 03, 19, 28, 33, 54

CONROD + CRANKSHAFT Unit: mm (in)

OIL PUMP

CLUTCH Unit: mm (in)

ITEM STANDARD LIMITPiston ring groove width 1st 1.01 – 1.03

(0.0398 – 0.0406) ––

2nd 1.01 – 1.03(0.0398 – 0.0406) ––

Oil 2.01 – 2.03(0.0791 – 0.0799) ––

Piston ring thickness 1st 0.97 – 0.99(0.0382 – 0.0390) ––

2nd 0.97 – 0.99(0.0382 – 0.0390) ––

Piston pin bore 20.002 – 20.008(0.7874 – 0.7877)

20.030(0.789)

Piston pin O.D. 19.992 – 20.000(0.7871 – 0.7874)

19.980(0.787)

ITEM STANDARD LIMITConrod small end I.D. 20.006 – 20.014

(0.7876 – 0.7880)20.040(0.789)

Conrod deflection –– 3.0(0.12)

Conrod big end side clearance 0.10 – 0.75(0.004 – 0.030)

1.0(0.04)

Conrod big end width 21.95 – 22.00(0.864 – 0.866) ––

Width between crankshaft webs 59.9 – 60.1(2.358 – 2.366) ––

Crankshaft runout –– 0.08(0.003)

ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 80 kPa (0.8 kgf/cm², 11 psi)

Below 160 kPa (1.6 kgf/cm², 23 psi)at 3 000 r/min

––

ITEM STANDARD LIMITClutch wheel I.D. 150.0 – 150.2

(5.906 – 5.913)150.5

(5.925)Clutch shoe thickness 3.0

(0.12)2.0

(0.08)Engagement r/min 2 300 – 2 900 rpm ––Lock-up r/min 3 500 – 4 500 rpm ––

SAM

4/8 E-02, 03, 19, 28, 33, 54

TRANSMISSION Unit: mm (in) Except ratio


FI SENSORS

ITEM STANDARD LIMITPrimary reduction ratio 1.000 ––Reduction ratio 2.203 – 0.854 ––Secondary reduction 2.214 ––Final reduction ratio 2.785 ––Drive V-belt width 21.85

(0.86)20.85(0.82)

Movable driven face spring free length

125(4.92)

118.7(4.67)

Movable drive face roller O.D. 23.72 – 23.88(0.93 – 0.94) ––

Drive/Driven face wear –– 0.4(0.02)

ITEM SPECIFICATION NOTEInjector resistance 10 – 18 Ω at 20 °C (68 °F) ––Fuel pump discharge amount 35 ml and more

For 10 sec, at 300 kPa (3.0 kgf/cm², 43 psi) ––

Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi) ––

ITEM SPECIFICATION NOTECKP sensor resistance 180 – 280 ΩCKP sensor peak voltage 4.5 V and more (When cranking) : G, : BIIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.6 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 0.6 kΩ


Opened Approx. 3.8 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 1.14 kΩ at 40 °C (104 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 1.14 kΩ at 40 °C (104 °F)TO sensor resistance 19.1 – 19.7 kΩTO sensor output voltage Normal 1.3 V and less

Leaning 3.8 V and moreInjector voltage Battery voltageIgnition coil primary peak voltage 150 V and more (when cranking) : W

: GroundPAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)HO2 sensor resistance 11.5 – 14.5 Ω at 23 °C (73.4 °F)HO2 sensor output voltage Idle speed 0.3 V and less

3 000 r/min 0.7 V and more

4

5/8 E-02, 03, 19, 28, 33, 54

THROTTLE BODY


ELECTRICAL Unit: mm (in)

ITEMSPECIFICATION

E-02, 03, 19, 28, 54 E-33ID No. 15G0 15G1Bore size 37.2 mm (1.46 in) ←Fast idle r/min 1600 – 2000 r/min ←Idle r/min 1400 ± 100 r/min ←Idle air screw opening 2 turns out ←IAC valve resistance Approx. 3 – 9 Ω at 20 – 24 °C (68 – 75 °F) ←Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in) ←

ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature Approx. 82 °C (180 °F) ± 1.5 ––

Thermostat valve lift Over 3.0 mm at 95 °C (203 °F) ––Engine coolant temperature sensor resistance

20 °C (68 °F) Approx. 2.58 kΩ ––40 °C (104 °F) Approx. 1.14 kΩ ––80 °C (176 °F) Approx. 0.28 kΩ ––

100 °C (212 °F) Approx. 0.16 kΩ ––Radiator cap valve opening pres-sure

107.9 – 137.3 kPa(1.1 – 1.4 kgf/cm², 16 – 20 psi) ––


ON 93 – 103 °C (199 – 217 °F) ––OFF 87 – 97 °C (189 – 207 °F) ––


––

Engine coolant including reserve Reserve tank side

Approx. 250 ml(8.45/8.80 US/Imp oz) ––

Engine side Approx. 1 300 ml(43.9/45.8 US/Imp oz) ––

ITEM STANDARD/SPECIFICATION NOTESpark plug Type NGK: CR7E

DENSO: U22ESR-N

Gap 0.7 – 0.8(0.28 – 0.03 in)

Spark performance 8.0 mm (0.31 in) and over at 1 atm.CKP sensor resistance 180 – 288 Ω G – BICKP sensor peak voltage 4.5 V and more : G/W

: BIIgnition coil resistance Primary 3 – 5 Ω

Secondary 17 – 30 kΩIgnition coil primary peak voltage 150 and more : W

: GroundGenerator coil resistance Charging 0.2 – 0.6 Ω Y – YGenerator no-load voltage(When cold) 55 V and more at 5 000 r/min

6/8 E-02, 03, 19, 28, 33, 54

WATTAGE Unit: W

ITEM STANDARD/SPECIFICATION NOTEGenerator Max. output Approx. 375 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type

designation FT12A-BS

Capasity 12 V 36 kC (10 Ah) /10 HRFuse size Head-

lightHI 10 ALO 10 A

Meter 10 AIgnition 10 A

Turn signal 15 APower source 10 A

Main 30 A


E-02, 19, 54 E-03, 28, 33Headlight HI 35 × 2 ←

LO 35 × 2 ←Parking or position light 5 × 2Brake light/Taillight 21/5 × 2 ←Turn signal light 21 × 4 ←License light 5 ←Instrument panel light 1.7 × 3 ←Oil change indicator light 1.7 ←FI indicator light 1.7 ←Brake-lock indicator light 1.7 ←High beam indicator light 1.7 ←Turn signal indicator light 1.7 × 2 ←Trunk light 5 ←

LE
P
7/8 E-02, 03, 19, 28, 33, 54

BRAKE + WHEEL Unit: mm (in)

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMITBrake disc thickness Front 4.5 ± 0.2

(0.18 ± 0.008)4.0

(0.16)

Rear 5.5 ± 0.2(0.22 ± 0.008)

4.5(0.18)

Brake disc runout –– 0.30(0.01)

Master cylinder bore Front 11.000 – 11.043(0.433 – 0.435) ––

Rear 14.000 – 14.043(0.551 – 0.553) ––

Master cylinder piston diameter Front 10.957 – 10.984(0.431 – 0.432) ––

Rear 13.957 – 13.984(0.549 – 0.551) ––

Brake caliper cylinder bore Front 33.960 – 34.010/22.650 – 22.700(1.337 – 1.339/0.892 – 0.894) ––

Rear 25.400 – 25.450(1.000 – 1.002) ––

Brake caliper piston diameter Front 33.878 – 33.928/22.568 – 22.618(1.334 – 1.336/0.889 – 0.890) ––

Rear 25.318 – 25.368(0.997 – 0.999) ––

Wheel rim runout Axial –– 2.0(0.08)

Radial –– 2.0(0.08)

Wheel axle runout Front –– 0.25(0.01)

Rear –– 0.25(0.01)

Wheel rim size Front 13M/C × MT3.00 ––Rear 13M/C × MT3.50 ––

ITEM STANDARD LIMITFront fork stroke 100 (3.94) ––Front fork spring free length 330.4 (13.01) 324

(12.76)Front fork oil type SUZUKI FORK OIL G-10 (#10) ––Front fork oil capacily (each leg) 284 ml ––Front fork oil level 96 (3.78) ––Rear wheel travel 100 (3.94) ––Rear shock absorber spring adjuster Standard 4 and 1/2 turns out from softest

position (9 clicks) ––

Range 17 turns (34 clicks) ––

SAM

8/8 E-02, 03, 19, 28, 33, 54

TIRE

FUEL + OIL

ITEM STANDARD LIMIT

Cold inflation tire pressure

Soloriding

Front 175 kPa(1.75 kgf/cm², 25 psi) ––

Rear 200 kPa(2.00 kgf/cm², 28 psi) ––

Dualriding

Front 175 kPa(1.75 kgf/cm², 25 psi) ––

Rear 225 kPa(2.25 kgf/cm², 32 psi) ––

Tire sizeFront 110/90-13 M/C 55P ––Rear 130/70-13 M/C 63P ––

Tire typeFront BRIDGESTONE HOOP B03G ––Rear BRIDGESTONE HOOP B02G ––


Front –– 1.6 mm(0.06 in)

Rear –– 2.0 mm(0.08 in)

ITEM SPECIFICATION NOTEFuel type Gasoline used should be graded 91 octane or

higher. An unleaded gasoline is recommended.Fuel tank capacity Including

reserve 13.0 L (13.7/11.4 US/Imp qt)

Fuel meter red zone

Approx. 3.0 L (3.17/2.64 US/Imp qt)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Oil change 1.9 L (2.00/1.67 US/Imp qt)

Filter change 2.0 L (2.11/1.76 US/Imp qt)Overhaul 2.3 L (2.43/2.02 US/Imp qt)

Transmission oil capacity Oil change 190 ml (6.42/6.69 US/Imp oz)Overhaul 200 ml (6.76/7.04 US/Imp oz)

5

AN650

1/9 E-02, 03, 19, 24, 28, 33

VALVE + GUIDE Unit: mm (in)


(1.16) —

EX. 25.0(0.98) —

Tappet clearance (when cold) IN. 0.10 – 0.20(0.0039 – 0.0079) —

EX. 0.20 – 0.30(0.0079 – 0.0118) —

Valve guide to valve stemclearance

IN. 0.010 – 0.040(0.0004 – 0.0016) —

EX. 0.030 – 0.060(0.0012 – 0.0024) —

Valve guide I.D. IN. & EX. 4.500 – 4.515(0.1772 – 0.1778) —

Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —

Valve stem deflection IN. & EX. — 0.35(0.014)

Valve stem runout IN. & EX. — 0.05(0.002)

Valve head thickness IN. & EX. — 0.5(0.02)

Valve seat width IN. & EX. 0.9 – 1.1(0.035 – 0.043) —

Valve head radial runout IN. & EX. — 0.03(0.001)

Valve spring free length (IN. & EX.) IN. & EX. — 40.6(1.60)

Valve spring tension (IN. & EX.)IN. & EX.

136 – 156 N (13.6 – 15.6 kgf, 30.0 – 34.4 lbs)

at length 33.4 mm (1.31 in)—

2/9 E-02, 03, 19, 24, 28, 33




(1.393 – 1.395)35.10

(1.382)

EX. 33.98 – 34.03(1.338 – 1.340)

33.70(1.327)

Camshaft journal oil clearance IN. & EX. 0.032– 0.066(0.0013 – 0.0026)

0.150(0.0059)

Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025(0.9454 – 0.9459) —

Camshaft journal O.D. IN. & EX. 23.959 – 24.000(0.9433 – 0.9449) —

Camshaft runout IN. & EX. — 0.10(0.004)

Cam chain pin (at arrow “3”) 15th pin —Cylinder head distortion — 0.10

(0.004)

ITEM STANDARD LIMITCompression pressure 1 500 – 1 900 kPa

(15.0 – 19.0 kgf/cm2, 213 – 270 psi)1 200 kPa

(12 kgf/cm2,171 psi)

Compression pressure difference—

200 kPa(2.0 kgf/cm2,

28 psi)Piston to cylinder clearance 0.045 – 0.055

(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 75.500 – 75.515

(2.9724 – 2.9730)75.585

(2.9758)Piston diam. 75.450 – 75.465

(2.9705 – 2.9711)Measure at 15 mm (0.6 in) from the skirt end.

75.380(2.9677)

Cylinder distortion — 0.10(0.004)


2nd RN Approx. 8.6 (0.34) 6.9(0.27)


0.50(0.020)

2nd 0.20 – 0.30(0.008 – 0.012)

0.50(0.020)

Piston ring to groove clearance 1st — 0.180(0.007)

2nd — 0.150(0.006)

Piston ring groove width 1st 1.01 – 1.03(0.040 – 0.041) —

2nd 1.01 – 1.03(0.040 – 0.041) —

Oil 2.01 – 2.03(0.079 – 0.080) —LE

P

3/9 E-02, 03, 19, 24, 28, 33


OIL PUMP

ITEM STANDARD LIMITPiston ring thickness 1st 0.97 – 0.99

(0.038 – 0.039) —

2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pin bore 16.002 – 16.008 (0.6300 – 0.6302)

16.030(0.6311)

Piston pin O.D. 15.995 – 16.000 (0.6297 – 0.6299)

15.980(0.6291)

ITEM STANDARD LIMITConrod small end I.D. 16.010 –16.018

(0.6303 – 0.6306)16.040

(0.6315)Conrod big end side clearance 0.10 – 0.20

(0.004 – 0.008)0.30

(0.012)Conrod big end width 19.950 – 20.000

(0.7854 – 0.7874) —

Crank pin width 20.100 – 20.150(0.7913 – 0.7933) —

Conrod big end oil clearance 0.032 – 0.056(0.0013 – 0.0022)

0.080(0.0031)

Crank pin O.D. 44.976 – 45.000(1.7707 – 1.7717) —

Crankshaft journal oil clearance 0.018 – 0.045(0.0007 – 0.0018)

0.080(0.0031)

Crankshaft journal O.D. 47.985 – 48.000(1.8892 – 1.8898) —

Crankshaft thrust bearing thickness 2.025 – 2.175(0.0797 – 0.0856) —

Crankshaft thrust clearance 0.10 – 0.15(0.0039 – 0.0059) —

Crankshaft runout — 0.05(0.002)

ITEM STANDARD LIMITOil pressure (at 60°C, 140°F) Above 350 kPa (3.5 kgf/cm2)

Below 550 kPa (5.5 kgf/cm2)at 3 000 r/min

—

SAM

4/9 E-02, 03, 19, 24, 28, 33



FI/CVT-SENSORS

ITEM STANDARD LIMITDrive plate thickness 2.92 – 3.08

(0.115 – 0.121) 2.62

(0.103)Drive plate claw width 13.85 – 13.96

(0.545 – 0.550)13.05

(0.514)Driven plate thickness 2.42 – 2.58

(0.095 – 0.102)2.27

(0.089)Driven plate distortion — 0.10

(0.004)Clutch spring free length 13.9

(0.547)13.2

(0.520)Clutch plate concaved washer height — 3.1

(0.12)Clutch engagement 1 500 – 2 100 r/min —Clutch lock-up 3 200 – 3 800 r/min —

ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F) —Fuel pump discharge amount More than 0.9 L (0.95/0.79 US/Imp qt)

For 30 sec, at 300 kPa (3.0 kgf/cm2, 43 psi)—

Fuel pressure regulator operating set pressure

Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —

ITEM SPECIFICATION NOTECMP sensor resistance 0.9 – 1.7 kΩCMP sensor peak voltage More than 0.5 V (When cranking) : B/Y, : BrCKP sensor resistance 150 – 300 ΩCKP sensor peak voltage More than 2.0 V (When cranking) : Bl, : GIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.6 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ


Opened Approx. 4.3 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 3.6 V at 760 mmHg (100 kPa)TO sensor resistance 19.1 – 19.7 kΩTO sensor output voltage Normal Less than 1.4 V

Leaning Less than 3.7 VInjector voltage Battery voltage

6

5/9 E-02, 03, 19, 24, 28, 33

THROTTLE BODY

ITEM SPECIFICATION NOTEIgnition coil primary peak voltage

More than 80 V (When cranking)#1 : W/Bl,: Ground#2 : B/Y,: Ground

HO2 sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)HO2 sensor output voltage Idle speed Less than 0.4 V

3 000 r/min More than 0.6 VPAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)CVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ

Extended 0.2 – 1.0 kΩCVT primary pulley position sensor output voltage

1st: Idle speed Approx. 3.3 V3rd: 3 000 r/min Approx. 1.3 V5th: 3 000 r/min Approx. 0.5 V

CVT secondary pulley revolution sensor resistance

400 – 600 Ω

CVT secondary pulley revolution sensor peak voltage

More than 5 V at idle speed : Y, : W

ITEM SPECIFICATIONID No. 10GOBore size 32 mmFast idle r/min 1 300 – 1600 r/minIdle r/min 1 200 ± 100 r/minSynchronizing screw opening 1 and 1/2 turns outIAC valve resistance Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

6/9 E-02, 03, 19, 24, 28, 33



ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature

Approx. 88 °C (190 °F) —

Thermostat valve lift Over 8.0 mm (0.3 in) at 100 °C (212 °F) —Engine coolant temperature sensor resistance

20 °C (68 °F) Approx. 2.45 kΩ —50 °C (122 °F) Approx. 0.811 kΩ —80 °C (176 °F) Approx. 0.318 kΩ —

110 °C (230 °F) Approx. 0.142 kΩ —Radiator cap valve opening pres-sure 110 kPa (1.1 kgf/cm²) —

Eclectic fan thermo-switch operat-ing temperature

ON 93 – 103 °C —OFF 87 – 97 °C —

Engine coolant type Use an anti-freeze/coolant compatible with alumi-num radiator, mixed with distilled water only, at the ratio of 50:50.

—

Engine coolant including reserve Reverse tank side

Approx. 250 ml —

Engine side Approx. 1 050 ml —

ITEM STD/SPEC. NOTEFiring order 1·2Spark plug Type NGK: CR8E

DENSO: U24ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8.0 mm (0.3) at 1 atm.CKP sensor peak voltage More than 2.0 V : Bl, :GIgnition coil resistance Primary 0.8 – 2.5 Ω

Secondary 8 – 18 kΩIgnition coil primary peak voltage

More than 80 V#1 : W/Bl,: Ground#2 : B/Y,: Ground

Generator coil resistance CKP sensor 150 – 300 Ω G – BICharging 0.1 – 1.0 Ω Y – Y

Generator no-load voltage(When cold)

More than 50 V at 5 000 r/min

Generator Max. output Approx. 500 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type

designationFTX14-BS

Capacity 12 V 43.2 kC (12 Ah)/10 HR

LE
P
7/9 E-02, 03, 19, 24, 28, 33

WATTAGE Unit: W

ITEM STD/SPEC. NOTEFuse size

Head-light

LO15 A ..........E-03, 24, 28, 33

10A ...........E-02, 19HI 15 A

Fuel pump 10 AIgnition 15 A

Turn signal 15 AFan motor 15 A

Main 40 ACVT 40 A

Power source 10 A

ITEMSTD/SPEC.

E-02, 19 E-03, 24, 28, 33Headlight HI 60 + 55 60 × 2

LO 55 55 × 2Parking or position light 5 × 2Brake light/Taillight 21/5 × 2 ←Turn signal light 21 × 4 ←License light 5 ←Instrument panel light 1.4 × 2 ←Engine coolant temp. indicator light 1.4 ←FI indicator light 1.4 ←Engine oil pressure indicator light 1.4 × 2 ←Brake-lock indicator light 1.4 ←High beam indicator light 1.4 ←Turn signal indicator light 1.4 × 2 ←Power mode indicator light 1.4 ←Drive indicator light 1.4 ←Gear position indicator light 1.4 × 5 ←Trunk light 5 ←

SAM

8/9 E-02, 03, 19, 24, 28, 33



ITEM STANDARD LIMITBrake disc thickness Front 4.5 ± 0.2

(0.177 ± 0.008) 4.0

(0.16)

Rear 5.5 ± 0.2(0.217 ± 0.008)

5.0(0.20)

Brake disc runout — 0.30(0.012)

Master cylinder bore Front 12.700 – 12.743(0.5000 – 0.5017) —

Rear 12.700 – 12.743(0.5000 – 0.5017) —

Master cylinder piston diameter Front 12.657 – 12.684(0.4983 – 0.4994) —

Rear 12.657 – 12.684(0.4983 – 0.4994) —

Brake caliper cylinder bore Front 25.400 – 25.450(1.0000 – 1.0020) —

Rear 27.000 – 27.050 (1.0630 – 1.0650) —

Brake caliper piston diameter Front 25.318 – 25.368(0.9968 – 0.9987) —

Rear 26.918 – 26.968(1.0598 – 1.0617) —

Brake fluid type DOT4 —Wheel rim runout Axial — 2.0

(0.08)

Radial — 2.0 (0.08)

Wheel axle runout Front — 0.25 (0.010)

Rear — 0.25(0.010)

Wheel rim size Front 15 M/C × MT3.50 —Rear 14 M/C × MT4.50 —

ITEM STANDARD LIMITFront fork stroke 110

(4.3) —

Front fork spring free length — 341(13.4)

Front fork oil type SUZUKI FORK OIL G-10 (#10) or an equivalent fork oil —

Front fork oil capacity (each leg) 458 ml —Front fork oil level 151

(5.9) —

Rear wheel travel 100(3.9) —

Rear shock absorber spring adjuster

2nd —

7

9/9 E-02, 03, 19, 24, 28, 33

TIRE

FUEL + OIL

ITEM STANDARD LIMITCold inflation tire pressure

Solo riding

Front 225 kPa(2.25 kgf/cm2, 33 psi) —

Rear 250 kPa(2.50 kgf/cm2, 36 psi) —

Dual riding

Front 225 kPa(2.25 kgf/cm2, 33 psi) —


Tire size Front 120/70R15M/C 56H —Rear 160/60R14M/C 65H —

Tire type Front BRIDGESTONE TH01F —Rear BRIDGESTONE TH01R —


Front — 1.6 mm (0.06 in)

Rear — 2.0 mm (0.08 in)

ITEM SPECIFICATION NOTEFuel type Use only unleaded gasoline of at least 87 pump

octane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33

Gasoline used should be graded 91 octane orhigher. An unleaded gasoline is recommended.

The others

Fuel tank capacity Including reserve

15.0 L(4.0/3.3 US/lmp gal)

Fuel meter mark

flickering

Approx. 3.0 L(0.79/0.66 US/lmp gal)

Fuel meter mark and

LCD flickering


Engine oil and transmission oil type SAE 10W-40, API, SF or SGEngine oil capacity Oil change 2.6 L (2.7/2.3 US/lmp qt)

Filter change 2.9 L (3.1/2.6 US/lmp qt)Overhaul 3.4 L (3.6/3.0 US/lmp qt)

Transmission oil capacity Oil change 360 ml (12.2/12.7 US/lmp oz)Overhaul 400 ml (13.5/14.1 US/lmp oz)

Final gear oil type Hypoid gear oil SAE #90 API grade GL-5Final gear oil capacity Oil change 300 ml (10.1/10.6 US/lmp oz)

Overhaul 430 ml (14.5/15.1 US/lmp oz)
LE P AN650A
1/7 E-02, 19

VALVE + GUIDE Unit: mm



EX. 25.0 —Tappet clearance (when cold) IN. 0.10 – 0.20 —

EX. 0.20 – 0.30 —Valve guide to valve stemclearance

IN. 0.010 – 0.040 —EX. 0.030 – 0.060 —


EX. 4.455 – 4.470 —Valve stem deflection IN. & EX. — 0.35Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length (IN. & EX.) IN. & EX. — 40.6Valve spring tension (IN. & EX.)

IN. & EX.136 – 156 N

(13.6 – 15.6 kgf)at length 33.4 mm

—


EX. 33.98 – 34.03 33.70Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 24.012 – 24.025 —Camshaft journal O.D. IN. & EX. 23.959 – 23.980 —Camshaft runout IN. & EX. — 0.10Cam chain pin (at arrow “3”) 15th pin —Cylinder head distortion — 0.10

SAM

2/7 E-02, 19



OIL PUMP


(15.0 – 19.0 kgf/cm2)1 200 kPa

(12 kgf/cm2)Compression pressure difference — 200 kPa


Measure at 15 mm from the skirt end. 75.380

Cylinder distortion — 0.10Piston ring free end gap 1st R Approx. 11.6 9.3

2nd RN Approx. 8.6 6.9Piston ring end gap 1st 0.20 – 0.30 0.50



2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —



ITEM STANDARD LIMITConrod small end I.D. 16.010 –16.018 16.040Conrod big end side clearance 0.10 – 0.20 0.30Conrod big end width 19.950 – 20.000 —Crank pin width 20.100 – 20.150 —Conrod big end oil clearance 0.032 – 0.056 0.080Crank pin O.D. 44.976 – 45.000 —Crankshaft journal oil clearance 0.018 – 0.045 0.080Crankshaft journal O.D. 47.985 – 48.000 —Crankshaft thrust bearing thickness 2.025 – 2.175 —Crankshaft thrust clearance 0.10 – 0.15 —Crankshaft runout — 0.05

ITEM STANDARD LIMITOil pressure (at 60 °C) Above 350 kPa (3.5 kgf/cm2)


—

8

3/7 E-02, 19

CLUTCH Unit: mm


FI/CVT-SENSORS

ITEM STANDARD LIMITDrive plate thickness 2.92 – 3.08 2.62Drive plate claw width 13.85 – 13.96 13.05Driven plate No. 2 thickness 2.42 – 2.58 2.27Driven plate distortion — 0.10Clutch spring free length 13.9 13.2Clutch plate concaved washer height 3.2 3.1

Clutch engagement 1 500 – 2 100 r/min —Clutch lock-up 3 200 – 3 800 r/min —

ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C —Fuel pump discharge amount More than 0.9 L

for 30 sec, at 300 kPa (3.0 kgf/cm2) —

Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm2) —

ITEM SPECIFICATION NOTECMP sensor resistance 0.9 – 1.7 kΩCMP sensor peak voltage More than 0.5 V (When cranking) : B/Y, : BrCKP sensor resistance 150 – 300 ΩCKP sensor peak voltage More than 2.0 V (When cranking) : Bl, : GIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.6 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ


Opened Approx. 4.3 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °CIAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °CAP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)TO sensor resistance 19.1 – 19.7 kΩTO sensor output voltage Normal 0.4 – 1.4 V : B, : B/Br

Leaning 3.7 – 4.4 V : B, : B/BrInjector voltage Battery voltageIgnition coil primary peak voltage

More than 80 V (When cranking)#1 : W/Bl,: Ground#2 : B/Y,: Ground

4/7 E-02, 19

THROTTLE BODY


ITEM SPECIFICATION NOTEHO2 sensor resistance 4 – 5 Ω at 23 °CHO2 sensor output voltage Idle speed Less than 0.4 V

3 000 r/min More than 0.6 VPAIR solenoid valve resistance 20 – 24 Ω at 20 °CCVT primary pulley position sensor Compressed 1.9 – 2.3 kΩ

Extended 0.2 – 1.0 kΩCVT primary pulley position sensor output voltage

1st: Idle speed Approx. 3.3 V3rd: 3 000 r/min Approx. 1.3 V5th: 3 000 r/min Approx. 0.5 V

CVT secondary pulley revolution sensor resistance 400 – 600 Ω

CVT secondary pulley revolution sensor peak voltage More than 5 V at idle speed : Y, : W

ITEM SPECIFICATIONID No. 10GOBore size 32 mmFast idle r/min 1 300 – 1600 r/minIdle r/min 1 200 ± 100 r/minSynchronizing screw opening 1-1/2 turns outIAC valve resistance Approx. 4 Ω at 20 – 24 °CThrottle cable play 2.0 – 4.0 mm


Approx. 88 °C —

Thermostat valve lift Over 8.0 mm at 100 °C —Engine coolant temperature sensor resistance

20 °C Approx. 2.45 kΩ —50 °C Approx. 0.811 kΩ —80 °C Approx. 0.318 kΩ —

110 °C Approx. 0.142 kΩ —Radiator cap valve opening pres-sure 110 kPa (1.1 kgf/cm²) —

Eclectic fan thermo-switch operat-ing temperature

ON 93 – 103 °C —OFF 87 – 97 °C —


—

Engine coolant including reserve Reverse tank side Approx. 250 ml —

Engine side Approx. 1 350 ml —

LE
P
5/7 E-02, 19

ELECTRICAL Unit: mm

ITEM STD/SPEC. NOTEFiring order 1·2Spark plug Type NGK: CR8E


Spark performance Over 8.0 at 1 atm.CKP sensor peak voltage More than 2.0 V : Bl, :GIgnition coil resistance Primary 0.8 – 2.5 Ω

Secondary 8 – 18 kΩIgnition coil primary peak voltage

More than 80 V#1 : W/Bl,: Ground#2 : B/Y,: Ground

Generator coil resistance CKP sensor 150 – 300 Ω G – BICharging 0.1 – 1.0 Ω Y – Y

Generator no-load voltage(When cold) More than 50 V at 5 000 r/min

Generator Max. output Approx. 500 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type

designation FTX14-BS

Capacity 12 V 43.2 kC (12 Ah)/10 HRFuse size Head-

lightLO 15 AHI 15 A

Fuel pump 10 AIgnition 15 A


Main 40 ACVT 40 A

Power source 10 A

ABS 15 A × 2

SAM

6/7 E-02, 19

WATTAGE Unit: W


ITEM STD/SPEC.Headlight HI 60 + 55

LO 55Parking/Position light 5 × 2Brake light/Taillight 21/5 × 2Turn signal light 21 × 4License light 5Instrument panel light 1.4 × 2Engine coolant temp. indicator light 1.4FI indicator light 1.4Engine oil pressure indicator light 1.4Brake-lock indicator light 1.4High beam indicator light 1.4Turn signal indicator light 1.4 × 2Power mode indicator light 1.4Drive indicator light 1.4Gear position indicator light 1.4 × 5ABS warning indicator light 1.4Trunk light 5

ITEM STANDARD LIMITBrake disc thickness Front 4.5 ± 0.2 4.0

Rear 5.5 ± 0.2 5.0Brake disc runout — 0.30Master cylinder bore Front 12.700 – 12.743 —

Rear 12.700 – 12.743 —Master cylinder piston diameter Front 12.657 – 12.684 —

Rear 12.657 – 12.684 —Brake caliper cylinder bore Front 25.400 – 25.450 —

Rear 27.000 – 27.050 —Brake caliper piston diameter Front 25.318 – 25.368 —

Rear 26.918 – 26.968 —Brake fluid type DOT 4 —Wheel rim runout Axial — 2.0


Rear — 0.25Wheel rim size Front 15 M/C × MT3.50 —

Rear 14 M/C × MT4.50 —

9

7/7 E-02, 19

SUSPENSION Unit: mm

TIRE

FUEL + OIL

ITEM STANDARD LIMITInner tube outside diameter 41 —Front fork stroke 110 —Front fork spring free length — 341Front fork oil type SUZUKI FORK OIL G-10 (#10) or

an equivalent fork oil —

Front fork oil capacity (each leg) 458 ml —Front fork oil level 151 —Rear wheel travel 100 —Rear shock absorber spring adjuster 2nd —

ITEM STANDARD LIMITCold inflation tire pressure Solo

ridingFront 225 kPa (2.25 kgf/cm2) —Rear 250 kPa (2.50 kgf/cm2) —

Dual riding

Front 225 kPa (2.25 kgf/cm2) —Rear 280 kPa (2.80 kgf/cm2) —

Tire size Front 120/70R 15M/C 56H —Rear 160/60R 14M/C 65H —

Tire type Front BRIDGESTONE TH01F —Rear BRIDGESTONE TH01R —


Front — 1.6 mmRear — 2.0 mm



reserve 15.0 L

Fuel meter mark

flickeringApprox. 3.0 L

Fuel meter mark and

LCD flickering

Approx. 1.5 L

Engine oil and transmission oil type SAE 10W-40, API SF or SGEngine oil capacity Oil change 2.6 L

Filter change 2.9 LOverhaul 3.4 L

Transmission oil capacity Oil change 360 mlOverhaul 400 ml

Final gear oil type Hypoid gear oil SAE #90 API grade GL-5Final gear oil capacity Oil change 300 ml

Overhaul 430 ml
LE P DL650
1/9 E-02, 03, 19, 24, 28, 33E-19


ITEM STANDARD LIMITValve diam. IN. 31

(1.2) —

EX. 25.5(1.0) —

Valve clearance (when cold) IN. 0.10 – 0.20(0.004 – 0.008) —

EX. 0.20 – 0.30(0.008 – 0.012) —

Valve guide to valve stem clearance IN. 0.020 – 0.047(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.465 – 4.480(0.1758 – 0.1764) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —






Valve spring free length(IN. & EX.) INNER — 36.8

(1.45)

OUTER — 39.8(1.57)

Valve spring tension(IN. & EX.) INNER

4.2 – 4.8 kgf(9.26 – 10.58 lbs)


OUTER17.0 – 19.6 kgf

(37.48 – 43.21 lbs)at length 33.4 mm (1.31 in)

—

SAM

2/9 E-02, 03, 19, 24, 28, 33E-19




(1.3968 – 1.3988)35.18

(1.3850)

EX. 33.48 – 33.53(1.3181 – 1.3201)

33.18(1.3063)

Camshaft journal oil clearance IN. & EX. 0.032 – 0.066(0.0013 – 0.0026)

0.150(0.0059)





(0.002)


(13 – 17 kgf/cm2, 185 – 242 psi)1 100 kPa

(11 kgf/cm2, 156 psi)


200 kPa(2 kgf/cm2,


(0.0022 – 0.0026)0.120

(0.0047)Cylinder bore 81.000 – 81.015

(3.1890 – 3.1896)Nicks or

ScratchesPiston diam. 80.950 – 80.955


80.88(3.184)


Piston ring free end gap 1st Approx. 9.5 (0.37) 7.6(0.30)

2nd Approx. 11 (0.43) 8.8(0.35)


0.70(0.028)

2nd 0.20 – 0.35(0.008 – 0.0014)

0.70(0.028)


2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —

10

3/9 E-02, 03, 19, 24, 28, 33E-19


OIL PUMP



(0.0461 – 0.0469) —

2nd 0.97 – 0.99(0.0382 – 0.0390) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.992 – 20.000(0.7871 – 0.7874)

19.98(0.7866)


(0.7878 – 0.7881)20.040


(0.0067 – 0.0126)0.5


(0.825 – 0.827) —

Crank pin width 42.17 – 42.22(1.660 – 1.662) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4960) —


0.080(0.0031)





—

ITEM STANDARD LIMITClutch cable play 10 – 15

(0.4 – 0.6) —

Clutch release screw 1/4 turns back —Drive plate thickness No. 1 & No. 2 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Drive plate claw width No. 1 & No. 2 13.7 – 13.8

(0.539 – 0.543)12.9



(2.09)50.5

(1.99)

4/9 E-02, 03, 19, 24, 28, 33E-19

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio


ITEM STANDARD LIMITPrimary reduction ratio 2.088 (71/34) —Final reduction ratio 3.133 (47/15) —Gear ratios Low 2.461 (32/13) —

2nd 1.777 (32/18) —3rd 1.380 (29/21) —4th 1.125 (27/24) —5th 0.961 (25/26) —Top 0.851 (23/27) —

Shift fork to groove clearance 0.1 – 0.3(0.004 – 0.012)

0.50(0.020)

Shift fork groove width 5.5 – 5.6(0.217 – 0.220) —

Shift fork thickness 5.3 – 5.4(0.209 – 0.213) —

Drive chainType D.I.D.525V8

——

Links 116 links —20-pitch length — 319.4

(12.57)Drive chain slack (on side-stand) 20 – 30

(0.79 – 1.18) —

Gearshift lever height 25(0.98) —

ITEM STANDARD NOTEThermostat valve opening tempera-ture Approx. 88 °C (190 °F) —

Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —ECT sensor resistance 20 °C

(68 °F) Approx. 2.45 kΩ —

40 °C(104 °F) Approx. 1.148 kΩ —

60 °C(140 °F) Approx. 0.587 kΩ —

80 °C(176 °F) Approx. 0.322 kΩ —

Radiator cap valve opening pressure 95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) —

Cooling fan thermo-switch operating temperature

OFF→ON Approx. 98 °C (208 °F) —ON→OFF Approx. 92 °C (198 °F) —

Engine coolant type Use an antifreeze/coolant compatible with aluminumradiator, mixed with distilled water only, at the ratioof 50:50.

—


Approx. 250 ml(0.53/0.44 US/lmp qt) —

Engine side

Approx. 1650 ml(3.49/2.90 US/lmp qt) —LE

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5/9 E-02, 03, 19, 24, 28, 33E-19


FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR

THROTTLE BODY

ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F)Fuel pump discharge amount Min. 168 ml (5.7/5.9 US/lmp oz)

for 10 sec. at 300 kPa (30 kgf/cm², 43 psi)Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi)

ITEM SPECIFICATION NOTECKP sensor resistance 130 – 240 Ω W – GCKP sensor peak voltage 3.7 V (When cranking) and moreIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage

Approx. 2.7 V at idle speed G/B – B/Br

TP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.12 kΩ

Opened Approx. 4.26 kΩTP sensor output voltage Closed Approx. 1.12 V P/W –

B/BrOpened Approx. 4.26 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)TO sensor resistance 19.1 – 19.7 kΩTO sensor voltage Normal 0.4 – 1.4 V Br/W –

B/BrLeaning 65° 3.7 – 4.4 VGP switch voltage 1.0 V and more (From 1st to Top)Injector voltage Battery voltageSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.58 kΩ

Y – BOpened Approx. 4.38 kΩ

STP sensor output voltage Closed Approx. 0.58 V Y – B/BrOpened Approx. 4.40 V

STV actuator resistance 7 – 14 ΩPAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)

ITEM SPECIFICATIONI.D. No. 27 G0 (Others), 27 G1 (For E-33)Bore size 39 mmFast idle r/min 1 800 – 2 400 r/min at 25 °C (77 °F)Idle r/min 1 300 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

SAM

6/9 E-02, 03, 19, 24, 28, 33E-19


WATTAGE Unit: W

ITEM SPECIFICATION NOTEFiring order 1.2Spark plug Type NGK: CR8E

DENSO: U24ESR-N

Gap 0.7 – 0.8 mm(0.028 – 0.031 in)

Spark performance Over 8 mm (0.3 in) at 1 atm.CKP sensor resistance 130 – 240 Ω W – GIgnition coil resistance Primary 2 – 5 Ω tap –

tap

Secondary 24 – 37 kΩ tap – Plug cap

CKP sensor peak voltage 3.7 V and more When cranking

Ignition coil primary peak voltage 150 V and moreGenerator coil resistance 0.2 – 0.7 ΩGenerator Max. output Approx. 375 W at 5 000 r/minGenerator no-load voltage(When cold) 60 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX12-BS

Capacity 12 V 36.0 kC (10 Ah)/10 HRFuse size

HeadlightHI 15 ALO 15 A

Fuel 10 AIgnition 10 A

Fan motor 15 ASignal 15 AMain 30 A

ITEMSPECIFICATION

E-03, 24, 28, 33 OthersHeadlight 12 V 60/55 W × 2 (H4) ←Position/Parking light 12 V 5 W × 2Brake light/Taillight 12 V 21/5 W × 2 ←Turn signal light 12 V 21 W ←License light 12 V 5 W ←Speedometer light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←Oil pressure/Coolant temp./Fuel injection warning LED ←

11


7/9 E-02, 03, 19, 24, 28, 33E-19

ITEM STANDARD LIMITRear brake pedal height 15 – 25 (0.59 – 0.98) —Brake disc thickness Front 5

(0.20)4.5

(0.18)

Rear 5(0.20)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —

Master cylinder piston diam. Front 15.827 – 15.854(0.6231 – 0.6242) —

Rear 13.957 – 13.984(0.5495 – 0.5506) —


Rear 38.180 – 38.256(1.5031 – 1.5061) —

Brake caliper piston diam. Front 30.150 – 30.200(1.1870 – 1.1890) —

Rear 38.098 – 38.148(1.4999 – 1.5019) —

Brake fluid type DOT 4Wheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Wheel axle runout Front — 0.25(0.010)

Rear — 0.25(0.010)

8/9 E-02, 03, 19, 24, 28, 33E-19

TIRE


ITEM STD/SPEC. LIMITCold inflation tire pressure(Solo riding) Front 225 kPa

(2.25 kgf/cm², 33 psi) —

Rear 250 kPa(2.50 kgf/cm², 36 psi) —

Cold inflation tire pressure(Dual riding) Front 225 kPa

(2.25 kgf/cm², 33 psi) —


Tire size Front 110/80 R19 M/C (59 H) —Rear 150/70 R17 M/C (69 H) —

Tire type Front BRIDGESTONE: TW101 F —Rear BRIDGESTONE: TW152 F —

Tire tread depth Front — 1.6(0.06)

Rear — 2.0(0.08)

ITEM STD/SPEC. LIMITFront fork stroke 150

(5.9) —

Front fork spring free length 444.1 (17.5) 435 (17.1)Front fork oil level (without spring, outer tube fully compressed) 143 (5.63) —

Front fork spring adjuster 3 groove from Top/Spring adjuster height 9 mm (0.35 in) —

Front fork oil type SUZUKI FORK OIL SS-08 or equivalent fork oil —

Front fork oil capacity (each leg) 524 ml(17.7/18.5 US/Imp oz) —

Rear shock absorber spring adjuster 2 groove from bottom —

Rear shock absorber damping force adjuster Rebound

1 turn back from stiffest position E-02, 19, 241 and 1/2 turns back from

stiffest position E-03, 28, 33

Rear wheel travel 150 mm (5.9 in) —

Swingarm pivot shaft runout — 0.3(0.01)

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9/9 E-02, 03, 19, 24, 28, 33E-19

FUEL + OILITEM STD/SPEC. NOTE

Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corrosioninhibitor is permissible.

E-03, 28, 33


Others

Fuel tank capacity 22 L (5.8/4.8 US/lmp gal)Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 2 300 ml

(2.4/2.0 US/lmp qt)

Filter change 2 700 ml(2.9/2.4 US/lmp qt)

Overhaul 3 100 ml(3.3/2.7 US/lmp qt)

SAM

12

DL1000VALVE + GUIDE Unit: mm (in)

1/10 E-02, 03, 19, 24, 28, 33


(1.42) —

EX. 33(1.30) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —






Valve spring free length IN. & EX. — 39.6(1.56)

Valve spring tensionIN. & EX.

197 – 227 N(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)


2/10 E-02, 03, 19, 24, 28, 33




(1.428 – 1.430)35.98

(1.417)

EX. 35.68 – 35.72(1.405 – 1.406)

35.38(1.393)


0.150(0.0059)




Cam drive idle gear/sprocket thrust clearance

0.15 – 0.29(0.006 – 0.011) —

Cylinder head distortion — 0.05(0.002)

ITEM STANDARD LIMITCompression pressure(Automatic de-comp. actuated) 1 000 – 1 400 kPa

(10 – 14 kgf/cm², 142 – 199 psi)800 kPa

(8 kgf/cm²,114 psi)

Compression pressure difference — 200 kPa(2 kgf/cm², 28 psi)


0.12(0.0047)

Cylinder bore 98.000 – 98.015(3.8583 – 3.8589)

Nicks or Scratches

Piston diam. 97.980 – 97.995(3.8575 – 3.8581)

Measure at 10 mm (0.4 in) from the skirt end.97.880

(3.8535)



2nd Approx. 10.1 (0.40) 8.1(0.32)


0.5(0.02)

2nd RN 0.30 – 0.45(0.012 – 0.018)

0.7(0.03)


2nd — 0.15(0.0059)

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3/10 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITPiston ring groove width

1st

0.93 – 0.95(0.0366 – 0.0374) —

1.55 – 1.57(0.0610 – 0.0618) —

2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —

Piston ring thickness

1st

0.86 – 0.91(0.034 – 0.036) —

1.38 – 1.40(0.054 – 0.055) —

2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pin bore I.D. 22.002 – 22.008(0.8662 – 0.8665)

22.030(0.8673)

Piston pin O.D. 21.992 – 22.000(0.8658 – 0.8661)

21.980(0.8654)


(0.8665 – 0.8668)22.040


(0.007 – 0.013)0.50


(0.864 – 0.866) —

Crank pin width 44.17 – 44.22(1.739 – 1.741) —


0.080(0.0031)

Crank pin O.D. 44.976 – 45.000(1.7707 – 1.7717) —


0.080(0.0031)


Crankshaft journal holder width 25.2 – 25.4(0.99 – 1.00) —

Crankshaft journal width 25.50 – 25.55(1.004 – 1.006) —


SAM

4/10 E-02, 03, 19, 24, 28, 33

OIL PUMP


THERMOSTAT + RADIATOR + FAN

ITEM STANDARD LIMITOil pressure (at 60°C, 140°F) Above 400 kPa (4.0 kgf/cm², 57 psi)


—

ITEM STANDARD LIMITDrive plate thickness No. 1 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)

No. 2 and 3 3.72 – 3.88(0.146 – 0.153)

3.42(0.135)

Drive plate claw width No.1 13.85 – 13.96(0.545 – 0.550)

13.05(0.514)

No. 2 and 3 13.90 – 14.00(0.547 – 0.551)

13.10(0.516)

Driven plate distortion — 0.10(0.004)

Clutch spring free length 61.5 – 62.5(2.42 – 2.46)

59.4(2.34)

Clutch master cylinder bore 14.000 – 14.043(0.5512 – 0.5528) —

Clutch master cylinder piston diam. 13.957 – 13.984(0.5495 – 0.5505) —

Clutch release cylinder bore 35.700 – 35.762(1.4055 – 1.4079) —

Clutch release cylinder piston diam.

35.650 – 35.675(1.4035 – 1.4045) —

ITEM STANDARD LIMITThermostat valve opening temper-ature

86.5 – 89.5 °C(188 – 193 °F) —

Thermostat valve lift Over 8 mm (0.31 in) at 100 °C (212 °F) —Radiator cap valve opening pres-sure

110 kPa(1.1 kgf/cm², 15.6 psi) —

Cooling fan ther-moswitch operating temperature

ON→OFF Approx. 105 °C (221 °F) —

ON→OFF Approx. 100 °C (212 °F) —

Engine coolant tem-perature sensor resis-tance

20 °C(68 °F) Approx. 2.45 kΩ —

40 °C(104 °F) Approx. 1.148 kΩ —

60 °C(140 °F) Approx. 0.587 kΩ —

80 °C(176 °F) Approx. 0.322 kΩ —

13

5/10 E-02, 03, 19, 24, 28, 33

DRIVE TRAIN Unit: mm (in) Expect ratio

INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR

ITEM STANDARD LIMITPrimary reduction ratio 1.838 (57/31) —Final reduction ratio 2.411 (41/17) —Gear ratio Low 3.000 (36/12) —

2nd 1.933 (29/15) —3rd 1.500 (27/18) —4th 1.227 (27/22) —5th 1.086 (25/23) —Top 0.913 (21/23) —


0.50(0.020)



Drive chain Type RK525SMOZ7 —Links 112 links, ENDLESS —

20-pitch length — 319.4(12.6)

Drive chain slack 20 – 30(0.8 – 1.2) —


ITEM SPECIFICATION NOTEInjector resistance 12 – 18 Ω at 20 °C (68 °F)Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)

for 1 minute at 300 kPa (3.0 kgf/cm², 43 psi)Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi)

6/10 E-02, 03, 19, 24, 28, 33

FI-SENSORS

THROTTLE BODY

ITEM SPECIFICATION NOTECMP sensor output voltage More than 3.7 VCKP sensor resistance 130 – 240 ΩCKP sensor peak voltage More than 3.7 V (When cranking)IAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.5 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ


Opened Approx. 4.3 VECT sensor input voltage 4.5 – 5.5 VECT sensor reisitance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input volatage 4.5 – 5.5 VIAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 4.0 V at 760 mmHg (100 kPa)TO sensor resistance 19.1 – 19.7 kΩTO sensor voltage Approx. 0.4 – 1.4 VGP switch voltage More than 1.0 V (From 1st to top)Injector voltage Battery voltageIgnition coil primary peak voltage More than 150 V (When cranking)STP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 1.1 kΩ

Opened Approx. 4.3 kΩSTP sensor output voltage Closed Approx. 1.1 V

Opened Approx. 4.3 VSTV actuator resistance 4.8 – 7.2 ΩHeated oxygen sensor output volt-age

Less than 0.4 V at idle speed(After warming up) European

marketsHeated oxygen sensor resistance 4 – 5 Ω at 23 °C (73.4 °F)PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

ITEM SPECIFICATIONID No. 06G3 (For E-02, 19), 06G4 (For E-33), 06G5 (For E-03, 24, 28)Bore size 45 mmFast idle r/min 1 500 – 2 100 r/min at 25 °C (77 °F)Idle r/min 1 200 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 r/min

(0.08 – 0.16 in)

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7/10 E-02, 03, 19, 24, 28, 33


ITEM SPECIFICATION NOTEIgnition timing 4° B.T.D.C. at 1 200 r/minFiring order 1·2Spark plug Type NGK: CR8EK

Denso: U24ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Crankshaft position sensor resis-tance 130 – 240 Ω Bl – G

Ignition coil resistance Primary 2 – 5 Ω tap – tapSecondary 24 – 37 kΩ tap – Plug cap

Crankshaft position sensor peak voltage More than 3.7 V When cranking

Ignition coil primary peak voltage More than 150 V When crankingGenerator coil resistance 0.2 – 0.5 Ω Y – YGenerator Max. output Approx. 400 W at 5 000 r/minGenerator no-load voltage(When engine is cold) More than 75 V (AC) at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type




Turn signal 15 AIgnition 10 A

Fan motor 15 AMeter 10 AMain 30 A

SAM

8/10 E-02, 03, 19, 24, 28, 33

WATTAGE Unit: W


ITEMSPECIFICATION

E-03, 24, 28, 33 OthersHeadlight 12 V 60/55 W × 2 (H4) ←Position/Parking light 12 V 5 W × 2

Brake light/Taillight 12 V 21/5 W × 2 ←Turn signal light 12 V 21 W ←License light 12 V 5 W ←Speedometer light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←Oil pressure/Coolant temp./Fuel injection warning LED ←

ITEM STANDARD LIMITRear brake pedal height 20 – 30

(0.8 – 1.2) —

Brake disc thickness Front 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)

Brake disc runout(Front & Rear) — 0.30

(0.012)Master cylinder bore Front 15.870 – 15.913

(0.6248 – 0.6265) —

Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —


Rear 38.180 – 38.230(1.5031 – 1.5051) —


Rear 38.098 – 38.148(1.4999 – 1.5019) —

Wheel rim runout(Front & Rear) Axial — 2.0

(0.08)

Radial — 2.0(0.08)

14

9/10 E-02, 03, 19, 24, 28, 33


TIRE PRESSURE

ITEM STANDARD LIMITWheel axle runout Front — 0.25

(0.010)

Rear — 0.25(0.010)

Wheel rim size Front 19M/C × MT 2.50 —Rear 17M/C × MT 4.00 —

Tire size Front 110/80R19M/C 59H —Rear 150/70R17M/C 69H —

Tire type Front BRIDGESTONE: TW101 F —Rear BRIDGESTONE: TW152 F —


Rear — 2.0(0.08)


(6.3) —

Front fork spring free length 433.6(17.07)

424(16.7)

Front fork oil level (without spring, inner tube fully compressed)

140.0(5.51) —

Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oilFront fork oil capacity (each leg) 496.0 ml

(16.76/17.46 US/lmp oz)Front fork spring adjuster 3rd groove from top —Rear shock absorber spring adjuster 2nd groove from bottom —

Rear shock absorber damping force adjuster Rebound 7/8 turn out from stiffest position —


Swingarm pivot shaft runput — 0.3(0.01)

COLD INFLATIONTIRE PRESSURE

SOLO RIDING DUAL RIDING

kPa kgf/cm² psi kPa kgf/cm² psiFRONT 250 2.50 36 250 2.50 36REAR 250 2.50 36 280 2.80 41

10/10 E-02, 03, 19, 24, 28, 33

FUEL + OIL + ENGINE COOLANTITEM SPECIFICATION NOTE

Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(Methyl Tertiary Butyl Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.

E-03, 28, 33


The others

Fuel tank 17 L(4.5/3.7 US/lmp gal)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 2 700 ml

(2.9/2.4 US/lmp qt)



Brake fluid type DOT 4Engine coolant type Use an anti-freeze/coolant compatible with alumi-

num radiator, mixed with distilled water only, at theratio of 50:50.

Engien coolant Reserve tank side

Approx. 250 ml(0.3/0.2 US/lmp qt)

Engine side Approx. 1 950 ml(2.1/1.7 US/lmp qt)

LE
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1/7 E-03, 28, 33



(1.3) —

EX. 28(1.1) —

Valve clearance (when cold) IN. & EX. 0.08 – 0.13(0.003 – 0.005) —

Valve guide to valve stemclearance IN. 0.010 – 0.037

(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2146 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —



Valve stem end length IN. & EX. — 2.6(0.1)




(1.38)

OUTER — 40.6(1.60)


7.1 – 9.2 kgf(15.7 – 20.3 lbs)




—

SAM

2/7 E-03, 28, 33




(1.3454 – 1.3472)33.870

(1.3335)

EX. 33.804 – 33.848(1.3309 – 1.3326)

33.500(1.3189)


0.150(0.0059)




Rocker arm I.D. IN. & EX. 12.000 – 12.018(0.4724 – 0.4731) —

Rocker arm shaft O.D. IN. & EX. 11.977 – 11.995(0.4715 – 0.4722) —


Cylinder head cover distortion — 0.05(0.002)

ITEM STANDARD LIMITCompression pressure 1 400 kPa

(14 kgf/cm2, 199 psi) 980 kPa

(9.8 kgf/cm2,139 psi)


0.120(0.0047)

Cylinder bore 66.000 – 66.015(2.5984 – 2.5990)

66.090(2.6020)

Piston diam. 65.955 – 65.970(2.5966 – 2.5972)


(2.5937)



2nd R Approx. 9.4 (0.37) 7.5(0.30)


0.5(0.02)

2nd 0.10 – 0.25(0.004 – 0.010)

0.5(0.02)


2nd — 0.15(0.006)

15

3/7 E-03, 28, 33


OIL PUMP



(0.040 – 0.041)

2nd 1.21 – 1.23(0.047 – 0.048)

Oil 2.01 – 2.03(0.079 – 0.080)

Piston ring thickness 1st 0.970 – 0.990(0.038 – 0.039) —

2nd 1.170 – 1.190(0.046 – 0.047) —

Piston pin bore 16.002 – 16.008 (0.6300 – 0.6302)

16.030(0.6311)

Piston pin O.D. 15.996 – 16.000 (0.6298 – 0.6299)

15.980(0.6291)


(0.6302 – 0.6305) 16.040

(0.6315)Conrod deflection — 3.0


(0.004 – 0.018)1.00


(0.707 – 0.709) —

Crank web to web width 53.0 ± 0.1(2.09 ± 0.004) —

Crankshaft runout — 0.08 (0.003)

ITEM STANDARD LIMITOil pump reduction ratio 2.000 (30/15) —Oil pressure (at 60 °C, 140 °F) Above 15 kPa (0.15 kgf/cm2, 2.1 psi)

Below 35 kPa (0.35 kgf/cm2, 4.9 psi)at 3 000 r/min

—

ITEM STANDARD LIMITClutch lever play 10 – 15

(0.4 – 0.6) —

Clutch release screw 1/4turn back —

Clutch plate thickness 1 pc. 2.9 – 3.1(0.114 – 0.122) 2.6

(0.10)5 pcs. 2.95 – 3.15

(0.116 – 0.124)Driven plate distortion — 0.10

(0.004)Clutch spring free length — 31.0

(1.22)

4/7 E-03, 28, 33

TRANSMISSTION + DRIVE CHAIN Unit: mm (in) Except ratio

CARBURETOR


2nd 1.933 (29/15) —3rd 1.437 (23/16) —4th 1.095 (23/21) —Top 0.913 (21/23) —

Shift fork to groove clearance 0.10 – 0.30(0.004 – 0.012) —

Shift fork groove width No.1, 2, 3 5.0 – 5.1(0.20 – 0.21) —

Shift fork thickness No.1, 2, 3 4.8 – 4.9(0.18 – 0.19) —

Drive chain Type D.I.D. 520VC5 —Links 112 links —

20-pitch length — 319.4

(12.57)Drive chain slack 25 – 40

(1.0 – 1.6) —

ITEMSPECIFICATION

E-03, 28 E-33Carburetor type MIKUNI BST31SS ←Bore size 31 mm ←I.D. No. 42AC 42AEIdle r/min 1 500 ± 100 r/min ←Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ←Main jet (M.J.) # ←Jet needle (J.N.) 5D77 ←Needle jet (N.J.) ←Throttle valve (Th.V.) #125 ←Pilot jet (P.J.) # ←Starter jet (G.S.) #25 ←Pilot screw (P.S.) PRE-SET ←Throttle cable play 2 – 4 mm (0.08 – 0.16 in) ←

LE
P

5/7 E-03, 28, 33

WATTAGE Unit: W

ITEM SPECIFICATION NOTESpark plug Type DENSO: X24ESR-U

NGK: CR8EA

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 mm (0.3) at 1 atm.Signal coil resitance 100 – 140 Ω G – BlIgnition coil resistance Primary 2 – 6 Ω Terminal –

Terminal

Secondary 20 – 30 kΩ Plug cap –Terminal

Generator coil resistance Charging 0.1 – 1.5 ΩGenerator no-load voltage More than 60 V (AC) at 5 000 r/minGenerator Max. output 150 W at 5 000 r/minRegulated voltage 13.0 – 16.0 V at 5 000 r/minStarter relay resistance 2 – 6 ΩBattery Type designation YTX7L-BS

Capacity 12 V 21.6 kC (6 Ah)/10 HRFuse size 20 A

ITEM SPECIFICATIONHeadlight HI 60

LO 55Brake light/Taillight 21/5Turn signal light 21Speedometer light 3.4Turn signal indicator light 3.4High beam indicator light 1.7Neutral indicator light 3.4

SAM

6/7 E-03, 28, 33


ITEM STANDARD LIMITBrake lever play 0.1 – 0.3

(0.004 – 0.010) —

Rear brake pedal free travel 20 – 30(0.8 – 1.2) —

Rear brake pedal height 2.5(0.10) —

Brake drum I.D. Rear — 130.7(5.15)

Brake lining thickness Rear — 1.5(0.06)


3.0(0.12)

Brake disc runout Front — 0.30(0.012)





Wheel rim runout Axial — 2.0(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front J21 × 1.60 —Rear J18 × 2.15 —

Tire size Front 70/100-21 44P or 70/100-21 M/C 44P —Rear 100/90-18 56P or 100/90-18 M/C 56P —


Rear — 3.0(0.12)

16

7/7 E-03, 28, 33


TIRE PRESSUER

FUEL + OIL

ITEM STANDARD LIMIT NOTEFront fork stroke 205

(8.1) —


Front fork oil level 179.5(7.07) —

Rear shock absorber springpre-set length

231(9.1) —




SOLO RIDING DUAL RIDINGkPa kgf/cm2 psi kPa kgf/cm2 psi

FRONT 150 1.50 22 150 1.50 22REAR 175 1.75 25 200 2.00 29


octane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(Methyl Tertiary Butyl Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.

Fuel tank including reserve 13.0 L(3.4/2.9 US/lmp qt) E-03, 28

12.5 L(3.3/2.7 US/lmp qt) E-33

reserve 2.5 L(0.7/0.5 US/lmp qt)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 850 ml

(0.90/0.75 US/lmp qt)

Filter change 950 ml(1.00/0.84 US/lmp qt)


Front fork oil type Fork oil #10Front fork oil capacity (each leg) 309 ml

(10.4/10.9 US/lmp oz)Brake fluid type DOT 4

LE
P DR200SE (E-06, 24)
1/7 E-06, 24



(1.3) —

EX. 28(1.1) —



(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2146 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —







(1.38)

OUTER — 40.6(1.60)


7.1 – 9.2 kgf(15.7 – 20.3 lbs)




—

SAM

2/7 E-06, 24




(1.3454 – 1.3472)33.870

(1.3335)

EX. 33.804 – 33.848(1.3309 – 1.3326)

33.500(1.3189)


0.150(0.0059)









(14 kgf/cm2, 199 psi) 980 kPa

(9.8 kgf/cm2,139 psi)


0.120(0.0047)

Cylinder bore 66.000 – 66.015(2.5984 – 2.5990)

66.090(2.6020)

Piston diam. 65.955 – 65.970(2.5966 – 2.5972)


(2.5937)



2nd R Approx. 9.4 (0.37) 7.5(0.30)


0.5(0.02)

2nd 0.10 – 0.25(0.004 – 0.010)

0.5(0.02)


2nd — 0.15(0.006)

17

3/7 E-06, 24


OIL PUMP



(0.040 – 0.041)

2nd 1.21 – 1.23(0.047 – 0.048)

Oil 2.01 – 2.03(0.079 – 0.080)


2nd 1.170 – 1.190(0.046 – 0.047) —

Piston pin bore 16.002 – 16.008 (0.6300 – 0.6302)

16.030(0.6311)

Piston pin O.D. 15.996 – 16.000 (0.6298 – 0.6299)

15.980(0.6291)


(0.6302 – 0.6305) 16.040



(0.004 – 0.018)1.00


(0.707 – 0.709) —





—


(0.4 – 0.6) —

Clutch release screw 1/4 turn back —

Clutch plate thickness 1 pc. 2.9 – 3.1(0.114 – 0.122) 2.6

(0.10)5 pcs. 2.95 – 3.15

(0.116 – 0.124)Driven plate distortion — 0.10


(1.22)

4/7 E-06, 24


CARBURETOR


2nd 1.933 (29/15) —3rd 1.437 (23/16) —4th 1.095 (23/21) —Top 0.913 (21/23) —

Shift fork to groove clearance 0.10 – 0.30(0.004 – 0.012) —

Shift fork groove width No.1, 2, 3 5.0 – 5.1(0.20 – 0.21) —

Shift fork thickness No.1, 2, 3 4.8 – 4.9(0.18 – 0.19) —

Drive chain Type D.I.D. 520VC5 —Links 112 links, ENDLESS —



(1.0 – 1.6) —

ITEM SPECIFICATIONCarburetor type MIKUNI BST31SSBore size 31 mmI.D. No. 42AAIdle r/min 1 500 ± 100 r/minFloat height 13.0 ± 1.0 mm (0.51 ± 0.04 in)Main jet (M.J.) #122.5Main air jet (M.A.J) 0.8 mmJet needle (J.N.) 5D26-3rdNeedle jet (N.J.) P-5Throttle valve (Th.V.) #125Pilot jet (P.J.) #40Valve seat (V.S.) 1.5 mmStarter jet (G.S.) #25Pilot screw (P.S.) 1 and 1/2 turns outThrottle cable play 3 – 6 mm (0.1 – 0.2 in)

LE
P
5/7 E-06, 24


WATTAGE Unit: W

ITEM SPECIFICATION NOTEIgnition timing 7°B.T.D.C. Below at 1 500 r/minSpark plug Type DENSO: X24ESR-U

NGK: CR8EA

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 mm (0.3) at 1 atm.Signal coil resitance 100 – 140 Ω G – BlIgnition coil resistance Primary 0.14 – 0.18 Ω Terminal –

Terminal


Signal coil peak voltage 3.0 – 4.6 V G/W – Bl/Y

Ignition coil primary peak voltage 125 – 195 V White – Ground

Generator coil resistance Charging 0.1 – 1.5 Ω —Generator no-load voltage More than 70 V (AC) at 5 000 r/minRegulated voltage 13.0 – 16.0 V at 5 000 r/minStarter relay resistance 2 – 6 ΩBattery Type designation YTX7L-BS

Capacity 12 V 21.6 kC (6 Ah)/10 HRStandard

electrolyte S.G. 1.32 at 20 °C (68 °F)

Fuse size 20 A


LO 55Brake light/Taillight 21/5Turn signal light(For South Africa) 21

Speedometer light 1.7Turn signal indicator light(Fpr South Afriaca) 2

High beam indicator light 2Neutral indicator light 2

SAM

6/7 E-06, 24



ITEM STANDARD LIMITBrake lever play 0.1 – 0.3

(0.004 – 0.010) —


Rear brake pedal height 2.5(0.10) —




3.0(0.12)







Radial — 2.0(0.08)


Rear — 0.25(0.010)

Tire size Front 70/100-21 44M —Rear 90/100-18 54M —

Tire tread depth Front — 40(0.16)

Rear — 4.0(0.16)


(8.1) —




231(9.1) —



18

7/7 E-06, 24

TIRE PRESSUERE-24

E-06

FUEL + OIL


SOLO RIDINGkPa kgf/cm2 psi

FRONT 100 1.0 15REAR 100 1.0 15



FRONT 100 1.0 15 100 1.0 15REAR 100 1.0 15 100 1.0 15

ITEM SPECIFICATION NOTEFuel type Gasoline used should be graded 85 – 95 octane or

higher. An unleaded gasoline is recommended.Fuel tank including reserve 13.0 L

(3.4/2.9 US/lmp qt)



(1.0/0.8 US/lmp qt)



Front fork oil type Fork oil #10Front fork oil capacity (each leg) 309 ml


LE
P DR650SE
1/8 E-03, 24, 28, 33



(1.3) —

EX. 28(1.1) —

Valve clearance(when engine is cold) IN. 0.08 – 0.13

(0.003 – 0.005) —

EX. 0.17 – 0.22(0.0067 – 0.0087) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —







(1.35)

OUTER — 38.1(1.50)

Valve spring tension (IN. & EX.)INNER

5.9 – 6.7 kg(13.0 – 14.8 lbs)


OUTER13.8 – 15.8 kg


—

SAM

2/8 E-03, 24, 28, 33




(1.3272 – 1.3287)33.410

(1.3154)

EX. 33.700 – 33.740(1.3268 – 1.3283)

33.400(1.3150)

Camshaft journal oil clearance Right &Center

0.032 – 0.066(0.0013 – 0.0026)

0.150(0.0059)

Left 0.028 – 0.059(0.0011 – 0.0023)

0.150(0.0059)

Camshaft journal holder I.D. Right &Center

22.012 – 22.025(0.8666 – 0.8671) —

Left 17.512 – 17.525(0.6894 – 0.6900) —

Camshaft journal O.D. Right & Center

21.959 – 21.980(0.8645 – 0.8654) —

Left 17.466 – 17.484(0.6877 – 0.6883) —

Camshaft runout — 0.10(0.004)





ITEM STANDARD LIMITPiston to cylinder clearance 0.020 – 0.030

(0.0008 – 0.0012)0.120

(0.0047)Cylinder bore 100.000 – 100.015

(3.9371 – 3.9376)Nicks or



99.880(3.9323)



2nd R Approx. 11.4 (0.45) 9.1(0.36)


0.50(0.039)

2nd 0.45 – 0.60(0.018 – 0.024)

1.00(0.039)

Compression pressure(Automatic decomp. actuated)

Approx. 850 kPa(8.5 kg/cm2, 120 psi) —

19

3/8 E-03, 24, 28, 33


OIL PUMP

ITEM STANDARD LIMITPiston ring to groove clearance 1st — 0.180

(0.0071)

2nd — 0.150(0.0059)


2nd 1.210 – 1.230(0.047 – 0.048) —

Oil 2.810 – 2.830(0.110 – 0.111) —


2nd 1.150 – 1.170(0.0453 – 0.0461) —

Piston pin bore 23.002 – 23.008(0.9056 – 0.9058)

23.030(0.9067)

Piston pin O.D. 22.996 – 23.000(0.9054 – 0.9055)

22.980(0.9047)


(0.9057 – 0.9061)23.040



(0.004 – 0.026)1.00


(0.982 – 0.984) —



ITEM STANDARD LIMITOil pump reduction ratio 1.633 (61/28 × 30/20 × 15/30) —Oil pressure (at 60 °C, 140 °F) Above 30 kPa (0.3 kg/cm2, 4.3 psi)

Below 70 kPa (0.7 kg/cm2, 10.0 psi)at 3 000 r/min

—

4/8 E-03, 24, 28, 33


DRIVE TRAIN Unit: mm (in) Except ratio


(0.4 – 0.6) —

Drive plate thickness No. 1 & No. 2

2.9 – 3.1(0.11 – 0.12)

2.6(0.10)


Clutch spring free length — 33.0(1.30)

ITEM STANDARD LIMITPrimary reduction ratio 2.178 (61/28) —Final reduction ratio E-03, 28,

33 2.800 (42/15) —

E-24 2.733 (41/15) —Gear ratios Low 2.416 (29/12) —

2nd 1.625 (26/16) —3rd 1.238 (26/21) —4th 1.000 (21/21) —Top 0.826 (19/23) —


0.50(0.020)



Drive chain Type DAIDO: D.I.D. 525V9 —Links 110 —

20-pitch length — 319.4(12.57)


LE
P
5/8 E-03, 24, 28, 33

CARBURETOR


ITEMSPECIFICATION

E-03, 28 E-33 E-24Carburetor type MIKUNI

BST40SS ← ←

Bore size 40 mm ← ←I.D. No. 32E1 32E6 32E3Idle r/min 1 500 ± 100 r/min ← ←Float height 14.7 ± 1.0 mm

(0.58 ± 0.04 in) ← ←

Main jet (M.J.) # ← #140Jet needle (J.N.) 6F23 ← 6F19-3rdNeedle jet (N.J.) ← Y-5Throttle valve (Th.V.) #95 ← ←Pilot jet (P.J.) # ← #42.5Starter jet (S.J.) #40 ← ←Pilot screw (P.S.) PRE-SET ← PRE-SET

(1.0 turn back)Throttle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in) ← ←

ITEM SPECIFICATION NOTESpark plug Type ND.: U31ESR-N

N.G.K.: CR10E

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 0.07 – 0.12 Ω B – B/W

Secondary 23 – 25 kΩ Plug cap – Plug cap

Generator coil resistance Charging 0.5 – 0.9 Ω Y – YPower source 0.1 – 0.2 Ω B – W

Pick-up 170 – 256 Ω Bl – GGenerator no-load voltage More than 75 V (AC) at 5 000 r/minGenerator Max. output Approx. 200 W at 5 000 r/minRegulated voltage 13.0 – 16.0 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation YTX9-BS



Fuse size Main 30 AHeadlight (H) 10 AHeadlight (L) 10 A

SAM

6/8 E-03, 24, 28, 33

WATTAGE Unit: W


ITEMSPECIFICATIONE-03, 24, 28, 33

Headlight HI 60LO 55

Parking or position lightBrake light/Taillight 21/5Turn signal light 21Speedometer light 1.7Turn signal indicator light 2High beam indicator light 2Neutral indicator light 2License light 5

ITEM STANDARD LIMIT

Rear brake pedal height 5(0.2) —


3.5(0.14)

Rear 4.5 ± 0.2(0.177 ± 0.008)

4.0(0.16)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 30.23 – 30.28(1.1902 – 1.1921) —


Rear 30.16 – 30.18(1.1874 – 1.1882) —


Radial — 2.0(0.08)


Rear — 0.25(0.010)

20

7/8 E-03, 24, 28, 33


TIRE PRESSURE

ITEM STANDARD LIMIT

Tire rim size Front 21 × 1.85 —Rear 17M/C × MT2.50 —

Tire size Front 90/90-21M/C 54S —Rear 120/90-17M/C 64S —


Rear — 3.0(0.12)


(10.2)—

220(8.7) — Low seat


Front fork oil level 164(6.5) —

150(5.9) — Low seat


247.5(9.74) —


220(8.7) — Low seat




FRONT 150 1.50 22 175 1.75 25REAR 175 1.75 25 200 2.00 29

8/8 E-03, 24, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe reserch method.Gasoline containing MTBE (MethyI Tertiary ButyIEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. E-24

Fuel tank capacityIncludingreserve

12 L(3.2/2.6 US/Imp gal) E-33

13 L(3.4/2.9 US/Imp gal) Others

Onlyreserve

3.0 L(0.8/0.7 US/Imp gal)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Oil

change2 300 ml

(2.4/2.0 US/lmp qt)Oil and

filter change2 400 ml

(2.5/2.1 US/lmp qt)Engine

overhaul2 600 ml

(2.7/2.3 US/lmp qt)Front fork oil type Fork oil #10Front fork oil capacity (each leg) 565 ml

(19.1/19.9 US/lmp oz)563 ml

(19.0/19.8 US/Imp oz) Low seat

Brake fluid type DOT 4

LE
P DR-Z110
1/5 P-03, 21, 24, 28

ENGINE TOP END Unit: mm (in)

ITEM STANDARD LIMITCam height

IN.28.984 – 29.164

(1.1411 – 1.1482)28.88

(1.137)

EX.29.021 – 29.201

(1.1426 – 1.1496)28.92

(1.139)

Camshaft chain 20-link length 127.00 – 127.48(5.000 – 5.014)

128.9(5.075)

Rocker arm inside diameter 10.000 – 10.015(0.3937 – 0.3943)

10.05(0.396)

Rocker arm shaft diameter 9.980 – 9.995(0.3929 – 0.3935)

9.95(0.392)

Cylinder compression Usable range865 – 1 320 kPa

(8.8 – 13.5 kgf/cm2, 125 – 192 psi)at 5 kicks

—

Cylinder head warp — 0.05(0.002)

Valve clearance IN. 0.04 – 0.08(0.0016 – 0.0031) —

EX. 0.04 – 0.08(0.0016 – 0.0031) —

Valve head thickness IN. 0.85 – 1.15(0.0335 – 0.0453)

0.5(0.02)

EX. 1.15 – 1.45(0.0453 – 0.0571)

0.5(0.02)

Valve stem bend TIR 0.01 (0.0004) or less TIR 0.05(0.002)

Valve stem diameter IN. 4.475 – 4.490(0.1762 – 0.1768)

4.46(0.176)

EX. 4.462 – 4.472(0.1757 – 0.1761)

4.44(0.175)

Valve guide inside diameter IN. & EX. 4.500 – 4.512(0.1772 – 0.1776)

4.55(0.179)

Valve/valve guide clearance(Wobble method)

IN. 0.02 – 0.07(0.0008 – 0.0028)

0.12(0.0047)

EX. 0.06 – 0.11(0.002 – 0.004)

0.19(0.007)

Valve seat cutting angle 45°, 32°, 60°, 67.5° —Valve seat width IN. & EX. 0.80 – 1.15

(0.0315 – 0.0453) —

Valve seat surface outside diame-ter

IN. 22.9 – 23.1(0.902 – 0.909) —

EX. 19.9 – 20.1(0.784 – 0.791) —

Valve spring free length 36.75(1.447)

35.5(1.40)

Cylinder inside diameter 52.997 – 53.009(2.0865 – 2.0870)

53.10(2.091)

SAM

2/5 P-03, 21, 24, 28

CRANKSHAFT/TRANSMISSION Unit: mm (in)

ITEM STANDARD LIMITPiston outside diameter 52.981 – 52.993

(2.0859 – 2.0863)52.83

(2.080)Piston/cylinder clearance 0.010 – 0.022

(0.0004 – 0.0009) —

Oversize piston and rings +0.50 (0.0197), +1.0 (0.0394) —Piston ring/groove clearance

Top0.02 – 0.06

(0.0008 – 0.0024)0.16

(0.0063)

Second0.01 – 0.05

(0.0004 – 0.0020)0.15

(0.0059)

Piston ring groove widthTop

0.81 – 0.83(0.0319 – 0.0327)

0.90(0.035)

Second0.80 – 0.82

(0.0315 – 0.0323)0.90

(0.035)

Piston ring thickness Top & Second

0.77 – 0.79(0.0303 – 0.0311)

0.7(0.028)

Piston ring end gapTop

0.15 – 0.30(0.0059 – 0.0118)

0.6(0.024)

Second0.30 – 0.45

(0.0118 – 0.0177)0.8

(0.032)

Oil0.10 – 0.60

(0.0039 – 0.0236)0.9

(0.035)

Piston pin diameter 12.995 – 13.000(0.5116 – 0.5118)

12.96(0.5102)

Piston pin hole inside diameter 13.001 – 13.007(0.5118 – 0.5121)

13.07(0.5146)

Connecting rod small end inside diameter

13.003 – 13.014(0.5119 – 0.5124)

13.05(0.5138)

ITEM STANDARD LIMITConnecting rod big end radial clearance

0.006 – 0.020(0.0002 – 0.0008)

0.07(0.0028)

Connecting rod big end side clear-ance

0.1 – 0.2(0.004 – 0.008)

0.4(0.016)

Crankshaft runoutLess than 0.03 mm (0.001 in) TIR

0.08(0.003)

Shift fork ear thickness 3.9 – 4.0(0.154 – 0.157)

3.8(0.15)

Gear shift fork groove width 4.05 – 4.15(0.159 – 0.163)

4.3(0.17)

Shift fork guide pin diameter 4.9 – 5.0(0.193 – 0.197)

4.8(0.19)

Shift drum groove width 5.05 – 5.20(0.199 – 0.205)

5.3(0.21)

21

3/5 P-03, 21, 24, 28


FINAL DRIVE Unit: mm (in)

FUEL SYSTEM Unit: mm (in)

ITEM STANDARD LIMITPrimary clutch housing inside diameter

104.0 – 104.2(4.094 – 4.102)

104.5(4.114)

Primary clutch shoe groove depth 1.0(0.04)

0.5(0.02)

Secondary clutch friction plate thickness

3.1 – 3.3(0.12 – 0.13)

2.9(0.11)

Secondary clutch friction plate warp

0.2 mm (0.008 in) or less 0.3(0.01)

Secondary clutch steel plate warp 0.15 mm (0.006 in) or less 0.3(0.01)

Clutch spring free length 22.04(0.87)

20.35(0.80)

Kick shaft diameter 15.941 – 15.968(0.6276 – 0.6287)

15.92(0.6268)

Kick gear inside diameter 16.000 – 16.018(0.6299 – 0.6306)

16.04(0.6315)

ITEM STANDARD LIMITDrive chain Type DAIDO: D.I.D. 420MBK1 —

Links 86 links —

20-link length 254.0 – 254.6(10.00 – 10.02)

259(10.20)

Drive chain slack 0 – 5(0 – 0.2)

—

Engline sprocket diameter 49.1 – 49.3(1.93 – 1.94)

48.4(1.91)

Rear sprocket diameter 126.24(4.97)

125.4(4.94)

Rear sprocket warp Less than 0.4 mm (0.016 in) 0.5(0.020)

ITEM STANDARD LIMITThrottole grip free play 2 – 3 (0.08 – 0.12) —Carburetor type KEIHIN PB18 —Main jet #80 —Jet needle NCFA —Throttle valve cutaway 3.0 —Pilot jet #38/38 —Air screw 1 and ¼ turns out —Idle speed 1 250 – 1 350 r/min (rpm) —Servise fuel level (below the bottom edge of carburetor body)

3.0 ± 1 (0.12 ± 0.04) —

Float height 10.7 ± 2 (0.42 ± 0.08) —Air cleaner element oil High quality foam air filter oil —

4/5 P-03, 21, 24, 28

ELECTRICAL SYSTEM Unit: mm (in)

BRAKES Unit: mm (in)

ITEM STANDARD NOTEPickup coil resistance 50 – 200 Ω Bl/Y – GroundAir gap 0.7 (0.028) —Ignition coil Primary

winding resistance

0.19 – 0.23 Ω —

Second-ary wind-

ing resistance

2.5 – 3.7 kΩ —

Exciter coil resistance 0.2 – 1.0 Ω W – Ground0.1 – 0.8 Ω Y – Ground

Spark plug type NGK CR6HSA —gap 0.6 – 0.7 (0.024 – 0.028) —

Ignition coil (primary) peak voltage 100 V or above —Pickup coil peak voltage 4.6 V or above —Exciter coil peak voltage 15 V or above —

ITEM STANDARD LIMITBrake lever free play 4 – 5 (0.16 – 0.20) —Brake pedal free play 20 – 30 (0.79 – 1.18) —Brake shoe lining thickness

Front2.10 – 3.00

(0.08 – 0.12)1.2

(0.05)

Rear3.85 – 4.15

(0.152 – 0.163)2.0

(0.08)

Brake shoe spring free lengthFront

30.8 – 31.2(1.213 – 1.228)

32.6(1.28)

Rear32.5

(1.280)34.1

(1.34)

Brake drum inside diameterFront

90.000 – 90.087(3.543 – 3.547)

90.75(3.57)

Rear110.000 – 110.087

(4.331 – 4.334)110.75(4.36)

Brake camshaft diameterFront

11.957 – 11.984(0.471 – 0.472)

11.88(0.468)

Rear14.957 – 14.984(0.589 – 0.590)

14.88(0.586)

Brake camshaft hole inside diame-ter

Front12.000 – 12.027(0.472 – 0.474)

12.15(0.478)

Rear15.000 – 15.027(0.591 – 0.592)

15.15(0.596)

Brake cam lever angle 80 – 90° —

LE
P
5/5 P-03, 21, 24, 28

WHEELS/TIRES Unit: mm (in)

SUSPENSIONS Unit: mm (in)

ENGINE OIL Unit: mm (in)

ITEM STANDARD LIMITWheel rim runout (Front & Rear)

Axial 0.5 mm (0.02 in) or less2

(0.08)

Radial 0.8 mm (0.03 in) or less2

(0.08)Axle runout Front

(/100 mm) 0.1 (0.004) 0.2(0.008)

Rear(/110 mm) 0.1 (0.004) 0.2

(0.008)Front tire Size 2.50-14MC 4PR —

Make CHENG SHIN —Type C803 —

Rear tire Size 3.00-12 4PR —Make CHENG SHIN —Type C803 —

Tire air pressure Front & Rear

100 kPa(1.0 kgf/cm2, 14 psi)

——

ITEM STANDARD LIMITFront fork oil viscosity SS-8 or SAE 10W-20 —Front fork oil capacity(completely dry)

163 ± 2.5 ml(5.51 ± 0.08 US oz) —

Front fork oil level(fully compressed, spring removed)

89 ± 2 (3.50 ± 0.08)from top of inner tube —


430.9(16.96)

ITEM STANDARD LIMITEngine oil type API SE, SF or SG

API SH or SJ with JASO MA —

Engine oil viscosity SAE 10W-40 —Engine oil capacity When engine is

completely dry1.1 L (1.2 US qt) —

When filter is removed

1.0 L (1.1 US qt) —

When filter is not removed

0.9 L (1.0 US qt) —

Engine oil level Between upper and lower level lines —

SAM

22

DR-Z125/L

1/8 E-28, 33


ITEM STANDARD LIMITValve diam.

IN.30

(1.2)—

EX.26

(1.0)—

Valve clearance (when cold)IN.

0.08 – 0.13(0.003 – 0.005)

—

EX.0.13 – 0.18

(0.005 – 0.007)—

Valve guide to valve stem clearance

IN.0.010 – 0.037

(0.0004 – 0.0015)—

EX.0.030 – 0.057

(0.0012 – 0.0022)—

Valve guide I.D.IN. & EX.

5.500 – 5.512(0.2165 – 0.2170)

—

Valve stem O.D.IN.

5.475 – 5.490(0.2156 – 0.2161)

—

EX.5.455 – 5.470

(0.2148 – 0.2154)—

Valve stem deflectionIN. & EX. —

0.35(0.014)

Valve stem runoutIN. & EX. —

0.05(0.002)

Valve head thicknessIN. & EX. —

0.5(0.014)

Valve stem end lengthIN. & EX. —

2.5(0.10)

Valve seat widthIN. & EX.

0.9 – 1.1(0.035 – 0.043)

—

Valve head radial runoutIN. & EX. —

0.03(0.001)

Valve spring free length(IN. & EX.)

INNER — 36.0(1.42)

OUTER — 39.3(1.55)


76 – 90 N(7.8 – 9.2 kgf, 17.2 – 20.3 lbs)


OUTER186 – 219 N

(18.9 – 22.3 kgf, 41.7 – 49.2 lbs)at length 36.0 mm (1.42 in)

—

2/8 E-28, 33



IN. & EX.33.13 – 33.17

(1.304 – 1.306)32.83(1.29)

Camshaft journal oil clearanceIN. & EX.

0.032 – 0.066(0.0013 – 0.0026)

0.150(0.0059)

Camshaft journal holder I.D.IN. & EX.

22.012 – 22.025(0.8666 – 0.8671)

—

Camshaft journal O.D.IN. & EX.

21.959 – 21.980(0.8645 – 0.8654)

—

Camshaft runoutIN. & EX. —

0.10(0.004)

Rocker arm I.D.IN. & EX.

12.000 – 12.018(0.4724 – 0.4731)

—

Rocker arm shaft O.D.IN. & EX.

11.977 – 11.995(0.4715 – 0.4722)

—

Cylinder head distortion—

0.05(0.002)

Cylinder head cover distortion—

0.05(0.002)

LE
P
3/8 E-28, 33



(12 – 16 kgf/cm2, 171 – 228 psi) 1 000 kPa

(10 kgf/cm2, 142 psi)Piston to cylinder clearance 0.020 – 0.030

(0.0008 – 0.0012)0.120

(0.0047)Cylinder bore 57.000 – 57.015

(2.2440 – 2.2447)57.110

(2.2484)Piston diam. 56.975 – 56.990


56.880(2.2394)

Cylinder distortion—

0.05(0.002)

Piston ring free end gap1st R Approx.

7.0(0.28)

5.6(0.22)

2nd R Approx. 8.5(0.33)

6.8(0.27)

Piston ring end gap1st

0.10 – 0.25(0.004 – 0.010)

0.5(0.02)

2nd0.10 – 0.25

(0.004 – 0.010)0.5

(0.02)Piston ring to groove clearance

1st —0.18

(0.007)

2nd —0.15

(0.006)Piston ring groove width

1st1.21 – 1.23

(0.047 – 0.048)—

2nd1.21 – 1.23

(0.047 – 0.048)—

Oil2.51 – 2.53

(0.099 – 0.100)—

Piston ring thickness1st

1.175 – 1.190(0.0463 – 0.0469)

—

2nd1.170 – 1.190

(0.0461 – 0.0469)—

Piston pin bore 14.002 – 14.008 (0.5513 – 0.5515)

14.030(0.5524)

Piston pin O.D. 13.994 – 14.002 (0.5509 – 0.5513)

13.980(0.5504)

SAM

4/8 E-28, 33


OIL PUMP



(0.5513 – 0.5517) 14.040

(0.5528)Conrod deflection

—3.0


(0.004 – 0.018)1.0


(0.628 – 0.630)—

Crank web to web width 53.0 ± 0.1(2.09 ± 0.004)

—

Crankshaft runout—

0.08 (0.003)

ITEM STANDARD LIMITOil pressure (at 60°C, 140°F) Above 15 kPa (0.15 kgf/cm2, 2.1 psi)


—


(0.4 – 0.6)—

Drive plate thickness 2.90 – 3.10(0.114 – 0.122)

2.60 (0.102)

Drive plate claw width 11.8 – 12.0(0.46 – 0.47)

11.5(0.45)

Driven plate distortion—

0.10 (0.004)


31.0 (1.22)

23

5/8 E-28, 33

DRIVE TRAIN + DRIVE CHAIN Unit: mm (in) Except ratio

CARBURETOR

ITEM STANDARD LIMITPrimary reduction ratio 3.470 (59/17) —Final reduction ratio DR-Z125 3.642 (51/14) —

DR-Z125L 4.071 (57/14) —Gear ratios Low 3.000 (33/11) —

2nd 1.857 (26/14) —3rd 1.368 (26/19) —4th 1.095 (23/21) —Top 0.923 (24/26) —


0.50(0.02)

Shift fork groove widthNo. 1

5.0 – 5.1(0.196 – 0.201)

—

No. 25.5 – 5.6

(0.217 – 0.224)—

Shift fork thicknessNo. 1

4.8 – 4.9(0.189 – 0.193)

—

No. 25.3 – 5.4

(0.209 – 0.213)—

Countershaft length(Low to 2nd) —

Drive chain Type D.I.D. 428HG —

LinksDR-Z125 122 —DR-Z125L 130 —

20-pitch length

—259.0

(10.20)Drive chain slack

25 – 4035 – 45

(1.4 – 1.8)—

Gearshift lever height –5 – 5(–0.2 – 0.2)

—

)(88.0 3.46+0.1-0-0+0.004

ITEMSPECIFICATION

E-33, 28Carburetor type MIKUNI

VM20SSBore size 20 mm (0.8 in)I.D. No. 08GIdle r/min 1 700 ± 100 r/minFloat height 18.9 ± 1.0 mm (0.74 ± 0.04 in)

6/8 E-28, 33

ELECTRICAL

ITEMSPECIFICATION

E-03, 28Main jet (M.J.) #102.5Jet needle (J.N.) 5HGM74-1Needle jet (N.J.) N-6MThrottle valve (Th.V.) #2.5Pilot jet (P.J.) #17.5Pilot screw

(P.S.)PRE-SET

(2 and turns back)Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in)

ITEM SPECIFICATION NOTESpark plug

TypeDENSO: X24ESR-U

NGK: DR8EA

Gap0.6 – 0.8 mm

(0.024 – 0.031 in)Spark performance Over 8 mm (0.3 in) at 1 atm.Ignition coil resistance Primary 0.1 – 0.8 Ω W/Bl – B/W

Secondary 13 – 18 kΩ Plug cap – W/BlGenerator coil resistance Charging 13 – 22 Ω Y – Y/R

Pick-up coil 140 – 230 Ω G – B/WPick-up coil peak voltage More than 2.0 V : G, : B/WIgnition coil primary peak voltage More than 150 V : B/W, : W/Bl

LE
P
7/8 E-28, 33


ITEM STANDARD/SPECIFICATION LIMITBrake lever play

DR-Z12515 – 25

(0.6 – 1.0)—

DR-Z1250.1 – 0.3

(0.004 – 0.012)—

Rear brake pedal free travel 20 – 30(0.8 – 1.2)

—

Rear brake pedal height –10 – 0(–0.4 – 0)

—

Brake drum I.D. Rear — 110.7Brake disc thickness

Front3.5 ± 0.2

(0.14 ± 0.008)3.0

(0.12)Brake disc runout

Front —0.30

(0.012)Master cylinder bore

Front11.000 – 11.043

(0.4331 – 0.4348)—

Master cylinder piston diam.Front

10.957 – 10.984(0.4314 – 0.4324)

—

Brake caliper cylinder boreFront

30.230 – 30.306(1.1902 – 1.1931)

—

Brake caliper piston diam.Front

30.150 – 30.200(1.1870 – 1.1890)

—

Brake fluid type DOT 4 —Wheel rim runout

Axial —2.0

(0.08)

Radial —2.0

(0.08)Wheel axle runout

Front —0.25

(0.010)

Rear —0.25

(0.010)Wheel rim size

FrontDR-Z125 J17 × 1.40 —DR-Z125L J19 × 1.40 —

RearDR-Z125 J14 × 1.60 —DR-Z125L J16 × 1.60 —

Tire sizeFront

DR-Z125 70/100-17 40M —DR-Z125L 70/100-19 42M —

RearDR-Z125 90/100-14 49M —DR-Z125L 90/100-16 52M —

Tire tread depthFront —

4.0(0.16)

Rear —4.0

(0.16)

SAM

8/8 E-28, 33


TIRE PRESSURE

FUEL + OIL

ITEM STANDARD/SPECIFICATION LIMITFront fork stroke 180 (7.1) —Front fork spring free length — 587 (23.1)Front fork oil level 173.0 (6.81) —Front fork oil type SUZUKI FORK OIL SS-08 (#10) or

an equivalent fork oli Front fork oil capacity (each leg) 172 ml (4.3/4.5 US/lmp oz) —Rear shock absorber springpre-set length

DR-Z125 240.5 (9.47) —DR-Z125L 241.1 (9.49) —

Rear wheel travel DR-Z125 160 (6.3) —DR-Z125L 170 (6.7) —

Swingarm pivot shaft runout — 0.6 (0.02)


kPa kgf/cm2 psi

FRONT 100 1.0 14REAR 105 1.0 14



Fuel tank including reserve 6.6 L (1.7/1.5 US/lmp qt)reserve 1.7 L (0.4/0.4 US/lmp qt)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 850 ml (0.9/0.7 US/lmp qt)

Filter change

950 ml (1.0/0.8 US/lmp qt)

Overhaul 1 100 ml (1.2/1.0 US/lmp qt)

24

DR-Z250 (E-03, 28, 33)

1/7 E-03, 28, 33




(1.12) —

EX. 25.0(0.98) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —






(1.52)

OUTER — 40.6(1.60)


48 – 58 N (4.8 – 5.8 kgf, 10.6 – 12.8 lbs)


OUTER133 – 153 N


—


(1.391 – 1.392) 35.02

(1.379)

EX. 35.22 – 35.26(1.387 – 1.388)

34.92 (1.375)

2/7 E-03, 28, 33


ITEM STANDARD LIMITCamshaft journal oil clearance 0.032 – 0.066

(0.0013 – 0.0026) 0.150

(0.0059)Camshaft journal holder I.D. 22.012 – 22.025

(0.8666 – 0.8671) —

Camshaft journal O.D. 21.959 – 21.980(0.8645 – 0.8654) —



(0.002)


(13 kgf/cm2, 185 psi) 910 kPa

(9.1 kgf/cm2,129 psi)


0.120 (0.0047)

Cylinder bore 73.000 – 73.015(2.8740 – 2.8746)

Nicks or scratches

Piston diam. 72.980 – 72.995(2.8732 – 2.8738)

Measure at 15 mm (0.6 in) from the skirt end. 72.880

(2.8693)


Piston ring free end gap 1st R Approx. 7.6 (0.30) 6.1 (0.24)

2nd R Approx. 7.7 (0.31) 6.2 (0.25)

Piston ring end gap 1st & 2nd 0.08 – 0.20(0.003 – 0.008)

0.50 (0.02)

Piston ring to groove clearance 1st & 2nd — 0.180(0.007)

Piston ring groove width 1st & 2nd 1.01 – 1.03(0.040 – 0.041) —

Oil 2.01 – 2.03(0.079 – 0.080) —

Piston ring thickness 1st & 2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pin bore 19.002 – 19.008(0.7481 – 0.7483)

19.030 (0.7492)

Piston pin O.D. 18.992 – 19.000(0.7477 – 0.7480)

18.980 (0.7472)

LE
P
3/7 E-03, 28, 33


OIL PUMP




(0.7483 – 0.7486) 19.040



(0.004 – 0.022) 1.0


(0.785 – 0.787) —





—


(0.4 – 0.6) —


2.62 (0.103)


12.9 (0.51)




2nd 1.733 (26/15) —3rd 1.333 (24/18) —4th 1.111 (20/18) —5th 0.952 (20/21) —Top 0.826 (19/23) —

SAM

4/7 E-03, 28, 33

CARBURETOR


ITEM STANDARD LIMITShift fork to groove clearance 0.1 – 0.3

(0.004 – 0.012) 0.5

(0.02)Shift fork groove width No. 1, No. 2

& No. 35.0 – 5.1

(0.197 – 0.201) —

Shift fork thickness No. 1, No. 2& No. 3

4.8 – 4.9(0.189 – 0.193) —

Drive chain Type D.I.D. 520V2 —Links 112 —

20-pitch length — 319.4(12.57)


ITEMSPECIFICATION

E-03, 28 E-33Carburetor type TM28SS BSR32Bore size 28 mm 32 mmI.D. No. 13E3 13E4Idle r/min 1 600 ± 100 r/min 1 500 ± 100 r/minFloat height 14.2 ± 1.0 mm

(0.56 ± 0.04 in)13.0 ± 1.0 mm(0.51 ± 0.04 in)

Main jet (M.J.) #127.5 #Jet needle (J.N.) 6FN3-3rd 5DH46Needle jet (N.J.) P-6MPilot jet (P.J.) #37.5 #Pilot screw (P.S.) 1 and 1/4 turns back PRE-SETThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in) ←

ITEM SPECIFICATION NOTESpark plug Type NGK: CR9E

DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 0.1 – 1.5 Ω Terminal –

Ground

Secondary 12 – 20 kΩ Plug cap – Terminal

Ignition coil primary peak voltage More than 150 V : B/W, : W/BlGenerator coil resistance Charging 0.7 – 1.5 Ω Y – Y

Signal coil 0.1 – 1.2 Ω W – BPick-up coil 390 – 620 Ω G – Bl

25

5/7 E-03, 28, 33

WATTAGE Unit: W


ITEM SPECIFICATION NOTEPickup coil peak voltage More than 5 V : G, : BlSignal coil peak voltage More than 1.2 V : W, : BGenerator no-load voltage(when engine is cold) More than 75 V (AC) at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation FTZ5L-BS

Capacity 12 V 16.2 kC (4.5 Ah)/10 HRFuse size 10 A

ITEM SPECIFICATIONHeadlight 35Taillight 5

ITEM STANDARD/SPECIFICATION LIMITBrake lever play 0.1 – 0.3

(0.004 – 0.010) —



2.5 (0.098)

Rear 4.0 ± 0.2(0.157 ± 0.008)

3.5 (0.138)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —


Rear 30.230 – 30.280(1.1902 – 1.1921) —


Rear 30.160 – 30.180(1.1874 – 1.1882) —

Brake fluid type DOT 4 —

6/7 E-03, 28, 33

TIRE


ITEM STANDARD/SPECIFICATION LIMITWheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)


ITEM STANDARD/SPECIFICATION LIMITCold inflation tire pressure(Solo riding) Front 100 kPa

(1.00 kgf/cm2, 14 psi) —



Tire tread depth Front — 4.0 mm(0.16 in)

Rear — 4.0 mm(0.16 in)

ITEM STANDARD/SPECIFICATION LIMITFront fork stroke 280

(11.0) —


492 (19.4)


Front fork oil type SUZUKI fork oil SS-07 or an equivalent fork oil —Front fork oil capacity(each leg)

526 ml(17.8/18.5 US/Imp oz) —

Front fork damping force adjuster Rebound 8 clicks turns back —Compression 7 clicks turns back —

Rear shock absorber gaspressure

1 000 kPa(10 kgf/cm2, 142 psi) —


269.4(10.6) —

Rear shock absorber damping force adjuster

Rebound 3 turns back —Compression 1 and 1/4 turns back —


Swingarm pivot shaft runout — 0.3(0.01)LE

P

7/7 E-03, 28, 33


Fuel type Use only unleaded gasoline of at least 90 pumpoctane (R/2 + M/2). Gasoline containing MTBE (MethyI Tertiary ButyIEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

Fuel tank capacity including reserve

10.5 L(2.8/2.3 US/Imp gal)

reserve 2.4 L(0.6/0.5 US/Imp gal)


(1.2/1.0 US/Imp qt)

Filter change 1 200 ml(1.3/1.1 US/Imp qt)

Overhaul 1 600 ml(1.7/1.4 US/Imp qt)

SAM

26

DR-Z250 (E-24)

1/7 E-24




(1.12) —

EX. 25.0(0.98) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —






(1.52)

OUTER — 40.6(1.60)


48 – 58 N (4.8 – 5.8 kgf, 10.6 – 12.8 lbs)


OUTER133 – 153 N


—


(1.391 – 1.392) 35.02

(1.379)

EX. 35.22 – 35.26(1.387 – 1.388)

34.92 (1.375)

2/7 E-24


ITEM STANDARD LIMITCamshaft journal oil clearance 0.032 – 0.066

(0.0013 – 0.0026) 0.150

(0.0059)Camshaft journal holder I.D. 22.012 – 22.025

(0.8666 – 0.8671) —




(0.002)


(13 kgf/cm2, 185 psi) 910 kPa

(9.1 kgf/cm2,129 psi)


0.120 (0.0047)

Cylinder bore 73.000 – 73.015(2.8740 – 2.8746)

Nicks or scratches

Piston diam. 72.980 – 72.995(2.8732 – 2.8738)


(2.8693)


Piston ring free end gap 1st R Approx. 7.6 (0.30) 6.1 (0.24)

2nd R Approx. 7.7 (0.31) 6.2 (0.25)


0.50 (0.02)

Piston ring to groove clearance 1st & 2nd — 0.180(0.007)


Oil 2.01 – 2.03(0.079 – 0.080) —

Piston ring thickness 1st & 2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pin bore 19.002 – 19.008(0.7481 – 0.7483)

19.030 (0.7492)

Piston pin O.D. 18.992 – 19.000(0.7477 – 0.7480)

18.980 (0.7472)

LE
P
3/7 E-24


OIL PUMP




(0.7483 – 0.7486) 19.040



(0.004 – 0.022) 1.0


(0.785 – 0.787) —





—


(0.4 – 0.6) —


2.62 (0.103)


12.9 (0.51)




2nd 1.733 (26/15) —3rd 1.333 (24/18) —4th 1.111 (20/18) —5th 0.952 (20/21) —Top 0.826 (19/23) —

SAM

4/7 E-24

CARBURETOR


ITEM STANDARD LIMITShift fork to groove clearance 0.1 – 0.3

(0.004 – 0.012) 0.5


& No. 35.0 – 5.1

(0.197 – 0.201) —


4.8 – 4.9(0.189 – 0.193) —

Drive chain Type D.I.D. 520V2 —Links 108 —

20-pitch length — 319.4(12.57)


ITEM SPECIFICATION

Carburetor type TM28SSBore size 28 mmI.D. No. 13E3Idle r/min 1 600 ± 100 r/minFloat height 14.2 ± 1.0 mm

(0.56 ± 0.04 in)Main jet (M.J.) #127.5Jet needle (J.N.) 6FN3-3rdNeedle jet (N.J.) P-6MPilot jet (P.J.) #37.5Pilot screw (P.S.) 1 and 1/4 turns backThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in)


DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Ground


Ignition coil primary peak voltage More than 150 V : B/W, : W/BlGenerator coil resistance Charging 0.7 – 1.5 Ω Y – Y

Signal coil 0.1 – 1.2 Ω W – BPick-up coil 390 – 620 Ω G – Bl

27

5/7 E-24

WATTAGE Unit: W


ITEM SPECIFICATION NOTEPickup coil peak voltage More than 5 V : G, : BlSignal coil peak voltage More than 1.2 V : W, : BGenerator no-load voltage(when engine is cold) More than 75 V (AC) at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation FTZ5L-BS

Capacity 12 V 16.2 kC (4.5 Ah)/10 HRFuse size 10 A


LO 55Brake light/Taillight 21/5Turn signal light 21Speedometer light LEDNeutral indicator light 2Turn signal indicator light 2High beam indicator light 2License plate light 5


(0.004 – 0.010) —



3.0 (0.118)

Rear 4.0 ± 0.2(0.157 ± 0.008)

3.5 (0.138)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —

6/7 E-24

TIRE


ITEM STANDARD/SPECIFICATION LIMITBrake caliper cylinder bore Front 27.000 – 27.050

(1.0630 – 1.0650) —

Rear 30.230 – 30.280(1.1902 – 1.1921) —


Rear 30.160 – 30.180(1.1874 – 1.1882) —

Brake fluid type DOT 4 —Wheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)



(1.50 kgf/cm2, 22 psi) —


Tire size Front 3.00-21 51P —Rear 4.60-18 63P —

Tire type Front DUNLOP: D903F —Rear DUNLOP: D903 —

Tire tread depth Front — 4.0 mm(0.16 in)

Rear — 4.0 mm(0.16 in)


(11.0) —


492 (19.4)


Front fork oil type SUZUKI fork oil SS-07 or an equivalent fork oil —Front fork oil capacity(each leg)

526 ml(17.8/18.5 US/Imp oz) —

Front fork damping force adjuster Rebound 8 clicks turns back —Compression 7 clicks turns back —LE

P

7/7 E-24

FUEL + OIL

ITEM STANDARD/SPECIFICATION LIMITRear shock absorber gaspressure

1 000 kPa(10 kgf/cm2, 142 psi) —


269.4(10.6) —


Rebound 3 turns back —Compression 1 and 1/4 turns back —




higher. An unleaded gasoline is recommended.Fuel tank capacity including

reserve10.5 L

(2.8/2.3 US/Imp gal)reserve 2.4 L

(0.6/0.5 US/Imp gal)Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 1 100 ml

(1.2/1.0 US/Imp qt)

Filter change 1 200 ml(1.3/1.1 US/Imp qt)

Overhaul 1 600 ml(1.7/1.4 US/Imp qt)

SAM

28

DR-Z400/E (E-01, 03, 28, 33)

1/9 E-01, 03E-01, 03, 28, 33



(1.42) —

EX. 29(1.14) —


EX. 0.20 – 0.30(0.0078 – 0.0118) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —






(1.28)

OUTER — 36.3(1.43)


56 – 64 N(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)


OUTER126 – 145 N

(12.6 – 14.5 kgf, 27.7 – 32.0 lbsat length 30.9 mm (1.22 in)

—

2/9 E-01, 03E-01, 03, 28, 33




E-01, 03, 28

IN. 36.910 – 36.960(1.4531 – 1.4551)

36.610(1.4413)

EX. 36.880 – 36.930(1.4520 – 1.4539)

36.580(1.4402)

E-33IN. 36.490 – 36.540

(1.4366 – 1.4386)36.190

(1.4248)

EX. 35.790 – 35.840(1.4091 – 1.4110)

35.490(1.3972)


0.150(0.0059)





(0.002)Cylinder head cover distortion — 0.05

(0.002)De-compression cable play(DR-Z400)

0 – 0.1(0 – 0.004) —

ITEM STANDARD LIMITCompression pressure(Automatic de-comp. actuated)Except for DR-Z400

1 000 kPa(10.0 kgf/cm2, 142 psi) —


0.120(0.0047)

Cylinder bore 90.000 – 90.015(3.5433 – 3.5439)

Nicks or scratches

Piston diam. 89.965 – 89.980(3.5419 – 3.5425)


(3.5386)


Piston ring free end gap 1st R Approx. 6.9(0.27)

5.5(0.22)

2nd R Approx. 11.5(0.45)

9.2(0.36)


0.50(0.020)

2nd 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)


2nd — 0.150(0.006)LE

P

3/9 E-01, 03E-01, 03, 28, 33


OIL PUMP

ITEM STANDARD LIMITPiston ring groove width

1st

0.78 – 0.80(0.0307 – 0.0315) —

1.30 – 1.32(0.0512 – 0.0520) —

2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —


1st

0.71 – 0.76(0.0280 – 0.0299) —

1.08 – 1.10(0.0425 – 0.0433) —

2nd 0.77 – 0.79(0.0303 – 0.0311) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881) 20.040



(0.012 – 0.026)1.0


(0.864 – 0.866) —



ITEM STANDARD LIMITOil pump reduction ratio 2.220 (74/25 × 20/16 × 12/20) —Oil pressure (at 60°C, 140°F) Above 40 kPa (0.4 kgf/cm2, 5.7 psi)


—

SAM

4/9 E-01, 03E-01, 03, 28, 33




(0.4 – 0.6) —

Drive plate thickness(No. 1 & No. 2)

2.92 – 3.08(0.115 – 0.121)

2.62 (0.103)

Drive plate claw width(No. 1 & No. 2)

13.7 – 13.8(0.539 – 0.543)

13.2(0.520)

Driven plate distortion — 0.10 (0.004)

Clutch spring free length — 49.9 (1.96)


2nd 1.733 (26/15) —3rd 1.375 (22/16) —4th 1.090 (24/22) —Top 0.863 (19/22) —


0.5(0.020)

Shift fork groove width No. 1, No. 2 & No. 3

4.8 – 4.9(0.189 – 0.193) —

Shift fork thickness No. 1, No. 2 & No. 3

4.6 – 4.7(0.181 – 0.185) —

Drive chain Type RK520KZO —Links 112 —



(1.6 – 2.0) —

29

5/9 E-01, 03E-01, 03, 28, 33

CARBURETOR

RADIATOR + ENGINE COOLANT

ITEMSPECIFICATION

DR-Z400 DR-Z400EE-01 E-03, 28 E-01 E-03, 28 E-33

Carburetor type KEIHINFCR39H ← ← ← MIKUNI

BSR36Bore size 39 mm

(1.5 in) ← ← ← 36 mm(1.4 in)

I.D. No. 29F0 29F1 29F3 29F4 29F2Idle r/min 1 800 ± 100

r/min ← ← ← 1 600 ± 100 r/min

Float height 9.0 ± 1.0 mm

(0.35 ± 0.04 in)

← ← ←13.0 ± 1.0

mm(0.51 ± 0.04

in)Main jet (M.J.) #165 #142 #165 #142 #Jet needle (J.N.) OBDXP-4th ← ← ← 5DH56Needle jet (N.J.) 2.9 mm

(0.11 in) ← ← ←

Slow jet (S.J.) #45 ← ← ← —Slow air jet (S.A.J.) #60 ← ← ← —Air jet (A.J.) #90 ← ← ← —Pilot screw (P.S.) 1 and ½

turns back ← ← ← 2 and ½ turns back

Throttle cable play(pulling cable)

2 – 4 mm(0.08 – 0.16

in)← ← ← ←

Pilot jet (P. J.) — — — — #Pilot air jet (P.A.J.) — — — — #

ITEM STANDARD/SPECIFICATION LIMITRadiator cap valve opening pres-sure

95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)


Engine coolant capacity 1 250 ml(1.3/1.1 US/lmp qt)

6/9 E-01, 03E-01, 03, 28, 33


TIRE

ITEM STANDARD/SPECIFICATION LIMITRear brake pedal height 5

(0.2) —


2.5(0.098)

Rear 4.5 ± 0.2(0.177 ± 0.008)

4.0(0.16)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.050(1.0630 – 1.0650) —


Rear 26.900 – 26.950(1.0591 – 1.0610) —


(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 1.60 × 21 —Rear 2.15 × 18 —


(1.0 kgf/cm2, 14 psi) —




Rear — 4.0(0.16)LE

P

7/9 E-01, 03E-01, 03, 28, 33



(11.3) —


500(19.7)

Front fork oil level(without spring)

122(4.8) —

Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oli —

Front fork oil capacity(each leg)

720 ml(24.3/25.4 US/lmp oz) —

Front fork damping force adjuster Rebound 15th clicks turn back —Compression 12th clicks turn back —

Rear shock absorber gas pressure 900 kPa(9.0 kgf/cm2, 128 psi) —

Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent suspension oli —

Rear shock absorber oil capacity 380 ml(12.8/13.4 US/lmp oz) —


258.0(10.2) —


Rebound 13th clicks turn back —

CompressionHigh speed 1 and ¼ turns out —Low speed 10th clicks turn back —



SAM

8/9 E-01, 03E-01, 03, 28, 33


WATTAGE Unit: W

ITEM SPECIFICATION NOTESpark plug Type DENSO: U24ESR-N

NGK: CR8E

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 mm (0.3 in) at 1 atm.Ignition coil resistance Primary 0.1 – 1.0 Ω Terminal –

Ground


Ignition coil primary peak voltage More than 150 V (: B/W, : B/Y)Generator coil resistance Charging 0.50 – 1.25 Ω Y – Y

Signal coil 0.05 – 0.20 Ω B – WPick-up coil 390 – 600 Ω G – Bl

Pick-up coil peak voltage More than 10.0 V (: Bl, : G) DR-Z400More than 5.0 V (: Bl, : G) DR-Z400E

Signal coil peak voltage More than 1.0 V (: B, : W) DR-Z400More than 1.4 V (: B, : W) DR-Z400E

Generator no-load voltage(When engine is cold)

More than 55 V (AC) at 5 000 r/min(Y – Y) DR-Z400

More than 75 V (AC) at 5 000 r/min(Y – Y) DR-Z400E

Regulated voltage 12.5 – 14.0 V at 5 000 r/min DR-Z40013.5 – 15.0 V at 5 000 r/min DR-Z400E

Generator Max. output 150 W at 5 000 r/min DR-Z400200 W at 5 000 r/min DR-Z400E

Starter relay resistance 3 – 5 Ω DR-Z400EBattery Type designation YT7B-BS

DR-Z400ECapacity 12 V 21.6 kC (6 Ah)/10 HR

ITEM SPECIFICATIONHeadlight 35Taillight LED

30

9/9 E-01, 03E-01, 03, 28, 33


Fuel type Use only unleaded gasoline of at least 90 pumpoctane (R/2 + M/2).Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28

Gasoline used should be graded 95 octane orhigher. An unleaded gasoline is recommended. E-01

Fuel tank including reserve 10.0 L(2.6/2.2 US/lmp qt)



(1.8/1.5 US/lmp qt)



LE
P DR-Z400E (E-24)
1/8 E-24



(1.42) —

EX. 29(1.14) —


EX. 0.20 – 0.30(0.0078 – 0.0118) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —






(1.28)

OUTER — 36.3(1.43)


56 – 64 N(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)


OUTER126 – 145 N


—

SAM

2/8 E-24




(1.4531 – 1.4551)36.610

(1.4413)

EX. 36.880 – 36.930(1.4520 – 1.4539)

36.580(1.4402)


0.150(0.0059)






(0.002)

ITEM STANDARD LIMITCompression pressure(Automatic de-comp. actuated)

1 000 kPa(10.0 kgf/cm2, 142 psi) —


0.120(0.0047)

Cylinder bore 90.000 – 90.015(3.5433 – 3.5439)

Nicks or scratches

Piston diam. 89.965 – 89.980(3.5419 – 3.5425)


(3.5386)



5.5(0.22)

2nd R Approx. 11.5(0.45)

9.2(0.36)


0.50(0.020)

2nd 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)


2nd — 0.150(0.006)

Piston ring groove width

1st

0.78 – 0.80(0.0307 – 0.0315) —

1.30 – 1.32(0.0512 – 0.0520) —

2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —

31

3/8 E-24


OIL PUMP


ITEM STANDARD LIMITPiston ring thickness

1st

0.71 – 0.76(0.0280 – 0.0299) —

1.08 – 1.10(0.0425 – 0.0433) —

2nd 0.77 – 0.79(0.0303 – 0.0311) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881) 20.040



(0.012 – 0.026)1.0


(0.864 – 0.866) —



ITEM STANDARD LIMITOil pump reduction ratio 2.220 (74/25 × 20/16 × 12/20) —Oil pressure (at 60°C, 140°F) Above 40 kPa (0.4 kgf/cm2, 5.7 psi)


—


(0.4 – 0.6) —


2.92 – 3.08(0.115 – 0.121)

2.62 (0.103)


13.7 – 13.8(0.539 – 0.543)

13.2(0.520)



4/8 E-24


CARBURETOR


2nd 1.733 (26/15) —3rd 1.375 (22/16) —4th 1.090 (24/22) —Top 0.863 (19/22) —


0.5(0.020)


4.8 – 4.9(0.189 – 0.193) —


4.6 – 4.7(0.181 – 0.185) —




(1.6 – 2.0) —

ITEM SPECIFICATIONCarburetor type KEIHIN FCR39HBore size 39 mm

(1.5 in)I.D. No. 29F6Idle r/min 1 800 ± 100 r/minFloat height 9.0 ± 1.0 mm

(0.35 ± 0.04 in)Main jet (M.J.) #165Jet needle (J.N.) OBDXP-4thNeedle jet (N.J.) 2.9 mm

(0.11 in)Slow jet (S.J.) #45Slow air jet (S.A.J.) #60Air jet (A.J.) #90Pilot screw (P.S.) 2 and ¾ turns backThrottle cable play(pulling cable)

2 – 4 mm(0.08 – 0.16 in)

LE
P
5/8 E-24

RADIATOR + ENGINE COOLANT


ITEM STANDARD/SPECIFICATION LIMITRadiator cap valve opening pres-sure

95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)


Engine coolant capacity 1 250 ml(1.3/1.1 US/lmp qt)


(0.004 – 0.010) —



2.5(0.098)

Rear 4.5 ± 0.2(0.177 ± 0.008)

4.0(0.16)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.050(1.0630 – 1.0650) —


Rear 26.900 – 26.950(1.0591 – 1.0610) —


(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)


SAM

6/8 E-24

TIRE


ITEM STANDARD/SPECIFICATION LIMITCold infation tire pressure(Solo riding) Front 125 kPa

(1.25 kgf/cm2, 18 psi) —




Rear — 4.0(0.16)


(11.3) —


500(19.7)


122(4.8) —


Front fork oil capacity(each leg)

720 ml(24.3/25.4 US/lmp oz) —



Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25or an equivalent suspension oli

Rear shock absorber oil capacity 380 ml(12.8/13.4 US/lmp oz)


258.0(10.2) —


Rebound 13th clicks turn back

CompressionHigh speed 1 and ¼ turns outLow speed 10th clicks turn back



32

7/8 E-24


WATTAGE Unit: W


NGK: CR8E

Gap 0.7 – 0.8(0.028 – 0.031)


Ground


Ignition coil primary peak voltage More than 150 V : B/W, : B/YGenerator coil resistance Charging 0.50 – 1.25 Ω Y – Y


Pick-up coil peak voltage More than 5.0 V : Bl, : GSignal coil peak voltage More than 1.4 V : B, : WGenerator no-load voltage(When engine is cold) More than 75 V (AC) at 5 000 r/min Y – Y

Regulated voltage 13.5 – 15.0 V at 5 000 r/minGenerator Max. output 200 W at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation YT7B-BS



LO 55Brake light/Taillight 21/5Turn signal light 21Speedometer light LEDNeutral indicator light 2High beam indicator light 2Turn signal indicator light 2

8/8 E-24



Fuel tank including reserve 10.0 L(2.6/2.2 US/lmp qt)



(1.8/1.5 US/lmp qt)



LE
P DR-Z400S
1/8 E-03, 28, 33



(1.42) —

EX. 29(1.14) —


EX. 0.20 – 0.30(0.0079 – 0.0118) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —






(1.28)

OUTER — 36.3(1.43)


56 – 64 N(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)


OUTER126 – 145 N


—

SAM

2/8 E-03, 28, 33




(1.4366 – 1.4386)36.190

(1.4248)

EX. 35.790 – 35.840(1.4091 – 1.4110)

35.490(1.3972)


0.150(0.0059)






(0.002)


950 kPa(9.5 kgf/cm2, 135 psi) —


0.120(0.0047)

Cylinder bore 90.000 – 90.015(3.5433 – 3.5439)

Nicks or scratches

Piston diam. 89.965 – 89.980(3.5419 – 3.5425)


(3.5386)



5.5(0.22)

2nd R Approx. 11.5(0.45)

9.2(0.36)


0.50(0.020)

2nd 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)


2nd — 0.150(0.006)


1st

0.78 – 0.80(0.0307 – 0.0315) —

1.30 – 1.32(0.0512 – 0.0520) —

2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —

33

3/8 E-03, 28, 33


OIL PUMP



1st

0.71 – 0.76(0.0280 – 0.0299) —

1.08 – 1.10(0.0425 – 0.0433) —

2nd 0.77 – 0.79(0.0303 – 0.0311) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881) 20.040



(0.012 – 0.026)1.0


(0.864 – 0.866) —



ITEM STANDARD LIMITOil pressure reduction ratio 2.220 (74/25 × 20/16 × 12/20) —Oil pressure (at 60°C, 140°F) Above 40 kPa (0.4 kgf/cm2, 5.7 psi)


—


(0.4 – 0.6) —


2.92 – 3.08(0.115 – 0.121)

2.62 (0.103)


13.7 – 13.8(0.539 – 0.543)

13.2(0.520)



4/8 E-03, 28, 33


CARBURETOR


2nd 1.733 (26/15) —3rd 1.375 (22/16) —4th 1.090 (24/22) —Top 0.863 (19/22) —


0.5(0.020)


4.8 – 4.9(0.189 – 0.193) —


4.6 – 4.7(0.181 – 0.185) —




(1.6 – 2.0) —

ITEMSPECIFICATION

E-03, 28 E-33Carburetor type MIKUNI BSR36 ←Bore size 36 mm (1.4 in) ←I.D. No. 29FB 29FCIdle r/min 1 500 ± 100 r/min ←Float height 130 ± 1.0 mm

(0.5 ± 0.04 in) ←

Main jet (M.J.) # ←Jet needle (J.N.) 5DH37 ←Needle jet (N.J.) ←Pilot jet (P.J.) # ←Pilot air jet (P.A.J.) #135 ←Pilot screw (P.S.) PRE-SET ←Throttle cable play(pulling cable)

2 – 4 mm(0.08 – 0.16 in) ←

LE
P
5/8 E-03, 28, 33

THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT


ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature Approx. 75 °C (167 °F) —

Thermostat valve lift Over 6 mm (0.24 in) at 90°C (194 °F) —Engine coolant temp. switch oper-ating temperature


Radiator cap valve opening pres-sure

95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) —




—

Engine coolant capacity 1 250 ml (1.3/1.1 US/lmp qt) —


(0.004 – 0.010) —



3.0(0.118)

Rear 4.5 ± 0.2(0.177 ± 0.008)

4.0(0.16)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.050(1.0630 – 1.0650) —


Rear 26.900 – 26.950(1.0591 – 1.0610) —


(0.08)

Radial — 2.0(0.08)

SAM

6/8 E-03, 28, 33

TIRE


ITEM STANDARD/SPECIFICATION LIMITWheel axle runout Front — 0.25

(0.010)

Rear — 0.25(0.010)



(1.25 kgf/cm2, 18 psi) —



(1.25 kgf/cm2, 18 psi) —



Tire type Front BRIDGESTONE TRAIL WING-41 —Rear BRIDGESTONE TRAIL WING-42 —


Rear — 3.0(0.12)


(11.3) —


561(22.1)


129(5.07) —


Front fork oil capacity (each leg) 710 ml(24.0/25.0 US/lmp oz) —




258.0(10.2) —


Rebound 13th clicks turn back —

CompressionHigh speed 1 and ¼ turns out —Low speed 10th clicks turn back —



34

7/8 E-03, 28, 33


WATTAGE Unit: W


NGK: CR8E

Gap 0.7 – 0.8(0.028 – 0.031)


Ground


Ignition coil primary peak voltage More than 150 V : B/W, : B/YGenerator coil resistance Charging 0.50 – 1.25 Ω Y – Y


Pick-up coil peak voltage More than 5.0 V : Bl, : GSignal coil peak voltage More than 1.4 V : B, : WGenerator no-load voltage(When engine is cold) More than 75 V (AC) at 5 000 r/min Y – Y

Regulated voltage 13.5 – 15.0 V at 5 000 r/minGenerator Max. output 200 W at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation YT7B-BS


ITEMSPECIFICATION

E-03, 28, 33Headlight HI 60

LO 55Position light

Brake light/Taillight 21/5Turn signal light 21Speedometer light LEDNeutral indicator light LEDTurn signal indicator light LEDHigh beam indicator light LEDWater temp. indicator light LED

8/8 E-03, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33

Fuel tank including reserve 9.5 L(2.5/2.1 US/lmp qt) E-33

10.0 L(2.6/2.2 US/lmp qt) The others



(1.8/1.5 US/lmp qt)



LE
P GS125T

1/6 P-31



EX. 22.5 —Valve clearance (when cold) IN. 0.04 – 0.07 —


IN. 0.010 – 0.037 —EX. 0.037 – 0.057 —


EX. 4.955 – 4.970 —Valve stem deflection IN. & EX. — 0.35Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. — 1.54

EX. — 1.54Valve seat width IN. & EX. 0.58 – 1.00 —Valve head radial runout IN. & EX. — 0.03Valve spring free length(IN. & EX.)

INNER — 31.3OUTER — 33.6


38.1 – 43.9 N(3.9 – 4.5 kgf)

at length 26.8 mm—

OUTER89.6 – 103.0 N(9.1 – 10.5 kgf)



EX. 33.30 – 33.34 33.00Camshaft journal oil clearance IN. & EX. 0.019 – 0.045 0.150Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —Camshaft journal O.D. IN. & EX. 21.993 – 21.980 —Camshaft runout IN. & EX. — 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.977 – 11.995 —Cylinder head distortion — 0.05Cylinder head cover distortion — 0.05

SAM

2/6 P-31



OIL PUMP


(10 – 14 kgf/cm2, 142 – 199 psi)800 kPa

(8 kgf/cm2, 114 psi)

Piston-to-cylinder clearance 0.04 – 0.05 0.12Cylinder bore 57.000 – 57.015 57.090Piston diam. 56.955 – 56.970


Cylinder distortion — 0.05Piston ring free end gap 1st 1R Approx. 7.2 5.7

2nd 2R Approx. 5.8 4.6Piston ring end gap 1st 0.20 – 0.32 0.7



2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —



ITEM STANDARD LIMITConrod small end I.D. 14.006 – 14.014 14.04Conrod deflection — 3.0Conrod big end side clearance — 1.0Conrod big end width 15.95 – 16.00 —Crank web to web width 52.90 – 53.10 —Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pump reduction ratio 2.000 (30/15) —Oil pressure (at 60 °C) Above 10 kPa (0.1 kgf/cm2)


—

35

3/6 P-31

CLUTCH Unit: mm

DRIVE TRAIN + DRIVE CHAIN Unit: mm Except ratio

CARBURETOR

ITEM STANDARD LIMITClutch lever play 10 – 15 —Clutch release screw 1/4 turn back —Drive plate thickness 2.9 – 3.1 2.6Drive plate claw width 11.8 – 12.0 11.0Driven plate distortion — 0.10Clutch spring free length 31.0 29.5


2nd 1.857 (26/14) —3rd 1.368 (26/19) —4th 1.095 (23/21) —Top 0.913 (21/23) —

Shift fork to groove clearance 0.10 – 0.30 0.50Shift fork groove width No. 1 & 2 5.0 – 5.1 —

No. 3 5.5 – 5.6 —Shift fork thickness No. 1 & 2 4.8 – 4.9 —

No. 3 5.3 – 5.4 —Countershaft length(Low to 2nd) —

Drive chain Type RK428FDZ —Links 116 —


Drive chain slack 25 – 35 —

ITEM SPECIFICATIONCarburetor type MIKUNI BS26SSBore size 26 mmI.D. No. 054JIdle r/min 1500 ± 100 r/minFloat height 17.1 ± 0.5 mmMain jet (M.J.) #110Jet needle (J.N.) 4DH41-2ndNeedle jet (N.J.) P-0Throttle valve (Th.V.) # 105Pilot jet (P.J.) # 12.5Pilot air screw (P.A.J.) 1.25Pilot screw (P.S.) 2 and 5/8 turns outThrottle cable play 2.0 – 4.0 mm

88.0 + 0.1– 0.2

4/6 P-31

ELECTRICAL

WATTAGE Unit: W


NGK: CR8EGap 0.7 – 0.8 mm

Spark performance Over 8 mm at 1 atm.Ignition coil resistance Primary 0.1 – 0.7 Ω tap – tap

Secondary 14 – 19 kΩ Plug cap – tap

Generator coil resistance 0.5 – 1.5 Ω Y – Y∞ Ω Ground – Y

Exciting coil peak voltage 150 V and more : B/R, : Ground

Ignition coil primary peak voltage 150 V and more : Ground, : W/Bl

Exciting coil resistance 190 – 300 Ω B/R – GroundPick-up coil resistance 210 – 350 Ω G – Bl

∞ Ω G – GroundPick-up coil peak voltage 8 V and more : Bl, : B/WGenerator no-load voltage(when engine is cold) 20 V

Regulated voltage 14.5 – 15.0 V at 5 000 r/minGenerator Max. output 120 W and more at 5 000 r/minBattery Type designation CB4L-B

Capacity 12 V 14.4 kC (4 Ah)/10 HRStandard electrolyte S.G 1.280 at 20 °C

Fuse size 15 A

ITEM STANDARD/SPECIFICATIONHeadlight HI 35

LO 35Position light 5Brake light/Taillight 21/5Turn signal light 10Speedometer light 1.7Tachometer light 1.7Turn signal indicator light 1.7High beam indicator light 1.7Neutral indicator light 1.7

LE
P
5/6 P-31


SUSPENSION Unit: mm

TIRE PRESSURE

ITEM STANDARD/SPECIFICATION LIMITFront brake cable play 15 – 25 —Rear brake pedal free travel 20 – 30 —Rear brake pedal height 0 —Brake drum I.D. Front — 130.7

Rear — 130.7Wheel rim runout Axial — 2.0


Rear — 0.25Wheel rim size Front 18 × 1.40 —

Rear 18 × 1.60 —Tire size Front 2.75-18 42P —

Rear 3.00-18 47P —Tire type Front TAIYO TYRE —

Rear TAIYO TYRE —Tire tread depth Front — 1.6

Rear — 1.6

ITEM STANDARD LIMITFront fork stroke 110 —Front fork spring free length 487 477Front fork oil level — —Front fork oil type MUSHAKU TOP 46# or an equivalent fork oil —Front fork oil capacity (each leg) 143 ml —Rear shock absorber spring adjuster 2nd —

Rear wheel travel 94 —Swingarm pivot shaft runout — 0.6

COLD INFLATION TIRE PRESSURE

SOLO RIDING DUAL RIDINGkPa kgf/cm2 kPa kgf/cm2

FRONT 150 1.50 150 1.50REAR 200 2.00 225 2.25

SAM
v
6/6 P-31


Fuel type Gasoline used should be graded 91 octane orhigher. An unleaded gasoline type is recom-mended.

Fuel tank capacity including reserve 12.0 L reserve 2.3 L


Filter change 950 mlOverhaul 1 300 ml

36

GS500/U/F/FU

1/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19



(1.5) —

EX. 32(1.3) —

Valve lift IN. 8.5(0.33) —

EX. 8.0(0.31) —

Tappet clearance (when cold) IN. & EX. 0.03 – 0.08(0.001 – 0.003) —


(0.0010 – 0.0022) —

EX. 0.040 – 0.070(0.0016 – 0.0028) —



Valve stem O.D. IN. 6.960 – 6.975(0.2740 – 0.2746) —

EX. 6.945 – 6.960(0.2734 – 0.2740) —






(1.40)

OUTER — 40.6(1.60)


10.9 – 12.5 kgf (24.0 – 27.6 lbs)




—

2/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19




(1.4208 – 1.4224)35.80

(1.409)

EX. 36.090 – 36.130(1.4208 – 1.4224)

35.80(1.409)


0.150(0.0060)





(0.004)


(10 – 14 kgf/cm2, 142 – 199 psi)800 kPa

(8 kgf/cm2, 144 psi)Compression pressure difference — 200 kPa


(0.0020 – 0.0024)0.120

(0.0047)Cylinder bore 74.000 – 74.015

(2.9134 – 2.9140)74.080

(2.9165)Piston diam. 73.945 – 73.960


73.880(2.9087)


Piston ring free end gap 1st N Approx. 7.0 (0.28) 5.6(0.22)

2nd N Approx. 11.0 (0.43) 8.8(0.35)


0.70(0.028)

2nd 0.10 – 0.25(0.004 – 0.010)

0.70(0.028)


2nd — 0.150(0.0059)

LE
P
3/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19

CONROD + CRANKSHAFT + BALANCER Unit: mm (in)

OIL PUMP


(0.047 – 0.048) —

2nd 1.21 – 1.23(0.047 – 0.048) —

Oil 2.51 – 2.53(0.099 – 0.100) —


2nd 1.17 – 1.19(0.046 – 0.047) —

Piston pin bore 18.002 – 18.008(0.7087 – 0.7090)

18.030 (0.7098)

Piston pin O.D. 17.995 – 18.000(0.7085 – 0.7087)

17.980 (0.7079)


(0.7089 – 0.7092)18.040


(0.004 – 0.008)0.3


(0.904 – 0.906) —

Crank pin width 23.10 – 23.15(0.909 – 0.911) —


0.080(0.0031)

Crank pin O.D. 33.976 – 34.000(1.3376 – 1.3386) —


0.080(0.0031)


Crankshaft thrust bearingthickness

2.950 – 2.975(0.1161 – 0.1171)

2.850(0.1122)


Balancer journal oil clearance 0.020 – 0.044(0.0008 – 0.0017)

0.080(0.0031)

Balancer journal O.D. 31.984 – 32.000(1.2592 – 1.2598) —

Balancer spring free length — 14.9(0.59)

ITEM STANDARD LIMITOil pump reduction ratio 1.879 (76/28 × 27/39) —Oil pressure (at 60 °C, 140 °F) Above 200 kPa (2.0 kgf/cm2, 28 psi)

Below 500 kPa (5.0 kgf/cm2, 71 psi)at 3 000 r/min

—

SAM

4/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19




(0.4 – 0.6) —

Clutch release screw 1/4 – 1/2 turn back —Drive plate thickness 2.92 – 3.08

(0.115 – 0.121)2.62


(0.62 – 0.63)15.0



(2.39)


2nd 1.777 (32/18) —3rd 1.380 (29/21) —4th 1.125 (27/24) —5th 0.961 (25/26) —Top 0.851 (23/27) —


0.5(0.020)

Shift fork groove width No. 1, No. 2& No. 3

5.5 – 5.6(0.217 – 0.220) —


5.3 – 5.4(0.209 – 0.213) —

Countershaft length(Low to 2nd) —

Drive chain Type D.I.D.: DID520VM —Links 110 —

20-pitch length — 319.4(12.57)


+ 0.1- 0+ 0.004- 0

114.74.516

37

5/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

GS500 P-02, 19, 24, 54GS500F P-02, 19, 24, 54

GS500U P-19GS500FU P-19

Carburetor type MIKUNIBSR34 ←

Bore size 34 mm ←I.D. No. 01DN 01DPIdle r/min 1 200 ±100 r/min ←Float height 13.0 ± 1.0 mm ←Main jet (M.J.) #130 #135Jet needle (J.N.) 5DH57-3rd ←Needle jet (N.J.) P-5M ←Throttle valve (Th.V.) #105 ←Pilot jet (P.J.) #17.5 ←Pilot screw (P.S.) 3 turns back ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEMSPECIFICATION

GS500 P-09, 28GS500F P-03, 28 GS500F P-33

Carburetor type MIKUNIBSR34 ←

Bore size 34 mm ←I.D. No. 01DS 01DUIdle r/min 1 200 ± 100 r/min ←Float height 13.0 ± 1.0 mm ←Main jet (M.J.) # ←Jet needle (J.N.) 5DH91 5DH60Needle jet (N.J.) ←Throttle valve (Th.V.) #105 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET (3 turns back) ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

6/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19


WATTAGE Unit: W

ITEM SPECIFICATION NOTEIgnition timing 5° B.T.D.C. at 1 200 r/min P-03, 28, 33

12° B.T.D.C. at 1 200 r/min OthersFiring order L·RSpark plug Type DENSO: X24EPR-U9

NGK: DPR8EA-9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Signal generator resistance 250 – 420 ΩIgnition coil resistance Primary 3 – 6 Ω Terminal –

Terminal


Signal generator peak voltage 1.8 V and more Probe: Br Probe: B/Bl

Ignition coil primary peak voltage100 V and more

Probe: W or B/Y

Probe: Ground

Generator Max. output Approx. 200 W at 5 000 r/minGenerator no-load voltage More than 75 V (AC) at 5 000 r/minRegulated voltage 13.5 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation CB10L-B2



Fuse size 20 A

ITEMSPECIFICATION

GS500/UP-02, 09, 19, 24, 54

GS500F/FUP-02, 19, 24, 54 P-03, 28, 33

Headlight HI 60 ← ←LO 55 ← ←

Position light 4 5 ←Brake light/Taillight 21/5 ← 32/3 cpTurn signal light 21 ← ←Tachometer light 1.7 ← ←Speedometer light 1.7 ← ←Turn signal indicator light 1.7 ← ←High beam indicator light 1.7 ← ←Neutral indicator light 1.7 ← ←Oil pressure indicator light 1.7 ← ←

LE
P
7/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19


ITEM STANDARD LIMITRear brake pedal height 55

(2.2) —


4.0(0.16)

Rear 6.0 ± 0.2(0.236 ± 0.008)

5.5(0.22)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 38.180 – 38.256(1.5031 – 1.5061) —


Rear 38.098 – 38.148(1.4999 – 1.5019) —


Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 17 × MT3.00, 17M/C × MT3.00 —Rear 17 × MT3.50, 17M/C × MT3.50 —

Tire size Front 110/70-17M/C 54H —Rear 130/70-17M/C 62H —


Rear — 2.0(0.08)

SAM

8/8

P-02, 09, 19, 24, 28, 54P-19P-02, 03, 19, 24, 28, 33, 54P-19


TIRE PRESSURE

FUEL + OIL


(4.7) —

Front fork spring free length 343(13.5)

336(13.2)


Front fork oil type Fork oil #10 —Front fork oil capacity(each leg)

380 ml(12.8/13.4 US/lmp oz) —

Front fork inner tube O.D. 36.9(1.45) —

Rear shock absorber spring adjuster 4th position among 7 —



COLD INFLATION TIRE PRES-SURE


FRONT 225 2.25 33 225 2.25 33REAR 250 2.50 36 280 2.80 41


octane (R/2 + M/2) or 91 octaneor higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

P-03, 28, 33

Gasoline used should be graded 91 octane orhigher. An unleaded gasoline is recommended. Others

Fuel tank including reserve 19 L(5.0/4.2 US/lmp gal) P-33

20 L(5.3/4.4 US/lmp gal) Others

reserve 4.3 L(1.1/0.9 US/lmp gal)


(2.7/2.3 US/lmp qt)




38

GSF600/U/Z/ZU

1/8

E-02, 19, P-37E-19E-02, 19E-19


ITEM STANDARD LIMITValve diameter IN. 23

(0.9) —

EX. 20(0.8) —


EX. 0.18 – 0.23(0.007 – 0.009) —


IN. 0.020 – 0.047(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.955 – 4.970(0.1950 – 0.1957) —


Valve face thickness IN. & EX. — 0.5(0.02)




Valve spring free length (IN. & EX.) INNER — 35.0(1.38)

OUTER — 38.4(1.51)


55 – 65 N(5.6 – 6.6 kgf, 12.3 – 14.6 lbs)

at length 28 mm (1.10 in)—

OUTER126 – 147 N


—

2/8

E-02, 19, P-37E-19E-02, 19E-19




(1.3043 – 1.3059)32.83

(1.2925)

EX. 32.85 – 32.89(1.2933 – 1.2949)

32.55(1.2815)


0.150(0.0059)




Cam chain pin (at arrow “3”) 24th pin —Rocker arm I.D. IN. & EX. 12.000 – 12.018

(0.4724 – 0.4731) —




(10 – 15 kgf/cm2, 142 – 213 psi)800 kPa

(8 kgf/cm2,114 psi)


200 kPa(2 kgf/cm2,


(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 62.600 – 62.615

(2.4646 – 2.4652)62.690

(2.4681)Piston diameter 62.555 – 62.570

(2.4628 – 2.4634)Measure at 15 mm (0.6) from the skirt end.

62.480(2.4598)



2nd RN Approx. 7.0 (0.28) 5.6(0.22)


0.5(0.02)

2nd 0.3 – 0.5(0.012 – 0.020)

0.7(0.03)


2nd — 0.150(0.006)LE

P

3/8

E-02, 19, P-37E-19E-02, 19E-19


OIL PUMP


(0.040 – 0.041) —

2nd 0.81 – 0.83(0.032 – 0.033) —

Oil 1.51 – 1.53(0.059 – 0.060) —


2nd 0.77 – 0.79(0.030 – 0.031) —

Piston pin bore 18.002 – 18.008 (0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.996 – 18.000 (0.7085 – 0.7086)

17.980(0.7079)


(0.7091 – 0.7094)18.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 33.976 – 34.000(1.3376 – 1.3386) —


0.080(0.0031)



Crankshaft thrust bearing thickness Left side 2.350 – 2.500(0.0925 – 0.0984) —

Right side 2.425 – 2.450(0.0955 – 0.0965) —



Below 600 kPa (6.0 kgf/cm2, 85 psi) at 3 000 r/min

—

SAM

4/8

E-02, 19, P-37E-19E-02, 19E-19




(0.4 – 0.6) —

Clutch release screw 1/4 turn back —Clutch drive plate thickness 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Clutch drive plate claw width 15.9 – 16.0

(0.626 – 0.630)15.1

(0.594)Clutch drive plate distortion — 0.10


(1.87)

ITEM STANDARD LIMITPrimary reduction ratio 1.744 (75/43) —Final reduction ratio 3.133 (47/15) —Gear ratios 1st (Low) 3.083 (37/12) —

2nd 2.062 (33/16) —3rd 1.647 (28/17) —4th 1.400 (28/20) —5th 1.227 (27/22) —

6th (Top) 1.095 (23/21) —Gearshift fork to groove clearance No. 1, No. 2

& No. 30.1 – 0.3

(0.004 – 0.012)0.50

(0.020)Gearshift fork groove width No. 1&

No. 34.8 – 4.9

(0.189 – 0.193) —

No. 2 5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1& No. 3

4.6 – 4.7(0.181 – 0.185) —

No. 2 4.8 – 4.9(0.189 – 0.193) —

Drive chain Type RKFS50SMOZ1 —Links 112 links —



(0.98 – 1.38) —

Gearshift lever height 55 (2.2) —

39

5/8

E-02, 19, P-37E-19E-02, 19E-19

CARBURETOR


ITEMSPECIFICATION

E-02, 19 E-19 (U-type) P-37Carburetor type KEIHIN CVR32SS ← ←Bore size 32 mm ← ←I.D. No. 31FA 31FB 31F9Idle r/min 1 200 ± 100 r/min ← ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ← ←

Main jet (M.J.) #92 ← #98Jet needle (J.N.) N1QH ← N1QJNeedle jet (N.J.) 3.4 ← ←Throttle Valve (Th.V) 11° ← ←Pilot jet (P.J.) #35 ← #38Pilot screw (P.S.) PRE-SET

(1 and 3/8 turns back)PRE-SET


(1 and 3/4 turns back)Throttle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in) ← ←

Starter (enricher) plunger cable play

0.5 – 1.0 mm(0.02 – 0.04 in) ← ←

ITEM SPECIFICATION NOTEIgnition timing 4° B.T.D.C. at 1 200 r/minFiring order 1·2·4·3Spark plug Type NGK: CR9EK

DENSO: U27ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Pickup coil resistance Approx. 135 – 200 Ω Tester range:

(× 100 Ω)Signal generator peak voltage More than 1.0 VIgnition coil resistance Primary tap – tap

Approx. 2 – 4 ΩTester range:

(× 1 Ω)

Secondary Spark plug cap – Spark plug capApprox. 30 – 40 kΩ

Tester range: (× 1 kΩ)

Ignition coil primary peakvoltage More than 140 V

Generator Slip ring O.D. Limit: 14.0 (0.55)

DENSOBrush length Limit: 4.5 (0.18)

Generator Maximum output More than 550 W at 5 000 r/minRegulated voltage 13.6 – 14.4 V at 5 000 r/minStarter relay resistance 3 – 6 Ω

6/8

E-02, 19, P-37E-19E-02, 19E-19

WATTAGE Unit: W


ITEM SPECIFICATION NOTEBattery Type

designation FTX9-BS



Fuse sizeHeadlight

HI 10 ALO 10 A

Turn signal 15 AIgnition 10 AMeter 10 AMain 30 A


LO 55Parking or position light 5Brake light/Taillight 21/5 × 2Turn signal light 21 × 4Speedometer light LEDTachometer light LEDTurn signal indicator light LED × 2High beam indicator light LEDNeutral position indicator light LEDOil pressure indicator light LEDLicense plate light 5

ITEM STANDARD LIMITRear brake pedal height 50 (2.0) —Brake disc thickness Front 4.5 ± 0.2

(0.177 ± 0.008) 4.0

(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —

Brake fluid type DOT 4 —LE
P
7/8

E-02, 19, P-37E-19E-02, 19E-19


TIRE

ITEM STANDARD LIMITBrake caliper cylinder bore Front 30.230 – 30.306

(1.1902 – 1.1931) —

Rear 38.180 – 38.256 (1.5031 – 1.5061) —


Rear 38.098 – 38.148(1.5000 – 1.5019) —

Wheel rim runout Axial — 2.0 (0.08)

Radial — 2.0 (0.08)


Rear — 0.25(0.010)


ITEM STANDARD LIMITFront fork stroke 130 (5.1) —Front fork spring free length 366.1 (14.41) 358 (14.1)Front fork oil level 114 (4.5) —Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil —Front fork oil capacity (each leg) 508 ml (17.2/17.9 US/lmp oz) —Front fork inner tube O.D. 41 (1.6) —Rear wheel travel 126 (5.0) —Swingarm pivot shaft runout — 0.3 (0.01)

ITEM STANDARD LIMITCold inflation tire pressure(Solo/Dual riding) Front 225 kPa

(2.25 kgf/cm2, 33 psi) —


Tire size Front 120/60 ZR17 M/C (55W) —Rear 160/60 ZR17 M/C (69W) —

Tire type Front BRIDGESTONE BT56F —Rear BRIDGESTONE BT56R —


Front — 1.6 mm (0.06 in)

Rear — 2.0 mm (0.08 in)

SAM

8/8

E-02, 19, P-37E-19E-02, 19E-19




20 L (5.3/4.4 US/lmp gal)

Reserve only 4.5 L (1.2/1.0 US/lmp gal)Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Oil change 3 300 ml (3.5/2.9 US/lmp qt)

Filter change 3 500 ml (3.7/3.1 US/lmp qt)Overhaul 4 600 ml (4.9/4.0 US/lmp qt)

40

GSF600S/SU

1/9 E-02, 03, 19, 28, 33E-19



(0.9) —

EX. 20(0.8) —


EX. 0.18 – 0.23(0.007 – 0.009) —


IN. 0.020 – 0.047(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.955 – 4.970(0.1950 – 0.1957) —






Valve spring free length (IN. & EX.) INNER — 35.0(1.38)

OUTER — 38.4(1.51)


5.6 – 6.6 kgf(12.3 – 14.6 lbs)




—

2/9 E-02, 03, 19, 28, 33E-19




(1.3043 – 1.3059)32.83

(1.2925)

EX. 32.85 – 32.89(1.2933 – 1.2949)

32.55(1.2815)


0.150(0.0059)




Cam chain pin (at arrow “3”) 24th pin —Rocker arm I.D.

IN. & EX.12.000 – 12.018

(0.4724 – 0.4731)—

Rocker arm shaft O.D.IN. & EX.

11.973 – 11.984(0.4714 – 0.4718)

—



(10 – 15 kgf/cm2, 142 – 213 psi)800 kPa

(8 kgf/cm2,114 psi)


200 kPa(2 kgf/cm2,


(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 62.600 – 62.615

(2.4646 – 2.4652)62.690

(2.4681)Piston diameter 62.555 – 62.570


62.480(2.4598)



2nd RN Approx. 7.0 (0.28) 5.6(0.22)


0.5(0.02)

2nd 0.3 – 0.5(0.012 – 0.020)

0.7(0.03)


2nd — 0.150(0.006)LE

P

3/9 E-02, 03, 19, 28, 33E-19


OIL PUMP


(0.040 – 0.041) —

2nd 0.81 – 0.83(0.032 – 0.033) —

Oil 1.51 – 1.53(0.059 – 0.060) —


2nd 0.77 – 0.79(0.030 – 0.031) —

Piston pin bore 18.002 – 18.008 (0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.996 – 18.000 (0.7085 – 0.7086)

17.980(0.7079)


(0.7091 – 0.7094)18.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 33.976 – 34.000(1.3376 – 1.3386) —


0.080(0.0031)




Right side 2.425 – 2.450(0.0955 – 0.0965) —


ITEM STANDARD LIMITOil pump reduction ratio 1.898 (75/43 × 37/34) —Oil pressure (at 60 °C, 140 °F) Above 300 kPa (3.0 kgf/cm2, 43 psi))


—

SAM

4/9 E-02, 03, 19, 28, 33E-19




(0.4 – 0.6) —

Clutch release screw 1/4 turn back —Clutch drive plate thickness 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Clutch drive plate claw width 15.9 – 16.0

(0.626 – 0.630)15.1

(0.594)Clutch drive plate distortion — 0.10


(1.87)

ITEM STANDARD LIMITPrimary reduction ratio 1.744 (75/43) —Final reduction ratio 3.133 (47/15) —Gear ratios 1st (Low) 3.083 (37/12) —

2nd 2.062 (33/16) —3rd 1.647 (28/17) —4th 1.400 (28/20) —5th 1.227 (27/22) —

6th (Top) 1.095 (23/21) —Gearshift fork to groove clearance No. 1, No. 2

& No. 30.1 – 0.3

(0.004 – 0.012)0.50

(0.020)Gearshift fork groove width No. 1&

No. 34.8 – 4.9

(0.189 – 0.193) —

No. 2 5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1& No. 3

4.6 – 4.7(0.181 – 0.185) —

No. 2 4.8 – 4.9(0.189 – 0.193) —

Drive chain Type RKFS50SMOZ1 —Links 112 links —



(0.98 – 1.38) —

Gearshift lever height 55 (2.2) —

41

5/9 E-02, 03, 19, 28, 33E-19

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-02, 19 E-03, 28Carburetor type KEIHIN CVR32SS ←Bore size 32 mm ←I.D. No. 31FA 31F7Idle r/min 1 200 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ←

Main jet (M.J.) #92 ←Jet needle (J.N.) N1QH N1QLNeedle jet (N.J.) 3.4 ←Throttle Valve (Th.V) 11° ←Pilot jet (P.J.) #35 ←Pilot screw (P.S.) PRE-SET



2.0 – 4.0 mm(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

ITEMSPECIFICATION

E-19 (U-type) E-33Carburetor type KEIHIN CVR32SS ←Bore size 32 mm ←I.D. No. 31FB 31F8Idle r/min 1 200 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04) ←

Main jet (M.J.) #92 ←Jet needle (J.N.) N1QH N1QLNeedle jet (N.J.) 3.4 ←Throttle Valve (Th.V) 11° ←Pilot jet (P.J.) #35 ←Pilot screw (P.S.) PRE-SET



2.0 – 4.0 mm(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

6/9 E-02, 03, 19, 28, 33E-19


ITEM SPECIFICATION NOTEIgnition timing 4° B.T.D.C. at 1 200 r/min E-03, 28, 33

10° B.T.D.C. at 1 200 r/min The othercountries

Firing order 1·2·4·3Spark plug Type NGK: CR9EK

DENSO: U27ETR

Gap 0.6 – 0.7(0.024 – 0.028)




(× 1 Ω)


Tester range:(× 1 kΩ)

Ignition coil primary peakvoltage More than 140 V

Generator Slip ring O.D. Limit: 14.0 (0.55)DENSO

Brush length Limit: 4.5 (0.18)Generator Maximum output More than 550 W at 5 000 r/minRegulated voltage 13.6 – 14.4 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type

designation FTX9-BS



Fuse sizeHeadlight

HI 10 ALO 10 A


LE
P
7/9 E-02, 03, 19, 28, 33E-19

WATTAGE Unit: W


ITEMSPECIFICATION

E-03, 28, 33 The other countriesHeadlight HI 60 ←

LO 51 ←Parking or position light 5Brake light/Taillight 21/5 × 2 ←Turn signal light 21 × 4 ←Speedometer light LED ←Tachometer light LED ←Turn signal indicator light LED × 2 ←High beam indicator light LED ←Neutral position indicator light LED ←Oil pressure indicator light LED ←License plate light 5 ←

ITEM STANDARD LIMITRear brake pedal height 50 (2.0) —Brake disc thickness Front 4.5 ± 0.2

(0.177 ± 0.008) 4.0

(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 38.180 – 38.256 (1.5031 – 1.5061) —


Rear 38.098 – 38.148(1.5000 – 1.5019) —

Wheel rim runout Axial — 2.0 (0.08)

Radial — 2.0 (0.08)


Rear — 0.25(0.010)

SAM

8/9 E-02, 03, 19, 28, 33E-19


TIRE

ITEM STANDARD LIMITWheel rim size Front 17 M/C × MT3.50 —

Rear 17 M/C × MT4.50 —

ITEM STANDARD LIMIT NOTEFront fork stroke 130 (5.1) —Front fork spring free length — 356 (14.0)Front fork oil level 116 (4.6) — E-03, 28, 33

112 (4.4) — The othercountries

Rear wheel travel 126 (5.0) —Swingarm pivot shaft runout — 0.3 (0.01)


(2.25 kgf/cm2, 33 psi) —



Tire type Front BRIDGESTONE BT56F —Rear BRIDGESTONE BT56R —


Front — 1.6 mm (0.06 in)

Rear — 2.0 mm (0.08 in)

42

9/9 E-02, 03, 19, 28, 33E-19



E-03, 28, 33


The othercountries


19 L (5.0/4.2 US/lmp gal) E-33

20 L (5.3/4.4 US/lmp gal) The othercountries

Reserve only 4.5 L (1.2/1.0 US/lmp gal)Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Oil change 3 300 ml (3.5/2.9 US/lmp qt)


Front fork oil type Fork oil #10Front fork oil capacity (each leg) 506 ml (17.1/17.8 US/lmp oz) E-03, 28, 33

510 ml (17.2/18.0 US/lmp oz) The othercountries


LE
P GSF1200/Z
1/9

E-02, 03, 19E-02,19


ITEM STANDARD LIMITValve diameter IN. 28.5

(1.12) —

EX. 25(1.0) —


EX. 0.18 – 0.23(0.007 – 0.009) —

Valve-guide to valve-stem clear-ance IN. 0.020 – 0.047

(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.945 – 4.960(0.1947 – 0.1953) —







(1.38)

OUTER — 37.8(1.49)


53 – 65 N(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)


OUTER131 – 151 N


—

SAM

2/9

E-02, 03, 19E-02,19




(1.3220 – 1.3236)33.28

(1.3102)

EX. 32.65 – 32.69(1.2854 – 1.2870)

32.35(1.2736)


0.150(0.0059)





(0.4724 – 0.4731) —




(12.5 kgf/cm2, 178 psi)875 kPa

(8.75 kgf/cm2, 124 psi)Compression pressure difference — 200 kPa

(2 kgf/cm2, 28 psi)Piston-to-cylinder clearance 0.040 – 0.070

(0.0016 – 0.0028)0.120

(0.0047)Cylinder bore 79.000 – 79.015

(3.1102 – 3.1108)79.080

(3.1134)Piston diameter 78.945 – 78.960

(3.1081 – 3.1087)Measure 15 mm (0.6 in) from the skirt end.

78.880(3.1055)


Piston ring free end gap 1st R Approx. 10 (0.39) 8.0(0.31)

2nd RN Approx. 12 (0.47) 9.6(0.38)


0.5(0.02)

2nd 0.35 – 0.50(0.014 – 0.020)

1.0(0.04)

Piston-ring to piston-ring-groove clearance 1st — 0.180

(0.007)

2nd — 0.150(0.006)

43

3/9

E-02, 03, 19E-02,19



(0.040 – 0.041) —

2nd 1.01 – 1.03(0.040 – 0.041) —

Oil 2.01 – 2.03(0.079 – 0.080) —


2nd 0.970 – 0.990(0.038 – 0.039) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.996 – 20.000(0.7872 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4961) —


0.080(0.0031)




Right side 2.420 – 2.440(0.0953 – 0.0961) —


4/9

E-02, 03, 19E-02,19

OIL PUMP



ITEM STANDARD LIMITOil pump reduction ratio 1.703 (72/46 × 37/34) —Oil pressure (at 60°C,140°F) Above 300 kPa (3.0 kgf/cm2, 43 psi)


—

ITEM STANDARD LIMITClutch drive plate thickness 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Clutch drive plate claw width — 13.0

(0.51)Clutch driven plate distortion — 0.10

(0.004)Clutch spring free height — 3.1

(0.12)Clutch master cylinder bore 14.000 – 14.043

(0.5511 – 0.5529) —

Clutch master cylinder piston diam. 13.957 – 13.984(0.5495 – 0.5506) —



35.650 – 35.675(1.4035 – 1.4045) —

ITEM STANDARD LIMITPrimary reduction ratio 1.565 (72/46) —Final reduction ratio 3.000 (45/15) —Gear ratios 1st (low) 2.384 (31/13) —

2nd 1.631 (31/19) —3rd 1.250 (25/20) —4th 1.045 (23/22) —

5th (top) 0.913 (21/23) —Gearshift-fork to gearshift-fork- groove clearance

No. 1, No. 2& No. 3

0.1 – 0.3(0.004 – 0.012)

0.50(0.020)

Gearshift fork groove width No. 1, No. 2& No. 3

5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1, No. 2& No. 3

4.8 – 4.9(0.189 – 0.193) —

Drive chain Type RK GB50GSVZ3 —Links 110 links —



(0.8 – 1.2) —

Gearshift lever height 55(2.2) —LE

P

5/9

E-02, 03, 19E-02,19

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-02, 19Carburetor type MIKUNI BSR36SSBore size 36 mmI.D. No. 32F0Idle r/min 1 200 ± 100 r/minFloat height 13.0 ± 1.0 mm

(0.51 ± 0.04 in)Main jet (M.J.) #Jet needle (J.N.) 5C70-3rdNeedle jet (N.J.)Throttle valve (Th. V.) #100Pilot jet (P.J.) #Pilot screw (P.S.) 3 turns backThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in)


0.5 – 1.0 mm(0.02 – 0.04 in)

ITEMSPECIFICATION

E-03Carburetor type MIKUNI BSR36SSBore size 36 mmI.D. No. 32F1Idle r/min. 1 300 ± 100 r/minFloat height 13.0 ± 1.0 mm

(0.51 ± 0.04 in)Main jet (M.J.) #Jet needle (J.N.) 5C71Needle jet (N.J.)Throttle valve (Th. V.) #100Pilot jet (P.J.) #Pilot screw (P.S.) PRE-SETThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in)


0.5 – 1.0 mm(0.02 – 0.04 in)

SAM
v
6/9

E-02, 03, 19E-02,19


ITEM SPECIFICATION NOTEIgnition timing 7° B.T.D.C. at 1 200 r/minFiring order 1•2•4•3Spark plug Type NGK: JR9B

Gap 0.6 – 0.7(0.024 – 0.028)




(× 1 Ω)



Ignition coil primary peak voltage More than 140 VGenerator Slip ring

O.D. Limit: 14.0 (0.55)DENSO

Brush length Limit: 4.5 (0.18)

Generator maximum output More than 550 W at 5 000 r/minRegulated voltage 13.5 – 15 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type

designation YTX12-BS

Capacity 12 V 36.0 kC (10 Ah)/10HRStandard


Fuse sizeHeadlight

HI 10 ALO 10 A


44

7/9

E-02, 03, 19E-02,19

WATTAGE Unit: W


ITEMSPECIFICATION

E-03 E-02, 19Headlight HI 60 ←



(2.2) —


4.0(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —

Brake caliper cylinder bore

FrontLeading 24.000 – 24.076

(0.9449 – 0.9479) —

Trailing 27.000 – 27.076(1.0630 – 1.0660) —

Rear 38.180 – 38.256(1.5031 – 1.5061) —

Brake caliper piston diameter


(0.9419 – 0.9439) —

Trailing 26.920 – 26.970(1.0598 – 1.0618) —

Rear 38.098 – 38.148(1.4999 – 1.5019) —


Radial — 2.0(0.08)

8/9

E-02, 03, 19E-02,19


TIRE

ITEM STANDARD LIMITWheel axle runout Front — 0.25

(0.010)

Rear — 0.25(0.010)



(5.1) —






(2.50 kgf/cm2, 36 psi) —



Tire type Front MACADAM 90XM —Rear MACADAM 90XM —

Tire tread depth(Recommended depth) Front — 1.6 mm

(0.06 in)

Rear — 2.0 mm(0.08 in)

LE
P
9/9

E-02, 03, 19E-02,19


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(MethyI Tertiary ButyI Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.

E-03


E-02, 19


20 L (5.3/4.4 US/lmp gal)

Reserve only

4.4 L(1.2/1.0 US/lmp gal)


(3.5/2.9 US/lmp qt)Filter

change3 500 ml

(3.7/3.1 US/lmp qt)


Front fork oil type Fork oil SS-08 or equivalent fork oilFront fork oil capacity (each leg) 507 ml

(17.1/17.9 US/Imp oz)Brake fluid type DOT 4

SAM

45

GSF1200S

1/9 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITValve diameter IN. 28.5

(1.12) —

EX. 25(1.0) —


EX. 0.18 – 0.23(0.007 – 0.009) —

Valve-guide to valve-stemclearance IN. 0.020 – 0.047

(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.945 – 4.960(0.1947 – 0.1953) —







(1.38)

OUTER — 37.8(1.49)


53 – 65 N(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)


OUTER131 – 151 N


—

2/9 E-02, 03, 19, 24, 28, 33


CYLINDER + PISTON + PISTON RING Unit: mm(in)


(1.3220 – 1.3236)33.28

(1.3102)

EX. 32.65 – 32.69(1.2854 – 1.2870)

32.35(1.2736)


0.150(0.0059)





(0.4724 – 0.4731) —




(12.5 kgf/cm2, 178 psi) 875 kPa



(0.0016 – 0.0028) 0.120

(0.0047)Cylinder bore 79.000 – 79.015

(3.1102 – 3.1108) 79.080(3.1134)

Piston diameter 78.945 – 78.960(3.1081 – 3.1087)

Measure 15 mm (0.6 in) from the skirt end. 78.880(3.1055)


Piston ring free end gap 1st R Approx. 10 (0.39) 8.0(0.31)

2nd RN Approx. 12 (0.47) 9.6(0.38)


0.5(0.02)

2nd 0.35 – 0.50(0.014 – 0.020)

1.0(0.04)

LE
P
3/9 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITPiston-ring to piston-ring-grooveclearance 1st — 0.180

(0.007)

2nd — 0.150(0.006)


2nd 1.01 – 1.03(0.040 – 0.041) —

Oil 2.01 – 2.03(0.079 – 0.080) —


2nd 0.970 – 0.990(0.038 – 0.039) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.996 – 20.000(0.7872 – 0.7874)

19.980 (0.7866)


(0.7878 – 0.7881)20.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4961) —


0.080(0.0031)



Crankshaft thrust bearing thickness Left side 2.360 – 2.520

(0.0929 – 0.0992) —

Right side 2.420 – 2.440(0.0953 – 0.0961) —


SAM

4/9 E-02, 03, 19, 24, 28, 33

OIL PUMP





—

ITEM STANDARD LIMITClutch drive plate thickness 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Clutch drive plate claw width — 13.0

(0.51)Clutch driven plate distortion — 0.10

(0.004)Clutch spring free height — 3.1


(0.5511 – 0.5529) —

Clutch master cylinder piston diam.

13.957 – 13.984(0.5495 – 0.5506) —



35.650 – 35.675(1.4035 – 1.4045) —


2nd 1.631 (31/19) —3rd 1.250 (25/20) —4th 1.045 (23/22) —

5th (top) 0.913 (21/23) —Gearshift-fork to gearshift-fork- groove clearance

No. 1, No. 2& No. 3

0.1 – 0.3(0.004 – 0.012)

0.50(0.020)

Gearshift fork groove width No. 1, No. 2& No. 3

5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1, No. 2& No. 3

4.8 – 4.9(0.189 – 0.193) —


20-pitch length — 319.4(12.57)



46

5/9 E-02, 03, 19, 24, 28, 33

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-02, 19, 24 E-03, 28Carburetor type MIKUNI BSR36SS ←Bore size 36 mm ←I.D. No. 32F0 32F1Idle r/min 1 200 ± 100 r/min 1 300 ± 100 r/minFloat height 13.0 ± 1.0 mm

(0.51 ± 0.04 in) ←

Main jet (M.J.) # ←Jet needle (J.N.) 5C70-3rd 5C71-1stNeedle jet (N.J.) ←Throttle valve (Th. V.) #100 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) 3 turns back PRE-SETThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

ITEMSPECIFICATION

E-33Carburetor type MIKUNI BSR36SSBore size 36 mmI.D. No. 32F2Idle r/min 1 300 ± 100 r/minFloat height 13.0 ± 1.0 mm

(0.51 ± 0.04 in)Main jet (M.J.) # Jet needle (J.N.) 5C71-1stNeedle jet (N.J.)Throttle valve (Th. V.) # 100Pilot jet (P.J.) # Pilot screw (P.S.) PRE-SETThrottle cable play(pulling cable)

2.0 – 4.0 mm(0.08 – 0.16 in)


0.5 – 1.0 mm(0.02 – 0.04 in)

6/9 E-02, 03, 19, 24, 28, 33


ITEM SPECIFICATION NOTEIgnition timing 7° B.T.D.C. at 1 200 r/minFiring order 1•2•4•3Spark plug Type NGK: JR9B

Gap 0.6 – 0.7(0.024 – 0.028)




(× 1 Ω)



Ignition coil primary peak voltage More than 140 V

Generator Slip ring O.D. Limit: 14.0 (0.55)DENSO

Brush length Limit: 4.5 (0.18)Generator maximum output More than 550 W at 5 000 r/minRegulated voltage 13.5 – 15 V at 5 000 r/minStarter relay resistance 3 – 5 ΩBattery Type designation YTX12-BS

Capacity 12 V 36.0 kC (10 Ah)/10HRStandard


Fuse sizeHeadlight

HI 10 ALO 10 A


LE
P
7/9 E-02, 03, 19, 24, 28, 33

WATTAGE Unit: W


ITEMSPECIFICATION

E-03, 24, 28, 33 The other countriesHeadlight HI 60 + 51 ←



(2.2) —


4.0(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —



(0.9449 – 0.9479) —

Trailing 27.000 – 27.076(1.0630 – 1.0660) —

Rear 38.180 – 38.256(1.5031 – 1.5061) —

Brake caliper piston diameter


(0.9419 – 0.9439) —

Trailing 26.920 – 26.970(1.0598 – 1.0618) —

Rear 38.098 – 38.148(1.4999 – 1.5019) —

SAM

8/9 E-02, 03, 19, 24, 28, 33


TIRE

ITEM STANDARD LIMITWheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)



(5.1) —

Front fork spring free length — 366(14.4) E-03, 28, 33

— 370(14.6)

The othercountries

Front fork oil level 107(4.2) — E-03, 28, 33

105(4.1) — The other

countriesRear wheel travel 125

(4.9) —


ITEM STANDARD LIMITCold inflation tire pressure (Solo/Dual riding) Front 250 kPa

(2.50 kgf/cm2, 36 psi) —


Tire size Front 120/70ZR17M/C (58W) —Rear 180/55ZR17M/C (73W) —

Tire type Front MICHELIN MACADAM 100X B —Rear MICHELIN MACADAM 100X —

Tire tread depth(Recommended depth) Front — 1.6 mm

(0.06 in)

Rear — 2.0 mm(0.08 in)

47

9/9 E-02, 03, 19, 24, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane or 91 octane (R/2 + M/2) or higher rated bythe Research Method.Gasoline containing MTBE (MethyI Tertiary ButyIEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33


The other countries

Fuel tank capacityIncluding reserve

19 L(5.0/4.2 US/lmp gal) E-33

20 L(5.2/4.4 US/lmp gal)

The other countries

Reserve only

4.4 L(1.2/1.0 US/lmp gal)



change3 500 ml

(3.7/3.1 US/lmp qt)


Front fork oil type Fork oil SS-08 or equivalent fork oilFront fork oil capacity (each leg) 507 ml

(17.1/17.9 US/lmp oz) E-03, 28, 33

509 ml(17.2/17.9 US/Imp oz)

The other countries


LE
P GSX600F
1/9 E-02, 03, 19, 28, 33



(1.9) —

EX. 20(0.8) —


EX. 0.18 – 0.23(0.007 – 0.009) —

Valve guide-to-valve stem clearance IN. 0.020 – 0.047

(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.955 – 4.970(0.1950 – 0.1957) —







INNER — 35.0 (1.38)

OUTER — 38.4(1.51)


5.6 – 6.6 kgf(12.3 – 14.6 lbs)




—

SAM

2/9 E-02, 03, 19, 28, 33




IN.E-18 32.38 – 32.42

(1.2748 – 1.2764)32.08

(1.2630)

Others 33.13 – 33.17(1.3043 – 1.3059)

32.83(1.2925)

EX.E-18 32.10 – 32.14

(1.2638 – 1.2654)31.80

(1.2520)

Others 32.85 – 32.89(1.2933 – 1.2949)

32.55(1.2815)


0.150(0.0059)





(0.4724 – 0.4731) —




(10 – 15 kgf/cm2, 142 – 213 psi) 800 kPa



(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 62.600 – 62.615

(2.4646 – 2.4652)62.690

(2.4681)Piston diameter 62.555 – 52.570


62.480(2.4598)



2nd RN Approx. 7.0 (0.28) 5.6(0.22)


0.5(0.02)

2nd 0.3 – 0.5(0.012 – 0.020)

0.7(0.03)

Piston ring-to-piston ring groove clearance 1st — 0.180

(0.007)

2nd — 0.150(0.006)

48

3/9 E-02, 03, 19, 28, 33


OIL PUMP


(0.040 – 0.041) —

2nd 0.81 – 0.83(0.032 – 0.033) —

Oil 1.51 – 1.53(0.059 – 0.060) —


2nd 0.77 – 0.79(0.030 – 0.031) —

Piston pim bore 18.002 – 18.008(0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.996 – 18.000(0.7085 – 0.7086)

17.980(0.7079)


(0.7091 – 0.7094)18.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 37.976 – 34.000(1.3376 – 1.3386) —


0.080(0.0031)



Crankshaft jounal width 24.00 – 24.05(0.945 – 0.947) —


ITEM STANDARD LIMITOil pump reduction ratio 1.898 (75/43 × 37/34) —Oil pressure (at 60°C, 140°F) Above 300 kPa (3.0 kgf/cm2, 43 psi)


—

4/9 E-02, 03, 19, 28, 33




(0.4 – 0.6) —

Clutch release screw 1/4 turn back —Clutch drive plate thickness No. 1 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)

No. 2 3.42 – 3.58(0.135 – 0.141)

3.12(0.123)

Clutch drive plate claw width No. 1 & No. 2

15.9 – 16.0(0.626 – 0.630)

15.1(0.594)

Clutch drive plate distortion — 0.10(0.004)



2nd 2.062 (33/16) —3rd 1.647 (28/17) —4th 1.400 (28/20) —5th 1.227 (27/22) —

6th (top) 1.095 (23/21) —Gearshift fork-to-gearshift fork groove clearance

No. 1, No. 2 & No. 3

0.1 – 0.3(0.004 – 0.012)

0.50(0.020)

Gearshift fork groove width No. 1 & No. 3

4.8 – 4.9(0.189 – 0.193) —

No. 2 5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1 & No. 3

4.6 – 4.7(0.181 – 0.185) —

No. 2 4.8 – 4.9(0.189 – 0.193) —

Drive chain Type RK50SMOZ1 —Links 118 links —



(0.79 – 1.18) —


LE
P
5/9 E-02, 03, 19, 28, 33

CABURETOR

CABURETOR

ITEMSTD/SPEC.

E-03, 28 E-33Caburetor type MIKUNI BSR32SS ←Bore size 32 mm ←I.D. No. 19E3 19E4Idle r/min 1 200 ± 100 r/min 1 300 ± 100 r/minFloat height 13.0 ± 0.5 mm

(0.51 ± 0.02 in) ←

Main jet (M.J.) Nos. 1&4: #Nos. 2&3: # ←

Jet needle (J.N.) 5DH30-54 ←Needle jet (N.J.) ←Throttle valve (Th.V.) #110 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET ←Throttle cable play (pulling cable) 2.0 – 4.0 mm

(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

ITEMSTD/SPEC.

E-02, 19Caburetor type MIKUNI BSR32SSBore size 32 mmI.D. No. 19E6Idle r/min 1 200 ± 100 r/minFloat height 13.0 ± 0.5 mm

(0.51 ± 0.02 in)Main jet (M.J.) No. 1&4: #

No. 2&3: #Jet needle (J.N.) 5DH53- 3rdNeedle jet (N.J.)Throttle valve (Th.V.) #110Pilot jet (P.J.) #Pilot screw (P.S.) 3 and 1/4 turns backThrottle cable play (pulling cable) 2.0 – 4.0 mm

(0.08 – 0.16 in)Starter (enricher) plunger cable play

0.5 – 1.0 mm(0.02 – 0.04 in)

SAM

6/9 E-02, 03, 19, 28, 33


ITEM STD/SPEC. NOTEIgnition timing 4° B.T.D.C. at 1 200 r/min E-03, 28, 33

10° B.T.D.C. at 1 200 r/min The othercountries

Firing order 1·2·4·3Spark plug Type NGK: CR9EK

DENSO: U27ETR

Gap 0.6 – 0.7(0.024 – 0.028)



Approx. 2 – 4 kΩTester range:

(× 1 Ω)


Tester range:(× 1 Ω)




Generator maximaum output Approx. 550 W at 5 000 r/minRegulated voltage 13.6 – 14.4 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX9-BS



Fuze size

HeadlightHI

15 A E-03, 28, 3310 A Others

LO15 A E-03, 28, 3310 A Others


49

7/9 E-02, 03, 19, 28, 33

WATTAGE Unit: W


ITEMSPECIFICATION

E-03, 28, 33 The other countriesHeadlight HI 60 × 2 55

LO 55 × 2 55Parking or position light 5 ←Brake light/taillight 21/5 × 2 ←Turn signal light 21 × 4 ←Speedometer light 1.7 × 2 ←Tachometer light 1.7 ←Fuel meter light 1.7 ←Turn signal indicator lights 1.4 × 2 ←High beam indicator light 1.4 ←Neutral position indicator light 1.4 ←Oil pressure indicator light 1.4 ←License plate light 5 ←

ITEM STD/SPEC. LIMITRear brake pedal height 54

(2.1) —


4.0(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 38.180 – 38.256(1.5031 – 1.5061) —


Rear 38.098 – 38.148(1.5000 – 1.5019) —

8/9 E-02, 03, 19, 28, 33


TIRE PRESSURE

ITEM STD/SPEC. LIMITWheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)


Tire size Front 120/70 ZR17 M/C (58 W) —Rear 150/70 ZR17 M/C (69 W) —


Rear — 2.0(0.08)

Tire type Front MICHELIN MACADAM 100X B —Rear MICHELIN MACADAM 100X —


(5.1) —







FRONT 225 2.25 33 225 2.25 33REAR 250 2.50 36 250 2.50 36

LE
P
9/9 E-02, 03, 19, 28, 33



E-03, 28, 33

Gasoline used should be graded 91 octone orhigher. An unleaded gasoline is recommended.

The other countries


18.5 L(4.9/4.1 US/lmp gal) E-33

20 L(5.3/4.4 US/lmp gal)

The other countries

Reserve only 5.0 L(1.3/1.1 US/lmp gal)

Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Change 3 300 ml

(3.5/2.9 US/lmp qt)



Fuel fork oil type Fork oil #10Front fork oil capacity (each leg) 499 ml


SAM

50

GSX750F

1/9 E-02, 03, 19, 24, 28, 33P-37



(1.1) —

EX. 24(0.9) —


EX. 0.18 – 0.23(0.007 – 0.009) —

Valve guide-to-valve stem clearance IN. 0.020 – 0.047

(0.0008 – 0.0019) —

EX. 0.040 – 0.067(0.0016 – 0.0026) —



Valve stem O.D. IN. 4.965 – 4.980(0.1955 – 0.1961) —

EX. 4.945 – 4.960(0.1947 – 0.1953) —







INNER — 33.9 (1.33)

OUTER — 37.3(1.47)


6.0 – 6.8 kgf(13.2 – 15.0 lbs)




—

2/9 E-02, 03, 19, 24, 28, 33P-37




(1.2858 – 1.2878)32.36

(1.2740)

EX. 32.65 – 32.70(1.2854 – 1.2874)

32.35(1.2736)


0.150(0.0059)





(0.4724 – 0.4731) —




(10 – 15 kgf/cm2, 142 – 213 psi) 800 kPa



(0.0022 – 0.0026) —

Cylinder bore 70.000 – 70.015(2.7559 – 2.7565)

70.075(2.7589)

Piston diameter 69.940 – 69.955(2.7535 – 2.7541)

Measure at 15 mm (0.6) from the skirt end.69.880

(2.7512)



2nd RN Approx. 10.5 (0.41) 8.4(0.33)


0.5(0.02)

2nd 0.25 – 0.40(0.010 – 0.016)

0.7(0.03)

Piston ring-to-piston ring groove clearance 1st — 0.180

(0.007)

2nd — 0.150(0.006)

LE
P
3/9 E-02, 03, 19, 24, 28, 33P-37


OIL PUMP


(0.040 – 0.041) —

2nd 1.004 – 1.027(0.0395 – 0.0404) —

Oil 1.51 – 1.53(0.059 – 0.060) —


2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pim bore 18.002 – 18.008(0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.992 – 18.000(0.7083 – 0.7086)

17.980(0.7079)


(0.7091 – 0.7094)18.040


(0.004 – 0.008)0.30


(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 33.976 – 34.000(1.3376 – 1.3386) —


0.080(0.0031)



Crankshaft jounal width 24.00 – 24.05(0.945 – 0.947) —


ITEM STD/SPEC. LIMITOil pump reduction ratio 1.898 (75/43 × 37/34) —Oil pressure (at 60°C, 140°F) Above 300 kPa (3.0 kgf/cm2, 43 psi)


—

SAM

4/9 E-02, 03, 19, 24, 28, 33P-37




(0.4 – 0.6) —

Clutch release screw 1/4 turn back —Clutch drive plate thickness No. 1 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)

No. 2 3.42 – 3.58(0.135 – 0.141)

3.12(0.123)

Clutch drive plate claw width No. 1 & No. 2

15.9 – 16.0(0.626 – 0.630)

15.1(0.594)

Clutch drive plate distortion — 0.10(0.004)


ITEM STD/SPEC. LIMITPrimary reduction ratio 1.744 (75/43) —Final reduction ratio 3.000 (45/15) —Gear ratios 1st (low) 3.083 (37/12) —

2nd 2.062 (33/16) —3rd 1.647 (28/17) —4th 1.400 (28/20) —5th 1.227 (27/22) —

6th (top) 1.095 (23/21) —Gearshift fork-to-gearshift fork groove clearance

No. 1, No. 2 & No. 3

0.1 – 0.3(0.004 – 0.012)

0.50(0.020)

Gearshift fork groove width No. 1 & No. 3

4.8 – 4.9(0.189 – 0.193) —

No. 2 5.0 – 5.1(0.197 – 0.201) —

Gearshift fork thickness No. 1 & No. 3

4.6 – 4.7(0.181 – 0.185) —

No. 2 4.8 – 4.9(0.189 – 0.193) —




(0.79 – 1.18) —


51

5/9 E-02, 03, 19, 24, 28, 33P-37

CABURETOR

CABURETOR

ITEMSPECIFICATION

E-24 E-02, 19Caburetor type MIKUNI BSR36 ←Bore size 36 mm ←I.D. No. 08F0 08F6Engine idle speed 1 200 ± 100 r/min ←Float height 13.0 ± 0.5 mm

(0.51 ± 0.02 in) ←

Main jet (M.J.) #117.5 ←Jet needle (J.N.) 5DF20-52-3 5DF25-3Needle jet (N.J.) P-0 P-0MThrottle valve (Th.V.) #100 ←Pilot jet (P.J.) #15 #12.5Pilot screw (P.S.) No.1&4: 2 turns back

No. 2&3 : 1 and 1/2 turns back 3 and 1/2 turns back

Throttle cable play (pulling cable) 2.0 – 4.0 mm(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

ITEMSPECIFICATION

E-03, 28 E-33Caburetor type MIKUNI BSR36 ←Bore size 36 mm ←Engine idle speed 08F3 08F4Idle r/min 1 200 ± 100 r/min ←Float height 13.0 ± 0.5 mm

(0.51 ± 0.02 in) ←

Main jet (M.J.) # ←Jet needle (J.N.) 5DF21-53 5DF22-53Needle jet (N.J.) ←Throttle valve (Th.V.) #100 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET ←Throttle cable play (pulling cable) 2.0 – 4.0 mm

(0.08 – 0.16 in) ←


0.5 – 1.0 mm(0.02 – 0.04 in) ←

6/9 E-02, 03, 19, 24, 28, 33P-37


ITEM SPECIFICATION NOTEFiring order 1·2·4·3Spark plug Type NGK: CR9EK

DENSO: U27ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Pickup coil resistance Approx. 135 – 200 ΩSignal generator peak voltage More than 1.0 VIgnition coil resistance Primary Approx. 2 – 4 kΩ tap – tap

Secondary Approx. 30 – 40 kΩ Spark plug cap – Spark plug cap




Generator maximaum output Approx. 550 W at 5 000 r/minRegulated voltage 13.6 – 14.4 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX9-BS



Fuse size

HeadlightHI

15 A E-03, 24, 28, 3310 A Others

LO15 A E-03, 24, 28, 3310 A Others

Ignition 10 ATurn signal 15 A

Meter 10 AMain 30 A

LE
P
7/9 E-02, 03, 19, 24, 28, 33P-37

WATTAGE Unit: W


ITEMSPECIFICATION

E-03, 24, 28, 33 The other countriesHeadlight HI 60 × 2 55

LO 55 × 2 55Parking or position light 5 ←Brake light/Taillight 21/5 × 2 ←Turn signal light 21 × 4 ←Speedometer light 1.7 × 2 ←Tachometer light 1.7 ←Fuel meter light 1.7 ←License plate light 5 ←Turn signal indicator light 1.4 × 2 ←High beam indicator light 1.4 ←Neutral position indicator light 1.4 ←Oil pressure indicator light 1.4 ←

ITEM STD/SPEC. LIMITRear brake pedal height 55

(2.17) —


4.0(0.16)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 38.180 – 38.256(1.5031 – 1.5061) —


Rear 38.098 – 38.148(1.5000 – 1.5019) —

SAM

8/9 E-02, 03, 19, 24, 28, 33P-37


TIRE PRESSURE


(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)




Rear — 2.0(0.08)

ITEM STD/SPEC. LIMIT NOTEFront fork stroke 130

(5.1) —


359(14.13)


Front fork damping force adjuster Rebound 3/4 —Rear shock absorber gas pressure (N2 gas)

1 000 kPa(10 kgf/cm2, 142 psi) —

Rear shock absorber damping force adjuster Rebound

1/4 — E-03, 33

2/4 — The other countries

CompressionAt punch mark

(About 1 and 3/4 turns out)

—

Rear shock absorber spring set length

158.5(6.24) — E-03, 33

160(6.30) — The other

countriesRear wheel travel 142

(5.6) —




FRONT 225 2.25 33 225 2.25 33REAR 250 2.50 36 250 2.50 36

52

9/9 E-02, 03, 19, 24, 28, 33P-37

FUEL + OILsITEM SPECIFICATION NOTE


E-03, 28, 33

Gasoline used should be graded 91 octone orhigher. An unleaded gasoline is recommended.

The other countries


18.5 L(4.9/4.1 US/lmp gal) E-33

20.0 L(5.3/4.4 US/lmp gal)

The other countries

Reserve only 5.0 L(1.3/1.1 US/lmp gal)

Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Oil change 3 300 ml

(3.5/2.9 US/lmp qt)Oil and filter

change3 500 ml


overhaul4 700 ml

(5.0/4.1 US/lmp qt)Fuel fork oil type Fork oil #10Front fork oil capacity (each leg) 513 ml


LE
P GSX1300R/RZ/RUD/RUF
1/9 E-02, 03, 19, 24, 28, 33, P-37E-19


ITEM STD/SPEC. LIMITValve diam. IN. 33

(1.30) —

EX. 27.5(1.08) —


EX. 0.20 – 0.30(0.008 – 0.012) —

Valve guide to valve stem clearance IN. 0.010 – 0.037

(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.975 – 4.490(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —







INNER — 35.1 (1.38)

OUTER — 45.2(1.77)


3.1 – 3.5 kgf(6.83 – 7.72 lbs)


OUTER 15.5 – 17.9 kgf


—

SAM

2/9 E-02, 03, 19, 24, 28, 33, P-37E-19



ITEM STD/SPEC. LIMITCam height IN. 36.780 – 36.848

(1.4480 – 1.4506) 36.48(1.436)

EX. 35.480 – 35.548(1.3968 – 1.3995)

35.18(1.385)


0.150(0.0059)





(0.008)

ITEM STD/SPEC. LIMITCompression pressure 1 200 – 1 600 kPa

(12 – 16 kgf/cm2, 17 – 228 psi) 900 kPa



(0.0008 – 0.0012)0.120

(0.0047)Cylinder bore 81.000 – 81.015

(3.1890 – 3.1896) Nicks or



80.880(3.1842)



2nd RN Approx. 11.4 (0.45) 9.1(0.36)

Piston ring end gap 1st R 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)

2nd RN 0.08 – 0.20(0.003 – 0.08)

0.50(0.020)


2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —

53

3/9 E-02, 03, 19, 24, 28, 33, P-37E-19


OIL PUMP


ITEM STD/SPEC. LIMITPiston ring thickness 1st 1.17 – 1.19

(0.0461 – 0.0469) —

2nd 0.97 – 0.99(0.0382 – 0.0390) —

Piston pin bore 20.002 – 20.008(0.7857 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.995 – 20.000(0.7872 – 0.7874)

19.980(0.7866)

ITEM STD/SPEC. LIMITConrod small end I.D. 20.010 – 20.018

(0.7878 – 0.7881) 20.040(0.7890)


0.30(0.012)

Conrod big end width 20.95 – 21.00(0.825 – 0.827) —

Crank pin width 21.10 – 21.15(0.831 – 0.833) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4960) —


0.080(0.0031)


Crankshaft thrust bearing thickness Right side 2.425 – 2.450

(0.0955 – 0.0965) —

Left side 2.350 – 2.500(0.0925 – 0.0984) —



ITEM STD/SPEC. LIMITOil pressure (at 60°C, 140°F) Above 200 kPa (2.0 kgf/cm2, 43 psi)


—

ITEM STD/SPEC. LIMITDrive plate thickness No. 1 2.92 – 3.08

(0.115 – 0.121) 2.62

(0.103)

No. 2 3.72 – 3.88(0.146 – 0.153)

3.42(0.135)

Drive plate claw width No. 1 13.85 – 13.96(0.542 – 0.550)

13.05(0.514)

No. 2 13.90 – 14.00(0.547 – 0.551)

13.10(0.516)

4/9 E-02, 03, 19, 24, 28, 33, P-37E-19


ITEM STD/SPEC. LIMITDriven plate distortion — 0.10

(0.004)Clutch spring free hength 28.96

(1.140) 27.6(1.09)



13.957 – 13.984(0.5495 – 0.5506) —



35.650 – 35.675(1.4035 – 1.4045) —

Clutch fluid type Brake fluid DOT 4 —

ITEM STD/SPEC. LIMITPrimary reduction ratio 1.596 (83/52) —Final reduction ratio 2.352 (40/17) —Gear ratios Low 2.615 (34/13) —

2nd 1.937 (31/16) —3rd 1.526 (29/19) —4th 1.285 (27/21) —5th 1.136 (25/22) —Top 1.043 (24/23) —


0.50(0.020)






(0.79 – 1.18) —

Gearshift lever height 50 – 60(1.97 – 2.36) —

LE
P

5/9 E-02, 03, 19, 24, 28, 33, P-37E-19


FI SENSORS + INTAKE AIR CONTROL VALVE

ITEM STD/SPEC. LIMITThermostat valve opening temperature Approx. 82 °C (179.6 °F) —

Thermostat valve lift Over 8 mm (0.31 in) at 95 °C (203 °F) —Engine coolant temperature sensor resistance

20 °C (68 °F) Approx. 2.45 kΩ —

50 °C (122 °F) Approx. 0.811 kΩ —

80 °C (176 °F) Approx. 0.318 kΩ —

110 °C (230 °F) Approx. 0.142 kΩ —

130 °C (226 °F) Approx. 0.088 kΩ —

Radiator cap valve opening prees-sure

95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) —




—


Approx. 250 ml (0.3/0.2 US/lmp qt) —

Engine side Approx. 2 700 ml (2.9/2.4 US/lmp qt) —

ITEM STD/SPEC. NOTEInjector resistance 11 – 16 Ω at 20 °C (68 °F) —Fuel pump discharge amount Approx. 1 200 ml (1.3/1.1 US/Imp oz) /30 sec.

at 300 kPa (3.0 kgf/cm2, 43 psi) —

Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm2, 43 psi) —

ITEM STD/SPEC. NOTECMP sensor resistance 0.9 – 1.3 kΩCMP sensor peak voltage More than 0.7 VCKP sensor resistance 180 – 280 ΩCKP sensor peak voltage More than 3 VIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.5 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.3 kΩ


Opened Approx. 4.3 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance 2.3 – 2.6 kΩ at 20 °C (68 °F)

SAM

6/9 E-02, 03, 19, 24, 28, 33, P-37E-19

THROTTLE BODY


ITEM STD/SPEC. NOTEIAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance 2.2 – 2.7 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 3.6 V at 100 kPa (760 mmHg)TO sensor resistance 60 – 64 kΩTO sensor voltage Approx. 2.5 VGP switch voltage More than 0.6 V (From 1st to top without neutral)Injector voltage Battery voltageIgnition coil primary peak voltage More than 80 V (When cranking)Heated oxygen sensor output volt-age Iess than 0.4 V at 1 150 rpm (After warming up)

For E-02,19Heated oxygen sensor resistance 4 – 5 kΩ at 23 °C (73.4 °F)PAIR solenoid valve resistance 16 – 24 kΩ at 20 °C (68 °F)VCSV resistance 36 – 44 ΩIntake air control valve operating rpm

Opening Above 2 500 rpmClosing Below 2 200 rpm

ITEM STD/SPEC.

Fast idle r/min 3 500 r/min (After warming up)Idle r/min 1 150 ± 100 r/minThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

ITEM STD/SPEC. NOTEFiring order 1·2·4·3Spark plug Type NGK: CR9E

DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.CKP sensor resistance 180 – 280 ΩCKP sensor peak voltage More than 3 V G – BIIgnition coil resistance Primary 1.0 – 1.6 Ω Terminal –

Terminal

Secondary 10 – 16.5 kΩ Plug cap –Terminal

Ignition coil primary peak voltage More than 80 VGenerator coil resistance 0.2 – 0.4 ΩGenerator Max. output Approx. 400 W at 5 00 r/minGenerator no-load voltage(When cold) More than 65 V (AC) at 5 000 r/min

Regulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 5 Ω

54

7/9 E-02, 03, 19, 24, 28, 33, P-37E-19

WATTAGE Unit: W


ITEM STD/SPEC. NOTEBattery Type

designation YT12A-BS

Capacity 12 V 36 kC (10 Ah)/10 HRFuse size


Signal 15 AIgnition 15 A

Fuel 10 AFan 10 AMain 30 A

ITEMSTD/SPEC.

E-03, 24, 28, 33 The other countriesHeadlight HI 65 + 55W ←

LO 55 W ←Parking or position light 5 WBrake light/Taillight 21/5 W × 2 ←Turn signal light 21 W × 4 ←License light 5 W ←Tachometer light LED ←Speedometer light LED ←Fuel meter light LED ←Engine coolant temp. meter light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←Oil pressure indicator light LED ←FI indicator light LED ←Fuel level indicator light LED ←Engine coolant temp. indicator light LED ←

ITEM STD/SPEC. LIMITRear brake pedal height 55 – 65

(2.2 – 2.6) —

Brake disc thickness Front 4.8 – 5.2(0.189 – 0.205)

4.5(0.177)

Rear 4.8 – 5.2(0.189 – 0.205)

4.5(0.177)



Rear 12.700 – 12.743(0.5000 – 0.5017) —

8/9 E-02, 03, 19, 24, 28, 33, P-37E-19

TIRE Unit: mm (in)

ITEM STD/SPEC. LIMITMaster cylinder piston diam. Front 15.827 – 15.854

(0.6231 – 0.6242) —

Rear 12.657 – 12.684(0.4983 – 0.4994) —



(0.9449 – 0.9479) —

Trailing 27.000 – 27.076(1.0630 – 1.0660) —

Rear 38.180 – 38.256(1.5031 – 1.5061) —

Brake caliper piston diam.


(0.9419 – 0.9439) —

Trailing 26.920 – 26.970(1.0598 – 1.0618) —

Rear 38.098 – 38.148(1.4999 – 1.5019) —


(0.08)

Radial — 2.0(0.08)

Wheel rim size Front 17 M/C × MT 3.50 —Rear 17 M/C × MT 6.00 —


Rear — 0.25(0.010)


(2.90 kgf/cm2, 42 psi) —



(2.90 kgf/cm2, 42 psi)

Rear 290 kPa(2.90 kgf/cm2, 42 psi)

Tire size Front 120/70ZR17M/C (58W) —Rear 190/50ZR17M/C (73W) —

Tire type Front BRIDGESTONE: BT56F J —Rear BRIDGESTONE: BT56R J —

Tire tread depth(Recommended depth) Front — 1.6

(0.06)

Rear — 2.0(0.08)

LE
P

9/9 E-02, 03, 19, 24, 28, 33, P-37E-19

FUEL + OIL


(4.7) —


240(9.4)

Front fork oil level (without spring, outer tube fully compressed)

98(3.9) —

Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil —Front fork oil capacity (each leg) 480 ml

(16.2/16.9 US/Imp oz) —

Front fork spring adjuster 5th groove from top —Front fork damping forceadjuster

Rebound 3 turns back —Compression 9 turns back —


183(7.20) —

Rear shock absorber dampingforce adjuster

Rebound 11 turns back —Compression 8 turns back —



ITEM STD/SPEC. NOTEFuel type Use only unleaded gasoline of at least 87 pump

octane (R/2 + M/2) or 91 octane or higher rated bythe research Method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33


The others


19 L(50/4.2 US/lmp gal) E-33

21L(5.5/4.6 US/lmp gal) The others

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 3.1 L

(3.3/2.7 US/lmp qt)

Filter change 3.3 L(3.5/2.9 US/lmp qt)

Overhaul 4.0 L(4.2/3.5 US/lmp qt)

SAM

55

GSX1400/UD

1/9 E-02, 19, 24E-19


ITEM STD/SPEC. LIMITValve diam. IN. 28.5

(1.12) —

EX. 25(0.98) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —







INNER — 38.6 (1.52)

OUTER — 40.6(1.60)


49 – 59 N(4.9 – 5.9 kgf, 10.8 – 13.0 lbs)


OUTER136 – 156 N


—

2/9 E-02, 19, 24E-19



ITEM STD/SPEC. LIMITCam height IN. 35.28 – 35.33

(1.389 – 1.391) 34.98(1.377)

EX. 34.18 – 34.22(1.346 – 1.347)

33.88(1.334)


0.150(0.0059)





(0.008)

ITEM STD/SPEC. LIMITCompression pressure 1 180 kPa

(11.8 kgf/cm2, 168 psi) 880 kPa



(0.0006 – 0.0010)0.120

(0.0047)Cylinder bore 81.000 – 81.015

(3.1890 – 3.1896) Nicks or



80.880(3.1842)



2nd 2N Approx. 11.0 (0.43) 8.8(0.35)

Piston ring end gap 1st N 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)

2nd 2N 0.18 – 0.30(0.007 – 0.012)

0.50(0.020)


2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —LE

P

3/9 E-02, 19, 24E-19


OIL PUMP

ITEM STD/SPEC. LIMITPiston ring thickness 1st 1.175 – 1.190

(0.0463 – 0.0469) —

2nd 0.970 – 0.990(0.0382 – 0.0390) —

Piston pin bore 18.002 – 18.008(0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.996 – 18.000(0.7085 – 0.7087)

17.980(0.7079)


(0.7091 – 0.7094) 18.040(0.7102)


0.30(0.012)

Conrod big end width 20.950 – 21.000(0.8248 – 0.8268) —

Crank pin width 21.100 – 21.150(0.8307 – 0.8327) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4961) —


0.080(0.0031)


Crankshaft thrust bearing thickness Right side 2.425 – 2.450

(0.0955 – 0.0965) —

Left side 2.430 – 2.585(0.0957 – 0.1018) —



ITEM STD/SPEC. LIMITOil pressure (at 60°C, 140°F) 300 – 600 kPa

(3.0 – 6.0 kgf/cm2, 43 – 85 psi)at 3 000 r/min

—

SAM

4/9 E-02, 19, 24E-19



ITEM STD/SPEC. LIMITDrive plate thickness No. 1, 2

and 33.22 – 3.38

(0.127 – 0.133) 2.92

(0.115)Drive plate claw width No. 1, 2

and 313.7 – 13.8

(0.5394 – 0.5433) 12.9



(1.140) 27.6


(0.5512 – 0.5529) —


13.957 – 13.984(0.5495 – 0.5506) —



35.650 – 35.675(1.4035 – 1.4045) —

Clutch fluid type Brake fluid DOT 4 —


2nd 1.937 (31/16) —3rd 1.526 (29/19) —4th 1.285 (27/21) —5th 1.136 (25/22) —Top 1.000 (24/24) —


0.50(0.020)



Drive chain Type RKGB50GSVZ3 —Links 116 links —



(0.79 – 1.18) —


56

5/9 E-02, 19, 24E-19


FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR

THROTTLE BODY

ITEM STD/SPEC. NOTEInjector resistance 12 – 18 Ω at 20 °C (68 °F)Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec.Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm2, 43 psi)

ITEM STD/SPEC. NOTECMP sensor peak voltage More than 3.7 VCKP sensor resistance 134 – 202 ΩCKP sensor peak voltage More than 2.7 VIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.5 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ


Opened Approx. 4.3 VEOT sensor input voltage 4.5 – 5.5 VEOT sensor resistance Approx. 61.3 kΩ at 20 °C (68 °F) W – WIAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.6 kΩ at 20 °C (68 °F) Terminal –

TerminalAP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 4.0 V at 100 kPa (760 mmHg)TO sensor resistance 60 – 64 kΩTO sensor voltage Approx. 3.8 VGP switch voltage More than 0.6 V (From 1st to Top)Injector voltage Battery voltageIgnition coil primary peak voltage More than 150 V (When cranking)STP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.8 kΩ


Opened Approx. 4.0 VSTV actuator resistance Approx. 4.8 – 7.2 Ω

ITEM STD/SPEC.

Bore size 34 mmI.D. No. 42F0Idle r/min 1 100 ± 100 r/minFast idle r/min 1 500 – 1 700 r/min (When engine is cold)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

6/9 E-02, 19, 24E-19


ITEM STD/SPEC. NOTEFiring order 1·2·4·3Spark plug Type NGK: CR8EK

DENSO: U24ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.CKP sensor resistance 134 – 202 ΩCKP sensor peak voltage More than 2.7 V : Y : BlIgnition coil resistance Primary 2 – 4 Ω Terminal –

Terminal

Secondary 25 – 40 kΩ Plug cap –Plug cap

Ignition coil primary peak voltage

More than 150 VNo. 1 & 4 : W/Bl

: O/W

No. 2 & 3 : B: O/W

Generator coil resistance 0.2 – 1.0 ΩGenerator no-load voltage(When engine is cold) More than 60 V (AC) at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩGP switch voltage More than 0.6 V (From 1st to top without neutral)Battery Type designa-

tion FTX14-BS





LE
P
7/9 E-02, 19, 24E-19

WATTAGE Unit: W


ITEM STD/SPEC.

Headlight HI 60 WLO 55 W

Parking or position light 5 W (Except for E-24)Brake light/Taillight 21/5 W × 2Turn signal light 21 W × 4Speedometer light LEDTachometer light LEDTurn signal indicator light LEDHigh beam indicator light LEDNeutral indicator light LEDFI indicator light LEDOil pressure indicator light LED

ITEM STD/SPEC. LIMITRear brake pedal height 35 – 45

(1.4 – 1.8) —


4.5(0.177)

Rear 5.3 – 5.7(0.209 – 0.224)

5.0(0.197)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —



(0.9449 – 0.9479) —

Trailing 27.000 – 27.076(1.0630 – 1.0660) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —

Brake caliper piston diam.


(0.9419 – 0.9439) —

Trailing 26.920 – 26.970(1.0598 – 1.0618) —

Rear 38.115 – 38.148(1.5006 – 1.5019) —


SAM

8/9 E-02, 19, 24E-19

TIRE Unit: mm (in)


(0.08)

Radial — 2.0(0.08)



Rear — 0.25(0.010)


(2.50 kgf/cm2, 36 psi) —



(2.50 kgf/cm2, 36 psi) —


Tire size Front 120/70ZR17M/C (58 W) —Rear 190/50ZR17M/C (73 W) —

Tire type Front BRIDGESTONE: BT020F F —Rear BRIDGESTONE: BT020R —

Tire tread depth(Recommended depth) Front — 1.6

(0.06)

Rear — 2.0(0.08)

57

9/9 E-02, 19, 24E-19


FUEL + OIL


(5.12) —


316(12.44)


108(4.25) —


(21.76/22.68 US/Imp oz) —

Front fork spring adjuster 5th groove from top —Front fork damping forceadjuster

Rebound 8 clicks out from stiffest position —Compression 7 clicks out from stiffest position —

Rear shock absorber springadjuster 1.5 —


Rebound —Compression 2 —



ITEM STD/SPEC. NOTEFuel type Gasoline used should be graded 95 octane or


reserve22 L

(5.8/4.8 US/lmp gal)Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Change 4 200 ml

(4.4/3.7 US/lmp qt)



LE
P GSX-R600/UE/UF
1/10

E-02, 03, 19, 24, 28, 33E-19E-19



(1.07) —

EX. 22.0(0.87) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —






Valve spring free length IN. — 36.2(1.43)

EX. — 36.0(1.42)

Valve spring tension IN.

155 – 179 N(15.8 – 18.3 kgf, 34.8 – 40.3 lbs)


EX.146 – 168 N


—

SAM

2/10

E-02, 03, 19, 24, 28, 33E-19E-19




(1.440 – 1.442)36.28

(1.428)

EX. 35.28 – 35.33(1.389 – 1.391)

34.98(1.377)


0.150(0.0059)





(0.008)


(11 – 15 kgf/cm², 156 – 213 psi)900 kPa

(9 kgf/cm², 128 psi)

Compression pressure difference —

200 kPa(2 kgf/cm²,


(0.0010 – 0.0014)0.120

(0.0047)Cylinder bore 67.000 – 67.015

(2.6378 – 2.6384)Nicks or



66.880(2.6331)


Piston ring free end gap 1st T Approx 5.5 (0.22) 4.4(0.17)

2nd T Approx 10.0 (0.39) 8.0(0.31)

Piston ring end gap 1st T 0.06 – 0.21(0.002 – 0.008)

0.50(0.020)

2nd T 0.06 – 0.18(0.002 – 0.007)

0.50(0.020)


2nd — 0.150(0.0059)


2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 1.51 – 1.53(0.0594 – 0.0602) —

58

3/10

E-02, 03, 19, 24, 28, 33E-19E-19


OIL PUMP


(0.0382 – 0.0390) —

2nd 0.77 – 0.79(0.0303 – 0.0311) —


14.030(0.5524)

Piston pin O.D. 13.995 – 14.000(0.5510 – 0.5512)

13.980(0.5504)


(0.5516 – 0.5519)14.040


(0.004 – 0.006)0.30


(0.7854 – 0.7874) —

Crank pin width 20.10 – 20.15(0.7913 – 0.7933) —


0.080(0.0031)

Crank pin O.D. 30.976 – 31.000(1.2195 – 1.2205) —


0.080(0.0031)


Crankshaft thrust bearing thickness Right side 2.425 – 2.450(0.0955 – 0.0965) —

Left side 2.350 – 2.500(0.0925 – 0.0984) —



ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) 200 – 500 kPa

(2.0 – 5.0 kgf/cm², 28 – 71 psi)at 3 000 r/min

—

4/10

E-02, 03, 19, 24, 28, 33E-19E-19




(0.4 – 0.6) —

Clutch release screw 1/4 turn out —Drive plate thickness No. 1, 2 and 3 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Drive plate claw width No. 1, 2 and 3 13.70 – 13.80

(0.5394 – 0.5433)12.90



(2.132)51.5

(2.028)


2nd 2.052 (39/19) —3rd 1.681 (37/22) —4th 1.450 (29/20) —5th 1.304 (30/23) —Top 1.181 (26/22) —

Shift fork-to-groove clearance 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)




20-pitch length — 336.5(13.25)

Drive chain slack (on side-stand) 20 – 30(0.8 – 1.2) —


LE
P
5/10

E-02, 03, 19, 24, 28, 33E-19E-19



ITEM STANDARD/SPECIFICATION NOTEThermostat valve opening temperature Approx. 88 °C (190 °F) —

Thermostat valve lift 8 mm (0.31 in) and over at 100 °C (212 °F) —ECT sensor resistance 20 °C

(68 °F) Approx. 2.45 kΩ —

50 °C (122 °F) Approx. 0.811 kΩ —

80 °C (176 °F) Approx. 0.318 kΩ —

110 °C (230 °F) Approx. 0.142 kΩ —

Radiator cap valve opening pressure

93 – 123 kPa(0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi) —



Engine coolant type Use an antifreeze/coolant compatible with aluminumradiator, mixed with distilled water only, at the ratio of50:50.

—

Engine coolant Reservoir tank side


Engine side

Approx. 2 700 ml(2.9/2.4 US/lmp qt) —

ITEM SPECIFICATION NOTEInjector resistance Approx. 12 Ω at 20 °C (68 °F)Fuel discharge amount 168 ml (5.7/5.9 US/lmp oz) and more/10 sec.Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi)

SAM

6/10

E-02, 03, 19, 24, 28, 33E-19E-19


THROTTLE BODY

ITEM SPECIFICATION NOTECMP sensor resistance 0.9 – 1.7 kΩCMP sensor peak voltage 0.7 V and more When

crankingCKP sensor resistance 142 – 194 ΩCKP sensor peak voltage 0.5 V and more When

crankingIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.7 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ


Opened Approx. 4.4 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 3.6 V at 760 mmHg (100 kPa)TO sensor resistance 16.5 – 22.3 kΩTO sensor voltage Normal 0.4 – 1.4 V

Leaning 3.7 – 4.4 V When leaning 65°

GP switch voltage 0.6 V and more From 1st to Top

Injector voltage Battery voltageIgnition coil primary peak voltage 85 V and more When

crankingSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.6 kΩ


Opened Approx. 4.5 VSTV actuator resistance Approx. 7 ΩPAIR control solenoid valve resistance 18 – 22 Ω (at 20 °C/68 °F – 30 °C/86 °F)

ITEM SPECIFICATIONBore size 38 mmI.D. No. 29G10 (For E-33), 29G00 (For the others)Idle r/min 1 300 ± 100 r/minFast idle r/min 1 500 – 2 000 r/min (When cold engine)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

59

7/10

E-02, 03, 19, 24, 28, 33E-19E-19


ITEM SPECIFICATION NOTEFiring order 1.2.4.3Spark plug Type NGK: CR9E

DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.CKP sensor resistance 142 – 194 ΩCKP sensor peak voltage 0.5 V and moreIgnition coil resistance Primary 1.3 – 1.9 Ω Terminal –

Terminal

Secondary 10.8 – 16.2 kΩ Plug cap – Terminal

Ignition coil primary peak voltage 85 V and moreGenerator coil resistance 0.2 – 0.9 ΩGenerator no-load performance(when engine is cold) 65 V and more at 5 000 r/min

Regulated voltage (charging output) 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩGP switch voltage 0.6 V and more (From 1st to top without neutral)Battery Type designation FTX9-BS


HeadlightHI

15 A E-03, 24, 28, 33

10 A E-02, 19LO 10 A



8/10

E-02, 03, 19, 24, 28, 33E-19E-19

WATTAGE Unit: W



E-03, 24, 28, 33 OthersHeadlight HI 60/55 W ←

LO 55/55 W 55 WPosition light 5 WBrake light/Taillight LED ←Turn signal light 18 W × 4 ←License plate light 5 W ←Combination meter light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←FI indicator light/Oil pressure indicator light/Engine coolant temp. indicator light

LED ←

Fuel level indicator light LED ←Engine RPM indicator light LED ←


(2.4 – 2.8) —


5.0(0.20)

Rear 4.8 – 5.2(0.189 – 0.205)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —

Master cylinder piston diam Front 19.007 – 19.034(0.7483 – 0.7494) —

Rear 13.957 – 13.984(0.5495 – 0.5506) —



(1.1902 – 1.1931) —

Trailing 33.960 – 34.036(1.3370 – 1.3400) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —

Brake caliper piston diam


(1.1902 – 1.1931) —

Trailing 33.960 – 34.036(1.3370 – 1.3400) —

Rear 38.080 – 38.130(1.4992 – 1.5012) —LE

P

9/10

E-02, 03, 19, 24, 28, 33E-19E-19

TIRE

ITEM STANDARD LIMITBrake fluid type DOT 4 —Wheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)



Rear — 0.25(0.010)

ITEM STANDARD LIMITCold inflation tire pressure(Solo riding) Front 250 kPa

(2.50 kgf/cm², 36 psi) —



(2.50 kgf/cm², 36 psi) —



Tire typeFront

DUNLOP: D218F E-03, 28, 33BRIDGESTONE: BT014F SF Others

RearDUNLOP:D218 E-03, 28, 33

BRIDGESTONE: BT014R F OthersTire tread depth(Recommended depth) Front — 1.6

(0.06)

Rear — 2.0(0.08)

SAM

10/10

E-02, 03, 19, 24, 28, 33E-19E-19


FUEL + OIL


(4.72) —

Front fork spring free length 244.6 (9.63)

239(9.41)


102 (4.02) —

Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil —Front fork oil capacity (each leg) 479 ml

(16.2/16.9 US/Imp oz) —

Front fork inner tube outside diam. 43(1.69) —

Front fork spring adjuster 4 th groove from top —Front fork damping force adjuster Rebound 1 and 3/4 turns out from stiffest position —

Compression 1 and 3/4 turns out from stiffest position —Rear shock absorber spring pre-set length

195.9 (7.71) —


Rebound 2 turns out from stiffest position —Compression 1 and 3/4 turns out from stiffest position —

Rear wheel travel 130 (5.1) —



octane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corrosioninhibitor is permissible.

E-03, 28, 33


Others


16.5 L(4.4/3.6 US/lmp gal) E-33


Fuel level indicator light

lightingApprox. 1.7 L

(1.8/1.5 US/lmp qt)

Engine oil type SAE 10 W-40, API, SF or SGEngine oil capacity Change 2.8 L

(3.0/2.5 US/lmp qt)



60

GSX-R750/UF

1/9

E-02, 13, 19, 24, 28, 33E-19




(1.14) —

EX. 24.0(0.94) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.475 – 4.490(0.1762 – 0.1768) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —








137 – 157 N(14.0 – 16.0 kgf, 30.9 – 35.3 lbs)



(1.448 – 1.450)36.48

(1.436)

EX. 35.28 – 35.33(1.389 – 1.391)

34.98(1.377)


0.150(0.0059)



2/9

E-02, 13, 19, 24, 28, 33E-19


ITEM STANDARD LIMITCamshaft runout — 0.10

(0.004)Cam chain pin (at arrow “3”) 14th pin —Cylinder head distortion — 0.20

(0.008)


(11 – 15 kgf/cm², 156 – 213 psi)Compression pressure difference —Piston-to-cylinder clearance 0.030 – 0.040

(0.0012 – 0.0016)0.120

(0.0047)Cylinder bore 72.000 – 72.015

(2.8346 – 2.8352)Nicks or



71.880(2.8299)


Piston ring free end gap 1st R Approx 8.2 (0.32) 6.5(0.26)

2nd RN Approx 7.8 (0.31) 6.2(0.24)

Piston ring end gap 1st R 0.06 – 0.21(0.002 – 0.008)

0.50(0.020)

2nd RN 0.06 – 0.18(0.002 – 0.007)

0.50(0.020)


2nd — 0.150(0.0059)


2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 1.51 – 1.53(0.0594 – 0.0602) —


2nd 0.77 – 0.79(0.0303 – 0.0311) —


15.030(0.5917)

Piston pin O.D. 14.995 – 15.000(0.5904 – 0.5906)

14.980(0.5898)

LE
P
3/9

E-02, 13, 19, 24, 28, 33E-19


OIL PUMP



(0.5909 – 0.5913)15.040


(0.004 – 0.008)0.30


(0.7854 – 0.7874) —

Crank pin width 20.10 – 20.15(0.7913 – 0.7933) —


0.080(0.0031)

Crank pin O.D. 32.976 – 33.000(1.2983 – 1.2992) —


0.080(0.0031)


Crankshaft thrust bearing thickness Right side 2.425 – 2.450(0.0955 – 0.0965) —

Left side 2.350 – 2.500(0.0925 – 0.0984) —




(1.0 – 4.0 kgf/cm², 14 – 57 psi)at 3 000 r/min

—


(0.4 – 0.6) —

Clutch release screw 1/4 turn out —Drive plate thickness No. 1, 2 and 3 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Drive plate claw width No. 1, 2 and 3 13.70 – 13.80

(0.5394 – 0.5433)12.90



(2.170)52.4

(2.063)

SAM

4/9

E-02, 13, 19, 24, 28, 33E-19




2nd 2.052 (39/19) —3rd 1.681 (37/22) —4th 1.450 (29/20) —5th 1.304 (30/23) —Top 1.181 (26/22) —

Shift fork-to-groove clearance 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)



Drive chain Type RK525ROZ5 —Links 110 links —

20-pitch length — 336.5(13.25)

Drive chain slack (on side-stand) 20 – 30(0.8 – 1.2) —

Gearshift lever height 60 – 70(4 – 8) —

ITEM STANDARD/SPECIFICATION NOTEThermostat valve opening temper-ature Approx. 88 °C (190 °F) —

Thermostat valve lift 8 mm (0.31 in) and over at 100 °C (212 °F) —ECT sensor resistance 20 °C

(68 °F) Approx. 2.45 kΩ —

50 °C (122 °F) Approx. 0.811 kΩ —

80 °C (176 °F) Approx. 0.318 kΩ —

110 °C (230 °F) Approx. 0.142 kΩ —


108 – 137 kPa(1.08 – 1.37 kgf/cm², 15.4 – 19.5 psi) —



Engine coolant type Use an antifreeze/coolant compatible with alumi-num radiator, mixed with distilled water only, at theratio of 50:50.

—



Engine side

Approx. 2 900 ml(3.1 – 2.6 US/lmp qt) —

61

5/9

E-02, 13, 19, 24, 28, 33E-19



ITEM SPECIFICATION NOTEInjector resistance Approx. 12 Ω at 20 °C (68 °F)Fuel discharge amount 168 ml (5.7/5.9 US/lmp OZ) and more/10 sec.Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi)

ITEM SPECIFICATION NOTECMP sensor resistance 0.9 – 1.7 kΩCMP sensor peak voltage 0.7 V and more When crankingCKP sensor resistance 142 – 194 ΩCKP sensor peak voltage 0.5 V and more When crankingIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.7 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ



Leaning 3.7 – 4.4 V When leaning 65°

GP switch voltage 0.6 V and more From 1st to TopInjector voltage Battery voltageIgnition coil primary peak voltage 85 V and more When crankingSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.6 kΩ


Opened Approx. 4.5 VSTV actuator resistance Approx. 7 ΩPAIR control solenoid valve resis-tance 18 – 22 Ω at 20 – 30 °C (68 – 86 °F)

6/9

E-02, 13, 19, 24, 28, 33E-19

THROTTLE BODY



(0.08 – 0.16 in)


DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Terminal


Ignition coil primary peak voltage 85 V and moreGenerator coil resistance 0.2 – 0.9 ΩGenerator no-load voltage(when engine is cold) 65 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩGP switch voltage 0.6 V and more (From 1st to top without neutral)Battery Type designa-

tion YT12A-BS


HeadlightHI

15 A E-03, 24, 28, 3310 A E-02, 19

LO 10 ASignal 10 AIgnition 15 A


LE
P
6/9

E-02, 13, 19, 24, 28, 33E-19

THROTTLE BODY



(0.08 – 0.16 in)


DENSO: U27ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Terminal


Ignition coil primary peak voltage 85 V and moreGenerator coil resistance 0.2 – 0.9 ΩGenerator no-load voltage(when engine is cold) 65 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩGP switch voltage 0.6 V and more (From 1st to top without neutral)Battery Type designa-

tion YT12A-BS


HeadlightHI

15 A E-03, 24, 28, 3310 A E-02, 19

LO 10 ASignal 10 AIgnition 15 A


7/9

E-02, 13, 19, 24, 28, 33E-19

WATTAGE Unit: W



E-03, 24, 28, 33 OthersHeadlight HI 55 W ←

LO 60/55 W ←Position light 5 WBrake light/Taillight LED ←Turn signal light 18 W × 4 ←License plate light 5 W ←Combination meter light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←FI indicator light/Oil pressure indi-cator light/Engine coolant temp. indicator light

LED ←



(2.4 – 2.8) —


5.0(0.20)

Rear 4.8 – 5.2(0.189 – 0.205)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —



(1.1902 – 1.1931) —

Trailing 33.960 – 34.036(1.3370 – 1.3400) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —



(1.1870 – 1.1890) —

Trailing 33.884 – 33.934(1.3340 – 1.3360) —

Rear 38.060 – 38.093(1.4984 – 1.4997) —


SAM

7/9

E-02, 13, 19, 24, 28, 33E-19

WATTAGE Unit: W





LED ←



(2.4 – 2.8) —


5.0(0.20)

Rear 4.8 – 5.2(0.189 – 0.205)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —



(1.1902 – 1.1931) —

Trailing 33.960 – 34.036(1.3370 – 1.3400) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —



(1.1870 – 1.1890) —

Trailing 33.884 – 33.934(1.3340 – 1.3360) —

Rear 38.060 – 38.093(1.4984 – 1.4997) —


8/9

E-02, 13, 19, 24, 28, 33E-19

TIRE


(0.08)

Radial — 2.0(0.08)



Rear — 0.25(0.010)


(2.50 kgf/cm², 36 psi) —



(2.50 kgf/cm², 36 psi) —



Tire typeFront

DUNLOP: D218F E-03, 28, 33BRIDGESTONE: BT014F SE Others

RearDUNLOP: D218 E-03, 28, 33

BRIDGESTONE: BT014R E OthersTire tread depth(Recommended depth) Front — 1.6

(0.06)

Rear — 2.0(0.08)

62

7/9

E-02, 13, 19, 24, 28, 33E-19

WATTAGE Unit: W





LED ←



(2.4 – 2.8) —


5.0(0.20)

Rear 4.8 – 5.2(0.189 – 0.205)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —



(1.1902 – 1.1931) —

Trailing 33.960 – 34.036(1.3370 – 1.3400) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —



(1.1870 – 1.1890) —

Trailing 33.884 – 33.934(1.3340 – 1.3360) —

Rear 38.060 – 38.093(1.4984 – 1.4997) —


8/9

E-02, 13, 19, 24, 28, 33E-19

TIRE


(0.08)

Radial — 2.0(0.08)



Rear — 0.25(0.010)


(2.50 kgf/cm², 36 psi) —



(2.50 kgf/cm², 36 psi) —



Tire typeFront

DUNLOP: D218F E-03, 28, 33BRIDGESTONE: BT014F SE Others

RearDUNLOP: D218 E-03, 28, 33

BRIDGESTONE: BT014R E OthersTire tread depth(Recommended depth) Front — 1.6

(0.06)

Rear — 2.0(0.08)

9/9

E-02, 13, 19, 24, 28, 33E-19


FUEL + OIL


(4.72) —


239(9.41)


100 (3.94) —


(16.3/16.9 US/Imp oz) —

Front fork inner tube outside diam. 43(1.69) —

Front fork spring adjuster 4 th groove from top —Front fork damping force adjuster Rebound 1 and 1/2 turns out from stiffest position —

Compres-sion 1 and 1/2 turns out from stiffest position —

Rear shock absorber spring pre-set length

195.3 (7.69) —


Rebound 1 and 3/4 turns out from stiffest position —Compres-

sion 1 turn out from stiffest position —




octane (R/2 + M/2).Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33


Others


16.5 L(4.4/3.6 US/lmp gal) E-33


Fuel level indicator light

lightingApprox. 1.7 L

(1.8/1.5 US/lmp qt)

Engine oil type SAE 10 W-40, API, SF or SGEngine oil capacity change 2.8 L

(3.0/2.5 US/lmp qt)


LE
P
GSX-R1000
1/11 E-02, 03, 19, 24, 28, 33E-19



ITEM STANDARD LIMITValve diam.

IN.29

(1.14)----

EX.24

(0.94)----

Tappet clearance (when cold)IN.

0.10 – 0.20(0.004 – 0.008)

----

EX.0.20 – 0.30

(0.008 – 0.012)----

Valve guide to valve stem clearance

IN.0.010 – 0.037

(0.0004 – 0.0015)----

EX.0.030 – 0.057

(0.0012 – 0.0022)----

Valve guide I.D.IN. & EX.

4.000 – 4.012(0.1575 – 0.1580)

----

Valve stem O.D.IN.

3.975 – 3.990(0.1565 – 0.1571)

----

EX.3.955 – 3.970

(0.1557 – 0.1563)----

Valve stem deflectionIN. & EX. ----

0.35(0.014)

Valve stem runoutIN. & EX. ----

0.05(0.002)

Valve head thicknessIN. & EX. ----

0.5(0.02)

Valve seat widthIN. & EX.

0.9 – 1.1(0.035 – 0.043)

----

Valve head radial runoutIN. & EX. ----

0.03(0.001)

Valve spring free lengthIN. & EX. ----

37.0(1.46)


127 – 147 N (13.0 – 15.0 kgf, 28.7 – 33.1 lbs)

at length 32.85 mm (1.29 in)----


IN.37.01 – 37.06

(1.457 – 1.459)36.71

(1.445)

EX.35.98 – 36.03

(1.417 – 1.418)35.68

(1.405)Camshaft journal oil clearance

IN. & EX.0.032 – 0.066

(0.0013 – 0.0026)0.150

(0.0059)

SAM

2/11 E-02, 03, 19, 24, 28, 33E-19


ITEM STANDARD LIMITCamshaft journal holder I.D.

IN. & EX.24.012 – 24.025

(0.9454 – 0.9459)----

Camshaft journal O.D.IN. & EX.

23.959 – 23.980(0.9433 – 0.9441)

----

Camshaft runout----

0.10(0.004)

Cam chain pin (at arrow “3”) 14th pin ----Cylinder head distortion

----0.20

(0.008)

ITEM STANDARD LIMITCompression pressure

1 300 – 1 700 kPa(13 – 17 kgf/cm², 185 – 242 psi)

Compression pressuredifference ----


0.120(0.0047)

Cylinder bore 73.000 – 73.015 (2.8740 – 2.8746)

Nicks orScratches

Piston diam. 72.965 – 72.980 (2.8726 – 2.8732)

Measure at 15 mm (0.6 in) from the skirt end.

72.880(2.8693)

Cylinder distortion----

0.02(0.008)

Piston ring free end gap1st R Approx 8.0 (0.31)

6.4(0.25)

2nd RN Approx 10.2 (0.40)8.2

(0.32)Piston ring end gap

1st R0.06 – 0.18

(0.002 – 0.007)0.50

(0.020)

2nd RN0.06 – 0.18

(0.002 – 0.007)0.50

(0.020)Piston ring to groove clearance

1st ----0.180

(0.0071)

2nd ----0.150


1st1.01 – 1.03

(0.0398 – 0.0406)----

2nd0.81 – 0.83

(0.0319 – 0.0327)----

Oil1.51 – 1.53

(0.0594 – 0.0602)----

)(1 000 kPa10 kgf/cm²,

142 psi

)(200 kPa

2 kgf/cm²,28 psi

63

3/11 E-02, 03, 19, 24, 28, 33E-19


BALANCER Unit: mm (in)


1st0.97 – 0.99

(0.0382 – 0.0390)----

2nd0.77 – 0.79

(0.0303 – 0.0311)----


16.030(0.6311)

Piston pin O.D. 15.995 – 16.000(0.6297 – 0.6299)

15.980(0.6291)


(0.6303 – 0.6306)16.040


(0.004 – 0.008)0.30


(0.7854 – 0.7874)----

Crank pin width 20.10 – 20.15(0.7913 – 0.7933)

----


0.080(0.0031)

Crank pin O.D. 34.976 – 35.000(1.3770 – 1.3780)

----


0.080(0.0031)

Crankshaft journal O.D. 34.976 – 35.000(1.3770 – 1.3780)

----

Crankshaft thrust bearingthickness

Right side2.420 – 2.440

(0.0953 – 0.0961)----

Left side2.360 – 2.500

(0.0929 – 0.0984)----

Crankshaft thrust clearance 0.070 – 0.110(0.0028 – 0.0043)

----

Crankshaft runout----

0.05(0.002)

ITEM STANDARD LIMITBalancer shaft journal oil clearance 0.020 – 0.044

(0.00079 – 0.00173)0.080

(0.00315)Balancer shaft journal O.D. 22.984 – 23.000

(0.9049 – 0.9055)----

4/11 E-02, 03, 19, 24, 28, 33E-19

OIL PUMP




(1.0 – 4.0 kgf/cm², 14 – 57 psi)at 3 000 r/min

----


(0.4 – 0.6)----

Clutch release screw 1/4 turn back ----Drive plate thickness

No. 1, 2 and 32.45 – 2.95

(0.096 – 0.116)2.15

(0.085)Drive plate claw width

No. 1, 2 and 313.85 – 13.96

(0.5453 – 0.5496)13.05

(0.5138)Driven plate distortion

----0.10

(0.004)Clutch spring free height 77.77

(3.062)73.9

(2.909)

ITEM STANDARD LIMITPrimary reduction ratio 1.553 (73/47) ----Final reduction ratio 2.470 (42/17) ----Gear ratios Low 2.687 (43/16) ----

2nd 2.052 (39/19) ----3rd 1.681 (37/22) ----4th 1.450 (29/20) ----5th 1.304 (30/23) ----Top 1.208 (29/24) ----


0.50(0.020)

Shift fork groove width 5.0 – 5.1(0.197 – 0.201)

----

Shift fork thickness 4.8 – 4.9(0.189 – 0.193)

----

Drive chain Type DID530 ----Links 110 links ----

20-pitch length ----319.4


(0.79 – 1.18)----

Gearshift lever height 60 – 70(2.36 – 2.76)

----LE
P
5/11 E-02, 03, 19, 24, 28, 33E-19



ITEM STANDARD/SPECIFICATION NOTEThermostat valve openingtemperature

Approx. 82 °C (180 °F) ----

Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F) ----ECT sensor resistance 20 °C

(68 °F)Approx. 2.45 kΩ ----

50 °C (122 °F)

Approx. 0.811 kΩ ----

80 °C (176 °F)

Approx. 0.318 kΩ ----

110 °C (230 °F)

Approx. 0.142 kΩ ----

Radiator cap valve openingpressure

93 – 123 kPa(0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)

----

Cooling fan thermo-switchoperating temperature

OFF ON Approx. 105 °C (221 °F) ----ON OFF Approx. 100 °C (212 °F) ----

Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

----

Engine coolant Reservetank side

Approx. 250 ml(0.3/0.2 US/lmp qt)

----

Engineside

Approx. 2 150 ml(2.3 – 1.9 US/lmp qt)

----

ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F)Fuel pump discharge amount Approx. 1.2 L (1.3/1.1 US/lmp qt)/30 sec.Fuel pressure regulator operatingset pressure

Approx. 300 kPa (3.0 kgf/cm², 43 psi)

SAM

6/11 E-02, 03, 19, 24, 28, 33E-19

FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATORITEM SPECIFICATION NOTE

CMP sensor resistance 0.9 – 1.7 kΩCMP sensor peak voltage

0.5 V and moreWhen

crankingCKP sensor resistance 70 – 220 ΩCKP sensor peak voltage

0.5 V and moreWhen

crankingIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.6 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.1 kΩ



Leaning 3.7 – 4.4 VWhen

leaning 65°GP switch voltage

0.6 V and moreFrom 1st to

TopInjector voltage Battery voltageIgnition coil primary peak voltage

80 VWhen

crankingSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.5 kΩ


Opened Approx. 3.7 VSTV actuator resistance Approx. 6.5 ΩEXCVA position sensorinput voltage

4.5 – 5.5 V

EXCVA position sensorresistance Approx. 3.1 kΩ

Atadjustment

positionEXCVA position sensoroutput voltage

Closed 0.5 – 1.3 VOpened 3.7 – 4.5 V

64

7/11 E-02, 03, 19, 24, 28, 33E-19

THROTTLE BODY


ITEM SPECIFICATIONBore size 42 mmI.D. No. 40F5 (For E-33), 40F4 (For the others)Idle r/min 1 150 ± 100 r/minFast idle r/min 2 200 r/min (After warming up)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

ITEM SPECIFICATION NOTEFiring order 1.2.4.3Spark plug

TypeNGK: CR9E

DENSO: U27ESR-N

Gap0.7 – 0.8

(0.028 – 0.031)Spark performance Over 8 (0.3) at 1 atm.CKP sensor resistance 70 – 220 ΩCKP sensor peak voltage 0.5 V and moreIgnition coil resistance

Primary 0.8 – 2.5 ΩTerminal – Terminal

Secondary 8 – 18 kΩPlug cap – Terminal

Ignition coil primary peak voltage 80 VGenerator coil resistance 0.2 – 0.9 ΩGenerator no-load voltage(when engine is cold)

65 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 5 ΩGP switch voltage 0.6 V and more (From 1st to top without neutral)Battery Type designation FTX12-BS

Capacity 12 V 36 kC (10 Ah)/10 HRFuse size

HeadlightHI 10 A (E-02, 19)/15 A (E-03, 24, 28, 33)LO 10 A



8/11 E-02, 03, 19, 24, 28, 33E-19

WATTAGE Unit: W



E-03, 24, 28, 33 OthersHeadlight HI 60/55 W ←

LO 55/55 W 55 WPosition/Parking light 5 WBrake light/Taillight LED ←Turn signal light 18 W × 4 ←License plate light 5 W ←Combination meter light LED ←Turn signal indicator light LED ←High beam indicator light LED ←Neutral indicator light LED ←FI indicator light/Oil pressureindicator light/Engine coolanttemp. indicator light

LED ←



(2.4 – 2.8)----

Brake disc thicknessFront

5.3 – 5.7(0.209 – 0.224)

5.0(0.177)

Rear4.8 – 5.2

(0.189 – 0.205)4.5

(0.177)Brake disc runout

----0.30

(0.012)Master cylinder bore Front &

Rear14.000 – 14.043

(0.5512 – 0.5529)----

Master cylinder piston diamFront

13.957 – 13.984(0.5495 – 0.5506)

----

Rear13.957 – 13.984

(0.5495 – 0.5506)----


FrontLeading

27.000 – 27.076(1.0630 – 1.0660)

----

Trailing32.030 – 32.106

(1.2610 – 1.2640)----

Rear38.180 – 38.230

(1.5031 – 1.5051)----

LE
P
9/11 E-02, 03, 19, 24, 28, 33E-19

TIRE

ITEM STANDARD LIMITBrake caliper piston diam

FrontLeading

26.920 – 26.970(1.0598 – 1.0618)

----

Trailing31.950 – 32.000

(1.2579 – 1.2598)----

Rear38.110 – 38.130

(1.5004 – 1.5012)----

Brake fluid type DOT 4 ----Wheel rim runout

Axial ----2.0

(0.08)

Radial ----2.0

(0.08)Wheel rim size Front 17 M/C × MT 3.50 ----

Rear 17 M/C × MT 6.00 ----Wheel axle runout

Front ----0.25

(0.010)

Rear ----0.25

(0.010)

ITEM STANDARD LIMITCold inflation tire pressure(Solo riding)

Front250 kPa

(2.50 kgf/cm², 36 psi)----

Rear290 kPa

(2.90 kgf/cm², 42 psi)----

Cold inflation tire pressure(Dual riding)

Front250 kPa

(2.50 kgf/cm², 36 psi)----

Rear290 kPa

(2.90 kgf/cm², 42 psi)----

Tire size Front 120/70 ZR17 M/C (58 W) ----Rear 190/50 ZR17 M/C (73 W) ----

Tire type Front BRIDGESTONE: BT011F F ----Rear BRIDGESTONE: BT012R F ----


Front ----1.6

(0.06)

Rear ----2.0

(0.08)

SAM

10/11 E-02, 03, 19, 24, 28, 33E-19



(4.92)----


225(8.86)

Front fork oil level (without spring,outer tube fully compressed)

101 (3.98)

----

Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil ----Front fork oil capacity (each leg) 509 ml

(17.2/17.9 US/Imp oz)----

Front fork spring adjuster 4.5 th groove from top ----Front fork damping forceadjuster

Rebound 6 clicks out from stiffest position ----Compression 11 clicks out from stiffest position ----


179.6 (7.07)

----


Rebound 8 clicks out from stiffest position ----Compression 8 clicks out from stiffest position ----

Rear wheel travel 130 (5.1)

----

Swingarm pivot shaft runout----

0.3(0.01)

65

11/11 E-02, 03, 19, 24, 28, 33E-19


Fuel type Use only unleaded gasoline of at least 90 pumpoctane (R/2 + M/2).Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corrosioninhibitor is permissible.

E-03, 28, 33


Others

Fuel tank capacity Includingreserve

18 L(4.8/4.0 US/lmp gal)

Fuel levelindicator light

lighting


Engine oil type SAE 10 W-40, API, SF or SGEngine oil capacity

change3.0 L

(3.2/2.6 US/lmp qt)

Filter change3.3 L

(3.5/2.9 US/lmp qt)

Overhaul3.6 L

(3.8/3.2 US/lmp qt)

LE
P GZ125/U
1/5P-02, 19P-19





EX. 0.13 – 0.18 —Valve guide to valve stem clearance

IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —

Valve stem deflection IN. & EX. — 0.35Valve guide I.D. IN. & EX. 5.000 – 5.012 —Valve stem O.D. IN. 4.975 – 4.990 —

EX. 4.955 – 4.970 —Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 1.7Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length (IN. & EX.) INNER — 31.3

OUTER — 33.6Valve spring tension (IN. & EX.)

INNER38.1 – 43.9 N(3.9 – 4.4 kgf)


OUTER89.6 – 103.0 N(9.1 – 10.5 kgf)


ITEM STANDARD LIMIT

Cam height IN. 33.620 – 33.660 33.320EX. 33.300 – 33.340 33.000

Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —Camshaft runout IN. & EX. — 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.977 – 11.995 —Cylinder head distortion — 0.05Cylinder head cover distortion — 0.05

SAM

2/5P-02, 19P-19



OIL PUMP

CLUTCH Unit: mm


(11.0 – 15.0 kgf/cm2) 800 kPa

(8 kgf/cm2)

Piston to cylinder clearance 0.040 – 0.050 0.120Cylinder bore 57.000 – 57.015 57.090Piston diam. 56.955 – 56.970



2nd R Approx. 5.0 4.0Piston ring end gap 1st 0.20 – 0.32 0.70



2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —



ITEM STANDARD LIMITConrod small end I.D. 14.006 – 14.014 14.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.45 1.0Conrod big end width 15.95 – 16.00 —Crankshaft web to web width 53.0 ± 0.1 —Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pump reduction ratio 2.000 (30/15) —Oil pressure (at 60°C, 140°F) Above 10 kPa (0.1 kgf/cm2)


—

ITEM STANDARD LIMITClutch cable play 10 – 15 —Clutch release screw 1/8 – 1/4 turn back —Drive plate thickness 2.9 – 3.1 2.6Drive plate claw width 11.8 – 12.0 11.0Driven plate distortion — 0.10Clutch spring free length — 29.5

66

3/5P-02, 19P-19

TRANSMISSION + DRIVE CHAIN Unit: mm Except ratio

CARBURETOR


2nd 1.857 (26/14) —3rd 1.368 (26/19) —4th 1.142 (24/21) —Top 0.956 (22/23) —

Shift fork to groove clearance 0.10 – 0.30 0.50Shift fork groove width No. 1, No. 2 5.0 – 5.1 —

No. 3 5.5 – 5.6 —Shift fork thickness No. 1, No. 2 4.8 – 4.9 —


Drive chain Type RK428FDZ —Links 132 —

20-pitch length — 259.0Drive chain slack 5 – 15 —

ITEM SPECIFICATIONCarburetor type MIKUNI BS26SSBore size 26 mmI.D. No. 12FHIdle r/min 1 500 ± 100 r/minFloat height 17.1 ± 0.5 mmMain jet (M.J.) # 112.5Jet needle (J.N.) 5D109-3rdNeedle jet (N.J.) P-0Pilot jet (P.J.) # 12.5Pilot screw (P.S.) 2 turns outThrottle cable play 2 – 4 mmStarter plunger cable play 0.5 – 1.0 mm

88.0 +0.1 - 0.2

4/5P-02, 19P-19

ELECTRICAL

WATTAGE Unit: W



DENSO: U24ESR-NGap 0.7 – 0.8 mm

Spark performance Over 8 mm at 1 atm.Ignition coil resistance Primary 3 – 5 Ω terminal –

terminal

Secondary 17 – 28 kΩ terminal – Plug cap

Ignition coil primary peak voltage More than 200 VGenerator coil resistance Pick-up 150 – 300 Ω Bl – G

Charging 0.3 – 1.5 Ω Y – YPick-up coil peak voltage More than 4.0 VGenerator Max. output 175 W at 5 000 r/minGenerator no-load voltage More than 45 V (AC) at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation FTX7L-BS

Capacity 12V 21.6 kC (6 Ah)/10HRFuse size 20A


LO 55Position light 4Brake light/Taillight 21/5Turn signal light 10Speedometer light 1.7Neutral indicator light 3.4Turn signal indicator light 3.4High beam indicator light 1.7

ITEM STANDARD/SPECIFICATION LIMIT

Rear brake pedal free travel 20 – 30 —Rear brake pedal height 50 —Brake disc thickness Front 5.0 ± 0.2 4.5Brake disc runout Front — 0.30Master cylinder bore 12.700 – 12.743 —Master cylinder piston diam. 12.657 – 12.684 —Brake caliper cylinder bore 42.850 – 42.900 —Brake caliper piston diam. 42.772 – 42.822 —Brake fluid type DOT 4 —Brake drum I.D. Rear — 130.7Brake lining thickness Rear — 1.5LE
P
5/5P-02, 19P-19

SUSPENSION Unit: mm

TIRE PRESSURE

FUEL + OIL



Rear — 0.25Wheel rim size Front 16M/C × MT 2.50 —

Rear 15M/C × MT 3.00 —Tire size Front 110/90-16 59P, 110/90-16M/C 59P or

110/90-16M/C 59S —

Rear 130/90-15M/C 66P or130/90-15M/C 66S —

Tire tread depth Front — 1.6Rear — 1.6

ITEM STANDARD/SPECIFICATION LIMITFront fork stroke 120 —Front fork spring free length 308 301Front fork inner tube O.D. 37 —Front fork oil type SUZUKI fork oil SS-08 (#10) —Front fork oil capacity (each leg) 336 ml —Front fork oil level 120 —Rear wheel travel 90 —Swingarm pivot shaft runout — 0.3


NORMAL RIDINGSOLO RIDING DUAL RIDING

kPa kgf/cm2 psi kPa kgf/cm2 psiFRONT 175 1.75 25 175 1.75 25REAR 200 2.00 29 225 2.25 33



reserve 2.9 LEngine oil type and grade SAE 10W-40, API SF or SGEngine oil capacity Change 850 ml

Filter change 950 ml

Overhaul 1 300 ml

SAM

67

GZ250

1/8 P-03, 09, 19, 28, 33



(1.0) —

EX. 22(0.9) —


EX. 0.08 – 0.13(0.003 – 0.005) —


(0.0010 – 0.0020) —

EX. 0.040 – 0.067(0.0016 – 0.0026) —



Valve stem O.D. IN. 5.460 – 5.475(0.2150 – 0.2156) —

EX. 5.445 – 5.460(0.2144 – 0.2150) —








18.4 – 21.6 kgf(40.56 – 47.62 lbs)


2/8 P-03, 09, 19, 28, 33




(1.3776 – 1.3795)34.690

(1.3657)

EX. 35.030 – 35.080(1.3791 – 1.3811)

34.730(1.3673)

Camshaft journal oil clearance 0.032 – 0.066(0.0013 – 0.0026)

0.150(0.0059)

Camshaft journal holder I.D. R. side 25.012 – 25.025(0.9847 – 0.9852) —

L. side 20.012 – 20.025(0.7879 – 0.7884) —

Camshaft journal O.D. R. side 24.959 – 24.980(0.9826 – 0.9835) —

L. side 19.959 – 19.980(0.7858 – 0.7866) —







(10.0 – 14.0 kgf/cm2, 142 – 199 psi)800 kPa


(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 72.000 – 72.015

(2.8346 – 2.8352)72.085

(2.8380)Piston diam. 71.950 – 71.965


71.880(2.8299)



2nd N Approx. 11.0 (0.43) 8.8(0.35)


0.50(0.020)

2nd 0.22 – 0.34(0.009 – 0.013)

0.70(0.028)


2nd — 0.150(0.0059)LE

P

3/8 P-03, 09, 19, 28, 33


OIL PUMP



(0.040 – 0.041) —

2nd 1.21 – 1.23(0.047 – 0.048) —

Oil 2.51 – 2.53(0.099 – 0.100) —


2nd 1.170 – 1.190(0.0461 – 0.0469) —

Piston pin bore 18.002 – 18.008(0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.992 – 18.000(0.7083 – 0.7087)

17.980(0.7079)


(0.7089 – 0.7092)18.040



(0.004 – 0.026)1.0


(0.825 – 0.827) —

Crankshaft web to web width 60.0 ± 0.1(2.362 ± 0.004) —



ITEM STANDARD LIMITOil pump reduction ratio 2.812 (68/21 × 33/38) —Oil pressure (at 60°C, 140°F) Above 30 kPa (0.3 kgf/cm2, 4.3 psi)


—


(0.4 – 0.6) —

Clutch release screw 1/4 turn back —Drive plate thickness No.1 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)

No.2 3.45 – 3.55(0.136 – 0.140)

3.15(0.124)


15.0(0.590)

SAM

4/8 P-03, 09, 19, 28, 33


CARBURETOR

ITEM STANDARD LIMITDriven plate distortion — 0.10


(1.61)


2nd 1.687 (27/16) —3rd 1.263 (24/19) —4th 1.000 (20/20) —Top 0.818 (18/22) —


0.60(0.024)



Drive chain Type D.I.D.520VC5 —Links 110 —



(0.2 – 0.6) —

ITEMSPECIFICATION

P-03, 09, 28 P-33Carburetor type MIKUNI BSR32 ←Bore size 32 mm ←I.D. No. 13F3 13F4Idle r/min 1 300 ± 100 r/min ←Float height 13.0 ± 0.5 mm ←Main jet (M.J.) # 120 ←Jet needle (J.N.) 5C65 ←Needle jet (N.J.) P-0M ←Pilot jet (P.J.) # 17.5 ←Pilot air jet No.1 (P.A.J.1) # 87.5 ←Pilot air jet No.2 (P.A.J.2) # 120 ←Pilot screw (P.S.) PRE-SET ←Throttle cable play 2 – 4 mm

(0.08 – 0.16 in) ←

Starter plunger cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ←

68

5/8 P-03, 09, 19, 28, 33

CARBURETOR


ITEMSPECIFICATION

P-19Carburetor type MIKUNI BSR32Bore size 32 mmI.D. No. 13F9Idle r/min 1 300 ± 100 r/minFloat height 13.0 ± 0.5 mmMain jet (M.J.) # 115Jet needle (J.N.) 5C60-3rdNeedle jet (N.J.) P-0Pilot jet (P.J.) # 17.5Pilot air jet No. 1 (P.A.J.1) # 87.5Pilot air jet No. 2 (P.A.J.2) # 140Pilot screw (P.S.) 2 and 1/2 turns outThrottle cable play 2 – 4 mm

(0.08 – 0.16 in)Starter plunger cable play 0.5 – 1.0 mm

(0.02 – 0.04 in)

ITEM SPECIFICATION NOTESpark plug Type NGK: DR8EA

DENSO: X24ESR-U

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 3 – 5 Ω Terminal –

Terminal

Secondary 17 – 28 kΩ Terminal – Plug cap

Ignition coil primary peak voltage More than 200 VGenerator coil resistance Pick-up 400 – 650 Ω Bl – G

Charging 0.1 – 1.5 Ω Y – YPick-up coil peak voltage More than 5.0 VGenerator Max. output 210 W at 5 000 r/minGenerator no-load voltage More than 60 V (AC) at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation FTX7L-BS

Capacity 12V 21.6 kC (6 Ah)/10HR

6/8 P-03, 09, 19, 28, 33

WATTAGE Unit: W


ITEM SPECIFICATION NOTEFuse size Main 20 A

HeadlightHI

10 A P-1915 A The others

LO10 A P-1915 A The others

Turn signal10 A P-1915 A The others

Ignition 10 ATaillight 10 A

ITEMSPECIFICATION

P-03, 28, 33 P-19 P-09Headlight HI 60 ← ←

LO 55 ← ←Position light 4Brake light/Taillight 21/5 ← ←Turn signal light 21 (rear) 10 ←Front turn signal light/Running light 21/5Speedometer light 1.7 ← ←Neutral indicator light 3.4 ← ←Turn signal indicator light 3.4 ← ←High beam indicator light 1.7 ← ←

ITEM STANDARD/SPECIFICATION LIMITRear brake pedal free travel 20 – 30

(0.8 – 1.2) —



4.5(0.18)


Master cylinder bore 12.700 – 12.743(0.4999 – 0.5017) —

Master cylinder piston diam. 12.657 – 12.684(0.4983 – 0.4994) —

Brake caliper cylinder bore 42.850 – 42.900(1.6870 – 1.6890) —

Brake caliper piston diam. 42.772 – 42.822(1.6839 – 1.6859) —

Brake fluid type DOT 4 —Brake drum I.D. Rear — 130.7

(5.15)Brake lining thickness Rear — 1.5

(0.06)LE
P
7/8 P-03, 09, 19, 28, 33


TIRE PRESSURE


(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 16 × MT2.50 or 16M/C × MT2.50 —Rear 15M/C × MT3.00 —

Tire size Front 110/90-16 59P, 110/90-16M/C 59P or 110/90-16M/C 59S —

Rear 130/90-15M/C 66P or130/90-15M/C 66S —


Rear — 2.0(0.08)


(4.7) —


301(11.9)

Front fork oil type SUZUKI fork oil SS-08 (#10) —Front fork oil capacity (each leg) 336 ml

(11.4/11.8 US/lmp oz) —







SAM

8/8 P-03, 09, 19, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE (MethyI Tertiary ButyIEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

P-03, 28, 33

Gasoline used should be graded 91 octane orhigher. An unleaded gasoline is recommended. The others

Fuel tank including reserve 13 L(3.4/2.9 US/lmp gal) P-19, 33

14 L(3.7/3.1 US/lmp gal) The others


Engine oil type and grade SAE 10W-40, API SF or SGEngine oil capacity Change 1 300 ml


change1 400 ml

(1.5/1.2 US/lmp qt)


69

LS650

1/8 E-03, 28, 33



(1.3) —

EX. 28(1.1) —


EX. 8.5(0.33) —



IN. 0.025 – 0.055(0.0010 – 0.0022) —

EX. 0.040 – 0.070(0.0016 – 0.0028) —



Valve stem O.D. IN. 6.960 – 6.975(0.2740 – 0.2746) —

EX. 6.945 – 6.960(0.2734 – 0.2740) —







(1.40)

OUTER — 40.4(1.59)


6.9 – 8.5 kgf(15.2 – 18.7 lbs)




—

2/8 E-03, 28, 33




(1.4242 – 1.4263)35.880

(1.4126)

EX. 36.419 – 36.473(1.4338 – 1.4359)

36.120(1.4220)


0.150(0.0060)

Camshaft journal holder I.D. Left 20.012 – 22.025(0.7879 – 0.7884) —

Right &Center

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. Left 19.959 – 19.976(0.7858 – 0.7865) —

Right &Center

24.959 – 24.976(0.9826 – 0.9833) —





Cylinder head cover distortion — 0.05 (0.002)

De-comp. cable play 3 – 5(0.12 – 0.20) —


(10 – 14 kgf/cm2, 142 – 200 psi)800 kPa

(8 kgf/cm2, 114 psi) Piston to cylinder clearance 0.050 – 0.060

(0.0020 – 0.0024)0.120

(0.0047)Cylinder bore 94.000 – 94.015

(3.7008 – 3.7014)94.080

(3.7039)Piston diam. 93.945 – 93.960


93.880(3.6961)


Piston ring free end gap 1st T Approx. 11.5 (0.45) 9.2(0.36)

2nd T Approx. 14.0 (0.55) 11.2(0.44)


1.00(0.039)

2nd 0.25 – 0.40(0.010 – 0.016)

1.00(0.039)


2nd — 0.15(0.006)LE

P

3/8 E-03, 28, 33

CONROD + CRANKSHAFT + BALANCER Unit: mm (in)

OIL PUMP



(0.0484 – 0.0492) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.81 – 2.83(0.1106 – 0.1114) —


2nd 1.175 – 1.190(0.0463 – 0.0469) —

Piston pin bore 23.000 – 23.006(0.9055 – 0.9057)

23.030(0.9067)

Piston pin O.D. 22.996 – 23.000 (0.9054 – 0.9055)

22.980(0.9047)

ITEM STANDARD LIMITCorod small end I.D. 23.006 – 23.014

(0.9057 – 0.9061)23.040



(0.004 – 0.026)1.0


(0.982 – 0.984) —




ITEM STANDARD LIMITOil pump reduction ratio 2.203 (68/36 × 35/30) —Oil pressure (at 60 °C, 140 °F) Above 50 kPa (0.50 kgf/cm2, 7.1 psi)

Below 75 kPa (0.75 kgf/cm2, 10.7 psI)at 3 000 r/min

—


(0.4 – 0.6) —

Drive plate thickness No. 1 2.92 – 3.08(0.115 – 0.121)

2.62(0.103)

No. 2 3.45 – 3.55(0.136 – 0.140)

3.15(0.124)

SAM

4/8 E-03, 28, 33


ITEM STANDARD LIMITDrive plate claw width No. 1 15.8 – 16.0

(0.622 – 0.630)15.0

(0.591)

No. 2 15.9 – 16.0(0.626 – 0.630)

15.1(0.594)




2nd 1.578 (30/19) —3rd 1.142 (24/21) —4th 0.956 (22/23) —Top 0.884 (23/26) —


0.50(0.020)

Shift fork groove width 3rd drivegear

5.50 – 5.60(0.217 – 0.220) —

4th drivengear

5.50 – 5.60(0.217 – 0.220) —

Top drivengear

5.50 – 5.60(0.217 – 0.220) —


5.30 – 5.40 (0.209 – 0.213) —

Drive belt Type BANDO: 133U-14M 40.0 —Number of

teeth 133 —


70

5/8 E-03, 28, 33

CARBURETOR


ITEMSPECIFICATION

E-03, 28 E-33Carburetor type MIKUNI BS40SS ←Bore size 40 mm ←I.D. No. 24C9 24CAIdle r/min 1 100 ± 100 r/min ←Float height 27.95 ± 1.0 mm

(1.1 ± 0.04 in) ←

Main jet (M.J.) # ←Jet needle (J.N.) 5C39 ←Needle jet (N.J.) ←Throttle valve (Th.V.) #120 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET (1 and 1/2 turns back) ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEM SPECIFICATION NOTESpark plug Type NGK: DPR8EA-9

N.D.: X24EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Solenoid resistance 0.1 – 1.0 ΩPick-up coil resistance 170 – 270 Ω O/GIgnition coil resistance Primary 1 – 7 Ω O/W – Ground

Secondary 10 – 25 kΩ Plug cap – Ground

Generator no-load voltage More than 100 V (AC) at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 2 – 6 ΩBattery Type designation YB14L-B2

Voltage 12 VCapacity 50.4 kC (14 Ah)/10 HRStandard


Fuse size 20 A

6/8 E-03, 28, 33

WATTAGE Unit: W


LO 55Parking or City lightBrake light/Taillight 21/5Turn signal light 21Running light(within front turn signal light) 5

Speedometer light 3Turn signal indicator light 3High beam indicator light 1.7Neutral indicator light 3License light 8

LE
P
7/8 E-03, 28, 33


ITEM STANDARD LIMIT






4.0(0.16)







Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 19 × 2.15 —Rear 15M/C × 2.75 —

Tire size Front 100/90-19M/C 57H —Rear 140/80-15 M/C 67H —


Rear — 2.0(0.08)

SAM

8/8 E-03, 28, 33


TIRE PRESSURE

FUEL + OIL


(5.5) —

Front fork spring free length — 392.5(15.45)






FRONT 200 2.00 29 200 2.00 29REAR 225 2.25 33 250 2.50 36


octane (R/2 + M/2) or 91 octane or higher rated bythe reserch method.Gasoline containing MTBE (MethyI Tertiary ButyIEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33

Fuel tank capacity Includingreserve

10.5 L(2.8/2.3 US/Imp gal)

Onlyreserve

2.5 L(0.66/0.55 US/lmp gal)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Oil

change1 800 ml

(1.9/1.6 US/lmp qt)Oil and

filter change2 000 ml


overhaul2 400 ml

2.5/2.1 US/lmp qt)Front fork oil type Fork oil #15Front fork oil capacity (each leg) 447 ml

(15.11/15.74 US/lmp oz)Spacer

L: 135 mmBrake fluid type DOT 4

71

LT-160/F160

1/7 P-03, 19, 24, 28, 33, 51



(1.1) —

EX. 25(1.0) —


EX. 0.05 – 0.10(0.002 – 0.004) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2155 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2153) —






Valve spring free length (IN. & EX.) — 39.5(1.56)

Valve spring tension (IN. & EX.) 18.4 – 21.6 kgf(40.6 – 47.6 lbs)


2/7 P-03, 19, 24, 28, 33, 51




P-03IN. 33.768 – 33.808

(1.3295 – 1.3310)33.470

(1.3177)

EX. 33.390 – 33.430(1.3146 – 1.3161)

33.090(1.3028)

P-33IN. 33.490 – 33.530

(1.3185 – 1.3201)33.190

(1.3067)

EX. 33.353 – 33.393(1.3131 – 1.3147)

33.060(1.3016)


0.150(0.0059)



Camshaft runout IN. & EX — 0.10(0.004)

Rocker arm I.D. IN. & EX 12.000 – 12.018(0.4724 – 0.4731) —

Rocker arm shaft O.D. IN. & EX 11.977 – 11.995(0.4715 – 0.4722) —




(10 – 14 kgf/cm2, 142 – 199 psi) 800 kPa


(0.0012 – 0.0016)0.120

(0.0047)Cylinder bore 58.000 – 58.015

(2.2835 – 2.2841)58.100

(2.2874)Piston diam. 57.965 – 57.980


57.880(2.2787)



2nd R Approx. 7.4 (0.29) 6.0(0.24)


0.70(0.028)


2nd — 0.150(0.0059)


Oil 2.51 – 2.53(0.0988 – 0.0996) —LE

P

3/7 P-03, 19, 24, 28, 33, 51


OIL PUMP


ITEM STANDARD LIMITPiston ring thickness 1st & 2nd 1.17 – 1.19

(0.046 – 0.047) —

Piston pin bore 14.002 – 14.008(0.5513 – 0.5515)

14.030(0.5524)

Piston pin O.D. 13.996 – 14.000(0.5510 – 0.5512)

13.980(0.5504)


(0.5513 – 0.5517)14.040



(0.0039 – 0.0177)1.00


(0.628 – 0.630) —





—

ITEM STANDARD LIMITClutch release screw 0 – 1/8 turn back —Drive plate thickness 2.7 – 2.9

(0.106 – 0.114)2.4


(0.46 – 0.47)11.0



(1.09)Clutch shoe — No groove at

any partsClutch engagement 2 200 ± 200 r/min —Clutch lock-up 3 500 ± 250 r/min —

SAM

4/7 P-03, 19, 24, 28, 33, 51


CARBRETOR


2nd 2.142 (30/14) —3rd 1.588 (27/17) —4th 1.200 (24/20) —Top 0.950 (19/20) —

Reverse 2.833 (29/12 × 34/29) —Shift fork to groove clearance 0.10 – 0.30

(0.004 – 0.012)0.50


& No. 34.50 – 4.60

(0.177 – 0.181) —

Reverse 4.00 – 4.10(0.157 – 0.161) —


4.30 – 4.40(0.169 – 0.173) —

Reverse 3.80 – 3.90(0.150 – 0.154) —

Drive chain Type TAKASAGO: RK520SM —Links 84 —



(0.8 – 1.2) —


ITEMSPECIFICATION

P-03 P-33Carburetor type MIKUNI VM20SS MIKUNI BS26SSBore size 20 mm 26 mmI.D. No. 02C02 02C1Idle r/min 1 500 ± 100 r/min ←Float height 25.8 ± 1.0 mm

(1.02 ± 0.04 in)21.4 ± 1.0 mm(0.84 ± 0.04 in)

Main jet (M.J.) #87.5 #Jet needle (J.N.) 5FU96-3rd 4DN13-1stNeedle jet (N.J.) O-1Pilot jet (P.J.) #22.5 #Starter jet (G.S.) #22.5 #20Pilot screw (P.S.) 1 and 5/8 turns back PRE-SETThrottle cable play 3 – 5 mm

(0.12 – 0.20 in) ←

Starter cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ←

72

5/7 P-03, 19, 24, 28, 33, 51


WATTAGE Unit: W

ITEM SPECIFICATION NOTESpark plug Type NGK: DPR7EA-9

ND: X22EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)


Ground


Magneto coil resistance Pulser 380 – 600 Ω BI – GCharging 0.5 – 1.2 Ω Y – Y

Generator no-load voltage More than 55 V (AC) at 5 000 r/minGenerator Max. output Approx. 150 W at 5 000 r/minRegulated voltage 13.5 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 7 ΩBattery Type designation YB9A-A



Fuse size 15 A


LO 45Taillight 5Reverse indicator light 3.4Neutral indicator light 3.4

6/7 P-03, 19, 24, 28, 33, 51


SUSPENSION

TIRE PRESSURE

ITEM STANDARD/SPECIFICATION LIMITFront brake lever free travel 30

(1.2) —


Brake drum I.D. Front — 120.7(4.75)

Rear — 150.7(5.93)

Brake lining thickness — 1.5(0.06)

Steering angle Inside 41° —Outside 30° —

Turning radius 2.4 m (7.9 ft) —Toe-in (with 75 kg, 165 lbs) 3 – 11 (0.1 – 0.4) —Caster 8° —Trail 31 (1.2) —Wheel axle runout Rear — 8.0

(0.31)Wheel rim size Front 8 × 5.5 AT —

Rear 8 × 8.0 AT —Tire size Front AT 20 × 7-8 —

Rear AT 22 × 10-8 —Tire tread depth Front 4.0

(0.16) —

Rear 4.0(0.16) —

ITEM STANDARD LIMIT NOTERear shock absorber springsetting 3rd position —

Front wheel travel 80(3.1) —




LOAD CAPACITY130 kg (285 lbs)

kPa kgf/cm2 psiFRONT 25 0.25 3.6REAR 20 0.20 2.9

LE
P
7/7 P-03, 19, 24, 28, 33, 51



Fuel tank including reserve 8.5 L(2.2/1.9 US/lmp gal)


Engine oil type SAE 10W-40, API, SF or SGEngine oil capacity Change 1 500 ml

(1.6/1.3 US/lmp qt)



SAM

73

LT-A400/F

1/7 P-17, 24, 28, 33




(1.20) —

EX. 27.0(1.06) —


EX. 0.22 – 0.27(0.009 – 0.011) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —


Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —









182 – 210 N(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)



(1.3043 – 1.3067)32.830

(1.2925)

EX. 33.130 – 33.190(1.3043 – 1.3067)

32.830(1.2925)

Camshaft journal oil clearance 22 0.032 – 0.066

(0.0013 – 0.0026)0.150

(0.0059)

17.5 0.028 – 0.059(0.0011 – 0.0023)

0.150(0.0059)

Camshaft journal holder I.D. 22 22.012 – 22.025

(0.8666 – 0.8671) —

17.5 17.512 – 17.525(0.6894 – 0.6900) —

2/7 P-17, 24, 28, 33


ITEM STANDARD LIMITCamshaft journal holder I.D.

22 22.012 – 22.025(0.8666 – 0.8671) —

17.5 17.512 – 17.525(0.6894 – 0.6900) —

Camshaft journal O.D. 22 21.959 – 21.980

(0.8645 – 0.8654) —

17.5 17.466 – 17.484(0.6876 – 0.6883) —






ITEM STANDARD LIMITCompression pressure(Automatic-decomp. actuated) Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi) —


0.120(0.0047)

Cylinder bore 82.000 – 82.015(3.2283 – 3.2289)

82.070(3.2311)

Piston diam. 81.930 – 81.945(3.2256 – 3.2262)


(3.2236)



2nd R Approx. 10.4 (0.41) 8.3(0.33)


0.50(0.020)

2nd 0.15 – 0.27(0.006 – 0.011)

0.50(0.020)


2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —LE

P

3/7 P-17, 24, 28, 33


OIL PUMP




(0.0382 – 0.0390) —

2nd 0.970 – 0.990(0.0382 – 0.0390) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.992 – 20.000 (0.7870 – 0.7874)

19.980(0.7866)


(0.7876 – 0.7879) 20.040



(0.004 – 0.022)1.0


(0.864 – 0.866) —



ITEM STANDARD LIMITOil pressure (at 60°C, 140°F) Above 110 kPa (1.1 kgf/cm2, 16 psi)


—


(5.512 – 5.520)140.5 (5.53)

Clutch shoe — No groove at any part

Clutch engagement r/min 1 900 – 2 300 r/min —Clutch lock-up r/min 3 400 – 4 000 r/min —

ITEM STANDARD LIMITAutomatic transmission ratio Variable change (2.938 – 0.813) —Secondary reduction ratio 2.730 (42/19 × 21/17) —Final reduction ratio Front 3.600 (36/10) —

Rear 3.600 (36/10) —Transfer gear ratio Low 2.500 (40/16) —

High 1.375 (33/24) —Reverse 2.000 (32/16) —

SAM

4/7 P-17, 24, 28, 33

ENGINE OIL TEMP. SWITCH + COOLING FAN THERMO-SWITCH

CARBURETOR

ITEM STANDARD LIMITDrive belt width 30.3

(1.19)29.3

(1.15)Movable driven face spring free length

215.0(8.46)

204.3(80.4)


0.50(0.020)

Shift fork groove width High/Low 5.50 – 5.60

(0.217 – 0.220) —

Reverse 5.50 – 5.60(0.217 – 0.220) —

Shift fork thickness High/Low 5.30 – 5.40(0.209 – 0.213) —

Reverse 5.30 – 5.40(0.209 – 0.213) —

Front/rear output shaft bevel gear backlash

0.03 – 0.15(0.001 – 0.006) —

Front drive (differential) gear backlash

0.05 – 0.10(0.002 – 0.004) —

Rear drive (final) gear backlash 0.08 – 0.013(0.0031 – 0.0051) —

ITEM STANDARD/SPECIFICATION LIMITEngine oil temp. indicator light switch operating temperature




ITEMSPECIFICATION

P-17, 24, 28 P-33Caburetor type KEIHIN CVK32 ←Bore size 32 mm ←I.D. No. 38F2 38F1Idle r/min 1 500 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ←

Main jet (M.J.) #122 #Jet needle (J.N.) NBZA ←Needle jet (N.J.) #6 #Slow jet (S.J.) #38 #Pilot screw (P.S.) 2 and 1/4 turns back PRE-SETThrottle cable play 3 – 5 mm

(0.12 – 0.20 in) ←

74

5/7 P-17, 24, 28, 33


WATTAGE Unit: W


DENSO: U22ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Terminal


Generator coil resistance Pick-up 130 – 250 Ω Bl – GPower source 0.05 – 1.2 Ω Y – W

Charging 0.1 – 1.5 Ω B – BGenerator no-load voltage(When engine is cold) More than 60 V (AC) at 5 000 r/min

Generator Max. output Approx. 225 W at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minIgnition coil primary peak voltage More than 180 V : Ground

: W/BIPick-up coil peak voltage More than 4.0 V : G, : BIPower source coil peak voltage More than 0.3 V : Y, : WStarter relay resistance 3 – 5 ΩBattery Type designation YTX14-BS

Capacity 12 V 43.2 kC (12 Ah)/10 HRFuse size Main 30 A

Power source 10 AHeadlight (HI) 10 AHeadlight (LO) 10 A

Taillight 10 AIgnition 10 A

Fan 10 A

ITEMSPECIFICATION

P-17 OthersHeadlight HI 30 × 2 pcs. ←

LO 30 × 2 pcs. ←Brake light/Taillight 21/5 ←Speedometer light 1.7 ←Reverse indicator light 3.4 ←Neutral indicator light 3.4 ←Engine oil temp. indicator light 3.4 ←High beam indicator light 3.4 —Reverse light 21 —

6/7 P-17, 24, 28, 33


ITEM STANDARD/SPECIFICATION LIMITRear brake cable play 3 – 5

(0.12 – 0.20) —

Rear brake pedal height 5 – 15(0.2 – 0.6) —



3.0(0.12)







Brake fluid type DOT 4 —Steering angle Right 47° —

Left 47° —Turning radius 3.1 m (10.2 ft) —Toe-in (with 75 kg, 165 lbs) 4 ± 4

(0.16 ± 0.16) —

Camber 0.3° —Caster 3° —Wheel rim size Front 12 × 6.0 AT —

Rear 12 × 7.5 AT —Tire size Front AT25 8-12 —

Rear AT25 10-12 —Tire tread depth Front — 4.0

(0.16)

Rear — 4.0(0.16)

LE
P
7/7 P-17, 24, 28, 33

TIRE PRESSURE LT-A400

LT-A400F

FUEL + OIL

COLD INFLATIONTIRE PRESSURE kPa kgf/cm2 psi NOTE

FRONT 32.5 0.325 4.7 LOAD CAPACITYREAR 27.5 0.275 4.0 UP TO 172 kg (380 lbs)


FRONT 32.5 0.325 4.7 LOAD CAPACITYREAR 30 0.30 4.4 UP TO 172 kg (380 lbs)



P-03, 28, 33


Fuel tank includingreserve

15.0 L(4.0/3.3 US/lmp gal)

reserve3.3 L

(0.9/0.7 US/lmp gal)Engine oil type SAE 10W-40, API SF or SGEngine oil capacity

Change2 900 ml

(3.1/2.6 US/lmp qt)

Filter change3 100 ml

(3.3/2.7 US/lmp qt)

Overhaul3 400 ml

(3.6/3.0 US/lmp qt)Front /Rear drive gear oil type Hypoid gear oil SAE #90,

API grade GL-5Front drive (differential) gear oil capacity

300 ml(10.1/10.6 US/lmp oz)

Rear drive gear oil capacity 350 ml(11.8/12.3 US/lmp oz)

SAM

75

LT-A500F

1/8 P-24, 28, 33



(1.20) —

EX. 27.0(1.06) —


EX. 0.17 – 0.22(0.007 – 0.009) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —


Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —









18.6 – 21.4 kgf(41.0 – 47.2 lbs)


2/8 P-24, 28, 33




(1.3161 – 1.3188)33.130

(1.3043)

EX. 33.500 – 33.568(1.3189 – 1.3216)

33.200(1.3071)

Camshaft journal oil clearance22 0.032 – 0.066

(0.0013 – 0.0026)0.150

(0.0059)

17.5 0.028 – 0.059(0.0011 – 0.0023)

0.150(0.0059)

Camshaft journal holder I.D.22 22.012 – 22.025

(0.8666 – 0.8671) —

17.5 17.512 – 17.525(0.6894 – 0.6900) —

Camshaft journal O.D.22 21.959 – 21.980

(0.8645 – 0.8654) —

17.5 17.466 – 17.484(0.6876 – 0.6883) —







Piston to cylinder clearance 0.030 – 0.040(0.0012 – 0.0016) —

Cylinder bore 87.500 – 87.515(3.4449 – 3.4455)

Nicks or Scratches

Piston diam. 87.465 – 87.480(3.4435 – 3.4441)


(3.4402)



2nd R Approx. 11.9 (0.47) 9.5(0.37)


0.50(0.020)

2nd 0.10 – 0.25(0.004 – 0.009)

0.50(0.020)

LE
P
3/8 P-24, 28, 33


OIL PUMP



(0.0071)

2nd — 0.150(0.0059)


2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


2nd 1.17 – 1.19(0.0461 – 0.0469) —

Piston pin bore 23.002 – 23.008 (0.9056 – 0.9058)

23.030(0.9067)

Piston pin O.D. 22.995 – 23.000 (0.9053 – 0.9055)

22.980(0.9047)


(0.9057 – 0.9061) 23.040



(0.004 – 0.026)1.0


(0.982 – 0.984) —





—


(5.512 – 5.520)140.5(5.53)

Clurch shoe — No groove at any part


SAM

4/8 P-24, 28, 33



ITEM STANDARD LIMITAutomatic transmission ratio Variable change (2.876 – 0.703) —Secondary reduction ratio 2.562 (41/16) —Final reduction ratio Front 3.600 (36/10) —

Rear 3.600 (36/10) —Transfer gear ratio Low 2.500 (40/16) —

High 1.200 (30/25) —Reverse 2.000 (28/16 × 32/28) —

Drive belt width 36.7(1.44)

35.7(1.41)

Movable driven face spring free length

153.0(6.02)

145.4(5.72)


0.50(0.020)

Shift fork groove width High/Low 5.50 – 5.60

(0.217 – 0.220) —

Reverse 5.50 – 5.60(0.217 – 0.220) —

Shift fork thickness High/Low 5.30 – 5.40(0.209 – 0.213) —

Reverse 5.30 – 5.40(0.209 – 0.213) —


0.03 – 0.15(0.001 – 0.006) —

Front drive (defferential) gear back-lash

0.05 – 0.10(0.002 – 0.004) —



73.5 – 76.5 °C(164 – 170 °F) —


95 – 125 kPa(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi) —

Engine coolant temp. indicator light switch operating temperature

OFF → ON Approx. 115 °C (239 °F) —ON → OFF Approx. 108 °C (226 °F) —




—

Engine coolant including reserve 2 000 ml(2.1/1.8 US/lmp qt) —

76

5/8 P-24, 28, 33

CARBURETOR

ELECTRICAL

ITEMSPECIFICATION

P-24, 28 P-33Carburetor type KEIHIN CVK36 ←Bore size 36 mm ←I.D. No. 03G0 03G1Idle r/min 1 300 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ←

Main jet (M.J.) #128 #Jet needle (J.N.) NBAY ←Needle jet (N.J.) #6 #Slow jet (S.J.) #35 #Pilot screw (P.S.) 1 and 7/8 turns back PRE-SET

Throttle cable play 3 – 5 mm(0.12 – 0.20 in) ←

Choke cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ←


DENSO: U20ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Ground





: W/BlPick-up coil peak voltage More than 4.0 V : G, : BlPower source coil peak voltage More than 0.3 V : Y, : WStarter relay resistance 3 – 5 ΩBattery Type designation YTX20CH-BS


6/8 P-24, 28, 33

WATTAGE


ITEM SPECIFICATION NOTEFuse size Main 30 A


Tail 10 AIgnition 15 A

Fan 10 A

ITEM SPECIFICATIONHeadlight HI 30 × 2 pcs.

LO 30 × 2 pcs.Auxiliary light 40Brake light/Taillight 21/5Speedometer light LEDReverse indicator light LEDNeutral indicator light LEDParking indicator light LEDHight beam indicator light LEDEngine coolant temp. indicator light LED


(0.12 – 0.20) —



3.0(0.12)

Rear 3.8 – 4.2(0.209 – 0.224)

3.5(0.197)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 33.960 – 34.036(1.3370 – 1.3400) —

LE
P
7/8 P-24, 28, 33

TIRE PRESSURE

VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs)

ITEM STANDARD/SPECIFICATION LIMITBrake caliper piston diam. Front 31.948 – 31.998

(1.2578 – 1.2598) —

Rear 33.884 – 33.934(1.3340 – 1.3360) —



(0.30 ± 0.16) —

Camber 0.45° —Caster 3.3° —Wheel rim size Front 12 × 6.0 AT —


Rear AT25 10-12 —Tire type Front DUNLOP: KT121D —

Rear DUNLOP: KT405D —Tire tread depth — 4.0

(0.16)

— 4.0(0.16)


kPa kgf/cm2 psi NOTE

FRONT 35 0.35 5.1 LOAD CAPACITYUP TO 172 kg (380 lbs)REAR 30 0.30 4.4

SAM

8/8 P-24, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(Methyl Tertiary Butyl Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.





change2 700 ml

(2.9/2.4 US/lmp qt)


Front/Rear drive gear oil type Hypoid gear oil SAE #90API grade GL-5

Front drive (differential) gear oil capacity

300 ml(10.1/10.6 US/lpm oz)

Rear drive gear oil capacity 350 ml(11.8/12. US/lpm oz)

77

LT-F250

1/7 E-17, 24, 28, 33



(1.3) —

EX. 28(1.1) —


EX. 0.08 – 0.13(0.003 – 0.005) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —


Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —









256 – 294 N(25.6 – 29.4 kgf, 56.4 – 64.8 lbs)


2/7 E-17, 24, 28, 33




(1.3299 – 1.3315)33.480

(1.3181)

EX. 32.990 – 33.030(1.2988 – 1.3004)

32.690(1.2870)


0.150(0.0059)

Camshaft journal holder I.D. 22.012 – 22.025(0.8666 – 0.8671) —







ITEM STANDARD LIMITCompression pressure Approx. 1 400 kPa (14 kgf/cm2, 199 psi) 1 200 kPa


(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 66.000 – 66.015

(2.5984 – 2.5990)66.090

(2.6020)Piston diam. 65.955 – 65.970


65.880(2.5937)



2nd R Approx. 9.0 (0.35) 7.2(0.28)


0.50(0.020)

2nd 0.10 – 0.25(0.004 – 0.010)

0.50(0.020)


2nd — 0.150(0.0059)

LE
P
3/7 E-17, 24, 28, 33


OIL PUMP


(0.0398 – 0.0406) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —


2nd 1.17 – 1.19(0.046 – 0.047) —

Piston pin bore 16.002 – 16.008(0.6300 – 0.6302)

16.030(0.6311)

Piston pin O.D. 15.992 – 16.000(0.6296 – 0.6299)

15.980(0.6291)


(0.6302 – 0.6305)16.040



(0.004 – 0.018)1.0


(0.707 – 0.709) —





—

SAM

4/7 E-17, 24, 28, 33



ITEM STANDARD LIMITClutch release screw 1/16 – 1/8 turn back —Drive plate thickness 2.7 – 2.9

(0.106 – 0.114)2.4


(0.46 – 0.47)11.0



(1.06)*25.7(1.01)

Clutch wheel I.D. 116.00 – 116.15(4.567 – 4.573)

116.5 (4.59)



ITEM STANDARD LIMITPrimary reduction ratio 3.250 (65/20) —Secondary reduction ratio 1.235 (21/17) —Final reduction ratio 3.200 (32/10) —Transmission gear ratio

Low 3.083 (37/12) —2nd 1.933 (29/15) —3rd 1.388 (25/18) —4th 1.095 (23/21) —Top 0.913 (21/23) —


(0.004 – 0.012)0.50

(0.020)Shift fork groove width 4.50 – 4.60

(0.177 – 0.181) —



Secondary bevel gear backlash 0.03 – 0.15(0.001 – 0.006) —

Rear drive (final) bevel gear back-lash

0.05 – 0.30(0.002 – 0.012) —

78

5/7 E-17, 24, 28, 33

CARBRETOR


ITEMSPECIFICATION

E-24, 28 E-17 E-33Carburetor type MIKUNI BS29 ← ←Bore size 29 mm ← ←I.D. No. 05G0 05G2 05G1Idle r/min 1 500 ± 100 r/min ← ←Float height 17.1 ± 1.0 mm

(0.67 ± 0.04 in) ← ←

Main jet (M.J.) #137.5 ← #Jet needle (J.N.) 4DJ24-1st ← ←Needle jet (N.J.) P-0M ←Throttle valve (Th.V.) #100 ← ←Pilot jet (P.J.) #17.5 ← #Pilot screw (P.S.) 2 and 7/8 turns back ← PRE-SETThrottle cable play 3 – 5 mm

(0.12 – 0.20 in) ← ←

Starter (enricher) cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ← ←


DENSO: X22ESR-U

Gap 0.6 – 0.7(0.024 – 0.028)


Terminal

Secondary 10 – 20 kΩ Plug cap –Ground

Ignition coil primary peak voltage More than 120 V : B/W,: W/Bl

Generator coil resistance Pick-up 80 – 155 Ω B/Y – G/WCharging 0.5 – 1.5 Ω Y – Y

Pick-up coil peak voltage More than 4.0 V : G/W,: B/Y

Generator no-load voltage(When engine is cold) More than 60 V (AC)

Generator Max. output Approx. 150 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX12-BS

Capacity 12V 36.0 kC (10 Ah)/10HRFuse size 20A

6/7 E-17, 24, 28, 33

WATTAGE Unit: W


ITEMSPECIFICATION

E-28, 33 E-24 E-17Headlight HI 30 × 2 pcs. ← ←

LO 30 × 2 pcs. ← ←Brake light/Taillight 21/5 ← ←Backup light 21Reverse indicator light 3 ← ←Neutral indicator light 3 ← ←High beam indicator light 3.4


(0.12 – 0.20) —



3.0(0.12)





Brake caliper cylinder bore Front 32.030 – 32.080(1.2610 –1.2630) —


Brake fluid type DOT 4 —Turning radius 2.6 m (8.5 ft) —Toe-in (with 75 kg, 165 lbs) 2 ± 4

(0.08 ± 0.16) —

Camber 0° —Caster 9°30’ —Wheel rim size Front 11 × 5.5 AT —

Rear 9 × 8.0 AT —Tire size Front AT22 × 7-11 —

Rear AT22 × 10-9 —Tire tread depth Front — 4.0

(0.16)

Rear — 4.0(0.16)

Wheel axle runout Rear — 3.0(0.12)LE

P

7/7 E-17, 24, 28, 33

TIRE PRESSURE


FUEL + OIL

COLD INFLATIONTIRE PRESSURE kPa kgf/cm2 psi

FRONT 25 0.25 3.6REAR 20 0.20 2.9

TEM SPECIFICATION NOTEFuel type Use only unleaded gasoline of at least 87 pump


E-28, 33


E-17, 24





change2 300 ml

(2.4/2.0 US/lmp qt)


Rear drive (final) gear oil type Hypoid gear oil SAE #90, API grade GL-5Rear drive (final) gear oil capacity 190 ml

(6.4/6.7 US/lmp oz)

SAM

79

LT-F300F

1/7 E-24, 28



(1.3) —

EX. 28(1.1) —


EX. 0.17 – 0.22(0.007 – 0.009) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —


Valve guide I.D. 5.500 – 5.512(0.2165 – 0.2170) —IN. & EX.

Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —







(1.38)

OUTER — 39.9(1.57)


7.1 – 9.2 kgf(15.7 – 20.3 lbs)




2/7 E-24, 28




(1.3430 – 1.3446)33.820

(1.3315)

EX. 33.790 – 33.830(1.3303 – 1.3319)

33.490(1.3185)


0.150(0.0059)









(10 – 14 kgf/cm2, 142 – 199 psi)800 kPa


(0.0020 – 0.0024)0.120

(0.0047)Cylinder bore 68.500 – 68.515

(2.6968 – 2.6974)68.580

(2.7000)Piston diam. 68.445 – 68.460


68.380(2.6921)



2nd R Approx. 8.5 (0.33) 6.8(0.27)


0.50(0.020)

2nd 0.50 – 0.65(0.020 – 0.026)

0.70(0.028)


2nd — 0.150(0.0059)


2nd 1.22 – 1.24(0.048 – 0.049) —

Oil 2.01 – 2.03(0.079 – 0.080) —LE

P

3/7 E-24, 28


OIL PUMP



(0.038 – 0.039) —

2nd 1.17 – 1.19(0.046 – 0.047) —

Piston pin bore 17.002 – 17.008(0.6694 – 0.6696)

17.030(0.6705)

Piston pin O.D. 16.996 – 17.000(0.6691 – 0.6693)

16.980(0.6685)


(0.6695 – 0.6698)17.040



(0.004 – 0.018)1.00


(0.707 – 0.709) —





—

ITEM STANDARD LIMITClutch release screw 1/8 turn back —Drive plate thickness 2.7 – 2.9

(0.106 – 0.114)2.4


(0.46 – 0.47)11.0



(1.08)Clutch wheel I.D. 116.00 – 116.15

(4.567 – 4.573)Scuffing or

scratch on con-tacting surface



SAM

4/7 E-24, 28

SHAFT DRIVE Unit: mm (in)

OIL TEMP. THERMO-SWITCH Unit: mm (in)

ITEM STANDARD LIMITSub-transmission fork to groove clearance

0.05 – 0.25(0.002 – 0.010)

0.50(0.020)

Reverse fork to groove clearance 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Shift fork groove width

No. 1, No. 2 & No. 3

4.50 – 4.60(0.177 – 0.181) —

Sub-transmission No. 1, No. 2

5.45 – 5.55(0.215 – 0.219) —

Reverse 4.00 – 4.10(0.157 – 0.161) —


4.30 – 4.40(0.169 – 0.173) —

Sub-transmission No. 1, No. 2

5.30 – 5.40(0.209 – 0.213) —

Reverse 3.80 – 3.90(0.150 – 0.154) —


ITEM STANDARD LIMITSecondary drive bevel gear back-lash (Engine side)

0.07 – 0.15(0.003 – 0.006) —

Final drive bevel gear pre-load(Dif. side)

30 – 70 N·cm(3 – 7 kgf·cm, 2.6 – 6.1 lb-in) —

Differential side gear backlash(Right side)

0.05 – 0.10(0.002 – 0.004) —

Final drive bevel gear backlash(Dif. side)

0.01 – 0.05(0.004 – 0.002) —

ITEM STANDARD LIMITOil temp. indicator light thermo-switch operating temperature

OFF → ON Approx. 160 °C (320 °F)E-28

ON → OFF Approx. 140 °C (284 °F)Cooling fan thermo-switch operat-ing temperature

OFF → ON Approx. 120 °C (248 °F)E-24

ON → OFF Approx. 110 °C (230 °F)

80

5/7 E-24, 28

CARBURETOR


ITEMSPECIFICATION

E-24, 28Carburetor type MIKUNI BSR29SSBore size 29 mmI.D. No. 39D2Idle r/min 1 500 ± 100 r/minFloat height 13 ± 0.5 mm

(0.51 ± 0.02 in)Main jet (M.J.) #117.5Jet needle (J.N.) 5D112-2ndNeedle jet (N.J.) P-0MThrottle valve (Th.V.) #105Pilot jet (P.J.) #15Starter jet (G.S.) #70Pilot screw (P.S.) 2 and 1/4 turns backPilot air jet (P.A.J.) #160Throttle cable play 3 – 5 mm

(0.12 – 0.20 in)


DENSO: X22ESR-U

Gap 0.6 – 0.7(0.024 – 0.028)


Ground


Ignition coil primary peak voltage More than 100 VGenerator coil resistance Pick-up 90 – 140 Ω B/Y – G/W

Charging 0.1 – 1.0 Ω Y – YPick-up coil peak voltage More than 2.5 VGenerator no-load voltage(When the engine is cold) More than 60 V (AC)

Generator Max. output Approx. 200 W at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation Y50-N18A-A

E-24, 28Capacity 12 V 72 kC (20 Ah)/10HRStandard electrolyte

S.G. 1.28 at 20 °C (68 °F)

Fuse size Main 20 AE-24Power source 5 A

Fan 10 A

6/7 E-24, 28

WATTAGE Unit: W


ITEMSPECIFICATION

E-24 E-28Headlight HI 30 × 2 pcs. ←

LO 30 × 2 pcs. ←Brake light 18 ←Taillight 5 × 2 pcs. ←Speedometer light 3 × 2 pcs. ←Reverse indicator light 3.4 ←Neutral indicator light 3.4 ←High beam indicator light 1.7Cooling fan indicator light 3.4Engine oil temp. indicator light 3.4

ITEM STANDARD LIMITRear brake lever cable play 3 – 5

(0.1 – 0.2) —


Rear brake pedal height 0 —Brake disc thickness Front 3.3 – 3.7

(0.130 – 0.146)3.0

(0.12)Brake disc runout Front — 0.30

(0.012)Brake caliper cylinder bore Front 25.400 – 25.450

(1.0000 – 1.0020) —


Brake hluid type DOT 4 —Brake drum I.D. Rear — 180.7

(7.11)Brake lining thickness Rear — 1.5


(0.5512 – 0.5529)Master cylinder piston diam. Front 13.957 – 13.984

(0.5495 – 0.5506) —

Steering angle Inside 36° ± 3° —Outside 26° ± 3° —

Turning radius 3.2 m (10.5 ft) —Toe-in (with 75 kg, 165 lbs) 16 – 24

(0.63 – 0.94) —

Camber (with 75 kg, 165 lbs) 1° (Negative) —Kingpin inclination 8° 54’Caster 5° 30’ —Wheel rim size Front 11 × 6.0 AT —

Rear 12 × 8.0 AT —LE
P
7/7 E-24, 28

TIRE PRESSUREFOR E-24

VEHICLE LOAD CAPACITY LIMIT: 177 kg

FOR E-28


FUEL + OIL

ITEM STANDARD LIMITTire size Front AT24 × 8-11 —


(0.16)

Rear — 4.0(0.16)

COLD INFLATION TIRE PRESSURE kPa kgf/cm2 psi

FRONT 30 0.30 4.4REAR 27.5 0.275 4.0


FRONT 30 0.30 4.4REAR 27.5 0.275 4.0


higher. An unleaded gasoline is recommended.E-24

Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-28

Fuel tank including reserve 12 L(3.2/2.6 US/lmp gal)




change3 600 ml

(3.8/3.2 US/lmp qt)


Differential gear oil type Hypoid gear oil SAE #90, API grade GL-5Differential gear oil capacity 150 ml


SAM

81

LT-F400F

1/8 P-17, 24, 28, 33



(1.20) —

EX. 27.0(1.06) —


EX. 0.22 – 0.27(0.009 – 0.011) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —


Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —









182 – 210 N(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)


2/8 P-17, 24, 28, 33




(1.3043 – 1.3067)32.830

(1.2925)

EX. 33.130 – 33.190(1.3043 – 1.3067)

32.830(1.2925)

Camshaft journal oil clearance 22 0.032 – 0.066

(0.0013 – 0.0026)0.150

(0.0059)

17.5 0.028 – 0.059(0.0011 – 0.0023)

0.150(0.0059)

Camshaft journal holder I.D. 22 22.012 – 22.025

(0.8666 – 0.8671) —

17.5 17.512 – 17.525(0.6894 – 0.6900) —

Camshaft journal O.D. 22 21.959 – 21.980

(0.8645 – 0.8654) —

17.5 17.466 – 17.484(0.6876 – 0.6883) —








0.120(0.0047)

Cylinder bore 82.000 – 82.015(3.2283 – 3.2289)

82.070(3.2311)

Piston diam. 81.930 – 81.945(3.2256 – 3.2262)


(3.2236)



2nd R Approx. 10.4 (0.41) 8.3(0.33)


0.50(0.020)

2nd 0.15 – 0.27(0.006 – 0.011)

0.50(0.020)LE

P

3/8 P-17, 24, 28, 33


OIL PUMP



(0.0071)

2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —


2nd 0.970 – 0.990(0.0382 – 0.0390) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.992 – 20.000 (0.7870 – 0.7874)

19.980(0.7866)


(0.7876 – 0.7879) 20.040



(0.004 – 0.022)1.0


(0.864 – 0.866) —





—


(0.115 – 0.121)2.62


(0.545 – 0.549)13.05


(0.004)

SAM

4/8 P-17, 24, 28, 33


ITEM STANDARD LIMITClutch spring free length 35.4

(1.39)33.7

(1.33)Clutch wheel I.D. 140.0 – 140.2

(5.512 – 5.520)140.5 (5.53)



ITEM STANDARD LIMITPrimary reduction ratio 2.392 (67/28) —Secondary reduction ratio 1.133 (17/15) —Final reduction ratio Front 3.600 (36/10) —

Rear 3.600 (36/10) —Transfer reduction ratio Low 2.453 (35/13 × 19/21) —

High 1.296 (35/27) —Transmission gear ratio Low 3.083 (37/12) —

2nd 1.933 (29/15) —3rd 1.388 (25/18) —4th 1.095 (23/21) —Top 0.913 (21/23) —

Reverse 2.833 (34/12) —Transmission shift fork to groove clearance

0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Transfer shift fork to groove clearance

0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Reverse shift fork to groove clearance

0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Shift fork groove width Transmission 4.50 – 4.60

(0.178 – 0.181) —

Transfer 5.50 – 5.60(0.217 – 0.220) —

Reverse 4.00 – 4.10(0.157 – 0.161) —

Shift fork thickness Transmission 4.30 – 4.40(0.169 – 0.173) —

Transfer 5.30 – 5.40(0.209 – 0.213) —

Reverse 3.80 – 3.90(0.150 – 0.154) —


0.03 – 0.15(0.001 – 0.006) —

Front drive (differential) gear backlash

0.05 – 0.10(0.002 – 0.004) —


82

5/8 P-17, 24, 28, 33

ENGINE OIL TEMP. SWITCH + COOLING FAN THERMO-SWITCH

CARBURETOR


ITEM STANDARD/SPECIFICATION LIMITEngine oil temp. indicator light switch operating temperature




ITEMSPECIFICATION

P-17, 24, 28 P-33Caburetor type KEIHIN CVK32 ←Bore size 32 mm ←I.D. No. 38FB 38FCIdle r/min 1 500 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ←

Main jet (M.J.) #122 #Jet needle (J.N.) NBZA ←Needle jet (N.J.) #6 #Slow jet (S.J.) #38 #Pilot screw (P.S.) 1 and 7/8 turns back PRE-SETThrottle cable play 3 – 5 mm

(0.12 – 0.20 in) ←


DENSO: U22ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Terminal





: W/BIPick-up coil peak voltage More than 4.0 V : G, : BIPower source coil peak voltage More than 0.3 V : Y, : WStarter relay resistance 3 – 5 Ω

6/8 P-17, 24, 28, 33

WATTAGE Unit: W


ITEM SPECIFICATION NOTEBattery Type designation YTX14-BS



Taillight 10 AIgnition 10 A

Fan 10 A

ITEMSPECIFICATION

P-17 OthersHeadlight HI 30 × 2 pcs. ←

LO 30 × 2 pcs. ←Brake light/Taillight 21/5 ←Speedometer light 1.7 ←Reverse indicator light 3.4 ←Neutral indicator light 3.4 ←Engine oil temp. indicator light 3.4 ←High beam indicator light 3.4 —Reverse light 21 —


(0.12 – 0.20) —




3.0(0.12)







Brake fluid type DOT 4 —LE
P
7/8 P-17, 24, 28, 33

TIRE PRESSURE LT-F400

LT-F400F

FUEL + OIL

ITEM STANDARD/SPECIFICATION LIMITSteering angle Right 47° —


(0.16 ± 0.16) —

Camber 0.3° —Caster 3° —Wheel rim size Front 12 × 6.0 AT —


Rear AT25 10-12 —Tire tread depth Front — 4.0

(0.16)

Rear — 4.0(0.16)


FRONT 32.5 0.325 4.7 LOAD CAPACITYREAR 27.5 0.275 4.0 UP TO 172 kg (380 lbs)


FRONT 32.5 0.325 4.7 LOAD CAPACITYREAR 30 0.30 4.4 UP TO 172 kg (380 lbs)



P-03, 28, 33


Fuel tank includingreserve

15.0 L(4.0/3.3 US/lmp gal)

reserve3.3 L

(0.9/0.7 US/lmp gal)Engine oil type SAE 10W-40, API SF or SG

SAM
]
8/8 P-17, 24, 28, 33

ITEM SPECIFICATION NOTEEngine oil capacity

Change3 000 ml

(3.2/2.6 US/lmp qt)

Filter change3 200 ml

(3.4/2.8 US/lmp qt)

Overhaul3 500 ml

(3.7/3.1 US/lmp qt)Front /Rear drive gear oil type Hypoid gear oil SAE #90,

API grade GL-5Front drive (differential) gear oil capacity

300 ml(10.1/10.6 US/lmp oz)

Rear drive gear oil capacity 350 ml(11.8/12.3 US/lmp oz)

83

LT-F500F

1/8 P-24, 28, 33



(1.20) —

EX. 27.0(1.06) —


EX. 0.17 – 0.22(0.007 – 0.009) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —



Valve stem O.D. IN. 4.975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —






Valve spring free length(IN. & EX.) — 38.3

(1.53)Valve spring tension (IN. & EX.) 18.2 – 21.0 kgf


—

2/8 P-24, 28, 33




(1.3161 – 1.3188)33.130

(1.3043)

EX. 33.500 – 33.568(1.3189 – 1.3216)

33.200(1.3071)

Camshaft journal oil clearance Right & Center

0.032 – 0.066(0.0013 – 0.0026)

0.150(0.0059)

Left 0.028 – 0.059(0.0011 – 0.0023)

0.150(0.0059)

Camshaft journal holder I.D. Right & Center

22.012 – 22.025(0.8666 – 0.8671) —

Left 17.512 – 17.525(0.6894 – 0.6900) —

Camshaft journal O.D. Right & Center

21.959 – 21.980(0.8645 – 0.8654) —

Left 17.466 – 17.484(0.6876 – 0.6883) —






ITEM STANDARD LIMITCompression pressure(Automatic-decomp. actuated) Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi)

800 kPa(8.0 kgf/cm2,


(0.0012 – 0.0016) —

Cylinder bore 87.500 – 87.515(3.4449 – 3.4455)

Nicks or Scratches

Piston diam. 87.465 – 87.480(3.4435 – 3.4441)


(3.4402)



2nd R Approx. 12.0 (0.47) 9.6(0.38)


0.50(0.020)

2nd 0.08 – 0.20(0.003 – 0.008)

0.50(0.020)LE

P

3/8 P-24, 28, 33


OIL PUMP


(0.0071)

2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.040 – 0.041) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


2nd 0.97 – 0.99(0.038 – 0.039) —

Piston pin bore 23.002 – 23.008 (0.9056 – 0.9058)

23.030(0.9067)

Piston pin O.D. 22.992 – 23.000 (0.9052 – 0.9055)

22.980(0.9047)


(0.9057 – 0.9061) 23.040



(0.004 – 0.026)1.0


(0.982 – 0.984) —

Crank web to web width 70.9 – 71.1(2.791 – 2.799) —




—

SAM

4/8 P-24, 28, 33



ITEM STANDARD LIMITClutch release screw 1/4 – 2/4 turn back —Drive plate tickness 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Drive plate claw width — 12.9



(1.33)Clutch wheel I.D. 140.0 – 140.2

(5.512 – 5.520)Scuffing or

scratch on con-tacting surface

Clurch shoe — No groove at any part


ITEM STANDARD LIMITPrimary reduction ratio 2.032 (63/31) —Final reduction ratio Front 4.080 (17/15 × 36/10) —

Rear 4.080 (17/15 × 36/10) —Transfer gear ratio Low 2.419 (22/23 × 27/17 × 43/27) —

High 1.592 (43/27) —Transmission gear ratio

Low 3.090 (34/11) —2nd 1.750 (28/16) —3rd 1.200 (24/20) —4th 0.875 (21/24) —Top 1.724 (21/29) —


(0.004 – 0.012)0.50

(0.020)Transfer fork to groove clearance 0.10 – 0.30

(0.004 – 0.012)0.50

(0.020)Reverse fork to groove clearance 0.10 – 0.30

(0.004 – 0.012)0.50

(0.020)Shift fork groove width No. 1 & No. 2 5.5 – 5.6

(0.217 – 0.220) —

Transfer 5.5 – 5.6(0.217 – 0.220) —

Reverse 5.0 – 5.1(0.197 – 0.201) —

Shift fork thickness No. 1 & No. 2 5.3 – 5.4(0.209 – 0.213) —

Transfer 5.3 – 5.4(0.209 – 0.213) —

Reverse 4.8 – 4.9(0.189 – 0.193) —

84

5/8 P-24, 28, 33



CARBURETOR

ITEM STANDARD LIMITSecondary drive bevel gear back-lash

0.05 – 0.15(0.002 – 0.006) —

Final drive bevel gear backlash 0.08 – 0.13(0.0031 – 0.0051) —

Front differential drive bevel gear backlash

0.05 – 0.10(0.0020 – 0.0040) —

ITEM STANDARD LIMITThermostat valve opening temper-ature

73.5 – 76.5 °C(164 – 170 °F) —


95 – 125 kPa(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi) —


OFF → ON Approx. 115 °C (239 °F)ON → OFF Approx. 108 °C (226 °F)


OFF → ON Approx. 88 °C (190 °F)ON → OFF Approx. 82 °C (180 °F)


Engine coolant including reserve 2 000 ml(2.1/1.8 US/lmp qt)

ITEMSPECIFICATION

E-03, 28 E-33Carburetor type KEIHIN CVK36 ←Bore size 36 mm ←I.D. No 03GF 03GGIdle r/min 1 300 ± 100 r/min ←Float height 17.0 ± 1.0 mm

(0.67 ± 0.04 in) ←

Main jet (M.J.) # ←Jet needle (J.N.) NBAY ←Needle jet (N.J.) # ←Slow jet (S.J.) # ←Pilot screw (P.S.) 1 and 3/8 turns back PRE-SET

Throttle cable play 3 – 5 mm(0.12 – 0.20 in) ←

Choke cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ←

6/8 P-24, 28, 33

ELECTRICAL

WATTAGE


DENSO: U20ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)


Ground




Generator Max. output Approx. 325 W at 5 000 r/min The rotation of the generator

Regulated voltage 14.0 – 15.5 V at 5 000 r/minIgnition coil primary peak voltage More than 150 V : Bl/W, : W/BStarter relay resistance 3 – 5 ΩBattery Type designation YTX20CH-BS



Tail 10 AIgnition 15 A

Aux 10 A


LO 30 × 2 pcs.Auxiliary light 40Brake light/Taillight 21/5Speedometer light LEDReverse indicator light LEDNeutral indicator light LEDParking indicator light LEDHight beam indicator light LEDEngine coolant temp. indicator light LED

LE
P
7/8 P-24, 28, 33


ITEM STANDARD/SPECIFICATION LIMITRear brake pedal height 15 – 25

(0.2 – 0.6) —


Rear 33.960 – 34.036(1.3346 – 1.3400) —


Rear 33.884 – 33.934(1.3340 – 1.3360) —


3.0(0.118)

Rear 3.8 – 4.2(0.150 – 0.165)

3.5(0.138)

Brake disc runout (Front & Rear) — 0.30(0.012)


Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —



(0.30 ± 0.16) —

Camber 0.45° —Caster 3.3° —Wheel rim size Front 12 × 6.0 AT —


Rear AT25 10-12 —Tire type Front DUNLOP: KT121D —

Rear DUNLOP: KT405D —Tire tread depth — 4.0

(0.16)

— 4.0(0.16)

SAM

8/8 P-24, 28, 33

TIRE PRESSURE


FUEL + OIL


kPa kgf/cm2 psi NOTE

FRONT 35 0.35 5.1 LOAD CAPACITYUP TO 172 kg (380 lbs)REAR 30 0.30 4.4


octane (R/2 + M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(Methyl Tertiary Butyl Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.

Fuel tank including reserve 19.0 L (5.0/4.2 US/lmp gal)reserve 4.2 L (1.1/0.9 US/lmp gal)



change3 600 ml

(3.8/3.2 US/lmp qt)


Front/Rear drive gear oil type Hypoid gear oil SAE #90, API grade GL-5

Front drive (differential) gear oil capacity

270 – 370 ml(9.1 – 12.5/9.5 – 13.0 US/lpm oz)

Rear drive gear oil capacity 250 – 350 ml(8.5 – 10.1/8.8 – 10.6 US/lpm oz)

85

LT-V700F

1/9 E-28, 33


TIR: Total Indicator Readings

ITEM STANDARD LIMITRocker arm inside diameter 12.000 – 12.018

(0.4724 – 0.4731)12.05

(0.474)Rocker shaft diameter 11.973 – 11.984

(0.4714 – 0.4718)11.95

(0.470)Cam height

IN.35.622 – 35.736

(1.4024 – 1.4069)35.52

(1.398)

EX.35.363 – 35.477

(1.3922 – 1.3967)35.26

(1.388)Camshaft bearing clearance

φ 180.016 – 0.052

(0.0006 – 0.0020)0.14

(0.0055)

φ 220.020 – 0.062

(0.0008 – 0.0024)0.15

(0.0059)Camshaft journal diameter

φ 1817.966 – 17.984

(0.7073 – 0.7080)17.94

(0.706)

φ 2221.959 – 21.980

(0.8645 – 0.8653)21.93

(0.863)Camshaft bearing inside diameter

φ 1818.000 – 18.018

(0.7087 – 0.7094)18.08

(0.712)

φ 2222.000 – 22.021

(0.8661 – 0.8670)22.08

(0.870)Camshaft runout

TIR 0.02 (0.0008) or lessTIR 0.1(0.0039)

KACR operating engine speed 760 ± 30 r/min —Cylinder compression(Electric starter)

Usable range294 – 520 kPa

(3.0 – 5.3 kgf/cm2, 43 – 75 psi)@ 280 r/min

—

Cylinder head warp — 0.05 (0.002)Valve clearance IN. 0.10 – 0.15

(0.0039 – 0.0059) —

EX. 0.20 – 0.25(0.0079 – 0.0098) —

Valve head thickness IN. 0.5 (0.020) 0.3 (0.012)EX. 0.8 (0.031) 0.5 (0.020)

Valve stem bend — TIR 0.05(0.002)

Valve stem diameter IN. 4.975 – 4.990(0.1959 – 0.1965)

4.96(0.1953)

EX. 4.955 – 4.970(0.1951 – 0.1957)

4.94(0.1945)

2/9 E-28, 33

ITEM STANDARD LIMITValve guide inside diameter

IN. & EX.5.000 – 5.012

(0.1969 – 0.1973)5.08

(0.20)Valve guide to valve stemclearance (Wobble method)

IN.0.03 – 0.11

(0.0012 – 0.0043)0.31

(0.0122)

EX.0.09 – 0.17

(0.0035 – 0.0067)0.37

(0.0146)Valve seat cutting angle 45°, 32°, 60° —Valve seat surface outsidediameter

IN.29.4 – 29.6

(1.157 – 1.165)—

EX.25.2 – 25.4

(0.992 – 1.000)—

Valve seat surface widthIN. & EX.

0.5 – 1.0(0.02 – 0.04)

—

Valve spring free lengthIN. & EX.

41.3(1.626)

39.5(1.555)


82.10(3.232)

Piston diameter 81.949 – 81.964(3.2263 – 3.2269)

at 5 (0.20) from the skirt end

81.80(3.220)


—

Oversize piston and rings +0.5 (0.020) —Piston ring to groove clearance

Top0.040 – 0.080

(0.0016 – 0.0032)0.18

(0.0071)

Second0.030 – 0.070

(0.0012 – 0.0028)0.17


Top1.030 – 1.050

(0.0405 – 0.0413)1.13

(0.0445)

Second1.020 – 1.040

(0.0402 – 0.0409)1.12

(0.0441)Piston ring thickness Top &

Second0.97 – 0.99

(0.0382 – 0.0390)0.90


Top0.20 – 0.30

(0.0079 – 0.0118)0.60

(0.0236)

Second0.30 – 0.45

(0.0118 – 0.0177)0.75

(0.0295)

Oil0.20 – 0.70

(0.0079 – 0.0276)1.00

(0.0394)

LE
P
5/9 E-28, 33


COOLING SYSTEM

ITEM STANDARDThrottle lever free play 2 – 3 (0.08 – 0.12)Choke lever free play About 3 (0.12)Carburetor type KEIHIN, CVKR-D32Main jet Front #138

Rear #142Main air jet #80Needle jet #6Jet needle NBZLPiot jet #40Pilot air jet #130Pilot screw 1 and 1/2 turns outCarburetor synchronizationvacuum

Less than 2.7 kPa (2 cmHg)difference between carburetors

Starter jet #95Idle speed 1 100 ± 50 r/minService fuel level 15 ± 1

(0.59 ± 0.04)below the punch mark

Float height 4.0 ± 1(0.16 ± 0.04)

Air cleaner element oil High-quality foam air filter oil

ITEM STANDARDCoolant type Permanent type of antifreeze

(Soft water and ethylene glycol plus corrosion andrust inhibitor chemicals for aluminum engines and radiators)

Coolant color GreenCoolant mixing ratio Soft water 50%, Coolant 50%Coolant freezing point –35 °C (–31 °F)Coolant total amount 2.4 L (2.54 US qt)

(Reserve tank full level including radiator and engine)Radiator cap relief pressure 93 – 123 kPa

(0.95 – 1.25 kgf/cm2, 14 – 18 psi)Thermostat valve opening temper-ature

69.5 – 72.5 °C (157 – 162 °F)

Thermostat valve full opening lift 8 mm (0.31 in) or more @ 85 °C (185 °F)Coolant valve closing temperature 70 °C (158 °F) or more at 25 kPa (0.25 kgf/cm2, 3.6 psi)

3/9 E-28, 33



ITEM STANDARD LIMITConnecting rod bend

—TIR 0.2/100(0.008/3.94)

Connecting rod twist—

TIR 0.2/100(0.008/3.94)

Connecting rod big end sideclearance

0.16 – 0.46(0.0063 – 0.0181)

0.7(0.028)

Connecting rod big end bearing insert to crankpin clearance

0.028 – 0.052(0.0011 – 0.0020)

0.09(0.0035)

Crankpin diameter 39.984 – 40.000(1.5742 – 1.5748)

39.97(1.5736)

markingNone

39.984 – 39.992(1.5742 – 1.57449)

—

39.993 – 40.000(1.57452 – 1.5748)

—

Connecting rod big end inside diameter

43.000 – 43.016(1.6929 – 1.6939)

—

markingNone

43.000 – 43.008(1.6929 – 1.69323)

—

43.009 – 43.016(1.69326 – 1.6935)

—

Connecting rod big end bearing insert thickness

Brown1.482 – 1.486

(0.05835 – 0.05850)—

Yellow1.486 – 1.490

(0.05850 – 0.05866)—

Green1.490 – 1.494

(0.05866 – 0.05882)—

Crankshaft runout TIR 0.04(0.0016) or less

TIR 0.10(0.0039)

Crankshaft main jour-nal diameter

φ 42 Side41.984 – 42.000

(1.6529 – 1.6535)41.96

(1.652)Crankshaft main bear-ing bore diameter

φ 42 Side42.025 – 42.041

(1.6545 – 1.6552)42.08

(1.6567)Shift fork ear thickness 5.9 – 6.0

(0.2322 – 0.2362)5.8

(0.228)Shift drum groove width

6.05 – 6.15(0.2382 – 0.2421)

6.25(0.246)

SAM

4/9 E-28, 33



ITEM STANDARD LIMITOutput bevel gear backlash 0.05 – 0.11

(0.0020 – 0.0043)at output drive shaft spline

—

Front final gear case oil(same engine oil)

TypeAPI SF or SG

API SH or SJ with JASO MA class—

Viscosity SAE 10W-40 —Oil level Filler opening bottom —Capacity 0.43 L (0.45 US qt) —

LSD clutch torque(when variable differential control lever is released.)

15 – 20 N·m(1.5 – 2.0 kgf-m, 11 – 14 ft-lb)

—

LSD clutch torque(when variable differential control lever is pulled in.)

157 N·m(16 kgf-m, 116 ft-lb) or more

—

Bevel gear backlash 0.10 – 0.20(0.004 – 0.008)

at pinion gear spline—

Rear axle shaft runoutTIR 1 (0.04) or less

TIR 2(0.08)

Rear final gear case oilType

MOBIL Fluid 424 or CITGO TRANS-GARD TRACTOR HYDRAULIC FLUID

—

Oil level Filler opening bottom —Capacity 0.9 L (0.95 US qt) —

Rear final bevel gear backlash 0.07 – 0.14(0.003 – 0.006)

at pinion gear spline—

86

5/9 E-28, 33


COOLING SYSTEM

ITEM STANDARDThrottle lever free play 2 – 3 (0.08 – 0.12)Choke lever free play About 3 (0.12)Carburetor type KEIHIN, CVKR-D32Main jet Front #138

Rear #142Main air jet #80Needle jet #6Jet needle NBZLPiot jet #40Pilot air jet #130Pilot screw 1 and 1/2 turns outCarburetor synchronizationvacuum

Less than 2.7 kPa (2 cmHg)difference between carburetors

Starter jet #95Idle speed 1 100 ± 50 r/minService fuel level 15 ± 1

(0.59 ± 0.04)below the punch mark

Float height 4.0 ± 1(0.16 ± 0.04)

Air cleaner element oil High-quality foam air filter oil

ITEM STANDARDCoolant type Permanent type of antifreeze

(Soft water and ethylene glycol plus corrosion andrust inhibitor chemicals for aluminum engines and radiators)

Coolant color GreenCoolant mixing ratio Soft water 50%, Coolant 50%Coolant freezing point –35 °C (–31 °F)Coolant total amount 2.4 L (2.54 US qt)

(Reserve tank full level including radiator and engine)Radiator cap relief pressure 93 – 123 kPa

(0.95 – 1.25 kgf/cm2, 14 – 18 psi)Thermostat valve opening temper-ature

69.5 – 72.5 °C (157 – 162 °F)

Thermostat valve full opening lift 8 mm (0.31 in) or more @ 85 °C (185 °F)Coolant valve closing temperature 70 °C (158 °F) or more at 25 kPa (0.25 kgf/cm2, 3.6 psi)

6/9 E-28, 33

CONVERTER SYSTEM Unit: mm (in)

ELECTRICAL SYSTEM

ITEM STANDARD LIMITTorque converter actuator lever guide shoe wear

—6

(0.24)

Drive belt deflection 22 – 27(0.87 – 1.06)

—

Drive belt height (parallel portion) 1.16 – 3.48(0.0457 – 0.1370)

0.64(0.0252)

Drive pulley shoe side clearance Up to 0.20 (0.008) —Drive pulley cover bushing inside diameter

27.985 – 28.085(1.1018 – 1.1057)

28.12(1.107)

Drive pulley sheave bushing inside diameter

37.985 – 38.085(1.4955 – 1.4994)

38.12(1.501)

Drive pulley spring free length 60.4 (2.38) —Driven pulley sheave bushing inside diameter

40.000 – 40.039(1.5748 – 1.5763)

40.07(1.578)

Driven pulley spring free length 99.5 (3.92) —

ITEM STANDARD NOTEBattery type Sealed Battery —Battery capacity 12 V 12 Ah —Alternator type Three-phase AC —Regulator/rectifier output voltage 14 – 15 V —Alternator output voltage 39 – 59 V@3 000 r/min B – BStator coil resistance 0.33 – 0.49 Ω B – BSpark plug Gap 0.7 – 0.8 mm (0.028 – 0.031 in) —

Cap resistance 3.75 – 6.25 kΩ —Ignition coil 3 needle arcing

distance7 mm (0.28 in) or more —

Primary winding resistance

0.09 – 0.13 Ω

Front:GW – BK/YRear:BL/W – BK/Y

Secondary wind-ing resistance

3.8 – 5.8 kΩ

Front:BK/Y – Plug capRear:BK/Y – Plug cap

Primary peak voltage

100 V or more

Front: Ground G/WRear: Ground BL/W

Crankshaft sensor resistance 110 – 140 Ω BK/W – BLCrankshaft sensor peak voltage 2 V or more Y, G/WLE
P
7/9 E-28, 33

ITEM STANDARD NOTEVehicle-down Sensor Detection

methodMagnetic flux detection method —

Detection angleMore than 65 ± 5 °

for each bank—

Detection time Within 0.5 – 1.0 sec. —

Output voltage

0.4 – 1.4 V (with sensor arrow mark pointed up)

—

3.7 – 4.4 V (with sensor tilted60 – 70 ° or more, right or left)

Y/G, BK/Y

Electric Starter motor Commutator diameter

28 mm (1.10 in)LIMIT27 mm (1.06 in)

Brush length 12 mm (0.47 in)LIMIT4 mm (0.16 in)

Fuel pump pressure 17.7 – 22.6 kPa(0.18 – 0.23 kgf/cm2, 2.6 – 3.3 psi)

—

Fuel level sensor resistance Fuel levelposition

120 Ω —

Empty levelposition

3 Ω —

2WD/4WD actuator resistance 4 (Red) –6 (Black)

3 – 15 Ω —

1 (Orange) –3 (Blue)

3.5 – 6.5 kΩ —

2 (Yellow) –3 (Blue)

630 – 3 720 Ω —

Engine brake actuator resistance 4 (Red) –6 (Black)

3 – 15 Ω —

1 (Orange) –3 (Blue)

3.5 – 6.5 kΩ —

2 (Yellow) –3 (Blue)

630 – 5 330 Ω —

Forward/reverse detecting sensor resistance

1.2 – 1.6 kΩ —

Rear brake light switch timing ON after 10 mm (0.4 in) of pedal travel —Radiator fan switch resistance ON: Less than 0.5 Ω

OFF: More than 1 MΩ—

Radiator fan switch operatingtemperature

OFF → ON 96 – 100 °C (205 – 212 °F) —ON → OFF 91 – 95 °C (196 – 203 °F) —

Coolant temperature warning light switch resistance

ON: less than 0.5 ΩOFF: More than 1 MΩ

—

Coolant temperature warning light switch operating temperature

OFF → ON 112 – 118 °C (234 – 244 °F) —ON → OFF 108 – 111 °C (226 – 232 °F) —

SAM

8/9 E-28, 33





STEERING Unit: mm (in)

ITEM STANDARD LIMITBrake fluid type DOT 3 or DOT 4 —Front brake pad lining thickness 4.0 (0.16) 1 (0.04)Front disc thickness 3.3 – 3.7

( 0.130 – 0.146)3 (0.12)

Front disc runout TIR 0.4(0.016) or less

TIR 0.5 (0.020)

Rear brake pedal position 60 – 65 (2.2 – 2.4)above footboad

—

Rear brake lever free play 1 – 2(0.04 – 0.08)

—

Rear brake pedal free play 15 – 25(0.6 – 1.0) —

ITEM STANDARD LIMITToe-in of front wheels 0 – 20 (0 – 0.79) at 1G —Front tire Size AT 25 × 8-12 —

Type DUNLOP, KT121A, Tubeless —Rear tire Size AT 25 × 10-12 —

Type DUNLOP, KT127A, Tubeless —Tire air pressure (when cold)

Front28 kPa

(0.28 kgf/cm2, 4.0 psi)—

Rear35 kPa

(0.35 kgf/cm2, 5.0 psi)—

Maximun tire air pressure(to seat beads, when cold)

250 kPa(2.5 kgf/cm2, 36 psi)

—

Tire tread depthFront —

3(0.12)

Rear —4

(0.16)

ITEM STANDARD LIMITShock absorbers spring preload setting position

RearSpring free length minus

29.9 (1.18)

Spring free length minus 22.9 (0.90) to

36.9 (1.45)

ITEM STANDARD LIMITTie-Rod Length 315 (12.4) —

87

9/9 E-28, 33


ITEM STANDARD NOTEEngine oil type API SF or SG

API SH or SJ with JASO MA classEngine oil viscosity SAE 10W-40Engine oil capacity When filter

is not removed1.54 L (1.63 US qt)


1.75 L (1.85 US qt)

When engine is completely dry

2.05 L (2.17 US qt)

Oil pressure@ 4500 r/min,oil temp. 110 °C (230 °F)

480 kPa (4.9 kgf/cm2, 69.7 psi)

LE
P LT-Z250
3/7 E-19, 28, 33


OIL PUMP



(0.0398 – 0.0406) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —


2nd 1.17 – 1.19(0.046 – 0.047) —

Piston pin bore 16.002 – 16.008(0.6300 – 0.6302)

16.030 (0.6311)

Piston pin O.D. 15.992 – 16.000(0.6296 – 0.6299)

15.980 (0.6291)


(0.6302 – 0.6305) 16.040



(0.004 – 0.018)1.0


(0.707 – 0.709) —



ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 30 kPa (0.3 kgf/cm2, 4.3 psi)


—


(0.106 – 0.114) 2.4


(0.469 – 0.472) 11.0



(1.14) 27.5

(1.08)Clutch wheel I.D. 116.00 – 116.15

(4.567 – 4.573)116.5 (4.59)


1/7 E-19, 28, 33



(1.3) —

EX. 28(1.1) —


EX. 0.08 – 0.13(0.003 – 0.005) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0024) —



Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —



Valve stem end lengthIN. & EX. —

2.5(0.10)



Valve spring free lengthIN. & EX. —

43.0(1.69)


256 – 294 N(26.1 – 30.0 kgf, 57.5 – 66.1 lbs)


SAM

2/7 E-19, 28, 33




(1.3299 – 1.3315) 33.480

(1.3181)

EX. 32.990 – 33.030(1.2988 – 1.3004)

32.690 (1.2870)


0.150(0.0059)









(14.0 kgf/cm2, 199 psi)1 200 kPa

(12.0 kgf/cm2,171 psi)


0.120(0.0047)

Cylinder bore 66.000 – 66.015(2.5984 – 2.5990)

66.090 (2.6020)

Piston diam. 65.955 – 65.970(2.5966 – 2.5972)

Measure at 18 mm (0.71 in) from the skirt end.

65.880 (2.5937)



2nd R Approx. 9.0 (0.35) 7.2(0.28)


0.50(0.020)

2nd 0.10 – 0.25(0.004 – 0.010)

0.5(0.020)


2nd — 0.150(0.006)

88

3/7 E-19, 28, 33


OIL PUMP



(0.0398 – 0.0406) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —


2nd 1.17 – 1.19(0.046 – 0.047) —

Piston pin bore 16.002 – 16.008(0.6300 – 0.6302)

16.030 (0.6311)

Piston pin O.D. 15.992 – 16.000(0.6296 – 0.6299)

15.980 (0.6291)


(0.6302 – 0.6305) 16.040



(0.004 – 0.018)1.0


(0.707 – 0.709) —



ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 30 kPa (0.3 kgf/cm2, 4.3 psi)


—


(0.106 – 0.114) 2.4


(0.469 – 0.472) 11.0



(1.14) 27.5

(1.08)Clutch wheel I.D. 116.00 – 116.15

(4.567 – 4.573)116.5 (4.59)


4/7 E-19, 28, 33


CARBRETOR

ITEM STANDARD LIMITClutch engagement r/min. 1 700 – 2 100 r/min —Clutch lock-up r/min. 3 100 – 3 700 r/min —

ITEM STANDARD LIMITPrimary reduction ratio 3.047 (64/21) —Secondary reduction ratio 1.133 (17/15) —Final reduction ratio 3.200 (32/10) —Gear ratios 1st 3.083 (37/12) —

2nd 1.933 (29/15) —3rd 1.388 (25/18) —4th 1.095 (23/21) —5th 0.913 (21/23) —

Reverse 2.833 (34/12) —Shift fork to groove clearance 0.10 – 0.30

(0.004 – 0.012)0.5


(0.169 – 0.173) —


Gearshift lever height 0 – 10(0 – 0.393) —

Secondary bevel gearbacklash

0.03 – 0.15(0.001 – 0.006) —

Rear drive (final) bevel gearbacklash

0.05 – 0.30(0.002 – 0.012) —

ITEMSPECIFICATION

E-19, 28 E-33Carburetor type MIKUNI BSR29 ←

Bore size 29 mm(1.14 in) ←

I.D. No. 21G0 21G1Idle r/min 1 500 ± 100 r/min ←

Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ←

Main jet (M.J.) #125 # Jet needle (J.N.) 5DH54-2nd ←Needle jet (N.J.) P-0M # Pilot jet (P.J.) #20 #

Pilot screw (P.S.) 1 and 1/2 turns back PRE-SET

Throttle cable play 3 – 5 mm (0.12 – 0.20 in) ←


0.5 – 1.0 mm (0.02 – 0.04 in) ←LE

P

5/7 E-19, 28, 33


WATTAGE Unit: W


DENSO: X22ESR-U

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 0.05 – 1.0 ΩΩΩΩ Terminal –

Terminal

Secondary 10.5 – 19.0 kΩΩΩΩ Plug cap – Terminal

Ignition coil primary peak voltage 120 V and more : B/W : W/BlGenerator coil resistance Pick-up 80 – 155 ΩΩΩΩ Bl/Y – G/W

Charging 0.5 – 1.2 ΩΩΩΩ Y – YPick-up coil peak voltage 4.0 V and more : G/W : Bl/YGenerator no-load voltage(When engine is cold)

65 V (AC) and more at 5 000 r/min

Generator Max. output Approx. 150 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩΩΩΩBattery Type designation YTX9-BS

Capacity 12V 28.8 kC (8 Ah)/10HRFuse size 20 A


LO 40Brake light/Taillight 21/5Reverse indicator light 3Neutral indicator light 3

SAM

6/7 E-19, 28, 33


TIRE PRESSURE


ITEM STANDARD/SPECIFICATION LIMITRear brake lever play 3 – 5

(0.12 – 0.20) —



2.5 (0.098)

Brake disc runout Front — 0.30 (0.012)




Brake caliper cylinder bore Front 32.030 – 32.080(1.2610 –1.2630) —


Brake fluid type DOT 4 —Turning radius 2.7 m (8.9 ft) —Toe-in (with 75 kg, 165 lbs) 5 ± 4

(0.20 ± 0.16) —

Camber 0° —Caster 7° 40’ —Wheel rim size Front 10 × 5.5 AT —

Rear 9 × 8.0 AT —Tire size Front AT22 × 7-10 —


(0.16)

Rear — 4.0 (0.16)

Wheel axle runout Rear — 3.0 (0.12)


FRONT 30 0.30 4.4REAR 25 0.25 3.6

89

7/7 E-19, 28, 33


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher ratedby the Research Method.Gasoline containing MTBE (MethyI TertiaryButyI Ether), less than 10% ethanol, or less than5% methanol with appropriate cosolvents andcorrosion inhibitor is permissible.

E-28, 33


The others


Reserve 2.6 L(0.7/0.6 US/lmp gal)


(2.3/1.9 US/lmp qt)



Final gear oil type Hypoid gear oil SAE #90, API grade GL-5Final gear oil capacity 190 ml

(6.4/6.7 US/lmp oz)

LE
P LT-Z400
1/7 E-19, 28, 33



(1.42) —

EX. 29(1.14) —


EX. 0.20 – 0.30(0.0078 – 0.0118) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 4-975 – 4.990(0.1959 – 0.1965) —

EX. 4.955 – 4.970(0.1951 – 0.1957) —







182 – 210 N (18.6 – 21.4 kgf, 41.0 – 47.2 lbs)


SAM

2/7 E-19, 28, 33




(1.4299 – 1.4319)36.020

(1.4181)

EX. 35.200 – 35.250(1.3858 – 1.3878)

34.900(1.3740)


0.150(0.0059)






(0.002)


1 000 kPa(10.0 kgf/cm2, 142 psi) —


0.120(0.0047)

Cylinder bore 90.000 – 90.015(3.5433 – 3.5439)

Nicks or Scratches

Piston diam. 89.965 – 89.980(3.5419 – 3.5425)


(3.5386)



2nd R Approx. 11.5 (0.45) 9.2(0.36)


0.50(0.020)

2nd 0.08 – 0.20(0.003 – 0.008)

0.5(0.020)


2nd — 0.150(0.006)


1st

0.78 – 0.80(0.0307 – 0.0315) —

1.30 – 1.32(0.0512 – 0.0520) —

2nd 0.81 – 0.83(0.0319 – 0.0327) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —

90

3/7 E-19, 28, 33


OIL PUMP



1st

0.71 – 0.76(0.0280 – 0.0299) —

1.08 – 1.10(0.0425 – 0.0433)

2nd 0.77 – 0.79(0.0303 – 0.0311) —

Piston pin bore 20.002 – 20.008 (0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.995 – 20.000 (0.7872 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040



(0.012 – 0.026)1.0


(0.864 – 0.866) —






—


(0.4 – 0.6) —


2.92 – 3.08(0.115 – 0.121)

2.62 (0.103)


13.7 – 13.8(0.539 – 0.543)

13.2(0.520)



4/7 E-19, 28, 33


CARBRETOR


2nd 1.666 (30/18) —3rd 1.238 (26/21) —4th 1.000 (23/23) —Top 0.846 (22/26) —

Reverse 2.153 (28/13) —Shift fork to groove clearance 0.1 – 0.3

(0.004 – 0.012)0.5


& No. 35.0 – 5.1

(0.197 – 0.201) —


4.8 – 4.9(0.189 – 0.193) —




(1.2 – 1.6) —

ITEMSPECIFICATION

E-03, 28 E-33Carburetor type MIKUNI BSR36 ←Bore size 36 mm ←I.D. No. 07G0 07G1Idle r/min 1 500 ± 100 r/min ←Float height 13.0 ± 1.0 mm

(0.51 ± 0.04 in) ←

Main jet (M.J.) #130 #Jet needle (J.N.) 5E26-1 ←Needle jet (N.J.) P-0MPilot jet (P.J.) #22.5 #Pilot screw (P.S.) 2 and 1/4 turns back PRE-SETThrottle cable play 3 – 5 mm

(0.12 – 0.20 in) ←

Starter (enricher) cable play 0.5 – 1.0 mm(0.02 – 0.04 in) ←

LE
P
5/7 E-19, 28, 33




73.5 – 76.5 °C(164 – 170 °F) —

Thermostat valve lift Over 6 mm (0.24 in) at 90°C (194 °F) —Radiator cap valve opening pres-sure

108 – 137 kPa(1.1 – 1.4 kgf/cm², 15.6 – 19.9 psi) —


ON→OFF Approx. 120 °C (248 °F) —ON→OFF Approx. 113 °C (235 °F) —


ON→OFF Approx. 88 °C (190 °F) —ON→OFF Approx. 82 °C (180 °F) —


—

Engine coolant including reserve 1 200 ml (1.3/1.1 US/lmp qt) —


DENSO: U22ESR-N

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 mm (0.3) at 1 atm.Ignition coil resistance Primary 0.1 – 1.0 Ω Terminal –

Ground


Ignition coil primary peak voltage More than 130 V : B/W, : BGenerator coil resistance Pick-up 350 – 670 Ω G – BI

Signal 0.09 – 0.50 Ω W – BCharging 0.1 – 1.5 Ω Br – Br

Pick-up coil peak voltage More than 2.0 V : G, :BlGenerator no-load voltage(When engine is cold) More than 65 V (AC)

Generator Max. output Approx. 150 W at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX9-BS

Capacity 12 V 28.8 kC (8 Ah)/10 HRFuse size * 20 A/10 A

SAM

6/7 E-19, 28, 33

WATTAGE Unit: W



LO 30 × 2 pcs.Brake light/Taillight 21/5Reverse indicator light 3Neutral indicator light 3Engine coolant temp. indicator light 3

ITEM STANDARD/SPECIFICATION LIMITRear brake pedal height 0 – 10

(0 – 0.4) —


Rear 33.96 – 34.01(1.3370 – 1.3390) —


Rear 33.878 – 33.928(1.3338 – 1.3357) —

Brake fluid type DOT 4 —Brake disc thickness Front 2.8 – 3.2

(0.110 – 0.126)2.5

(0.098)

Rear 3.8 – 4.2(0.150 – 0.165)

3.5(0.138)

Brake disc runout (Front & Rear) — 0.30(0.012)


Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —

Turning radius 3.1 m (10.2 ft)Toe-in (with 75 kg, 165 lbs) 5 ± 4

(0.20 ± 0.16)Camber –0.9°Caster 8.5°

91

7/7 E-19, 28, 33

TIRE PRESSURE


FUEL + OIL

ITEM STANDARD/SPECIFICATION LIMITWheel rim size Front 10 × 5.5 AT —

Rear 9 × 8.0 AT —Tire size Front AT22 × 7R10 —

Rear AT20 × 10R9 —Tire type Front DUNLOP: KT331 —

Rear DUNLOP: KT335 —Tire tread depth Front — 4.0

(0.16)

Rear — 4.0(0.16)

Wheel axle runout Rear — 6.0(0.24)


FRONT 30 0.30 4.4REAR 27.5 0.275 4.0



Fuel tank including reserve 10.0 L (2.6/2.2 US/lmp qt)reserve 2.7 L (0.7/0.6 US/lmp qt)

Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 2 000 ml (2.1/1.8 US/lmp qt)


LE
P RM-Z250
1/6 P-03, 19, 28, 24




IN.34.642 – 34.758

(1.3639 – 1.3684)34.54

(1.3598)

EX.33.941 – 34.057

(1.3363 – 1.3408)33.84

(1.3322)Camshaft journal clearance 0.020 – 0.062

(0.0008 – 0.0024)0.15

(0.0059)Camshaft journal diameter 21.959 – 21.980

(0.8645 – 0.8654)21.93

(0.8634)Camshaft journal inside diameter 22.000 – 22.021

(0.8661 – 0.8670)22.08

(0.8693)Camshaft journal runout

TIR 0.02 (0.0008) or lessTIR 0.1(0.0039)

Cylinder compression Usable range431 – 706 kPa

(4.4 – 7.2 kgf/cm2, 62.5 – 102 psi)@ 5 kicks

—

Cylinder head warp — 0.05 (0.0020)Valve clearance

IN.0.10 – 0.15

(0.0039 – 0.0059)—

EX.0.17 – 0.22

(0.0067 – 0.0087)—

Valve stem bendTIR 0.01 (0.0004) or less

TIR 0.05(0.0020)

Valve stem diameterIN.

4.475 – 4.490(0.1762 – 0.1768)

4.46(0.1756)

EX.4.455 – 4.470

(0.1754 – 0.1760)4.44

(0.1748)Valve guide inside diameter

IN. & EX.4.500 – 4.512

(0.1772 – 0.1776)4.57

(0.1779)Valve/valve guide clearance(Wobble method)

IN.0.03 – 0.10

(0.0012 – 0.0039)0.26

(0.0102)

EX.0.08 – 0.16

(0.0031 – 0.0063)0.32

(0.0126)Valve seat cutting angle 45°, 32°, 60°, 67.5° —Valve seat surface outsidediameter

IN.30.62 – 30.82

(1.2055 – 1.2134)—

EX.24.62 – 24.82

(0.9693 – 0.9772)—

Valve seat surface widthIN. & EX.

0.50 – 1.0(0.0197 – 0.0394)

—

Valve spring free length 37.88 (1.4913) 37.0 (1.4567)

SAM

2/6 P-03, 19, 28, 24


ITEM STANDARD LIMITCylinder inside diameter 77.000 – 77.012

(3.0315 – 3.0320)77.06

(3.0339)Piston diameter 76.955 – 96.970

(3.0297 – 3.0303)76.82

(3.0244)Piston/cylinder clearance 0.030 – 0.057

(0.0012 – 0.0022)—

Piston ring/ring groove clearanceTop

0.04 – 0.08(0.0016 – 0.0031)

0.18(0.0071)

Piston ring groove widthTop

0.83 – 0.85(0.0327 – 0.0335)

0.93(0.0366)

Piston ring thicknessTop

0.77 – 0.79(0.0303 – 0.0311)

0.70(0.0276)

Piston ring end gapTop

0.15 – 0.25(0.0059 – 0.0098)

0.55(0.0217)

Oil0.20 – 0.70

(0.0079 – 0.0276)1.0

(0.0394)Piston pin diameter 15.992 – 15.997

(0.6296 – 0.6298)15.96

(0.628)Piston pin hole diameter 16.004 – 16.010

(0.6301 – 0.6303)16.07

(0.633)Connecting rod small end inside diameter

16.010 – 16.018(0.6303 – 0.6306)

16.05(0.632)

ITEM STANDARD LIMITConnecting rod big end radial clearance

0.002 – 0.014(0.00008 – 0.0006)

0.06(0.0024)

Connecting rod big end sideclearance

0.25 – 0.35(0.0098 – 0.0138)

0.55(0.0217)

Crankshaft runoutTIR 0.03 (0.012) or less

TIR 0.08 (0.0031)


4.8(0.1890)


5.25(0.2070)


5.8(0.2283)


6.3(0.2480)

92

3/6 P-03, 19, 28, 24




ITEM STANDARD LIMITClutch lever free play 2.0 – 3.0

(0.08 – 0.12)—

Friction plate thickness 2.72 – 2.88(0.107 – 0.113)

2.62(0.1031)

Steel plate thickness 1.5 – 1.7(0.059 – 0.067)

1.4(0.055)

Friction plate warp 0.15 (0.0059) or less 0.3 (0.0118)Steel plate warp 0.2 (0.0079) or less 0.3 (0.0118)Clutch spring free length 46.8 (1.843) 44.9 (1.768)Friction plate/clutch housingclearance

0.04 – 0.55(0.0016 – 0.0217)

0.9(0.035)

ITEM STANDARD LIMITDrive chain Type DAIDO: D.I.D 520DMA2 —

Links 114 links —

20-link length317.5 – 318.2

(12.50 – 12.53)323


(2.05 – 2.44)—

Engline sprocket diameter 55.48 – 55.68 (2.184 – 2.192) /13T 54.8 (2.157)Rear sprocket diameter 232.62 – 233.12 (9.158 – 9.178) /48T 232.1 (9.138)Rear sprocket warp Under 0.4 (0.016) 0.5 (0.020)

ITEM STANDARDCarburetor type KEIHIN FCR37Starter jet #68Leak jet #60Main jet #178Throttle valve cutaway #1.5Jet needle 0BEKSJet needle clip position 3rd groove from the topSlow jet #40Slow air jet #100Pilot air screw 2 and 1/4 turns outServise fuel level (above the bot-tom edge of the carburetor body)

6.5 ± 1(0.256 ± 0.039)

Float height 8 ± 1(0.315 ± 0.039)

4/6 P-03, 19, 28, 24

COOLING SYSTEM

ELECTRICAL SYSTEM)

ITEM STANDARDCoolant type Permanent type anti-freeze for aluminum engines and radiatorsCoolant color GreenCoolant mixing ratio Soft water 50%, anti-freeze 50%Coolant total amount 1.2 L (1.27 US qt)Radiator cap relief pressure 93 – 123 kPa

(0.95 – 1.25 kgf/cm2, 13 – 18 psi)

ITEM STANDARD NOTECrankshaft sensor resistance 80 – 120 ΩMagneto output voltage(Reading @ 4 000 r/min)

(Tester range)250 V AC

59 V or more: B/R –: R/W

(Tester range)50 V AC

16 V or more: Y –: Y

Magneto coil resistance (Tester range)× 1 Ω

27.2 – 40.8 Ω: B/R –: R/W

(Tester range)× 1 Ω

1.76 – 2.64 Ω: Y/W –

: YIgnition timing (Disconnect the throttle sensor lead)

8° BTDC @ 2 000 r/min

Ignition coil 3 needle arcing distance

7 mm (0.26 in) or more

Secondarywinding

resistance0.28 – 0.34 Ω (@ 20 °C)

Primarywinding

resistance7.65 – 10.35 kΩ (@ 20 °C)

Spark plug type NGK CR8EB

gap0.7 – 0.8 mm

(0.026 – 0.031 in)Throttle sensor ignition coil primary peak voltage

176 V or above

Throttle sensor input voltage Around 5 VOutput voltage When the

throttle valve completely

closed

0.58 – 0.78 V

When thethrottle fully

opened3.5 – 3.7 V

LE
P
5/6 P-03, 19, 28, 24



EU: European Model


ITEM STANDARD LIMITBrake lever free play Adjustable (to suit rider) —Brake fluid type Front DOT 3 or DOT 4 —

Rear DOT 4 —Brake pad lining thickness Front 3.8 (0.150) 1 (0.04)

Rear 6.4 (0.252) 1 (0.04)Brake disc thickness

Front2.85 – 3.15

(0.112 – 0.124)2.5

(0.10)

Rear3.85 – 4.15

(0.152 – 0.163)3.5

(0.14)Brake disc runout Front &

RearNot more than 0.25 (0.098) 0.3 (0.01)

ITEM STANDARD LIMITWheel rim runout Axial &

Radial1.0 (0.039) or less 2 (0.08)

Axle runout (/100 mm) Front & Rear

0.1 (0.004) 0.2 (0.008)


100 kPa(1.0 kgf/cm2, 14 psi)

—

Front tire Size 80/100-21 51M —

TypeBRIDGESTONE M601, Tube

M201, Tube (EU)—

Rear tire Size 100/90-19 57M —

TypeBRIDGESTONE M602, Tube

M202, Tube (EU)—

ITEM STANDARD LIMITFront fork air pressure Atmospheric pressure —Front fork rebound dampingadjustment(From the seated position; adjuster turned fully clockwise)

11 clicks counterclockwise12 clicks counterclockwise (EU)

(Adjustable range)

16 clicks

Front fork compression damping adjustment(From the seated position; adjuster turned fully clockwise)

8 clicks counterclockwise11 clicks counterclockwise (EU)

(Adjustable range)

16 clicks

Front fork oil viscosity KAYABA 01 or SAE 0W CORRESPOND —Front fork oil capacity 564 ± 4 ml

(19.07 ± 0.14 US oz)—

SAM

6/6 P-03, 19, 28, 24


ITEM STANDARD LIMITFront fork oil level(Fully compressed, spring removed)

95 (3.7) from top of outer tube

(Adjustable range)

70 –120(2.8 – 4.7)

Front fork spring free length 460 (18.11) 450 (17.72)Rear shock absorber rebound damping adjustment(From the seated position; adjuster turned fully clockwise)

12 clicks counterclockwise(Adjustable

range)16 clicks

Rear shock absorber springpreload adjustment(Adjusting nut position from the center of the upper mounting hole)

113 (4.41)

(Adjustable range)

109 –129.5(4.29 – 5.098)

Rear shock absorber spring free length

260 (10.24) 255 (10.04)

Gas reservoir compressiondamping adjustment(From the seated position; adjuster turned fully clockwise)

11 clicks counterclockwise(Adjustable

range)16 clicks

Gas reservoir pressure 980 kPa(10 kgf/cm2, 142 psi)

—

Sleeve outside diameterTie-rod

19.987 – 20.000(0.7869 – 0.7874)

19.85(0.781)

Rocker armLarge

19.987 – 20.000(0.7869 – 0.7874)

19.85(0.781)

Rocker armSmall

15.995 – 16.000(0.6297 – 0.6299)

15.85(0.624)

Rocker arm mounting bolt runout Under 0.1 (0.004) 0.2 (0.008)

ITEM STANDARD NOTEEngine oil type Castrol “R4 Superbike” 5W-40

API SH or SJ with JASO MAEngine oil viscosity SAE 10W-30, 10W-40 or 10W-50Engine oil capacity When filter is not

removed1.3 L (1.4 US qt)


1.35 L (1.43 US qt)

When engine is completely dry

1.5 L (1.6 US qt)

Engine oil level(After warm-up or driving)

Upper level

Engine oil pressure(Oil temperature 90 °C,engine speed 4 000 r/min)

19.6 kPa(0.2 kgf/cm2, 2.8 psi)

93

RV125

1/6 E-02, 19



ITEM STANDARD LIMITValve diam. IN. 30 —

EX. 26 —Valve clearance (when cold) IN. 0.08 – 0.13 —


IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —


EX. 5.455 – 5.470 —Valve stem deflection IN. & EX. — 0.35Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 2.5Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length INNER — 36.8(IN. & EX.) OUTER — 40.1Valve spring tension(IN. & EX.) INNER

76 – 90 N(7.8 – 9.2 kgf)


OUTER186 – 219 N

(18.9 – 22.3 kgf)at length 36.0 mm

—


EX. 33.80 – 33.85 33.50Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —Camshaft runout IN. & EX. — 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.977 – 11.995 —Cylinder head distortion — 0.05Cylinder head cover distortion — 0.05

2/6 E-02, 19



OIL PUMP

CLUTCH Unit: mm


(13 – 17 kgf/cm2, 185 – 242 psi)980 kPa

(9.8 kgf/cm2,140 psi)

Piston-to-cylinder clearance 0.040 – 0.055 0.120Cylinder bore 57.000 – 57.015 57.090Piston diam. 56.955 – 56.970






2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —



ITEM STANDARD LIMITConrod small end I.D. 14.006 – 14.014 14.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.45 1.0Conrod big end width 15.95 – 16.00 —Crank web to web width 53.0 ± 0.1 —Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 15 kPa (0.15 kgf/cm2)


—

ITEM STANDARD LIMITClutch lever play 10 – 15 —Drive plate thickness 2.95 – 3.15 2.65Drive plate claw width 11.8 – 12.0 11.5Driven plate distortion — 0.10Clutch spring free length 32.6 31.0LE
P
3/6 E-02, 19

DRIVE TRAIN + DRIVE CHAIN Unit: mm (Except ratio)

PAIR SYSTEM

CARBURETOR


2nd 1.857 (26/14) —3rd 1.368 (26/19) —4th 1.095 (23/21) —5th 0.923 (24/26) —Top 0.833 (20/24) —

Shift fork to groove clearance 0.10 – 0.30 0.50Shift fork groove width No. 1 5.0 – 5.1 —

No. 2 5.5 – 5.6 —Shift fork thickness No. 1 4.8 – 4.9 —


Drive chain Type DID 428 —Links 132 —


Drive chain slack 15 – 25 —Gearshift lever height 20

(between footrest top and gearshift lever top) —

ITEM STANDARD LIMITNegative pressure range –37.3 – –60.0 kPa (–280 – –450 mmHg) —

ITEMSPECIFICATION

E-02, 19Carburetor type MIKUNI BS26Bore size 26 mmI.D. No. 13GAIdle r/min 1 500 ± 100 r/minFloat height 17.1 ± 1.0 mmMain jet (M.J.) # 115Jet needle (J.N.) 4EJ44-2ndNeedle jet (N.J.) P-0MThrottle valve (Th.V.) # 105Pilot jet (P.J.) # 15Pilot screw (P.S.) PRE-SET (2 turns out)Throttle cable play 2.0 – 4.0 mm

88.0+0.1-0

SAM

4/6 E-02, 19

ELECTRICAL

WATTAGE Unit: W


NGK: CR8EGap 0.7 – 0.8 mm

Spark performance Over 8 mm at 1 atm.Ignition coil resistance Primary 1.6 – 2.7 Ω tap –

tap


Generator coil resistance 0.4 – 0.8 Ω B – B∞ Ω Ground – B

Pick-up coil peak voltageMore than 2.0 V

: Bl, : B/W: Bl, : G

Ignition coil primary peak voltage More than 200 V : B, : Ground

Pick-up coil resistance 172 – 288 Ω G – Bl∞ Ω G – Ground

Generator no-load voltage(when engine is cold) More than 60 V (AC) at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX7L-BS



E-02 E-19Headlight HI 60 ←

LO 55 ←Position light 5 4Brake light/Taillight 21/5 ←Turn signal light 21 ←Speedometer light 1.7 ←Turn signal indicator light 3.4 ←High beam indicator light 1.7 ←Neutral indicator light 3.4 ←

94

5/6 E-02, 19


SUSPENSION Unit: mm

TIRE PRESSURE

ITEM STANDARD/SPECIFICATION LIMITRear brake pedal free travel 20 – 30 —Rear brake pedal height 5 – 15 —Brake drum I.D. Rear — 110.7Brake disc thickness Front 4.0 ± 0.2 3.5Brake disc runout Front — 0.30Master cylinder bore Front 12.700 – 12.743 —Master cylinder piston diam. Front 12.657 – 12.684 —Brake caliper cylinder bore Front 30.230 – 30.306 —Brake caliper piston diam. Front 30.150 – 30.200 —Brake fluid type DOT 4 —Wheel rim runout Axial — 2.0


Rear — 0.25Wheel rim size Front 18 M/C × MT 2.50 —

Rear 14 M/C × MT 4.50 —Tire size Front 130/80-18 M/C 66P —

Rear 180/80-14 M/C 78P —Tire tread depth Front — 4.0

Rear — 4.0

ITEM STANDARD/SPECIFICATION LIMITFront fork stroke 110 —Front fork spring free length 382.9 375Front fork oil level 171 —Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil —Front fork oil capacity (each leg) 230 ml —Rear wheel travel 136 —Swingarm pivot shaft runout — 0.6

COLD INFLATION TIRE PRESSURE(SOLO AND DUAL RIDING) kPa kgf/cm2

FRONT 125 1.25REAR 125 1.25

6/6 E-02, 19


Fuel type Gasoline used should be graded 91 octane orhigher. An unleaded gasoline type is recom-mended.

Fuel tank including reserve 7.5 L reserve 1.8 L


Filter change 950 mlOverhaul 1 200 ml

LE
P SD110/S
1/6 P-42






IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —


EX. 4.955 – 4.970 —Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 2.3Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length IN. & EX. — 30.9Valve spring tension IN. & EX. 147 N (14.9 kgf) at length 25.8 mm —


EX. 27.42 – 27.52 27.12Rocker arm I.D. IN. & EX. 10.003 – 10.018 —Rocker arm shaft O.D. IN. & EX. 9.981 – 9.990 —Cylinder head distortion — 0.05

SAM

2/6 P-42



OIL PUMP

CLUTCH Unit: mm


1 400 kPa(14.0 kgf/cm2)

950 kPa(9.5 kgf/cm2,)







2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —



ITEM STANDARD LIMITConrod small end I.D. 14.006 – 14.024 14.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.45 1.00Conrod big end width 16.95 – 17.00 —Crank web to web width 42.0 ± 0.1 —Crankshaft thrust clearance 0.02 – 0.07 —Crankshaft runout — 0.08



—

ITEM STANDARD LIMITClutch lever play 10 – 15 —Drive plate thickness 2.65 – 2.95 2.35Drive plate claw width 11.8 – 12.0 11.0Driven plate distortion — 0.10Clutch spring free length — 29.2

95

3/6 P-42


CARBURETOR


2nd 1.875 (30/16) —3rd 1.368 (26/19) —Top 1.052 (20/19) —

Shift fork to groove clearance 0.10 – 0.30 0.50Shift fork groove width No. 1 & No. 2 4.5 – 4.6 —Shift fork thickness No. 1 & No. 2 4.3 – 4.4 —Drive chain Type D. I. D. 428 —

Links 100 —20-pitch length — 256

ITEM SPECIFICATIONCarburetor type MIKUNI BS22SSBore size ø 22 mmI.D. No. 23F5Idle r/min 1500 ± 100 r/minFloat height 10.5 ± 0.5 mmMain jet (M.J.) # 92.5Jet needle (J.N.) 4J61-2ndNeedle jet (N.J.) E-1Throttle valve (Th.V.) # 80Pilot jet (P.J.) # 15Pilot screw (P.S.) 2-3/8 turns outThrottle cable play 2 – 4 mm

4/6 P-42

ELECTRICAL

WATTAGE Unit: W

ITEM STD/SPEC. NOTESpark plug Type NGK: C6HSA

DENSO: U20FS-UGap 0.6 – 0.7 mm

Spark performance Over 8 mm at 1 atm.Ignition coil resistance Primary 0.2 – 1.5 Ω Terminal –

Ground

Secondary 10 – 20 kΩ Plug cap –Ground

Ignition coil primary peak voltage 130 V and more : Ground – : White/Blue

Pickup coil peak voltage 4.0 V and more : Green/White: Blue/Yellow

Generator coil resistance Pickup 180 – 280 Ω Black – Light green

Charging 0.5 – 2.0 Ω White/Red – Ground

Lighting 0.3 – 1.5 Ω Gray – GroundGenerator Max. output Approx. 100 W at 5 000 r/minRegulated voltage 13.0 – 16.0 V at 5 000 r/minBattery Type designation OEM2.5E

Capacity 12 V 9 kC (2.5 Ah)/10 HRStandard

electrolyte S.G 1.280

Fuse size 10 A

ITEM STD/SPEC.Headlight HI 25

LO 25Brake light/Taillight 18/5Turn signal light 10Speedometer light 3.4Neutral indicator light 3.4Turn signal indicator light 3.4High beam indicator light 1.7

LE
P
5/6 P-42


TIRE

ITEM STANDARD LIMITFront brake cable play (SD110) 15 – 25 —Rear brake pedal free travel 20 – 30 —Brake drum I.D. Front — 110.7

Rear — 110.7Brake disc thickness (SD110S) Front 3.8 – 4.2 3.0Brake disc runout (SD110S) Front — 0.3Master cylinder bore (SD110S) Front 12.700 – 12.743Master cylinder piston diam. (SD110S) Front 12.657 – 12.684

Brake caliper cylinder bore (SD110S) Front 27.00 – 27.05

Brake caliper piston diam. (SD110S) Front 26.93 – 26.95

Brake fluid type (SD110S) DOT 4Wheel rim runout Axial — 2.0

Radial — 2.0Wheel rim size Front 1.40 × 18 —

Rear 1.60 × 18 —Wheel axle runout Front — 0.25

Rear — 0.25

ITEM STD/SPEC. LIMITCold inflation pressure Solo riding

Front 175 kPa (1.75 kgf/cm2) —Rear 200 kPa (2.00 kgf/cm2) —

Dual ridingFront 175 kPa (1.75 kgf/cm2) —Rear 280 kPa (2.80 kgf/cm2) —

Tire size Front 2.50-18 6PR —Rear 2.75-18 6PR —

Tire type Front PANTHER —Rear PANTHER —

Tire tread depth Front — 1.6 mmRear — 1.6 mm

SAM

6/6 P-42

SUSPENSION Unit: mm

FUEL + OIL

ITEM STD/SPEC. LIMITFront fork stroke 90 —Front fork inner tube O.D. 27 —Front fork spring free length 297 291Front fork oil level (without spring, inner tube fully compressed) 137 —

Front fork oil type Suzuki fork oil G-10 (#10) or equivalent fork oil —Front fork oil capacity (each leg) 101 ml —Rear shock absorber spring adjuster 1st set —

Swingarm pivot shaft runout — 0.6



reserve 2.0 L Engine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 700 ml

Filter change 800 mlOverhaul 900 ml

96

SV650/S/SU/U

1/10

SV650 E-02, 03, 19, 24, 28, 33SV650S E-02, 03, 19, 24, 28, 33SV650SU E-02, 19SV650U E-02, 19



(1.2) —

EX. 25.5(1.0) —


EX. 0.2 – 0.3(0.008 – 0.012) —


(0.0008 – 0.0019) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —


Valve stem O.D. IN. 4.465 – 4.480(0.1758 – 0.1764) —

EX. 4.455 – 4.470(0.1754 – 0.1760) —







(1.45)

OUTER — 39.8(1.57)


41 – 47 N(4.2 – 4.8 kgf, 9.03 – 10.36 lbs)


OUTER166 – 192 N


—

2/10





(1.4196 – 1.4214)35.76

(1.408)

EX. 34.680 – 34.725(1.3654 – 1.3671)

34.38(1.354)


0.150(0.0059)





(0.002)


(15 kgf/cm2, 213 psi)1 100 kPa

(11 kgf/cm2, 156 psi)


200 kPa(2 kgf/cm2,


(0.0022 – 0.0026)0.120

(0.0047)Cylinder bore 81.000 – 81.015

(3.1890 – 3.1896)81.075

(3.1919)Piston diam. 80.940 – 80.955


80.88(3.184)



2nd Approx. 11 (0.43) 8.8(0.34)


0.70(0.028)

2nd 0.20 – 0.35(0.008 – 0.0014)

0.70(0.028)


2nd — 0.150(0.0059)


2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.01 – 2.03(0.0791 – 0.0799) —LE

P

3/10



OIL PUMP



(0.0461 – 0.0469) —

2nd 0.97 – 0.99(0.0382 – 0.0390) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.992 – 20.000(0.7871 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040


(0.0067 – 0.0126)0.5


(0.825 – 0.827) —

Crank pin width 42.17 – 42.22(1.660 – 1.662) —


0.080(0.0031)

Crank pin O.D. 37.976 – 38.000(1.4951 – 1.4960) —


0.080(0.0031)





—


(0.4 – 0.6) —

Clutch release screw 1/4 turns back —Drive plate thickness No. 1 & No. 2 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)Drive plate claw width No. 1 & No. 2 13.7 – 13.8

(0.539 – 0.543)12.9



(2.09)50.5

(1.99)

SAM

4/10



ITEM STANDARD LIMITPrimary reduction ratio 2.088 (71/34) —Final reduction ratio SV650S 2.933 (44/15) —

SV650 3.000 (45/15) —Gear ratios Low 2.461 (32/13) —

2nd 1.777 (32/18) —3rd 1.380 (29/21) —4th 1.125 (27/24) —5th 0.961 (25/26) —Top 0.851 (23/27) —


0.50(0.020)



Drive chain Type DID525V8 —

LinksSV650 110 links —

SV650S 108 links —20-pitch length — 319.4


(0.79 – 1.18) —

Gearshift lever height SV650 60 – 70(2.4 – 2.8) —

SV650S 55 – 60(2.2 – 2.4) —

97

5/10




ITEM STANDARD NOTEThermostat valve opening tempera-ture Approx. 88 °C (190 °F) —

Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —Engine coolant temperature sensor resistance

20 °C(68 °F) Approx. 2.45 kΩ —

40 °C(104 °F) Approx. 1.148 kΩ —

60 °C(140 °F) Approx. 0.587 kΩ —

80 °C(176 °F) Approx. 0.322 kΩ —

Radiator cap valve opening pressure 95 – 125 kPa(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi) —



Engine coolant type Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

—



Engine side


ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F)Fuel pump discharge amount Min. 168 ml (5.7/5.9 US/lmp oz)

for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi)Fuel pressure regulator operating set pressure Approx. 300 kPa (3.0 kgf/cm², 43 psi)

6/10



THROTTLE BODY

ITEM SPECIFICATION NOTECKP sensor resistance 130 – 240 ΩCKP sensor peak voltage 3.7 V (When cranking) and moreIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.7 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.12 kΩ


Opened Approx. 4.26 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)TO sensor resistance 19.1 – 19.7 kΩTO sensor voltage Approx. 0.4 – 1.4 VGP switch voltage 1.0 V and more (From 1st to Top)Injector voltage Battery voltageSTP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.58 kΩ


Opened Approx. 4.38 VSTV actuator resistance 7 – 14 ΩPAIR solenoid valve resistance 20 – 24 kΩ at 20 °C (68 °F)

ITEM SPECIFICATIONI.D. No. 17G0 (Others), 17G1 (For E-33)Bore size 39 mmFast idle r/min 1 800 – 2 400 r/min at 25 °C (77 °F)Idle r/min 1 300 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

LE
P
7/10



ITEM SPECIFICATION NOTEFiring order 1.2Spark plug Type NGK: CR8E

DENSO: U24ESR-N

Gap 0.7 – 0.8 mm(0.028 – 0.031 in)

Spark performance Over 8 mm (0.3 in) at 1 atm.Crankshaft position sensor resistance 130 – 240 Ω BI – GIgnition coil resistance Primary 2 – 5 Ω tap –

tap

Secondary 24 – 37 kΩ tap – Plug cap

Crankshaft position sensor peak volt-age 3.7 V and more When

crankingIgnition coil primary peak voltage 150 V and moreGenerator coil resistance 0.2 – 0.7 ΩGenerator Max. output Approx. 375 W at 5 000 r/minGenerator no-load voltage(When cold) 60 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX12A-BS


HeadlightHI

SV650S 15 ASV650 10 A

LOSV650S 15 ASV650 10 A


Fan motor 15 ASignal 10 AMain 30 A

SAM

8/10


WATTAGE Unit: W


ITEMSPECIFICATION

SV650SSV650

E-03, 24, 28, 33 OthersHeadlight HI 60 W × 2 60 W ←

LO 55 W × 2 55 W ←Parking or position light 5 W 5 WBrake light/Taillight LED ← ←Turn signal light 21 W ← ←License light 5 W ← ←Speedometer light LED ← ←Turn signal indicator light LED ← ←High beam indicator light LED ← ←Neutral indicator light LED ← ←Oil pressure/Coolant temp./FI indicator light LED ← ←Fuel indicator light LED ← ←

ITEM STANDARD LIMITRear brake pedal height SV650 50 – 60

(1.97 – 2.36) —

SV650S 60 – 70(2.36 – 2.76) —

Brake disc thickness Front 4.5(0.18)

4.0(0.16)

Rear 5.0(0.20)

4.5(0.18)



Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —


Rear 38.180 – 38.230(1.5031 – 1.5051) —


Rear 38.098 – 38.148(1.4999 – 1.5019) —


(0.08)

Radial — 2.0(0.08)

98

9/10


TIRE

ITEM STANDARD LIMITWheel rim size Front 17 M/C × MT3.50 —

Rear 17 M/C × MT4.50 —Wheel axle runout Front — 0.25

(0.010)

Rear — 0.25(0.010)


(2.25 kgf/cm², 33 psi) —



(2.25 kgf/cm², 33 psi) —



Tire type Front DUNLOP: D220FST L —Rear DUNLOP: D220ST L —


Rear — 2.0(0.08)

10/10



FUEL + OIL


(5.1) —

Front fork spring free length SV650 429(16.89)

420(16.5)

SV650S 437.4(17.22)

428(16.8)

Front fork oil level (without spring,outer tube fully compressed) SV650 92

(3.62) —

SV650S 96(3.78) —

Front fork spring adjuster 3rd groove from Top —Front fork oil type SUZUKI FORK OIL SS8 or

equivalent fork oil —

Front fork oil capacity (each leg) SV650 490 ml(20.2/17.3 US/Imp oz) —

SV650S 485 ml(16.4/17.1 US/Imp oz) —


SV650 4/7 —SV650S 3/7 —




octane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corrosioninhibitor is permissible.

E-03, 28, 33


Others

Fuel tank capacity 16 L (4.2/3.5 US/lmp gal) E-3317 L (4.5/3.7 US/lmp gal) Others


(2.4/2.0 US/lmp qt)



LE
P SV1000/UD/UF
1/9 E-02, 03, 19, 24, 28, 33E-19




(1.42) —

EX. 33(1.30) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0018) —

EX. 0.030 – 0.066(0.0012 – 0.0026) —


Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —








197 – 227 N(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)



(1.487 – 1.489)37.48

(1.476)

EX. 36.38 – 36.42(1.432 – 1.434)

36.08(1.420)


0.150(0.0059)



ITEM STANDARD LIMITCamshaft runout IN. & EX. — 0.10

(0.004)Cam drive idle gear/sprocket thrust clearance

0.15 – 0.29(0.006 – 0.011) —

SAM

2/9 E-02, 03, 19, 24, 28, 33E-19




(10 – 14 kgf/cm2, 142 – 199 psi)800 kPa

(8 kgf/cm2,114 psi)

Compression pressure differ-ence —

200 kPa(2 kgf/cm2,


(0.0006 – 0.0010)0.12

(0.0047)Cylinder bore 98.000 – 98.015

(3.8583 – 3.8589)Nicks or



97.880(3.8535)



2nd Approx. 10.1 (0.40) 8.1(0.32)


0.7(0.03)

2nd 0.30 – 0.45(0.012 – 0.018)

0.7(0.03)


2nd — 0.15(0.0059)


1st

0.93 – 0.95(0.0366 – 0.0374) —

1.55 – 1.57(0.0610 – 0.0618) —

2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


1st

0.86 – 0.91(0.034 – 0.036) —

1.38 – 1.40(0.054 – 0.055) —

2nd 0.97 – 0.99(0.038 – 0.039) —

99

3/9 E-02, 03, 19, 24, 28, 33E-19


OIL PUMP


ITEM STANDARD LIMITPiston pin bore I.D. 22.002 – 22.008

(0.8662 – 0.8665)22.030

(0.8673)Piston pin O.D. 21.993 – 22.000

(0.8658 – 0.8661)21.980

(0.8654)


(0.8665 – 0.8668)22.040


(0.007 – 0.013)0.50


(0.864 – 0.866) —

Crank pin width 44.17 – 44.22(1.739 – 1.741) —


0.080(0.0031)

Crank pin O.D. 44.976 – 45.000(1.7707 – 1.7717) —


0.080(0.0031)



ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 50 psi)


—


(0.115 – 0.121)2.62

(0.103)

No. 2 and 3 3.72 – 3.88(0.146 – 0.153)

3.42(0.135)


13.05(0.514)

No. 2 and 3 13.90 – 14.00(0.547 – 0.551)

13.10(0.516)



26.7(1.05)



13.957 – 13.984(0.5495 – 0.5505) —

4/9 E-02, 03, 19, 24, 28, 33E-19



ITEM STANDARD LIMITClutch release cylinder bore 35.700 – 35.762

(1.4055 – 1.4079) —


35.650 – 35.675(1.4035 – 1.4045) —

Clutch fluid type DOT 4 —

ITEM STANDARD LIMITThermostat valve opening tem-perature

86.5 – 89.5 °C(188 – 193 °F) —

Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —Radiator cap valve opening pressure

110 kPa (1.1 kgf/cm2, 15.6 psi) —

Cooling fan thermo-switch oper-ating temperature


Engine coolant temperature sensor resistance

20 °C(68 °F) Approx. 2.45 kΩ —

40 °C(104 °F) Approx. 1.15 kΩ —

60 °C(140 °F) Approx. 0.58 kΩ —

80 °C(176 °F) Approx. 0.32 kΩ —

Engine coolant type Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

—



Engine side



2nd 1.933 (29/15) —3rd 1.500 (27/18) —4th 1.227 (27/22) —5th 1.086 (25/23) —Top 1.000 (24/24) —


0.50(0.020)


Shift fork thickness 4.8 – 4.9(0.189 – 0.193) —LE

P

5/9 E-02, 03, 19, 24, 28, 33E-19


FI-SENSORS

ITEM STANDARD LIMITDrive chain Type RK50SMOZ1 —

Links 110 links, ENDLESS —20-link length — 319.4


(0.8 – 1.2) —


ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F)Fuel pump discharge amount 168 ml and more (5.7/5.9 US/lmp oz)

for 10 seconds at 300 kPa (3.0 kgf/cm2, 43 psi)Fuel pressure regulator operat-ing set pressure Approx. 300 kPa (3.0 kgf/cm2, 43 psi)

ITEM SPECIFICATION NOTECMP sensor peak voltage 3.7 V and moreCKP sensor resistance 130 – 240 ΩCKP sensor peak voltage 5.0 V and more (When cranking)IAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.5 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.12 kΩ


Opened Approx. 4.26 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 4.0 V at 100 kPa (760 mmHg)TO sensor resistance 19.1 – 19.7 kΩTO sensor voltage 1.4 V and lessGP switch voltage 0.6 V and more (From 1st to top)Injector voltage Battery voltageIgnition coil primary peak volt-age 200 V and more (When cranking)

STP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.58 kΩ

Opened Approx. 4.38 kΩ

SAM

6/9 E-02, 03, 19, 24, 28, 33E-19

THROTTLE BODY


ITEM STANDARD NOTESTP sensor output voltage Closed Approx. 0.58 V at input voltage is 5.0 V

Opened Approx. 4.38 V at input voltage is 5.0 VSTV actuator resistance 7 – 14 ΩHeated oxygen sensor output voltage

0.4 V and less at idle speed E-02, 190.6 V and more at 3 000 r/min E-02, 19

Heated oxygen sensor resis-tance 4 – 5 Ω at 23 °C (73.4 °F) E-02, 19

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

ITEM SPECIFICATIONI.D. No. 16G1 (For E-33), 16G2 (Others)Bore size 52 mmFast idle r/min 1 900 – 2 500 r/min at 25 °C (77 °F)Idle r/min 1 200 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

ITEM SPECIFICATION NOTEFiring order 1·2Spark plug Type NGK: CR8EK

DENSO: U24ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Crankshaft position sensor resistance 130 – 240 Ω Bl – G

Ignition coil resistance Primary 2.8 – 4.2 Ω tap – tapSecondary 24 – 36 kΩ tap – Plug cap

Crankshaft position sensor peak voltage 5.0 V and more When cranking

Ignition coil primary peak volt-age 200 V and more When cranking

Generator coil resistance 0.2 – 0.7 Ω Y – YGenerator Max. output Approx. 400 W at 5 000 r/minGenerator no-load voltage(When engine is cold) 75 V and more (AC) at 5 000 r/min




100

7/9 E-02, 03, 19, 24, 28, 33E-19

WATTAGE Unit: W


ITEM STANDARD NOTEFuse size




Main 30 A


LO 55Position light (For E-02, 19) 5Brake light/Taillight LEDTurn signal light 21 × 4Speedometer/Tachometer light LEDTurn signal indicator light LEDHigh beam indicator light LEDNeutral indicator light LEDFuel indicator light LEDCoolant temperature/oil pres-sure/FI indicator light LED

License light 5


(2.17 – 2.56) —


4.5(0.18)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



(0.6248 – 0.6265) —

Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —

Brake caliper cylin-der bore Leading

Front

30.230 – 30.280(1.1902 – 1.1921) —

Trailing 33.960 – 34.010(1.3370 – 1.3389) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —

8/9 E-02, 03, 19, 24, 28, 33E-19


ITEM STANDARD LIMITBrake caliper pis-ton diam. Leading

Front

30.167 – 30.200(1.1876 – 1.1890)

Trailing 33.901 – 33.934(1.3346 – 1.3360)

Rear 38.115 – 38.148(1.5005 – 1.5019)

Brake fluid type DOT 4 —Wheel rim runout(Front & Rear) Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)


Tire size Front 120/70 ZR17M/C (58W), tubeless —Rear 180/55 ZR17M/C (73W), tubeless —

Tire type Front MICHELIN: PILOT ROAD B —Rear MICHELIN: PILOT ROAD B —


Rear — 2.0(0.08)


(4.7) —


298(11.7)


147(5.8) —


(17.2/17.9 US/lmp oz) —

Front fork spring adjuster 7th groove from top —Front fork damping force adjuster

Rebound 1 and 1/4 turns out from stiffest position —Compres-



202(8.0) —


Rebound 3/4 turn out from stiffest position —Compres-

sion 1 and 3/4 turns out from stiffest position —LE
P
9/9 E-02, 03, 19, 24, 28, 33E-19

TIRE PRESSURE

FUEL + OIL

ITEM STANDARD NOTERear wheel travel 130

(5.1)—






octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10 % ethanol, or less than 5 % methanol with appropriate cosolvents and corrosion inhibitor is permissible.

E-03, 28, 33

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. The others

Fuel tank 16 L (4.2/3.5 US/lmp gal) E-3317 L (4.5/3.7 US/lmp gal) The others


(2.9/2.4 US/lmp qt)



SAM

101

SV1000SD/SF

1/9 E-02, 03, 19, 24, 28, 33E-19




(1.42) —

EX. 33(1.30) —


EX. 0.20 – 0.30(0.008 – 0.012) —


(0.0004 – 0.0018) —

EX. 0.030 – 0.066(0.0012 – 0.0026) —


Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —








197 – 227 N(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)



(1.487 – 1.489)37.48

(1.476)

EX. 36.38 – 36.42(1.432 – 1.434)

36.08(1.420)


0.150(0.0059)




2/9 E-02, 03, 19, 24, 28, 33E-19


ITEM STANDARD LIMITCam drive idle gear/sprocket thrust clearance

0.15 – 0.29(0.006 – 0.011) —



(10 – 14 kgf/cm2, 142 – 199 psi)800 kPa

(8 kgf/cm2,114 psi)

Compression pressure differ-ence —

200 kPa(2 kgf/cm2,


(0.0006 – 0.0010)0.12

(0.0047)Cylinder bore 98.000 – 98.015

(3.8583 – 3.8589)Nicks or



97.880(3.8535)



2nd Approx. 10.1 (0.40) 8.1(0.32)


0.7(0.03)

2nd 0.30 – 0.45(0.012 – 0.018)

0.7(0.03)


2nd — 0.15(0.0059)


1st

0.93 – 0.95(0.0366 – 0.0374) —

1.55 – 1.57(0.0610 – 0.0618) —

2nd 1.01 – 1.03(0.0398 – 0.0406) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


1st

0.86 – 0.91(0.034 – 0.036) —

1.38 – 1.40(0.054 – 0.055) —

2nd 0.97 – 0.99(0.038 – 0.039) —


22.030(0.8673)

Piston pin O.D. 21.993 – 22.000(0.8658 – 0.8661)

21.980(0.8654)LE

P

3/9 E-02, 03, 19, 24, 28, 33E-19


OIL PUMP



(0.8665 – 0.8668)22.040


(0.007 – 0.013)0.50


(0.864 – 0.866) —

Crank pin width 44.17 – 44.22(1.739 – 1.741) —


0.080(0.0031)

Crank pin O.D. 44.976 – 45.000(1.7707 – 1.7717) —


0.080(0.0031)



ITEM STANDARD LIMITOil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kgf/cm2, 50 psi)


—


(0.115 – 0.121)2.62

(0.103)

No. 2 and 3 3.72 – 3.88(0.146 – 0.153)

3.42(0.135)


13.05(0.514)

No. 2 and 3 13.90 – 14.00(0.547 – 0.551)

13.10(0.516)



26.7(1.05)



13.957 – 13.984(0.5495 – 0.5505) —



35.650 – 35.675(1.4035 – 1.4045) —

Clutch fluid type DOT 4 —

SAM

4/9 E-02, 03, 19, 24, 28, 33E-19



ITEM STANDARD LIMITThermostat valve opening tem-perature

86.5 – 89.5 °C(188 – 193 °F) —

Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) —Radiator cap valve opening pressure 110 kPa (1.1 kgf/cm2, 15.6 psi) —

Cooling fan thermo-switch oper-ating temperature


Engine coolant temperature sensor resistance

20 °C(68 °F) Approx. 2.45 kΩ —

40 °C(104 °F) Approx. 1.15 kΩ —

60 °C(140 °F) Approx. 0.58 kΩ —

80 °C(176 °F) Approx. 0.32 kΩ —

Engine coolant type Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

—



Engine side



2nd 1.933 (29/15) —3rd 1.500 (27/18) —4th 1.227 (27/22) —5th 1.086 (25/23) —Top 1.000 (24/24) —


0.50(0.020)



Drive chain Type RK50SMOZ1 —Links 108 links, ENDLESS —

20-link length — 319.4


(0.8 – 1.2) —


102

5/9 E-02, 03, 19, 24, 28, 33E-19


FI-SENSORS

ITEM SPECIFICATION NOTEInjector resistance 11 – 13 Ω at 20 °C (68 °F)Fuel pump discharge amount 168 ml and more (5.7/5.9 US/lmp oz)

for 10 seconds at 300 kPa (3.0 kgf/cm2, 43 psi)Fuel pressure regulator operat-ing set pressure Approx. 300 kPa (3.0 kgf/cm2, 43 psi)

ITEM SPECIFICATION NOTECMP sensor peak voltage 3.7 V and moreCKP sensor resistance 130 – 240 ΩCKP sensor peak voltage 5.0 V and more (When cranking)IAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.5 V at idle speedTP sensor input voltage 4.5 – 5.5 VTP sensor resistance Closed Approx. 1.12 kΩ


Opened Approx. 4.26 VECT sensor input voltage 4.5 – 5.5 VECT sensor resistance Approx. 2.45 kΩ at 20 °C (68 °F)IAT sensor input voltage 4.5 – 5.5 VIAT sensor resistance Approx 2.45 kΩ at 20 °C (68 °F)AP sensor input voltage 4.5 – 5.5 VAP sensor output voltage Approx. 4.0 V at 100 kPa (760 mmHg)TO sensor resistance 19.1 – 19.7 kΩTO sensor voltage 1.4 V and lessGP switch voltage 0.6 V and more (From 1st to top)Injector voltage Battery voltageIgnition coil primary peak volt-age 200 V and more (When cranking)

STP sensor input voltage 4.5 – 5.5 VSTP sensor resistance Closed Approx. 0.58 kΩ

Opened Approx. 4.38 kΩSTP sensor output voltage Closed Approx. 0.58 V at input voltage is 5.0 V

Opened Approx. 4.38 V at input voltage is 5.0 VSTV actuator resistance 7 – 14 ΩHeated oxygen sensor output voltage

0.4 V and less at idle speed E-02, 190.6 V and more at 3 000 r/min E-02, 19

Heated oxygen sensor resis-tance 4 – 5 Ω at 23 °C (73.4 °F) E-02, 19

PAIR solenoid valve resistance 20 – 24 Ω at 20 °C (68 °F)

6/9 E-02, 03, 19, 24, 28, 33E-19

THROTTLE BODY


ITEM SPECIFICATIONID No. 16G0 (For E-02, 19), 16G1 (For E-33), 16G2 (For E-03, 24, 28)Bore size 52 mmFast idle r/min 1 900 – 2 500 r/min at 25 °C (77 °F)Idle r/min 1 200 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in)

ITEM SPECIFICATION NOTEFiring order 1·2Spark plug Type NGK: CR8EK

DENSO: U24ETR

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Crankshaft position sensor resistance 130 – 240 Ω Bl – G

Ignition coil resistance Primary 2.8 – 4.2 Ω tap – tapSecondary 24 – 36 kΩ tap – Plug cap

Crankshaft position sensor peak voltage 5.0 V and more When cranking

Ignition coil primary peak volt-age 200 V and more When cranking

Generator coil resistance 0.2 – 0.7 Ω Y – YGenerator Max. output Approx. 400 W at 5 000 r/minGenerator no-load voltage(When engine is cold) 75 V and more (AC) at 5 000 r/min







Main 30 A

LE
P
7/9 E-02, 03, 19, 24, 28, 33E-19

WATTAGE Unit: W


ITEM SPECIFICATIONHeadlight HI 60 × 2

LO 55 × 2Position light 5 × 2Brake light/Taillight LEDTurn signal light 21 × 4Speedometer/Tachometer light LEDTurn signal indicator light LEDHigh beam indicator light LEDNeutral indicator light LEDFuel indicator light LEDCoolant temperature/oil pres-sure/FI indicator light LED

License light 5


(2.17 – 2.56) —


4.5(0.18)

Rear 5.0 ± 0.2(0.197 ± 0.008)

4.5(0.18)



(0.6248 – 0.6265) —

Rear 14.000 – 14.043(0.5512 – 0.5529) —


Rear 13.957 – 13.984(0.5495 – 0.5506) —

Brake caliper cylin-der bore Leading

Front

30.230 – 30.280(1.1902 – 1.1921) —

Trailing 33.960 – 34.010(1.3370 – 1.3389) —

Rear 38.180 – 38.230(1.5031 – 1.5051) —

Brake caliper piston diam. Leading

Front

30.167 – 30.200(1.1876 – 1.1890) —

Trailing 33.901 – 33.934(1.3346 – 1.3360) —

Rear 38.115 – 38.148(1.5005 – 1.5019) —


SAM

8/9 E-02, 03, 19, 24, 28, 33E-19


ITEM STANDARD LIMITWheel rim runout(Front & Rear) Axial — 2.0

(0.08)

Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 17 × MT 3.50, 17M/C × MT 3.50 —Rear 17 × MT 5.50, 17M/C × MT 5.50 —

Tire size Front 120/70 ZR17M/C (58W), tubeless —Rear 180/55 ZR17M/C (73W), tubeless —

Tire type Front MICHELIN: PILOT SPORT E —Rear MICHELIN: PILOT SPORT L —


Rear — 2.0(0.08)


(4.5) —


289(11.4)


164(6.5) —


(17.0/17.7 US/lmp oz) —

Front fork spring adjuster 6th groove from top —Front fork damping force adjuster

Rebound 1 turn out from stiffest position —Compres-



199.3(7.85) —


Rebound 3/4 turn out from stiffest position —Compres-

sion 2 and 1/4 turns out from stiffest position —



103

9/9 E-02, 03, 19, 24, 28, 33E-19

TIRE PRESSURE

FUEL + OIL





octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

E-03, 28, 33

Gasoline used should be graded 91 octane or higher. An unleaded gasoline is recommended. The others

Fuel tank 16 L (4.2/3.5 US/lmp gal) E-3317 L (4.5/3.7 US/lmp gal) The others


(2.9/2.4 US/lmp qt)



LE
P UH125
1/6 E-02, 19



ITEM STANDARD LIMITValve diam. IN. 22.0 ----

EX. 19.0 ----Valve clearance (When cold) IN. 0.05 – 0.10 ----

EX. 0.10 – 0.15 ----Valve guide to valve stem clear-ance

IN. 0.010 – 0.037 ----EX. 0.030 – 0.057 ----

Valve guide I.D. IN. & EX. 5.000 – 5.012 ----Valve stem O.D. IN. 4.975 – 4.990 ----

EX. 4.955 – 4.970 ----Valve stem deflection IN. & EX. ---- 0.35Valve stem runout IN. & EX. ---- 0.05Valve head thickness IN. & EX. ---- 0.5Valve stem end length IN. & EX. ---- 1.8Valve seat width IN. & EX. 0.9 – 1.1 ----Valve head radial runout IN. & EX. ---- 0.03Valve spring free length (IN. & EX.) INNER ---- 35.0

OUTER ---- 37.8Valve spring tension (IN. & EX.)

INNER53 – 65 N

(5.3 – 6.5 kgf)at length 28 mm

----

OUTER131 – 151 N

(13.1 – 15.1 kgf)at length 31.5 mm

----


EX. 31.92 – 31.99 31.62Camshaft journal oil clearance φ 22 0.032 – 0.066 0.150

φ 17.5 0.028 – 0.059 0.150Camshaft journal holder I.D. φ 22 22.012 – 22.025 ----

φ 17.5 17.512 – 17.525 ----Camshaft journal O.D. φ 22 21.959 – 21.980 ----

φ 17.5 17.466 – 17.484 ----Camshaft runout ---- 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 ----Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 ----Cylinder head distortion ---- 0.05

SAM

2/6 E-02, 19



OIL PUMP

CLUTCH Unit: mm


(17.0 kgf/cm2)1550 kPa



Cylinder distortion ---- 0.05Piston ring free end gap 1st R Approx. 7.2 5.8


2nd 0.20 – 0.32 0.70Piston ring to groove clearance 1st ---- 0.18

2nd ---- 0.15Piston ring groove width 1st 1.01 – 1.03 ----

2nd 1.01 – 1.03 ----Oil 2.01 – 2.03 ----

Piston ring thickness 1st 0.97 – 0.99 ----2nd 0.97 – 0.99 ----


ITEM STANDARD LIMITConrod small end I.D. 16.006 – 16.014 16.040Conrod deflection ---- 3.0Conrod big end side clearance 0.10 – 0.45 1.00Conrod big end width 16.95 – 17.00 ----Crank web to web width 53.0 ± 0.1 ----Crankshaft runout ---- 0.10

ITEM STANDARD LIMITOil pressure (at 60 °C) Above 120 kPa (1.2 kgf/cm2)

Below 180 kPa (1.8 kgf/cm2) at 3000 r/min

----

ITEM STANDARD LIMITClutch wheel I.D. 125.0 – 125.2 125.5Clutch shoe thickness ---- 2.0Clutch engagement Approx. 3 800 ± 300 ----Clutch lock-up Approx. 6 000 ± 500 ----

104

3/6 E-02, 19

REDUCTION GEAR + DRIVE BELT Unit: mm Except ratio

CARBURETOR


ITEM STD/SPEC. LIMITReduction ratio Variable change (2.930 – 0.770) ----Final reduction ratio 9.965 (45/17 × 64/17) ----Drive belt width 22.1 21.1Movable driven face spring free length 150 142.5

ITEMSPECIFICATION

E-02, 19Carburator type KEIHIN CVK24Bore size 24 mmI.D. No. 49F0Idle r/min 1 600 ± 100 r/minFuel level 7.0 ± 1.0 mmFloat height 16.0 ± 1.0 mmMain jet (M.J.) #115Main air jet (M.A.J.) Press-fittedJet needle (J.N.) NCHANeedle jet (N.J.) φ 2.1Throttle valve (Th.V.) θ = 12°Pilot jet (P.J.) #35Pilot screw (P.S.) PRE-SETThrottle cable play 2.0 – 4.0 mm

ITEM STD/SPEC. LIMITThermostat valve opening temper-ature Approx. 82 °C ----

Thermostat valve lift Over 3 mm at 95 °C ----Engine coolant temperature switch resistance

Approx. 80 °C 47.5 – 56.8 Ω ----Approx. 100 °C 26.2 – 29.3 Ω ----

Radiator cap valve opening pres-sure 110 kPa (1.1 kgf/cm2) ----

Electric fan thermo-switch operat-ing temperature

OFF → ON Approx. 105 °C ----ON → OFF Approx. 100 °C ----

Engine coolant type Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

----

Engine coolant capacity Reserve tank only Approx. 250 ml ----

Including reserve Approx. 1 250 ml ----

4/6 E-02, 19

ELECTRICAL

WATTAGE Unit: W

ITEM STD/SPEC. NOTEIgnition timing 10° B.T.D.C. at 1 600 r/minSpark plug Type NGK: CR8E


Spark performance Over 8 mm at 1 atm.Signal generator resistance 148 – 222 Ω Green – WhiteSignal generator peak voltage More than 1.3 V White –

GreenIgnition coil resistance Primary 0.09 – 0.13 Ω White/Blue –

Black/White

Secondary 15.4 – 18.1 kΩ Plug cap – White/Blue

Ignition coil primary peak voltage More than 150 V Black/White – Black/Yellow

Generator coil resistance 0.50 – 0.62 ΩGenerator Max.output Approx. 225 W at 5 000 r/minGenerator no-load voltage (When cold) More than 40 V (AC) at 5 000 r/min

Regulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 1 – 7 ΩBattery Type des-

ignation FTX9-BS

Capacity 12 V 28.8 kC (8 Ah)/10HRFuse size Main 20 A


LO 35Parking or position light 5 × 2Brake light/Taillight 21/5 × 2Turn signal light 21 × 4License light 5Speedometer light 1.2Fuel meter light 1.2Water temp. meter light 1.2Turn signal indicator light 1.2High beam indicator light 1.2Trunk light 5

LE
P
5/6 E-02, 19


TIRE

SUSPENSION Unit: mm

ITEM STANDARD LIMITBrake disc thickness Front &

Rear 3.8 – 4.2 3.5

Brake drum I.D. Parking ---- 130.7Brake disc runout Front &

Rear ---- 0.3

Brake fluid type Front & Rear DOT 4 ----

Wheel rim runout Axial ---- 2.0Radial ---- 2.0

Wheel rim size Front 12 × MT 2.50 ----Rear 12 × MT 3.00 ----

Wheel axle runout Front ---- 0.25

ITEM STD/SPEC. LIMITCOLD INFLATION PRESSURE(SOLO/DUAL RIDING) Front 200/200 kPa

(2.00/2.00 kgf/cm2) ----

Rear 225/280 kPa(2.25/2.80 kgf/cm2) ----

Tire size Front 110/90-12 64L ----Rear 130/70-12 62L ----

Tire type Front HOOP B03G ----Rear HOOP B02G ----

Tire tread depth(Recommend depth) Front ---- 0.8 mm

(1.6 mm)

Rear ---- 0.8 mm (1.6 mm)

ITEM STD/SPEC. LIMITFront fork stroke 100 ----Front fork spring free length 301 294Front fork oil level (without spring, inner tube fully compressed) 87.7 ----

Front fork oil type Suzuki fork oil G-10 (#10) or equivalent fork oil ----Front fork oil capacity (each leg) 106 ml ----Rear wheel travel 83 ----

SAM

6/6 E-02, 19



Fuel tank capacity 10.0 LiterFuel level gauge resistance Full 4 – 10 Ω

Empty 90 – 100 ΩEngine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 1 200 ml

Filter change 1 300 ml

Overhaul 1 500 mlReduction gearbox oil type SAE 10W-40, API SF or SGReduction gearbox oil capacity Change 120 ml

Overhaul 130 ml

105

UH150

1/8 E-02, 03, 19, 24, 28, 33



(1.3) —

EX. 40(1.6) —

Lash-adjuster plunger stroke 0 – 0.5(0 – 0.02) —


(0.0004 – 0.0015) —

EX. 0.040 – 0.070(0.0016 – 0.0028) —


Valve guide I.D. IN. 5.500 – 5.512(0.2165 – 0.2170) —

EX. 7.000 – 7.015(0.2756 – 0.2762) —

Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 6.945 – 6.960(0.2734 – 0.2740) —



Valve stem end length IN. — 2.5(0.10)

EX. — 2.2(0.09)

Valve seat width IN. 0.9 – 1.1(0.035 – 0.043) —

EX. 1.0 – 1.2(0.039 – 0.047) —


Valve spring free length(INTAKE) INNER — 35.0

(1.38)

OUTER — 37.8 (1.49)

Valve spring free length(EXHAUST) — 40.6

(1.60)Valve spring tension (INTAKE)

INNER5.3 – 6.5 kgf

(11.68 – 14.33 Ibs)at length 28.0 mm (1.10 in)

—



—

Valve spring tension (EXHAUST) 20.3 – 23.3 kgf(44.75 – 51.37 Ibs)


1/6 E-19



ITEM STANDARD LIMITValve diam. IN. 22.0 ----

EX. 19.0 ----Valve clearance (When cold) IN. 0.05 – 0.10 ----

EX. 0.10 – 0.15 ----Valve guide to valve stem clear-ance

IN. 0.010 – 0.037 ----EX. 0.030 – 0.057 ----

Valve guide I.D. IN. & EX. 5.000 – 5.012 ----Valve stem O.D. IN. 4.975 – 4.990 ----

EX. 4.955 – 4.970 ----Valve stem deflection IN. & EX. ---- 0.35Valve stem runout IN. & EX. ---- 0.05Valve head thickness IN. & EX. ---- 0.5Valve stem end length IN. & EX. ---- 1.8Valve seat width IN. & EX. 0.9 – 1.1 ----Valve head radial runout IN. & EX. ---- 0.03Valve spring free length (IN. & EX.)

INNER ---- 35.0OUTER ---- 37.8

Valve spring tension (IN. & EX.) INNER

53 – 65 N(5.3 – 6.5 kgf)

at length 28 mm----

OUTER131 – 151 N

(13.1 – 15.1 kgf)at length 31.5 mm

----


EX. 32.66 – 32.73 32.36Camshaft journal oil clearance φ 22 0.032 – 0.066 0.150

φ 17.5 0.028 – 0.059 0.150Camshaft journal holder I.D. φ 22 22.012 – 22.025 ----

φ 17.5 17.512 – 17.525 ----Camshaft journal O.D. φ 22 21.959 – 21.980 ----

φ 17.5 17.466 – 17.484 ----Camshaft runout ---- 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 ----Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 ----Cylinder head distortion ---- 0.05

2/8 E-02, 03, 19, 24, 28, 33




(1.4047 – 1.4067)35.38

(1.393)

EX. 36.880 – 36.930(1.4521 – 1.4537)

36.58(1.440)


0.150(0.0060)

Camshaft journal holder I.D. Front head right side, rear head left side

20.012 – 20.025(0.7879 – 0.7884) —

Front head left side, rear head right side

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. Front head right side, rear head left side

19.959 – 19.980(0.7858 – 0.7866) —


24.959 – 24.980(0.9826 – 0.9835) —

Camshaft runout Front & Rear — 0.10(0.004)

Rocker arm I.D. IN. 14.000 – 14.018(0.5511 – 0.5519) —

EX. 16.000 – 16.018(0.6299 – 0.6303) —

Rocker arm shaft O.D. IN. 13.966 – 13.984(0.5498 – 0.5506) —

EX. 15.966 – 15.984(0.6286 – 0.6293) —



ITEM STANDARD LIMITCampression pressure(Automatic de-compression actuated)

1 000 – 1 400 kPa(10 – 14 kgf/cm2, 142 – 199 psi) —

Campression pressure difference — 200 kPa (2 kgf/cm2)


0.120(0.0047)

Cylinder bore 96.000 – 96.015(3.7795 – 3.7801)

Nicks or Scratches

Piston diam. 95.975 – 95.990(3.7785 – 3.7791)


(37.7748)



2nd T Approx. 14.0 (0.55) 11.2(0.44)

2/6 E-19



OIL PUMP

CLUTCH Unit: mm


(16.0 kgf/cm2)1 450 kPa



Cylinder distortion ---- 0.05Piston ring free end gap 1st R Approx. 8.6 6.9


2nd 0.20 – 0.32 0.70Piston ring to groove clearance 1st ---- 0.18

2nd ---- 0.15Piston ring groove width 1st 1.01 – 1.03 ----

2nd 1.01 – 1.03 ----Oil 2.01 – 2.03 ----

Piston ring thickness 1st 0.97 – 0.99 ----2nd 0.97 – 0.99 ----


ITEM STANDARD LIMITConrod small end I.D. 16.006 – 16.014 16.040Conrod deflection ---- 3.0Conrod big end side clearance 0.10 – 0.45 1.00Conrod big end width 16.95 – 17.00 ----Crank web to web width 53.0 ± 0.1 ----Crankshaft runout ---- 0.10



----

ITEM STANDARD LIMITClutch wheel I.D. 125.0 – 125.2 125.5Clutch shoe thickness ---- 2.0Clutch engagement Approx. 3 600 ± 300 ----Clutch lock-up Approx. 6 500 ± 500 ----LE
P
3/8 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITPiston ring end gap 1st 0.30 – 0.45

(0.012 – 0.018)0.70

(0.028)

2nd 0.45 – 0.60(0.018 – 0.024)

1.00(0.039)


2nd — 0.150(0.006)


2nd 1.510 – 1.530(0.0594 – 0.0602) —

Oil 2.810 – 2.830(0.1106 – 0.1114) —


2nd 1.470 – 1.490(0.0579 – 0.0587) —

Piston pin bore 23.002 – 23.008(0.9056 – 0.9058)

23.030(0.9067)

Piston pin O.D. 22.992 – 23.000(0.9052 – 0.9055)

22.980(0.9047)


(0.9061 – 0.9064)23.040


(0.004 – 0.008)0.3


(0.864 – 0.866) —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 49.982 – 50.000(1.9678 – 1.9685) —


0.080(0.0031)


Crankshaft journal I.D. 52.000 – 52.015(2.0472 – 2.0478) —

Crankshaft thrust bearing thickness

1.925 – 2.175(0.0758 – 0.0856) —



3/6 E-19

REDUCTION GEAR + DRIVE BELT Unit: mm Except ratio

CARBURETOR


ITEM STD/SPEC. LIMITReduction ratio Variable change (2.930 – 0.770) ----Final reduction ratio 9.264 (45/17 × 63/18) ----Drive belt width 22.1 21.1Movable driven face spring free length 150 142.5

ITEM SPECIFICATIONCarburator type KEIHIN CVK24Bore size 24 mmI.D. No. 49FAIdle r/min 1 600 ± 100 r/minFuel level 7.0 ± 1.0 mmFloat height 16.0 ± 1.0 mmMain jet (M.J.) #112Main air jet (M.A.J.) Press-fittedJet needle (J.N.) NBUBNeedle jet (N.J.) φ 2.1Throttle valve (Th.V.) θ = 12°Pilot jet (P.J.) #20Pilot screw (P.S.) PRE-SETThrottle cable play 2.0 – 4.0 mm

ITEM STD/SPEC. LIMITThermostat valve opening temper-ature Approx. 82 °C ----

Thermostat valve lift Over 3 mm at 95 °C ----Engine coolant temperature sensor resistance

Approx. 80 °C 47.5 – 56.8 Ω ----Approx. 100 °C 26.2 – 29.3 Ω ----

Radiator cap valve opening pres-sure 110 kPa (1.1 kgf/cm2) ----

Electric fan thermo-switch operat-ing temperature

OFF → ON Approx. 105 °C ----ON → OFF Approx. 100 °C ----

Engine coolant type Use an anti-freeze/engine coolant compatible withan aluminum radiator, mixed with distilled wateronly, at the ratio of 50:50.

----

Engine coolant capacity Reserve tank only Approx. 250 ml ----

Including reserve Approx. 1 250 ml ----

SAM

4/8 E-02, 03, 19, 24, 28, 33

OIL PUMP





—


(0.114 – 0.122)2.60


(0.614 – 0.622)14.8



(1.357)32.7


(0.5512 – 0.5529) —


13.957 – 13.984(0.5495 – 0.5506) —



33.550 – 33.575(1.3209 – 1.3218) —

ITEM STANDARD LIMITPrimary reduction ratio 1.490 (76/51) —Secondary reduction ratio 0.852 (29/34) —Final reduction ratio 2.666 (19/19 × 32/12) —Gear ratios Low 3.000 (36/12) —

2nd 1.823 (31/17) —3rd 1.333 (28/21) —4th 1.041 (25/24) —Top 0.884 (23/26) —


0.5(0.020)



Damper spring free length — 73.6(2.90)



Final bevel gear backlash 0.03 – 0.64(0.001 – 0.025) —

4/6 E-19

ELECTRICAL

WATTAGE Unit: W

ITEM STD/SPEC. LIMITIgnition timing 10° B.T.D.C. at 1 600 r/minSpark plug Type NGK: CR8E


Spark performance Over 8 mm at 1 atm.Signal generator resistance 148 – 222 Ω Green – WhiteSignal generator peak voltage More than 1.3 V White –

GreenIgnition coil resistance Primary 0.09 – 0.13 Ω White/Blue –

Black/White

Secondary 15.4 – 18.1 kΩ Plug cap – White/Blue

Ignition coil primary peak voltage More than 150 V Black/White – Black/Yellow

Generator coil resistance 0.50 – 0.62 ΩGenerator Max. output Approx. 225 W at 5 000 r/minGenerator no-load voltage (When cold) More than 40 V (AC) at 5 000 r/min

Regulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 1 – 7 ΩBattery Type des-

ignation FTX9-BS



LO 35Parking or position light 5 × 2Brake light/Taillight 21/5 × 2Turn signal light 21 × 4License light 5Speedometer light 1.2Fuel meter light 1.2Water temp. meter light 1.2Turn signal indicator light 1.2High beam indicator light 1.2Trunk light 5

106

5/8 E-02, 03, 19, 24, 28, 33

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-28 E-24 E-02, 19Carburetor type BDSR36 ← ←Bore size 36.5 mm ← ←I.D. No. 10F1 10F2 10F9Idle r/min 1 000 ± 100 r/min ← ←Float height 7.0 ± 0.5 mm

(0.28 ± 0.02 in) ← ←

Main jet (M.J.) F: #R: #

F: #112.5R: #110 ←

Jet needle (J.N.) F: 5D95-56R: 5E9-56

F: 5D94-56-3R: 5E8-56-3

F: 5D124-3R: 5E19-3

Needle jet (N.J.) P-0 P-0MThrottle valve (Th.V.) #90 ← ←Pilot jet (P.J.) # #32.5 ←Pilot screw (P.S.)

Throttle cable play 2.0 – 4.0 mm(0.08 – 0.16 in) ← ←

ITEMSPECIFICATION

E-03 E-33Carburetor type BDSR36 ←Bore size 36.5 mm ←I.D. No. 10F1 10F7Idle r/min 1 000 ± 100 r/min ←Float height 7.0 ± 0.5 mm

(0.28 ± 0.02 in) ←

Main jet (M.J.) F: #R: # ←

Jet needle (J.N.) F: 5D95-56R: 5E9-56 ←

Needle jet (N.J.) ←Throttle valve (Th.V.) #90 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

PRE-SETF: 2 1/4 turns backR: 2 1/8 turns back

PRE-SETF: 2 turns backR: 2 turns back

5/6 E-19


TIRE

SUSPENSION Unit: mm

ITEM STANDARD LIMITBrake disc thickness Front &

Rear 3.8 – 4.2 3.5

Brake drum I.D. Parking ---- 130.7Brake disc runout Front &

Rear ---- 0.3

Brake fluid type Front & Rear DOT 4

Wheel rim runout Axial ---- 2.0Radial ---- 2.0

Wheel rim size Front 12 × MT 2.50 ----Rear 12 × MT 3.00 ----

Wheel axle runout Front ---- 0.25

ITEM STD/SPEC. LIMITCOLD INFLATION PRESSURE(SOLO/DUAL RIDING) Front 200/200 kPa

(2.00/2.00 kgf/cm2) ----

Rear 225/280 kPa(2.25/2.80 kgf/cm2) ----

Tire size Front 110/90-12 64L ----Rear 130/70-12 62L ----

Tire type Front HOOP B03G ----Rear HOOP B02G ----

Tire tread depth(Recommend depth) Front ---- 0.8 mm

(1.6 mm)

Rear ---- 0.8 mm(1.6 mm)

ITEM STD/SPEC. LIMITFront fork stroke 100 ----Front fork spring free length 301 294Front fork oil level (without spring, inner tube fully compressed) 87.7 ----

Front fork oil type Suzuki fork oil G-10 (#10) or equivalent fork oil ----Front fork oil capacity (each leg) 106 ml ----Rear wheel travel 83 ----

6/6 E-19



Fuel tank capacity 10.0 LiterFuel level gauge resistance Full 4 – 10 Ω

Empty 90 – 100 ΩEngine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 1 200 ml

Filter change 1 300 ml

Overhaul 1 500 mlReduction gearbox oil type SAE 10W-40, API SF or SGReduction gearbox oil capacity Change 120 ml

Overhaul 130 ml

LE
P VL125/U
1/6 E-02, 19E-19




EX. 19 —Valve clearance (when cold) IN. 0.10 – 0.15 —


IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —


EX. 4.455 – 4.470 —Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 2.2Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length IN. & EX. — 37.2Valve spring tension

IN. & EX.118 – 136 N

(12.0 – 13.9 kgf)at length 33.7 mm

—


EX.Front 32.893 – 32.933 32.60Rear 32.628 – 32.668 32.33

Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —Camshaft runout IN. & EX. — 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —Cylinder head distortion — 0.05Cylinder head cover distortion — 0.05

SAM

2/6 E-02, 19E-19



OIL PUMP


(11 – 15 kgf/cm2) —







2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —


Piston pin bore 12.002 – 12.008 12.030Pisron pin O.D. 11.996 – 12.000 11.980

ITEM STANDARD LIMITConrod small end I.D. 12.006 – 12.014 12.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.56 1.0Conrod big end width 15.95 – 16.00 —Crank web to web width 66.9 – 67.1 —Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pressure (at 60 °C) 35 – 60 kPa

(0.35 – 0.60 kgf/cm2)at 3 000 r/min

—

107

3/6 E-02, 19E-19

CLUTCH Unit: mm


CARBURETOR

ITEM STANDARD LIMITClutch cable play 10 – 15 —Drive plate thickness No. 1 2.92 – 3.08 2.6

No. 2 3.42 – 3.58 3.1Drive plate claw width No. 1 & 2 15.9 – 16.0 15.1Driven plate distortion — 0.10Clutch spring free length 40.5 38.5

ITEM STANDARD LIMITPrimary reduction ratio 3.173 (73/23) —Secondary reduction ratio 4.000 (56/14) —Gear ratios Low 2.636 (29/11) —

2nd 1.647 (28/17) —3rd 1.217 (28/23) —4th 0.952 (20/21) —Top 0.818 (18/22) —

Shift fork to groove clearance 0.20 – 0.40 0.60Shift fork groove width 4.25 – 4.35 —Shift fork thickness 3.95 – 4.05 —Drive chain Type RK428HO —

Links 142 links —20-pitch length 254 269.2


ITEM SPECIFICATIONCarburetor type MIKUNI BDS26Bore size 26 mmI.D. No. 26F5Idle r/min 1 400 ± 100 r/minFuel level 11.0 ± 1.0 mmFloat height 9.9 ± 1.0 mmMain jet (M.J.) # 102.5Jet needle (J.N.) 4DP24-3rdNeedle jet (N.J.) O-1Pilot jet (P.J.) # 17.5Pilot screw (P.S.) 3 turns backThrottle cable play 2 – 4 mm

4/6 E-02, 19E-19

ELECTRICAL Unit: mm

ITEM SPECIFICATION NOTEIgnition timing 10° B.T.D.C. at 1 400 r/minSpark plug Type NGK: CR8E


Spark performance Over 8 at 1 atm.Ignition coil resistance Primary 1.8 – 3.0 Ω terminai –

terminal


Ignition coil primary peak voltage More than 250 V W or B/Y – Ground

Generator coil resistance 0.3 – 1.1 Ω Y – YSignal generator coil resistance 180 – 280 Ω Bl – GSignal generator peak voltage More than 4.5 V B – G

Generator Max. output 200 W at 5 000 r/minGenerator no-load voltage More than 60 V (AC) at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX7L-BS

Capacity 12 V 21.6 kC (6 Ah)/10HRFuse size 20 A

LE
P
5/6 E-02, 19E-19

WATTAGE Unit: W


SUSPENSION Unit: mm

ITEMSPECIFICATION


LO 55 ←Position/parking light 5 4Brake light/Taillight 21/5 ←Turn signal light 21 ←Speedmeter light 1.7 ←Neutral indicator light 1.7 ←Turn signal indicator light 1.7 ←High beam indicator light 1.7 ←

ITEM STANDARD LIMITRear brake pedal free travel 20 – 30 —Rear brake pedal height 50 – 60 —Brake disc thickness Front 5.0 4.5Brake disc runout Front — 0.30Master cylinder bore Front 12.700 – 12.743 —Master cylinder piston diam. Front 12.657 – 12.684 —Brake caliper cylinder bore Front 42.85 – 42.90 —Brake caliper piston diam. Front 42.772 – 42.822 —Brake fluid type DOT 4 —Brake drum I.D. Rear — 130.7Wheel rim runout Axial — 2.0


Rear — 0.25Wheel rim size Front 18M/C × MT2.50 —

Rear 15M/C × MT3.00 —

ITEM STD/SPEC. LIMITFront fork stroke 120 —Front fork spring free length 290.3 284Front fork oil level 88 —Front fork oil type SUZUKI FORK OIL #10 or equivalent fork oil —Front fork oil capacity (each leg) 406 ml —Rear wheel travel 90 —Swingarm pivot shaft runout — 0.3

SAM

6/6 E-02, 19E-19

TIRE

FUEL + OIL


(1.75 kgf/cm2) —



(1.75 kgf/cm2) —


Tire size Front 90/90-18M/C 51P —Rear 130/90-15M/C 66P —

Tire type Front IRC: GS-21F —Rear IRC: NR31 —


Front — 1.6 mmRear — 1.6 mm


higher. An unleaded gasoline is recommended.Fuel tank capacity Including reserve 12.0 L

reserve 3.0 LEngine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 1 800 ml

Filter change 1 900 mlOverhaul 2 100 ml

108

VL250

1/6 E-19, 24






IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —


EX. 4.455 – 4.470 —Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 2.2Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length IN. — 37.2

EX. — 37.2Valve spring tension

IN. & EX.118 – 136 N

(12.0 – 13.9 kgf)at length 33.7 mm

—


EX.Front 33.10 – 33.14 32.80Rear 32.96 – 33.00 32.66

Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —Camshaft runout IN. & EX. — 0.10Rocker arm I.D. IN. & EX. 12.000 – 12.018 —Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —Cylinder distortion — 0.05Cylinder head distortion — 0.05Cylinder head cover distortion — 0.05

2/6 E-19, 24



OIL PUMP

ITEM STANDARD LIMITCompression pressure 800 – 1 200 kPa

(8 – 12 kgf/cm2) —

Compression pressure difference — 200 kPa(2 kgf/cm2)



Piston ring free end gap 1st R Approx. 6.0 4.82nd R Approx. 4.9 3.9

Piston ring end gap 1st 0.15 – 0.30 0.502nd 0.15 – 0.30 0.50

Piston ring to groove clearance 1st — 0.182nd — 0.15

Piston ring groove width 1st 1.01 – 1.03 —2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —


Piston pin bore 15.002 – 15.008 15.030Pisron pin O.D. 14.992 – 15.000 14.980

ITEM STANDARD LIMITConrod small end I.D. 15.006 – 15.014 15.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.56 1.0Conrod big end width 15.95 – 16.00 —Crank web to web width 66.9 – 67.1 —Crankshaft runout — 0.080


(0.2 – 0.7 kgf/cm2)at 3 000 r/min

—

LE
P
3/6 E-19, 24



CARBRETOR

ITEM STANDARD LIMITClutch cable play 10 – 15 —Drive plate thickness No. 1 2.92 – 3.08 2.6

No. 2 3.42 – 3.58 3.1Drive plate claw width No. 1 & 2 15.9 – 16.0 15.1Driven plate distortion — 0.10Clutch spring free length 43.0 40.9

ITEM STANDARD LIMITPrimary reduction ratio 3.173 (73/23) —Secondary reduction ratio 2.866 (43/15) —Gear ratios Low 2.636 (29/11) —

2nd 1.647 (28/17) —3rd 1.217 (28/23) —4th 0.952 (20/21) —Top 0.818 (18/22) —

Shift fork to groove clearance 0.20 – 0.40 0.60Shift fork groove width 4.25 – 4.35 —Shift fork thickness 3.95 – 4.05 —Drive chain Type D.I.D.520V —

Links 114 links —20-pitch length — 319.4


ITEMSPECIFICATION

E-19 E-24Carburetor type MIKUNI BDS28SS ←Bore size 28 mm ←I.D. No. 27F5 27F2Idle r/min 1300 ± 100 r/min ←Fuel level 11.0 ± 1.0 mm ←Float height 9.9 ± 1.0 mm ←Main jet (M.J.) #97.5 #107.5Jet needle (J.N.) 4DM11-3rd ←Needle jet (N.J.) O-2M O-0Pilot jet (P.J.) #15 #17.5Throttle valve (Th.V.) #140 ←Pilot screw (P.S.) 2 and 1/4 turns back 3 turns backThrottle cable play 2 – 4 mm ←

SAM
v
4/6 E-19, 24


WATTAGE Unit: W



Spark performance Over 8 at 1 atm.Ignition coil resistance Primary 1.8 – 3.0 Ω terminai –

terminal


Ignition coil primary peak voltage More than 250 V W or B/Y – Ground

Generator coil resistance 0.3 – 1.1 Ω Y – YSignal generator coil resistance 180 – 280 Ω Bl – GSignal generator peak voltage More than 4.5 V B – G Generator Max. output 200 W at 5 000 r/minGenerator no-load voltage More than 60 V (AC) at 5 000 r/minRegulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type designation YTX7L-BS

Capacity 12 V 21.6 kC (6 Ah)/10HRFuse size Main 20 A

Headlight (HI) 15 AHeadlight (LO) 15 A

Ignition 10 ASignal 15 AMeter 10 A

ITEMSPECIFICATION


LO 55 ←Position light 4Brake light/Taillight 21/5 ←Turn signal light 21 ←Speedmeter light 1.7 ←Neutral indicator light 1.7 ←Turn signal indicator light 1.7 ←High beam indicator light 1.7 ←

109

5/6 E-19, 24



ITEM STANDARD LIMITRear brake pedal free travel 20 – 30 —Rear brake pedal height 50 – 60 —Brake disc thickness Front 5.0 4.5Brake disc runout Front — 0.30Master cylinder bore Front 12.700 – 12.743 —Master cylinder piston diam. Front 12.657 – 12.684 —Brake caliper cylinder bore Front 42.85 – 42.90 —Brake caliper piston diam. Front 42.772 – 42.822 —Brake fluid type Front DOT 4 —Brake drum I.D. Rear — 130.7Wheel rim runout Axial — 2.0


Rear — 0.25Wheel rim size Front 18 × MT2.15 or 18M/C × MT2.15 —

Rear 15M/C × MT3.00 —

ITEM STD/SPEC. LIMITFront fork stroke 120 —Front fork spring free length 300.5 294Front fork oil level 111 —Front fork oil type SUZUKI FORK OIL #10 or equivalent fork oil —Front fork oil capacity (each leg) 388 ml —Rear wheel travel 90 —Swingarm pivot shaft runout — 0.3

6/6 E-19, 24

TIRE Unit: mm (in)

FUEL + OIL


(1.75 kgf/cm2) —



(1.75 kgf/cm2) —


Tire size Front 90/90-18 51P or 90/90-18M/C 51P —Rear 150/80-15M/C 70P —

Tire type Front IRC: GS-21F —Rear IRC: GS-21R —

Tire tread depth Front — 1.6 mmRear — 2.0 mm



reserve 3.0 LEngine oil type SAE 10W-40, API SF or SGEngine oil capacity Change 1 800 ml

Filter change 1 900 mlOverhaul 2 100 ml

LE
P VL800/Z
E-02, 03, 19, 24, 28, 331/8

4 STROKEVALVE + GUIDE Unit: mm (in)


(1.18) —

EX. 26(1.02) —

Valve clearance(when cold) IN. 0.08 – 0.13

(0.003 – 0.005) —

EX. 0.17 – 0.22(0.007 – 0.009) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —






Valve spring free length INNER — 38.3(1.51)

OUTER — 40.1(1.58)

Valve spring tensionINNER

120 – 139 N(6.51 – 7.49 kgf, 14.35 – 16.51 lbs)


OUTER65 – 74 N


—

SAM

E-02, 03, 19, 24, 28, 332/8




FrontIN. 35.95 – 35.99

(1.415 – 1.417)35.65

(1.404)

EX. 36.92 – 36.96(1.454 – 1.455)

36.62(1.442)

RearIN. 35.50 – 35.54

(1.398 – 1.399)35.20

(1.386)

EX. 36.58 – 36.62(1.440 – 1.442)

36.28(1.428)


0.150(0.0059)

Camshaft journal holder I.D. No.1 Left sideNo.2 Right side

20.012 – 20.025(0.7879 – 0.7884) —

No.1 Right sideNo.2 Left side

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. No.1 Left sideNo.2 Right side

19.959 – 19.980(0.7858 – 0.7866) —

No.1 Right sideNo.2 Left side

24.959 – 24.980(0.9826 – 0.9835) —







(13 – 17 kgf/cm2, 185 – 242 psi)1 100 kPa



(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 83.000 – 83.015

(3.2677 – 3.2683)83.085

(3.2711)Piston diam. 82.950 – 82.965


82.880(3.2630)


2nd R Approx. 11.8 (0.46) 9.4(0.37)


0.70(0.028)

2nd 0.20 – 0.35(0.008 – 0.014)

0.70(0.028)

110

E-02, 03, 19, 24, 28, 333/8


OIL PUMP

ITEM STANDARD LIMITPiston ring groove clearance 1st — 0.180

(0.007)

2nd — 0.150(0.006)


2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


2nd 1.170 – 1.190(0.0461 – 0.0469) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.992 – 20.000(0.7871 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040


(0.004 – 0.008)0.30


(0.864 – 0.866) —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 40.982 – 41.000(1.6135 – 1.6142) —


0.080(0.0031)







—

E-02, 03, 19, 24, 28, 334/8





(0.4 – 0.6) —

Clutch release screw 1/4 turn backDrive plate thickness No.1 2.92 – 3.08

(0.115 – 0.121)2.62

(0.103)

No.2 3.42 – 3.58(0.135 – 0.141)

3.12(0.123)


15.1(0.594)



46.8(1.84)

ITEM STANDARD LIMITPrimary reduction ratio 1.690 (71/42) —Secondary reduction ratio 1.133 (17/15) —Final reduction ratio 3.090 (34/11) —Gear ratios Low 2.461 (32/13) —

2nd 1.631 (31/19) —3rd 1.227 (27/22) —4th 1.000 (25/25) —Top 0.814 (22/27) —

Shift fork to groove clearance No.1 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

No.2 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Shift fork groove width No.1 5.50 – 5.60(0.217 – 0.220) —

No.2 4.50 – 4.60(0.177 – 0.181) —

Shift fork thickness No.1 5.30 – 5.40(0.209 – 0.213) —

No.2 4.30 – 4.40(0.169 – 0.173) —

ITEM STANDARD LIMITSecondary bevel gear backlash 0.05 – 0.32

(0.002 – 0.013) —

Final bevel gear backlash Drive side 0.03 – 0.064(0.001 – 0.025) —


LE
P
E-02, 03, 19, 24, 28, 335/8

CARBURETOR


ITEMSPECIFICATION

E-02, 19, 24 E-03, 28 E-33Carburetor type MIKUNI BDSR34 ← ←Bore size 34 mm ← ←I.D. No. 41F1 41F2 41F3Idle r/min 1 100 ± 100 r/min ← ←Fuel level 9 ± 1.0 mm

(0.35 ± 0.04 in) ← ←

Float height 7.0 ± 0.5 mm(2.76 ± 0.02 in) ← ←

Main jet (M.J.) #132.5 # ←Jet needle (J.N.) 5E22-3rd 5E23 ←Needle jet (N.J.) P-0M ←Throttle valve (Th.V.) #95 ← ←Pilot jet (P.J.) #27.5 # ←Pilot air jet (P.A.J.) #55 ← ←Pilot screw (P.S.) PRE-SET

(3 turns back) PRE-SET ←

Throttle cable play 2 – 4 mm(0.08 ± 0.16 in) ← ←

ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature Approximately 75 °C (167 °F) —

Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —Engine coolant temp. switch oper-ating temperature

OFF → ON Approximately 120°C (248°F) —

ON → OFF Approximately 113°C (235.4°F) —


95 – 125 kPa(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi) —

Cooling fan thermoswitch operating temperature

OFF → ON Approximately 105°C (221°F) —

ON → OFF Approximately 100°C (212°F) —

Engine coolant type Use an antifreeze/coolant compatible with alumi-num radiators, mixed with distilled water only, at theratio of 50:50

—

Engine coolant capacity 1 500 ml(1.6 US qt, 1.3 lmp qt) —

SAM

E-02, 03, 19, 24, 28, 336/8


WATTAGE Unit: W

ITEM SPECIFICATION NOTEFiring order 1·2Spark plug Type NGK: DPR7EA-9

DENSO: X22EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 2 – 6 Ω Terminal –

Terminal


Ignition coil primary peak voltageMore than 200 V

#1: W, : Ground#1: B/Y, : Ground

Generator coil resistance Pickup coil 160 – 300 Ω G – BlCharging coil 0.2 – 1.5 Ω Y – Y

Pickup coil peak voltage More than 1.5 V : Bl, : GGenerator no-load voltage(When engine cold) More than 70 V (AC) at 5 000 r/min Y – Y

Regulated voltage 14.0 – 15.5 V at 5 000 r/minGenerator maximum output 375 W at 5 000 r/minStarter relay resistance 3 – 7 ΩBattery Type


Capacity 12 V 36 kC (10Ah)/10HRFuse size


Signal 15 AIgnition 15 AMeter 10 AMain 30 A

Power source 10 A

ITEMSPECIFICATION

E-03, 28, 33 E-24 The othersHeadlight HI 60 ← ←

LO 55 ← ←Position/Parking light 4Brake light/Taillight 21/5 ← ←Turn signal light 21/5 (Front), 21 (Rear) 21 ←Speedometer light LED ← ←Engine coolant temp. warning light LED ← ←Turn signal indicator light LED ← ←High beam indicator light LED ← ←Neutral indicator light LED ← ←Oil pressure indicator light LED ← ←

111

E-02, 03, 19, 24, 28, 337/8




(5.51) —


540.6(21.29)

Front fork oil level (without spring) 177(6.96) —


(24.0 US oz, 25.0 lmp oz)Front fork spring adjuster — —Rear shock absorber spring adjuster (4) —



ITEM STANDARD LIMITRear brake pedal free travel 20 – 30

(0.8 – 1.2) —




4.5(0.18)







Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front J16 M/C × MT3.00 —Rear J15 M/C × MT4.00 —

E-02, 03, 19, 24, 28, 338/8

TIRE Unit: mm (in)

FUEL + OIL + COOLANT


(2.00 kgf/cm2, 29 psi) —



(2.00 kgf/cm2, 29 psi) —


Tire size Front 130/90-16M/C 67H —Rear 170/80-15 M/C 77H —

Tire type Front IRC GS-23F —Rear IRC GS-23R —


Rear — 2.0(0.08)


octane or 91 octane (R/2 + M/2) or higher rated bythe Research Method.Gasoline containing MTBE (Methyl Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corro-sion inhibitor is permissible.

E-03, 28, 33


Other models


reserve(flicker)

1.5 L(0.4/0.3 US/lmp gal)



change3 400 ml

(3.6/3.0 US/lmp qt)


Final bevel gear oil type SAE 90 hypoid gear oil with GL-5 under API classification

Final bevel gear oil capacity 200 – 220 ml(6.8/7.0 – 7.4/7.7 US/lmp oz)

Brake fluid type DOT 4Coolant capacity 1 500 ml

(1.6/1.3 US/lmp qt)

LE
P VL1500
1/8 E-02, 03, 19, 24, 28, 33



(1.3) —

EX. 40(1.6) —



(0.0004 – 0.0015) —

EX. 0.040 – 0.070(0.0016 – 0.0028) —


Valve guide I.D. IN. 5.500 – 5.512(0.2165 – 0.2170) —

EX. 7.000 – 7.015(0.2756 – 0.2762) —

Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 6.945 – 6.960(0.2734 – 0.2740) —



Valve stem end length IN. — 2.5(0.10)

EX. — 2.2(0.09)

Valve seat width IN. 0.9 – 1.1(0.035 – 0.043) —

EX. 1.0 – 1.2(0.039 – 0.047) —



(1.38)

OUTER — 37.8 (1.49)


(1.60)Valve spring tension (INTAKE)



—



—

Valve spring tension (EXHAUST) 20.3 – 23.3 kgf(44.75 – 51.37 Ibs)


SAM

2/8 E-02, 03, 19, 24, 28, 33




(1.4047 – 1.4067)35.38

(1.393)

EX. 36.880 – 36.930(1.4521 – 1.4537)

36.58(1.440)


0.150(0.0060)

Camshaft journal holder I.D. Front head right side, rear head left side

20.012 – 20.025(0.7879 – 0.7884) —


25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. Front head right side, rear head left side

19.959 – 19.980(0.7858 – 0.7866) —


24.959 – 24.980(0.9826 – 0.9835) —


Rocker arm I.D. IN. 14.000 – 14.018(0.5511 – 0.5519) —

EX. 16.000 – 16.018(0.6299 – 0.6303) —


EX. 15.966 – 15.984(0.6286 – 0.6293) —



ITEM STANDARD LIMITCampression pressure(Automatic de-compression actuated)

1 000 – 1 400 kPa(10 – 14 kgf/cm2, 142 – 199 psi) —

Campression pressure difference — 200 kPa (2 kgf/cm2)


0.120(0.0047)

Cylinder bore 96.000 – 96.015(3.7795 – 3.7801)

Nicks or Scratches

Piston diam. 95.975 – 95.990(3.7785 – 3.7791)


(37.7748)



2nd T Approx. 14.0 (0.55) 11.2(0.44)

112

3/8 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITPiston ring end gap 1st 0.30 – 0.45

(0.012 – 0.018)0.70

(0.028)

2nd 0.45 – 0.60(0.018 – 0.024)

1.00(0.039)


2nd — 0.150(0.006)


2nd 1.510 – 1.530(0.0594 – 0.0602) —

Oil 2.810 – 2.830(0.1106 – 0.1114) —


2nd 1.470 – 1.490(0.0579 – 0.0587) —

Piston pin bore 23.002 – 23.008(0.9056 – 0.9058)

23.030(0.9067)

Piston pin O.D. 22.992 – 23.000(0.9052 – 0.9055)

22.980(0.9047)


(0.9061 – 0.9064)23.040


(0.004 – 0.008)0.3


(0.864 – 0.866) —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 49.982 – 50.000(1.9678 – 1.9685) —


0.080(0.0031)


Crankshaft journal I.D. 52.000 – 52.015(2.0472 – 2.0478) —

Crankshaft thrust bearing thickness

1.925 – 2.175(0.0758 – 0.0856) —



4/8 E-02, 03, 19, 24, 28, 33

OIL PUMP





—


(0.114 – 0.122)2.60


(0.614 – 0.622)14.8



(1.357)32.7


(0.5512 – 0.5529) —


13.957 – 13.984(0.5495 – 0.5506) —



33.550 – 33.575(1.3209 – 1.3218) —

ITEM STANDARD LIMITPrimary reduction ratio 1.490 (76/51) —Secondary reduction ratio 0.852 (29/34) —Final reduction ratio 2.666 (19/19 × 32/12) —Gear ratios Low 3.000 (36/12) —

2nd 1.823 (31/17) —3rd 1.333 (28/21) —4th 1.041 (25/24) —Top 0.884 (23/26) —


0.5(0.020)






Final bevel gear backlash 0.03 – 0.64(0.001 – 0.025) —LE

P

5/8 E-02, 03, 19, 24, 28, 33

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-28 E-24 E-02, 19Carburetor type BDSR36 ← ←Bore size 36.5 mm ← ←I.D. No. 10F1 10F2 10F9Idle r/min 1 000 ± 100 r/min ← ←Float height 7.0 ± 0.5 mm

(0.28 ± 0.02 in) ← ←

Main jet (M.J.) F: #R: #

F: #112.5R: #110 ←

Jet needle (J.N.) F: 5D95-56R: 5E9-56

F: 5D94-56-3R: 5E8-56-3

F: 5D124-3R: 5E19-3

Needle jet (N.J.) P-0 P-0MThrottle valve (Th.V.) #90 ← ←Pilot jet (P.J.) # #32.5 ←Pilot screw (P.S.)

Throttle cable play 2.0 – 4.0 mm(0.08 – 0.16 in) ← ←

ITEMSPECIFICATION

E-03 E-33Carburetor type BDSR36 ←Bore size 36.5 mm ←I.D. No. 10F1 10F7Idle r/min 1 000 ± 100 r/min ←Float height 7.0 ± 0.5 mm

(0.28 ± 0.02 in) ←

Main jet (M.J.) F: #R: # ←

Jet needle (J.N.) F: 5D95-56R: 5E9-56 ←

Needle jet (N.J.) ←Throttle valve (Th.V.) #90 ←Pilot jet (P.J.) # ←Pilot screw (P.S.) PRE-SET ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

PRE-SETF: 2 1/4 turns backR: 2 1/8 turns back

PRE-SETF: 2 turns backR: 2 turns back

SAM

6/8 E-02, 03, 19, 24, 28, 33


WATTAGE Unit: W

ITEM SPECIFICATION NOTEFiring order R · FSpark plug Type NGK: DPR7EA-9

DENSO: X22EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Signal coil resistance 178 – 242 Ω Bl – GSignal coil peak voltage More than 2.4 VIgnition coil resistance Primary 1 – 7 Ω tap – tap


Ignition coil primary peak voltage Front More than 190 V B/Y – GroundRear More than 200 V W – Ground

Generator Max. output Approx. 340 W at 5 000 r/minGenerator no-load voltage(when engine is cold) More than 80 V (AC) at 5 000 r/min

Regulated voltage 13.5 – 15.0 V at 5 000 r/minStarter relay resistance 3 – 6 ΩDe-comp. solenoid resistance 0.1 – 1.0 ΩFuel pump resistance 1 – 2.5 ΩFuel pump discharge amount More than 600 ml (1.27 US qt)/minBattery Type designation FTH16-BS-1

Voltage 12 VCapacity 50.4 kC (14 Ah)/10HR Standard


Fuse sizeHeadlight

HI 10 ALO 10 A

Signal 15 A Ignition 15 A Main 30 A

Power source 10 A Speedometer 10 A

ITEMSPECIFICATION

E-03, 28, 33 E-24 OthersHeadlight HI 60 ← ←

LO 55 ← ←Position/Parking light 4Brake light/Taillight 21/5 ← ←Turn signal light Front 21/5 21 ←

Rear 21 ← ←Speedometer light 0.84 ← ←Turn signal indicator light 1.7 ← ←

113

7/8 E-02, 03, 19, 24, 28, 33


ITEMSPECIFICATION

E-03, 28, 33 E-24 OthersHigh beam indicator light 1.7 ← ←Neutral indicator light 1.7 ← ←Fuel level warning light 1.7 ← ←Oil pressure indicator light LED ← ←


(3.86) —


4.5(0.18)

Rear 6.6 – 7.0(0.260 – 0.276)

6.3(0.25)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 30.230 – 30.306(1.1902 – 1.1931) —


Rear 30.150 – 30.200(1.1870 – 1.1890) —


Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front 16 × MT3.50, 16M/C × MT3.50 —Rear 15M/C × MT5.00 —

Tire size Front 150/80-16 71H, 150/80-16M/C 71H —Rear 180/70-15M/C 76H —


Rear — 2.0(0.08)

8/8 E-02, 03, 19, 24, 28, 33


TIRE PRESSURE

FUEL + OIL


(5.5) —


573(22.56)


Rear shock absorber spring set length

222.0(8.74) —




FRONT 200 2.00 29 200 2.00 29REAR 250 2.50 36 250 2.50 36

ITEM SPECIFICATION LIMITFuel type Use only unleaded gasoline of at least 87 pump

octane (R/2+M/2) or 91 octane or higher rated bythe research method. Gasoline containing MTBE(Methyl Tertiary Butyl Ether), less than 10% etha-nol, or less than 5% methanol with appropriatecosolvents and corrosion inhibitor is permissible.

E-03, 28, 33


The others

Fuel tank 15.0 L(4.0/3.3 US/Imp gal)



change4 300 ml

(4.5/3.8 US/lmp qt)


Fuel fork oil type SUZUKI FORK OIL SS-08 (#10) orequivalent fork oil

Fuel fork oil capacity (each leg) 439 ml(14.8/15.5 US/lmp oz)

Bevel gear oil type Hypoid Gear oil #90 API GL-5Bevel gear oil capacity Final 200 – 220 ml

(6.8/7.0 – 7.4/7.7 US/lmp oz)Brake fluid type DOT 4

LE
P VS800GL
1/9 E-03, 28, 33



(1.18) —

EX. 26(1.02) —


EX. 8.5(0.33) —

Valve clearance(when cold) IN. & EX. 0.08 – 0.13

(0.003 – 0.005) —


(0.0004 – 0.0015) —

EX. 0.036 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —



Valve stem and length IN. & EX. — 4.0(0.16)



Valve spring free length INNER — 38.3 (1.51)

OUTER — 40.1(1.58)


6.51 – 7.49 kgf(14.35 – 16.51 lbs)


OUTER12.09 – 13.91 kgf


—

SAM

2/9 E-03, 28, 33




(1.4155 – 1.4171)35.660

(1.4039)

EX. 36.919 – 36.959(1.4535 – 1.4551)

36.620(1.4417)


0.150(0.0060)

Camshaft journal holder I.D. No. 1 Left sideNo. 2 Right side

20.012 – 20.025(0.7879 – 0.7884) —

No. 1 Right sideNo. 2 Left side

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. No. 1 Left sideNo. 2 Right side

19.959 – 19.980(0.7858 – 0.7866) —

No. 1 Right sideNo. 2 Left side

24.959 – 24.980(0.9826 – 0.9835) —







(13 – 16 kgf/cm2, 185 – 228 psi) 1 100 kPa(11 kgf/cm2,

156 psi)Compression pressure difference — 200 kPa


(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 83.000 – 83.015

(3.2677 – 3.2683)83.085

(3.2711)Piston diam. 82.950 – 82.965


82.880(3.2630)



2nd R Approx. 11.8 (0.465) 9.4(0.370)


0.70(0.028)

2nd 0.20 – 0.35(0.008 – 0.014)

0.70(0.028)


2nd — 0.150(0.006)

114

3/9 E-03, 28, 33


OIL PUMP


(0.0398 – 0.0406) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.51 – 2.53(0.0988 – 0.0996) —


2nd 1.170 – 1.190(0.0461 – 0.0469) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

20.030(0.7886)

Piston pin O.D. 19.996 – 20.000(0.7827 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040


(0.004 – 0.008)0.30


(0.864 – 0.866 —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 40.982 – 41.000(1.6135 – 1.6142) —


0.080(0.0031)





ITEM STANDARD LIMITOil pump reduction ratio 1.859 (71/42 × 32/29) —Oil pressure (at 60 °C, 140 °F) Above 350 kPa (3.5 kg/cm2, 50 psi)

Below 650 kPa (6.5 kg/cm2, 92 psi)at 3 000 r/min

—

4/9 E-03, 28, 33




(0.115 – 0.121)2.62

(0.103)

No. 2 3.45 – 3.55(0.136 – 0.140)

3.15(0.124)


15.0(0.591)





13.957 – 13.984(0.5495 – 0.5506) —



38.042 – 38.075(1.4977 – 1.4990) —

ITEM STANDARD LIMITPrimary reduction ratio 1.690 (71/42) —Secondary reduction ratio 1.133 (30/30 × 17/15) —Final reduction ratio 3.090 (34/11) —Gear ratios Low 2.285 (32/14) —

2nd 1.631 (31/19) —3rd 1.227 (27/22) —4th 1.000 (25/25) —Top 0.851 (23/27) —

Shift fork to groove clearance No. 1 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

No. 2 0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Shift fork groove width No. 1 5.50 – 5.60(0.217 – 0.220) —

No. 2 4.50 – 4.60(0.177 – 0.181) —

Shift fork thickness No. 1 5.30 – 5.40(0.209 – 0.213) —

No. 2 4.30 – 4.40(0.169 – 0.173) —

LE
P
5/9 E-03, 28, 33


CARBURETOR

CARBURETOR


(0.002 – 0.013) —


ITEMSPECIFICATION

E-03Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No. 2)Bore size 36 mm ←I.D. No. 38E1 ←Idle r/min 1 200 ± 50 r/min ←Float height 27.7 ± 1.0 mm

(1.09 ± 0.04 in)9.1 ± 1.0 mm

(0.36 ± 0.04 in)Main jet (M.J.) # #Jet needle (J.N.) 5D35-1st 5D47-1stNeedle jet (N.J.)Throttle valve (Th.V.) #125 #110Pilot jet (P.J.) # #Pilot screw (P.S.) (PRE-SET) (PRE-SET)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEMSPECIFICATION


(1.09 ± 0.04 in)9.1 ± 1.0 mm

(0.36 ± 0.04 in)Main jet (M.J.) #132.5 #127.5Jet needle (J.N.) 5D61-3rd 5D48-3rdNeedle jet (N.J.) P-7 P-2Throttle valve (Th.V.) #125 #110Pilot jet (P.J.) #45 #40Pilot screw (P.S.) (PRE-SET) 1 and 1/8 turns back (PRE-SET) 1 and 1/4 turns backThrottle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

SAM

6/9 E-03, 28, 33

CARBURETOR


ITEMSPECIFICATION


(1.09 ± 0.04 in)9.1 ± 1.0 mm

(0.36 ± 0.04 in)Main jet (M.J.) # #Jet needle (J.N.) 5D35-1st 5D47-1stNeedle jet (N.J.)Throttle valve (Th.V.) #125 #110Pilot jet (P.J.) # #Pilot screw (P.S.) (PRE-SET) (PRE-SET)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEM SPECIFICATION NOTEFiring order 1·2Spark plug Type N.G.K.: DPR8EA-9

N.D.: X24EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Signal coil resistance Approx. 50 – 200 Ω (G – Bl)Ignition coil resistance Primary 2 – 6 Ω tap – tap


Generator no-load voltage(When engine cold) More than 75 V (AC) at 5 000 r/min

Generator Max. output 250 W at 5 000 r/min —Regulated voltage 13.5 – 15.5 V at 5 000 r/minStarter motor brush length Limit: 9.0 (0.35) N.D.Commutator under-cut Limit: 0.2 (0.008)Starter relay resistance 2 – 6 ΩBattery Type designation YB16B-A1



Fuse size Headlight 10 ASignal 10 AIgnition 10 AMain 25 A

Power source 10 A

115

7/9 E-03, 28, 33

WATTAGE Unit: W


ITEM SPECIFICATION

Headlight HI 60LO 55

Parking light 3.4Brake light/Taillight 21/5Turn signal light 21/5 (Front), 21 (Rear)Speedometer light 3.4Water temp. meter light 1.7Turn signal indicator light 3High beam indicator light 1.7Neutral indicator light 1.7Oil pressure indicator light 1.7License light 8


(0.8 – 1.2) —





4.5(0.18)







Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front J19 × 2.15 —Rear J15M/C × MT3.00 —

8/9 E-03, 28, 33


TIRE PRESSURE

ITEM STANDARD LIMITTire size Front 100/90-19 57H, 100/90-19M/C 57H —

Rear 140/90-15 70H, 140/90-15M/C 70H —Tire tread depth Front — 1.6

(0.06)

Rear — 2.0(0.08)


(5.12) —

Front fork spring free length — 348.3(13.71)






kPa kg/cm2 psi kPa kg/cm2 psiFRONT 200 2.00 29 225 2.25 33REAR 225 2.25 33 250 2.50 36

LE
P
9/9 E-03, 28, 33


THERMOSTAT + RADIATOR + FAN



E-03, 28, 33

Fuel tank including reserve 11.0 L(2.9/2.4 US/lmp gal) E-33

12.0 L(3.2/2.6 US/lmp gal) Others



(2.5/2.1 US/lmp qt)



Front fork oil type Fork oil #10Front fork oil capacity(each leg)

413 ml(14.0/14.5 US/lmp oz)

Final bevel gear oil type SAE 90 hypoid gear oil with GL-5 under API classification

Final bevel gear oil capacity 200 – 220 ml(6.8/7.0 – 7.4/7.7 US/lmp oz)


(1.8/1.5 US/lmp qt)

ITEM STANDARD LIMITThermostat valve opening temperature 75.0 ± 1.5 °C (167 ± 2.7 °F) —

Thermostat valve lift Over 6 mm (0.24 in) at 90 °C (194 °F) —Radiator cap valve release pressure

1.1 ± 0.15 kg/cm2

(15.6 ± 2.1 psi, 110 ± 15 kPa) —

Electric fan thermo- switch operating temperature

ON Approx. 105 °C (221 °F) —

OFF Approx. 100 °C (212 °F) —

SAM

116

VS1400GLP

1/9 E-03, 28, 33



(1.3) —

EX. 40(1.6) —

Valve lift IN. 8(0.31) —

EX. 9(0.35) —



(0.0004 – 0.0015) —

EX. 0.040 – 0.070(0.0016 – 0.0028) —


Valve guide I.D. IN. 5.500 – 5.512(0.2165 – 0.2170) —

EX. 7.000 – 7.012(0.2756 – 0.2761) —

Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 6.945 – 6.960(0.2734 – 0.2740) —



Valve stem and length IN. & EX. — 2.6(0.10)




(1.38)

OUTER — 37.8(1.49)


(1.59)

2/9 E-03, 28, 33


ITEM STANDARD LIMITValve spring tension (INTAKE)



—



—

Valve spring tension (EXHAUST) 20.3 – 23.3 kgf(44.75 – 51.37 lbs)



(1.4048 – 1.4064)35.41

(1.394)

EX. 36.883 – 36.923(1.4521 – 1.4537)

35.61(1.378)


0.150(0.0060)

Camshaft journal holder I.D. Front head right side,rear head left side

22.012 – 22.025(0.7879 – 0.7884) —

Front head left side,rear head right side

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. Front head right side,rear head left side

19.959 – 19.980(0.7858 – 0.7866) —

Front head left side,rear head right side

24.959 – 24.980(0.9826 – 0.9835) —


Rocker arm I.D. IN. 14.000 – 14.018(0.5511 – 0.5519) —

EX. 16.000 – 16.018(0.6299 – 0.6303) —


EX. 15.966 – 15.984(0.6286 – 0.6293) —



De-comp. lever clearance Front 1.5 – 2.5(0.06 – 0.10) —

Rear 1.0 – 2.0(0.04 – 0.08) —

LE
P
3/9 E-03, 28, 33



(10 – 14 kgf/cm2, 142 – 199 psi) 880 kPa



(0.0020 – 0.0024)0.120

(0.0047)Cylinder bore 94.000 – 94.015

(3.7008 – 3.7014)94.080

(3.7039)Piston diam. 93.945 – 93.960


93.880(3.6960)



2nd T Approx. 11.5 (0.45) 9.2(0.36)


0.70(0.028)

2nd 0.25 – 0.40(0.010 – 0.016)

0.70(0.028)

Piston ring to groove clearance 1st 0.040 – 0.075(0.0016 – 0.0030)

0.180(0.0071)

2nd 0.025 – 0.060(0.0010 – 0.0024)

0.150(0.0059)


2nd 1.510 – 1.530(0.0594 – 0.0602) —

Oil 2.810 – 2.830(0.1106 – 0.1114) —


2nd 1.470 – 1.485(0.0579 – 0.0585) —

Piston pin bore 23.000 – 23.006(0.9055 – 0.9057)

23.030(0.9067)

Piston pin O.D. 22.996 – 23.000(0.9054 – 0.9055)

22.980(0.9047)

SAM
v
4/9 E-03, 28, 33


OIL PUMP



(0.9057 – 0.9061)23.040


(0.004 – 0.008)0.3


(0.864 – 0.866 —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 49.982 – 50.000(1.9678 – 1.9685) —


0.080(0.0031)







—


(0.107 – 0.113)2.42

(0.095)

No. 2 3.45 – 3.55(0.136 – 0.140)

3.15(0.124)


15.2(0.600)

No. 2 15.9 – 16.0(0.626 – 0.630)

15.2(0.600)


Clutch spring free length No. 1 — 27.6(1.09)

No. 2 — 20.0(0.79)



13.957 – 13.984(0.5495 – 0.5506) —

117

5/9 E-03, 28, 33



ITEM STANDARD LIMITClutch release cylinder bore 35.700 – 35.762

(1.4055 – 1.4079) —


35.650 – 35.675(1.4035 – 1.4045) —

ITEM STANDARD LIMITPrimary reduction ratio 1.645 (79/48) —Secondary reduction ratio 0.852 (29/34 × 19/19) —Final reduction ratio 2.666 (32/12) —Gear ratios Low 3.000 (36/12) —

2nd 1.823 (31/17) —3rd 1.333 (28/21) —4th 1.086 (25/23) —Top 0.960 (24/25) —


0.50(0.020)


No. 2 5.50 – 5.60(0.217 – 0.220) —

No. 3 5.50 – 5.60(0.217 – 0.220) —


No. 2 5.30 – 5.40(0.209 – 0.213) —

No. 3 5.30 – 5.40(0.209 – 0.213) —




(0.001 – 0.006) —


6/9 E-03, 28, 33

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-03 E-33Carburetor type MIKUNI

BS36SS(No. 1)

MIKUNIBDS36SS

(No. 2)

MIKUNIBS36SS(No. 1)

MIKUNIBDS36SS

(No. 2)Bore size 36 mm ← 36 mm ←I.D. No. 38BE ← 38BF ←Idle r/min 1 000 ± 100

r/min ← 1 000 ± 100r/min ←

Fuel level 9.5 ± 0.5 mm(0.37 ± 0.02 in)

17.0 ± 0.5 mm(0.67 ± 0.02 in)

9.5 ± 0.5 mm(0.37 ± 0.02 in)

17.0 ± 0.5 mm(0.67 ± 0.02 in)

Float height 27.7 ± 0.5 mm(1.09 ± 0.02 in)

9.1 ± 0.5 mm(0.36 ± 0.02 in)

27.7 ± 0.5 mm(1.09 ± 0.02 in)

9.1 ± 0.5 mm(0.36 ± 0.02 in)

Main jet (M.J.) # # # #Jet needle (J.N.) 5D35-1st 5D51-1st 5D35-1st 5D51-1stNeedle jet (N.J.)Throttle valve (Th.V.) #120 #110 #120 #110Pilot jet (P.J.) # # # #Pilot screw (P.S.)

PRE-SET ←PRE-SET

(1 and 1/16 turns back)

PRE-SET(1 and 3/4turns back)

Throttle cable play 2.0 – 4.0 mm(0.08 – 0.16 in) ← 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEMSPECIFICATION

E-28Carburetor type MIKUNI

BS36SS(No. 1)

MIKUNIBDS36SS

(No. 2)Bore size 36 mm ←I.D. No. 38BE ←Idle r/min 1 000 ± 100

r/min ←

Fuel level 9.5 ± 0.5 mm(0.37 ± 0.02 in)

17.0 ± 0.5 mm(0.67 ± 0.02 in)


9.1 ± 0.5 mm(0.36 ± 0.02 in)

Main jet (M.J.) # #Jet needle (J.N.) 5D35-1st 5D51-1stNeedle jet (N.J.)Throttle valve (Th.V.) #120 #110Pilot jet (P.J.) # #Pilot screw (P.S.) PRE-SET


(1 and 3/4 turns back)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←LE
P
7/9 E-03, 28, 33


WATTAGE Unit: W

ITEM SPECIFICATION NOTEFiring order 1.2Spark plug Type N.G.K.: DPR8EA-9

DENSO: X24EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Signal coil resistance 240 ± 20 % Ω Bl – G, B – YIgnition coil resistance Primary 1 – 7 Ω tap – tap


Generator Max. output Approx. 340 W at 5 000 r/minGenerator no-load voltage More than 80 V (AC) at 5 000 r/minRegulated voltage 14.0 – 15.5 V at 5 000 r/minStarter motor brush length N.D. Limit: 9.0 (0.35)Commutator under-cut Limit: 0.2 (0.008)Starter relay resistance 2 – 6 ΩDe-comp. solenoid resistance 0.1 – 1.0 ΩSide stand and neutral relay 120 ± 20 % ΩFuel pump resistance 1 – 2 ΩFuel pump discharge amount More than 600 ml (1.27 US qt)/minBattery Type designation FTH 16 – BS-1

Voltage 12 VCapacity 50.4 kC (14 Ah)/10 HRStandard


Fuse size HEADLIGHT 10 ASIGNAL 10 A

IGNITION 10 AMAIN 25 A

POWER SOURCE 10 A

ITEMSPECIFICATION

E-03, 28, 33Headlight HI 60

LO 55Parking or city lightBrake light/Taillight 27/8Turn signal light 21Running light 5Speedometer light 3

SAM

8/9 E-03, 28, 33


ITEMSPECIFICATION

E-03, 28, 33Turn signal indicator light 1.7High beam indicator light 1.7Neutral indicator light 1.7Oil pressure indicator light 1.7License light 7.5


(2.6) —


4.5(0.18)

Rear 6.0 ± 0.2(0.236 – 0.008)

5.5(0.22)



Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 42.850 – 42.926(1.6870 – 1.6900) —


Rear 42.770 – 42.820(1.6839 – 1.6858) —


Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front J19 × 2.15 —Rear J15M/C × MT4.00 —

Tire size Front 110/90-19 62H, 110/90-19M/C 62H —Rear 170/80-15 77H, 170/80-15 M/C 77H —


Rear — 2.0(0.08)

118

9/9 E-03, 28, 33


TIRE PRESSURE

FUEL + OIL


(6.3) —



Rear shock absorber spring adjuster 2/5




SOLO RIDING DUAL RIDINGkPa kg/cm2 psi kPa kg/cm2 psi

FRONT 200 2.00 29 200 2.00 29REAR 200 2.00 29 225 2.25 33



E-03, 28, 33




(3.9/3.3 US/lmp qt)




353 ml(11.9/12.4 US/lmp oz)

Bevel gear oil type Hypoid Gear oil #90 API GL-5Bevel gear oil capacity Final 200 – 220 ml

(6.8 – 7.4/7.0 – 7.7 US/lmp oz)Brake fluid type DOT 4
LE
P
VZ800
1/9 E-03, 28, 33P-37



(1.18) —

EX. 26(1.02) —

Valve clearance(when cold) IN. & EX. 0.08 – 0.13

(0.003 – 0.005) —


(0.0004 – 0.0015) —

EX. 0.030 – 0.057(0.0012 – 0.0022) —



Valve stem O.D. IN. 5.475 – 5.490(0.2156 – 0.2161) —

EX. 5.455 – 5.470(0.2148 – 0.2154) —






Valve spring free length INNER — 38.3 (1.51)

OUTER — 40.1(1.58)


6.51 – 7.49 kgf(14.35 – 16.51 lbs)


OUTER12.09 – 13.91 kgf


—

SAM

2/9 E-03, 28, 33P-37




(1.4155 – 1.4174)35.660

(1.4039)

EX. 36.919 – 36.967(1.4535 – 1.4554)

36.620(1.4417)


0.150(0.0059)

Camshaft journal holder I.D. No.1 Left sideNo.2 Right side

20.012 – 20.025(0.7879 – 0.7884) —

No.1 Left sideNo.2 Right side

25.012 – 25.025(0.9847 – 0.9852) —

Camshaft journal O.D. No.1 Left sideNo.2 Right side

19.959 – 19.980(0.7858 – 0.7866) —

No.1 Left sideNo.2 Right side

24.959 – 24.980(0.9826 – 0.9835) —






ITEM STANDARD LIMITCampression pressure 1 500 kPa

(15 kg/cm2, 213 psi) 1 100 kPa

(11 kg/cm2, 156 psi)Campression pressure difference — 200 kPa

(2 kg/cm2, 28 psi)Piston to cylinder clearance 0.045 – 0.055

(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 83.000 – 83.015

(3.2677 – 3.2683)83.085

(3.2711)Piston diam. 82.950 – 82.965


82.880(3.2630)



2nd R Approx. 11.8 (0.465) 9.44(0.372)


0.50(0.020)

2nd 0.20 – 0.35(0.008 – 0.014)

0.50(0.020)


2nd — 0.150(0.0059)

119

3/9 E-03, 28, 33P-37


OIL PUMP


(0.0398 – 0.0406) —

2nd 1.21 – 1.23(0.0476 – 0.0484) —

Oil 2.51 – 2.53(0.0988 – 0.0966) —


2nd 1.170 – 1.190(0.0461 – 0.0469) —

Piston pin bore 20.002 – 20.008(0.7875 – 0.7877)

23.030(0.7886)

Piston pin O.D. 19.996 – 20.000(0.7827 – 0.7874)

19.980(0.7866)


(0.7878 – 0.7881)20.040


(0.004 – 0.008)0.30


(0.864 – 0.866) —

Crank pin width 22.10 – 22.15(0.870 – 0.872) —


0.080(0.0031)

Crank pin O.D. 40.982 – 41.000(1.6135 – 1.6142) —


0.080(0.0031)


Crankshaft journal bearing I. D. 48.000 – 48.015(1.8898 – 1.8904) —






—

4/9 E-03, 28, 33P-37


RADIATOR + FAN



(0.4 – 0.6) —


2.62(0.103)

No. 2 3.42 – 3.58(0.135 – 0.141)

3.12(0.123)


15.1(0.594)


Clutch spring free length No. 1 — 24.6(0.97)

No. 2 — 23.3(0.92)

ITEM STANDARD LIMITRadiator cap valve releasepressure

110 ± 15 kPa(1.1 ± 0.15 kg/cm2, 15.6 ± 2.1 psi) —

Cooling fan thermo-switchoperating temperature

ON Approx. 105 °C (221 °F) —OFF Approx. 100 °C (212 °F) —

Engine coolant temperature switch operating temperature

ON Approx. 120 °C (248 °F) —OFF Approx. 113 °C (235 °F) —


2nd 1.578 (30/19) —3rd 1.200 (24/20) —4th 0.956 (22/23) —Top 0.800 (20/25) —


0.50(0.020)



Drive chain Type D.I.D. 50VM —Links 116 links, ENDLESS —

20-pitchlength — 319.4


(0.6 – 1.0) —

Gearshift lever height 50(2.0) —LE

P

5/9 E-03, 28, 33P-37

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-03Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BS36SS (No. 2)Bore size 36 mm ←I.D. No. 48EF ←Idle r/min 1 200 ± 100 r/min ←Fuel level 7.3 ± 0.5 mm

(0.29 ± 0.02 in)15.0 ± 0.5 mm(0.59 ± 0.02 in)


9.1 ± 1.0 mm(0.36 ± 0.04 in)

Main jet (M.J.) # #Jet needle (J.N.) 5D83 5C43Needle jet (N.J.)Throttle valve (Th.V.) #115 ←Pilot jet (P.J.) # #Pilot screw (P.S.) PRE-SET ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEMSPECIFICATION

E-28Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No. 2)Bore size 36 mm ←I.D. No. 48FF ←Idle r/min 1 200 ± 100 r/min ←Fuel level 7.3 ± 0.5 mm

(0.29 ± 0.02 in)15.0 ± 0.5 mm(0.59 ± 0.02 in)


9.1 ± 1.0 mm(0.36 ± 0.04 in)

Main jet (M.J.) # #Jet needle (J.N.) 5D83 5C43Needle jet (N.J.)Throttle valve (Th.V.) #115 ←Pilot jet (P.J.) # #Pilot screw (P.S.) PRE-SET (1 and 1/2 turns back) ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

SAM

6/9 E-03, 28, 33P-37

CARBURETOR

CARBURETOR

ITEMSPECIFICATION

E-33Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No. 2)Bore size 36 mm ←I.D. No. 48EG ←Idle r/min 1 200 ± 100 r/min ←Fuel level 7.3 ± 0.5 mm

(0.29 ± 0.02 in)15.0 ± 0.5 mm(0.59 ± 0.02 in)


9.1 ± 1.0 mm(0.36 ± 0.04 in)

Main jet (M.J.) # #Jet needle (J.N.) 5D83 5C43Needle jet (N.J.)Throttle valve (Th.V.) #115 ←Pilot jet (P.J.) # #Pilot screw (P.S.) PRE-SET ←Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

ITEMSPECIFICATION

P-37Carburetor type MIKUNI BS36SS (No. 1) MIKUNI BDS36SS (No. 2)Bore size 36 mm ←I.D. No. 48EK ←Idle r/min 1 200 ± 100 r/min ←Fuel level 7.3 ± 0.5 mm

(0.29 ± 0.02 in)15.0 ± 0.5 mm(0.59 ± 0.02 in)


9.1 ± 1.0 mm(0.36 ± 0.04 in)

Main jet (M.J.) #105 #95Jet needle (J.N.) 5D105-3 5C29-4Needle jet (N.J.) P-3 P-7Throttle valve (Th.V.) #115 ←Pilot jet (P.J.) #70 #42.5Pilot screw (P.S.) PRE-SET (2 and 1/2 turns back) PRE-SET (2 and 3/8 turns back)Throttle cable play 2.0 – 4.0 mm

(0.08 – 0.16 in) ←

120

7/9 E-03, 28, 33P-37


WATTAGE Unit: W

ITEM SPECIFICATION NOTEFiring order 1·2Spark plug Type NGK: DPR8EA-9

DENSO: X24EPR-U9

Gap 0.8 – 0.9(0.031 – 0.035)

Spark performance Over 8 (0.3) at 1 atm.Signal coil resistance 170 – 280 Ω G – BlIgnition coil resistance Primary 2 – 6 Ω tap – tap


Generator coil resistance Changing 0.2 – 1.5 Ω Y – YGenerator no-load voltage(when engine cold) More than 75 V (AC) at 5 000 r/min

Generator Max. output 250 W at 5 000 r/minRegulated voltage 13.5 – 15.5 V at 5 000 r/minStarter relay resistance 3 – 6 ΩBattery Type


Capacity 12V 36 kC (10Ah)/10HRStandard


Fuse sizeHeadlight

(HI) 10 A(LO) 10 A


Tail 10 AMain 30 A

ITEMSPECIFICATION

E-03, 28, 33 P37Headlight HI 60 ←

LO 55 ←Brake light/Taillight 21/5 ←Turn signal light Front 21/5 21

Rear 21 ←Speedometer light 1.7 ←Water temp. warning light 1.7 ←Turn signal indicator light 3.4 ←High beam indicator light 1.7 ←Neutral indicator light 3.4 ←Oil pressure warning light 1.7 ←

8/9 E-03, 28, 33P-37




(0.8 – 1.2) —



Brake drum I. D. Rear — 180.7(7.11)


4.0(0.16)







Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front J16 × MT3.00, J16M/C × MT3.00 —Rear J15M/C × MT3.50 —

Tire size Front 130/90-16 67H, 130/90-16 M/C 67H —Rear 150/90-15 74H, 150/90-15 M/C 74H —


Rear — 2.0(0.08)


(5.5) —

Front fork damper free length — 156(6.1)

Front fork oil level(At outer tube 177 mm up position)

154(6.1) —


Swingarm pivot shaft runout — 0.3(0.01)LE

P

9/9 E-03, 28, 33P-37

TIRE PRESSURE




kPa kg/cm2 psi kPa kg/cm2 psiFRONT 200 2.00 29 200 2.00 29REAR 225 2.25 33 225 2.25 33



E-03, 28, 33


The others




(1.8/1.5 US/lmp qt)




838 ml(28.3/29.5 US/lmp oz)


(1.6/1.3 US/lmp qt)

SAM

121

VZ1600

1/9 E-02, 03, 19, 24, 28, 33



IN.33.928 – 34.044

(1.33575 – 1.34031)33.83

(1.3319)

EX.33.741 – 33.857

(1.32839 – 1.33295)33.64

(1.3244)Camshaft/rocker case clearance

φ 250.020 – 0.062

(0.000787 – 0.00244)0.15

(0.00591)

φ 170.016 – 0.055

(0.000630 – 0.00217)0.14

(0.00551)Camshaft journal diameter

φ 2524.959 – 24.980

(0.982638 – 0.983465)24.93

(0.98150)

φ 1716.966 – 16.984

(0.667953 – 0.668661)16.93

(0.66654)Rocker case bearing insidediameter

φ 2525.000 – 25.021

(0.984252 – 0.985079)25.08

(0.98740)

φ 1717.000 – 17.021

(0.669291 – 0.670118)17.08

(0.67244)Camshaft runout

TIR 0.02 (0.00079) or lessTIR 0.1(0.0039)

Rocker arm inside diameter 16.000 – 16.018(0.629921 – 0.630630)

16.05(0.63189)

Rocker shaft diameter 15.966 – 15.984(0.628583 – 0.629291)

15.94(0.62756)

Cylinder compression usable range 340 – 590 kPa(3.5 – 6.0 kgf/cm2, 50 – 85 psi)

@ 300 r/min with electric starter—

Cylinder head warp — 0.05 (0.0020)Valve clearance Non-adjustable (Auto-adjuster) —Valve head thickness

IN.0.9 – 1.1

(0.035 – 0.0433)

0.5(0.020)

EX.0.7

(0.028)Valve stem bend

TIR 0.01 (0.00039) or lessTIR 0.05(0.0020)

Valve stem diameterIN.

6.965 – 6.980(0.27421 – 0.27480)

6.95(0.2736)

EX.6.955 – 6.970

(0.27382 – 0.27441)6.94

(0.2732)

2/9 E-02, 03, 19, 24, 28, 33

ITEM STANDARD LIMITValve guide inside diameter

IN. & EX.7.000 – 7.015

(0.27559 – 0.27618)7.08

(0.2787)Valve/valve guide clearance(Wobble method)

IN.0.05 – 0.13

(0.0020 – 0.00512)0.27

(0.0106)

EX.0.08 – 0.16

(0.0031 – 0.0063)0.30

(0.0118)Valve seat cutting angle 45°, 32°, 55° —Valve outside diameter

IN.36.4 – 36.6

(1.433 – 1.441)—

EX.31.9 – 32.1

(1.256 – 1.264)—

Valve widthIN.

0.5 – 1.0(0.020 – 0.039)

—

EX.0.8 – 1.2

(0.031 – 0.047)—

Valve spring free length Outer(IN. & EX.)

44.76 (1.7622) Orange 43.2 (1.700)

Inner(IN. & EX.)

39.82 (1.5677) Orange 38.3 (1.508)


102.10(4.01969)

Piston diameter 101.942 – 101.957(4.013457 – 4.014047)

101.79(4.00748)

Piston/cylinder clearance 0.043 – 0.070(0.00169 – 0.00276)

—

Oversize piston and rings + 0.5 (0.020) —Piston ring groove clearance

Top0.05 – 0.09

(0.00197 – 0.00354)0.19

(0.00748)

Second0.03 – 0.07

(0.0012 – 0.0028)0.17


Top1.24 – 1.26

(0.048819 – 0.049606)1.34

(0.05276)

Second1.22 – 1.24

(0.04803 – 0.04882)1.32

(0.05197)Piston ring thickness Top &

Second1.17 – 1.19

(0.04606 – 0.04685)1.10


Top0.25 – 0.35

(0.0098 – 0.0138)0.7

(0.028)

Second0.40 – 0.55

(0.0157 – 0.0217)0.8

(0.031)

Oil0.3 – 0.9

(0.012 – 0.035)1.2

(0.0472)

LE
P
3/9 E-02, 03, 19, 24, 28, 33


ITEM STANDARD LIMITConnecting rod bend

—TIR 0.2/100 mm

(0.08/3.94 in)Connecting rod twist

—TIR 0.2/100 mm

(0.08/3.94 in)Connecting rod big end sideclearance

0.16 – 0.46(0.0062 – 0.0181)

0.7(0.028)

Connecting rod big end bearing insert/crankpin clearance

0.026 – 0.057(0.001024 – 0.0022)

0.10(0.0039)

Crankpin diameter 54.981 – 55.000(2.1646 – 2.1654)

54.97(2.1642)

MarkingNone

54.981 – 54.991(2.1646 – 2.16500)

—

54.992 – 55.000(2.16504 – 2.1654)

—

Connecting rod big end borediameter

58.000 – 58.020(2.2835 – 2.2843)

—

MarkingNone

58000 – 58.010(2.2835 – 2.28386)

—

58.011 – 58.020(2.28390 – 2.2843)

—

Connecting rod big end bearing insert thickness

Brown1.483 – 1.487

(0.05839 – 0.05854)—

Black1.487 – 1.491

(0.05854 – 0.05870)—

Blue1.491 – 1.495

(0.05870 – 0.05886)—

Crankshaft side clearance 0.05 – 0.55(0.00197 – 0.0217)

0.75(0.0295)

Crankshaft web length 96.85 – 96.95(3.8130 – 3.8169)

96.6(3.803)

Crankshaft runoutTIR 0.02 (0.0008) or less

TIR 0.05 (0.0020)

Crankshaft main bearing/journal clearance

0.025 – 0.052(0.00098 – 0.00205)

0.10(0.00394)

Crankshaft main journal diameter 54.986 – 55.000(2.1648 – 2.1654)

54.96(2.1638)

Crank case main bearing bore diameter

55.025 – 55.038(2.1663 – 2.1669)

55.07(2.1681)


5.8(0.228)


6.3(0.248)


7.8(0.307)


8.3(0.327)

SAM

4/9 E-02, 03, 19, 24, 28, 33


FINAL DRIVE

FUEL SYSTEM

ITEM STANDARD LIMITClutch fluid grade DOT 4 (provided when shipping) —Clutch lever position No.1 (to suit rider) —Clutch lever free play Non-adjustable —Clutch spring free height 4.3 (0.235) 4 (0.16)Spring plate gap (usable range) 1.95 – 2.45

(0.0768 – 0.0965)—

Friction plate thickness 3.3 – 3.5(0.130 – 0.138)

3.1(0.122)

Friction plate/steel plate warp 0.2 (0.0079) or less 0.3 (0.012)

ITEM STANDARDFinal gear case oil Grade API service classification: GL-5 hypoid gear oil

ViscosityWhen above 5 °C (41 °F) SAE90When below 5 °C (41 °F) SAE80

Oil level Filler opening bottomAmount 200 mL (6.76 US oz)

Final bevel gear backlash 0.06 – 0.09 mm (0.0024 – 0.0035 in) (at gear hub splines)Preload for pinion gear bearing Torque wrench 0.6 – 1.0 N·m (0.06 – 0.10 kgf-m, 5.2 – 8.7 in-lb)

Spring scale 3.0 – 5.0 N (0.3 – 0.5 kgf, 0.7 – 1.1 lb)Propeller shaft joint grease 20 mL (0.68 US oz), high-temperature greaseFront bevel gear backlash 0.10 – 0.15 mm (0.0039 – 0.0059 in) (at gear teeth)Preload for front bevel gear bearing Torque wrench 0.5 – 0.9 N·m (0.05 – 0.09 kgf-m, 4.3 – 7.8 in-lb)

Spring scale 3 – 4 N (0.3 – 0.5 kgf, 0.6 – 1.0 lb)

ITEM STANDARD NOTEThrottle grip free play 2 – 3 mm (0.079 – 0.118 in) —Air cleaner element Paper filter —DFI (Digital Fuel Injecton) system make

Mitsubishi Electric —

Idle speed 950 ± 50 r/min —Throttle assy

Type × boreTwo barrel type ×φ 40 mm (1.57 in)

—

ECU (Electronic Control Unit)Type

Digital memory type, with built in IC igniter, sealed with resin

—

Usable engine speed

100 – 6 300 r/min —

ISC valves(Idle speed control valve or fast idle solenoid valve)

Maximum air flow rate

75 ± 7 L/min —

Solenoidresistance

13.6 – 20.4 Ω —

122

5/9 E-02, 03, 19, 24, 28, 33

ITEM STANDARD NOTEFuel filter Filtration area More than 200 cm2 —

Rated flow 1.0 L/min —Fuel pressure (high pressure line) Right after

ignition SW ON310 kPa (3.2 kgf/cm2, 46 psi)

with fuel pump running—

After pump runs 3 sec. and stops

280 kPa (2.9 kgf/cm2, 41 psi)with fuel pump stopped

—

With engine idling

260 kPa (2.7 kgf/cm2, 38 psi)with fuel pump running

—

With enginerunning atfull throttle

260 – 280 kPa(2.7 – 2.9 kgf/cm2, 38 – 41 psi)

with fuel pump running—

Pressure regulatorRegulated fuel

pressure

294 ± 4.9 kPa(3.00 ± 0.05 kgf/cm2,

43 ± 0.73 psi)—

Throttle sensorType

Non-adjustableand non-removable

—

Input voltage 4.75 – 5.25 V DC: BL/W –: BR/BK

Output voltage at idle throttle

opening0.584 – 0.604 V DC

: Y/W –: BR/BK

Output voltage at full throttleopening

4.29 – 4.59 V DC: Y/W –: BR/BK

Resistance 4 – 6 kΩ BL/W – BR/BKAtmospheric pressure sensor

Input voltage 4.75 – 5.25 V DC: BL/W –: BR/BK

Output voltage3.74 – 4.26 V DC at standard

atmospheric pressure: BL/Y –: BR/BK

Inlet air pressure sensorInput voltage 4.75 – 5.25 V DC

: BL/W –: BR/BK

Output voltage3.74 – 4.26 V DC at standard

atmospheric pressure: W/BL –: BR/BK

Inlet air temperature sensorresistance

5.4 – 6.6 kΩ at 0 °C (32 °F)2.26 – 2.86 kΩ at 20 °C (68 °F)

0.29 – 0.39 kΩ at 80 °C (176 °F)—

Water temperature sensorresistance

2.162 – 3.112 kΩ at 20 °C (68 °F)0.785 – 1.049 kΩ at 50 °C (122 °F)

0.207 – 0.253 kΩ at 100 °C (212 °F)—

Vehicle-down sensor Detection method

Magnetic flux detection method —

Detection angleMore than 45° ± 5°

for each bank—

Detection time Within 0.5 – 1.0 sec. —

6/9 E-02, 03, 19, 24, 28, 33

COOLING SYSTEM

ELECTRICAL SYSTEM

ITEM STANDARD NOTEFuel injectors Type INP-786 —

Injection timing 60° BTDC at each cylinder —Static injection

quantity273.1 – 289.4 mL/min —

Nozzle type × diameter

Two spray type with four holes × 0.3 mm (0.012 in)

—

Resistance 14.2 – 14.8 Ω —Fuel pump

TypeIn-tank pump (friction pump)75 mL or more for 3 seconds

—

Discharge(90 L or more/h) with the filter

installed at 12 Vatmospheric pressure

—

Air swiching valve resistance 18 – 22 Ω at 20 °C (68 °F)

ITEM STANDARDCoolant provided when shipping

Type(recommended)

Permanent type antifreeze (soft water andethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Color GreenMixed ratio Soft water 50 %, coolant 50 %

Freezing point – 35 °C (– 31 °F)

Total amount2.3 L (2.4 US qt, reserve tank full level

including radiator and engine)Radiator cap relief pressure 93 – 123 kPa (0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)Thermostat Valve opening

temperature58 – 62 °C (136 – 144 °F)

Valve fullopening lift

8 mm (0.3 in) or more @ 75 °C (167 °F)

ITEM STANDARD NOTEBattery Type Sealed battery —

Model name FTZ16-BS —Capacity 12 V 18 Ah —Voltage 12.6 V or more —

Alternator type Three-phase AC with delta connectoin,and rare-earth single magnet rotor

—

DC battery charging voltage 14.2 – 15.2 V @ 3 000 r/min —Alternator output voltage (no load) 64 – 96 V @ 3 000 r/min —Stator coil (battery charging coil) resistance

0.33 – 0.49 Ω —

Regulator/rectifier type Load dumping regulator with full-wave rectifier —LE
P
)

7/9 E-02, 03, 19, 24, 28, 33

ITEM STANDARD NOTEIgnition coil

Primary peak voltage

Front 208 V or more: BK –

: Ground

Rear 192 V or more: BK/G –: Ground

3 needle arcing distance

6 mm (0.24 in) or more —

Ignition coilprimary winding

resistance1.9 – 2.9 Ω —

Ignition coil sec-ondary winding

resistance18 – 28 kΩ —

Spark plug gap 0.8 – 0.9 mm (0.031 – 0.035 in) —Spark plug cap resistance 3.75 – 6.25 kΩ —Pickup coil

Peak voltageFront 2.2 V or more —Rear 2.0 V or more —

Air gap1.0 mm (0.04 in)

(Non-measurable andnon-adjustable)

—

Resistance 380 – 560 Ω —Starter motor

Brush length 12 mm (0.47 in)Service limit

8.5 mm (0.33 in)Commutator

diameter28 mm (1.1 in)

Service limit27 mm (1.06 in)

Rear brake light switch timing ON after about 10 mm (0.39 in) pedal travel —Engine oil pressure switchconnections

When engine is stopped

ON —

When engine is running

OFF —

Radiator fan switch Risingtemperature

From OFF to ON@ 102 – 108 °C (212 – 226 °F)

—

Fallingtemperature

From ON to OFF@ 97 – 103 °C (207 – 217 °F)

—

ResistanceON Less than 0.5 Ω —OFF More than 1 MΩ —

Water temperature switch Risingtemperature

From OFF to ON@ 113 – 117 °C (235 – 243 °F)

—

Fallingtemperature

From ON to OFF @108 °C (226 °F) – temperature

less than ON temperature—

ResistanceON Less than 0.5 Ω —OFF More than 1 MΩ —

Fuel level switch resistance FULL position 4 – 10 Ω —EMPTY position 90 – 100 Ω —

SAM

8/9 E-02, 03, 19, 24, 28, 33



AT: Republic of AustriaCH: Swiss ConfederatoinDE: Federal Republic of Germany

ITEM STANDARD LIMITBrake lever position No.1 5-way adjustableBrake lever free play Non-adjustable —Brake pedal free play Non-adjustable —Brake pedal position About 110 (4.33)

(height from pedal top to footpeg top)—

Brake fluid grade DOT 4 —Brake pad lining thickness Front 4.0 (0.157) 1 (0.04)

Rear 7.5 (0.295) 1 (0.04)Brake disc thickness

Front4.8 – 5.1

(0.19 – 0.20)4.5

(0.18)

Rear6.8 – 7.2

(0.268 – 0.283)6.0

(0.24)Brake disc runout Front &

RearTIR 0.15 (0.0059) or less TIR 0.3 (0.01)

ITEM STANDARD LIMITWheel rim runout Axial — TIR 0.5 (0.02)

Radial — TIR 0.8 (0.03)Axle runout/100 mm TIR 0.05 (0.002) or less TIR 0.2 (0.008)Wheel balance 10 g (0.35 oz) or less —Balance weight 10 g (0.35 oz), 20 g (0.71 oz), 30 g (1.1 oz) —Tire air pressure (when cold) Front &

RearUp to 184 kg (405 lb) load:

250 kPa (2.5 kgf/cm2, 36 psi)—

Tire thread depthFront DUNLOP: 4.4 (0.17)

1 (0.04)[AT, CH, DE1.6 (0.063)]

Rear DUNLOP: 6.9 (0.27)

Up to 130 km/h(80 mph):2 (0.08)

Over 130 km/h(80 mph):

3 (0.1)Front tire Type DUNLOP D220F ST G —

Size 130/70R17 M/C 62H —Rear tire Type DUNLOP D220 ST G —

Size 170/60R17 M/C 72H —

123

9/9 E-02, 03, 19, 24, 28, 33


ENGINE LUBRICATOIN SYSTEM)

ITEM STANDARD LIMITFront fork inner tube diameter φ 43 (φ 1.7) —Front fork spring setting Non-adjustable —Front fork air pressure Atmospheric pressure (Non-adjustable) —Front fork rebound damper setting Non-adjustable —Front fork oil viscosity SAE 10W-20 —Front fork oil capacity

Right fork leg

507 ± 2.5 mL (17.1 ± 0.085 US oz) (Completely disassembled and dry)

Approx. 430 mL (14.5 US oz)(When changing oil)

—

Left fork leg

601 ± 2.5 mL (20.3 ± 0.085 US oz) (Completely disassembled and dry)

—

Front fork oil level(Fully compressed, without fork spring, below from inner tube top)

Right fork leg

142 (5.59) —

Left fork leg

136 (5.35) —

Front fork spring free length 333.7 (13.14) 327 (12.9)Rear shock absorber rebound damper setting

No.II of 4 positions —

Rear shock absorber air pressure Standard Atmospheric pressure —Usable renge

Atmospheric pressure –290 kPa (3.0 kgf/cm2, 43 psi)

—

ITEM STANDARD NOTEEngine oil type API SE, SF or SG

API SH or SJ with JASO MA—

Engine oil viscosity SAE 10W-40 —Engine oil capacity When filter is not

removed2.9 L (3.1 US qt) —


3.1 L (3.3 US qt) —

When engine is completely

disassembled and dry

3.5 L (3.7 US qt) —

Engine oil level(Wait 2 – 3 minutes after idling or running)

Between upper and lower lines —

Engine oil pressure[2 000 r/min, oil temperature 90 °C (194 °F)]

340 – 440 kPa (3.5 – 4.5 kgf/cm2, 50 – 64 psi) —

LE
P
SAM

124

A100X/XS

1/5 P-42



OIL PUMP

CLUTCH Unit: mm

ITEM STANDARD LIMITPiston to cylinder clearance 0.035 – 0.045 0.120Cylinder bore 50.000 – 50.015

Measure at 20 mm from the top surface. 50.095

Piston diam. 49.960 – 49.975Measure at 21 mm from the skirt end. 49.880

Cylinder distortion — 0.05Cylinder head distortion — 0.05Piston ring free end gap 1st &

2ndT Approx. 4.5 3.6

RN Approx. 5.0 4.0Piston ring end gap 0.15 – 0.35 0.80Piston ring to groove clearance 1st &

2nd 0.04 – 0.08 —


ITEM STANDARD LIMITConrod small end I.D. 18.003 – 18.011 18.040Conrod deflection — 3.0Crank web to web width 50.0 ± 0.1 —Crankshaft runout — 0.05

ITEM SPECIFICATIONOil pump reduction ratio 5.729 (50/16 × 26/18 × 33/26)Oil pump discharge rate (full open) 1.5 – 1.8 ml

for 2 minutes at 2 000 r/min

ITEM STANDARD LIMITClutch cable play 10 – 15 —Clutch release screw 1/4 – 1/2 turn back —Drive plate thickness 2.9 – 3.1 2.6Drive plate claw width 9.8 – 10.0 9.0Driven plate distortion — 0.10Clutch spring free length — 34.5

2/5 P-42


CARBURETOR


2nd 1.800 (27/15) —3rd 1.277 (23/18) —Top 0.954 (21/22) —

Shift fork to groove clearance 0.2 – 0.4 0.6Shift fork groove width 5.6 – 5.7 —Shift fork thickness 5.3 – 5.4 —Drive chain Type D.I.D.: DID 428

TAKASAGO: RK428M —

Links 108 —20-pitch length — 259.0


ITEM SPECIFICATIONCarburetor type MIKUNI VM20SCBore size 20 mmI.D. No. 12630Idle r/min 1300 ± 100 r/minFloat height 25.1 ± 1.0 mmMain jet (M.J.) #100Main air jet (M.A.J.) 0.5 mmJet needle (J.N.) 4FM37-4thNeedle jet (N.J.) O-4Cut-away (C.A.) 2.5Pilot jet (P.J.) # 20By-pass (B.P.) 1.0 mmPilot outlet (P.O.) 0.7 mmAir screw (A.S.) 2 and 1/8 turns backStarter jet (G.S.) # 50Valve seat (V.S.) 2.0 mmThottle cable play 3 – 6 mm

LE
P
3/5 P-42

ELECTRICAL

WATTAGE Unit: W

ITEM SPECIFICATION NOTEIgnition timing 22° B.T.D.C. at 4 000 r/minSpark plug Type ND: W20FP

NGK: BP6HSGap 0.6 – 0.7 mm

Spark performance Over 8 mm at 1 atm.Ignition coil resistance Secondary 15 – 25 kΩ Plug cap –

GroundMagneto coil resistance Primary 120 – 200 Ω B/R – B/W

Lighting 0.1 – 1.0 Ω Y/W – B/WCharging 0.1 – 1.5 Ω W/R – B/W

Magneto no-load voltage(when engine is cold) 27 V and more (AC) at 5 000 r/min

Regulated voltage 13 – 16 V at 5 000 r/minResistor resistance 2.0 ± 0.5 ΩBattery Type designation GM2.5 A-3C-2H

Capacity 12 V 9 kC (2.5 Ah)/10 HRStandard electrolyte S.G. 1.28 at 20 °C

Fuse size 15 A


LO 25Tail/Brake light 5/18Turn signal light 10Speedometer light 3.4Turn signal indicator light 3.4High beam indicator light 1.7Neutral indicator light 3.4Oil level indicator light 3.4

SAM

4/5 P-42


SUSPENSION Unit: mm

TIRE PRESSURE

ITEM STANDARD LIMITFront brake cable play 3 – 7 —Rear brake pedal free travel 20 – 30 —Brake drum I.D. A100X Front — 110.7

Rear — 110.7Brake lining thickness A100X Front — 1.5

Rear — 1.5Brake disc thickness A100XS Front 4.0 ± 0.2 3.0Brake disc runout A100XS Front — 0.30Master cylinder bore A100XS Front 12.700 – 12.743 —Master cylinder piston diam. A100XS Front 12.657 – 12.684 —

Brake caliper cylinder bore A100XS Front 27.000 – 27.050 —

Brake caliper piston diam. A100XS Front 26.900 – 26.950 —

Wheel rim runout Axial — 2.0Radial — 2.0

Wheel axle runout Front — 0.25Rear — 0.25

Tire size Front 2.50-18 4PR —Rear 2.75-18 4PR —

Tire tread depth Front — 1.6Rear — 1.6

ITEM STANDARD LIMITFront fork stroke 90 —Front fork spring free length 297 291Front fork oil level 137 —Rear shock absorber spring adjuster 1st set —

Swingarm pivot shaft runout — 0.6


SOLO RIDING DUAL RIDINGkPa kgf/cm2 kPa kgf/cm2

FRONT 175 1.75 175 1.75REAR 200 2.00 225 2.25

125

5/5 P-42


Fuel type Gasoline used should be graded 85 – 95 octane orhigher. An unleaded gasoline is recommended.

Fuel tank including reserve 10.5 L reserve 2.0 L

Engine oil type Use SUZUKI CCI or CCI SUPER OIL or an equiva-lent good quality synthetic based 2-cycle oil.

Engine oil tank capacity 1.2 LTransmission oil type SAE 10W-40Transmission oil capacity Change 650 ml

Overhaul 700 mlFront fork oil type Fork oil #10Front fork oil capacity (eah leg) 101 mlBrake fluid type DOT 4 A100XS

LE
P AY50
1/4 P-02, 19



OIL PUMP

CLUTCH Unit: mm




Cylinder distortion — 0.05Cylinder head distortion — 0.05Piston ring free end gap 1st R Approx. 4.0 3.2

2nd R Approx. 4.3 3.4Piston ring end gap 1st &

2nd R 0.10 – 0.25 0.80

Piston ring to groove clearance 1st 0.03 – 0.07 —2nd 0.02 – 0.06 —



ITEM SPECIFICATIONOil pump reduction ratio 30.000 (30/1)Oil pump discharge rate 0.9 – 1.1 ml


ITEM STANDARD LIMITClutch wheel I.D. 110.00 – 110.15 110.50Clutch shoe thickness 3.0 2.0Clutch engagement 3 300 ± 200 r/min —Clutch lock-up 4 500 ± 300 r/min —

SAM

2/4 P-02, 19


CARBURETOR

ELECTRICAL Unit: mm

ITEM STANDARD LIMITReduction ratio Variable 2.768 – 1.005 —Final reduction ratio 14.960 (51/15 × 66/15) —Drive belt width 16.9 15.9

18.4 17.4Driven face spring free length 110 104.5

ITEM SPECIFICATIONCarburetor type KEIHIN PWS14Bore size 14 mmI.D. No. 35EJIdle r/min 1 900 ± 200 r/minFloat height 5.1 ± 0.5 mmMain jet (M.J.) #65Jet needle (J.N.) N5GJ-3rdPilot jet (P.J.) #40Air screw (A.S.) 1 and 3/4 turns backThrottle cable play 2 – 4 mm

ITEM SPECIFICATION NOTESpark plug Type NGK: BPR6HS

DENSO: W20FPR-UGap 0.6 – 0.7

Spark performance Over 8 at 1 atm.Ignition coil resistance

Secondary 4 – 10 kΩPlug cap –

B/W lead wire terminal

Generator coil resistance Charging 0.2 – 1.5 Ω Y – GroundPick-up 100 – 270 Ω R – Ground

Regulated voltage 13.5 – 15.5 V at 5 000 r/minGenerator Max. output 100 W at 5 000 r/minStarter relay resistance 50 – 90 ΩBattery Type

designation YT4L-BS


126

3/4 P-02, 19

WATTAGE Unit: W


SUSPENSION Unit: mm


LO 35Brake light/Taillight 21/5Turn signal light 10Speedometer light 1.2 × 2Fuel meter light 1.2Turn signal indicator light 2Oil level indicator light 2High beam indicator light 1.7Trunk light 2

ITEM STANDARD LIMITBrake lever play Rear 15 – 20 —Brake drum I.D. Rear — 120.7Brake disc thickness Front 4.0 ± 0.2 3.5Brake disc runout Front — 0.30Master cylinder bore Front 11.000 – 11.043 —Master cylinder piston diam. Front 10.957 – 10.984 —Brake caliper cylinder bore Front 30.230 – 30.306 —Brake caliper piston diam. Front 30.150 – 30.200 —Brake fluid type DOT 4 —Wheel rim runout Axial — 2.0

Radial — 2.0Wheel axle runout Front — 0.25Wheel rim size Front J12 × MT3.50 —

Rear J12 × MT3.50 —Tire size Front 120/70-12 51L —

Rear 130/70-12 56L —Tire type Front MICHELIN: DEXTER —

Rear MICHELIN: DEXTER —Tire tread depth Front — 1.6

Rear — 1.6

ITEM STANDARD LIMITFront fork stroke 77 —Front fork spring free length 124.7 122Rear wheel travel 60 —

4/4 P-02, 19

TIRE PRESSURE

FUEL + OIL



FRONT 125 1.25 18 125 1.25 18REAR 175 1.75 25 230 2.30 33


higher. An unleaded gasoline is recommended.Fuel tank capacity 6.8 LEngine oil type Use SUZUKI CCI SUPER OIL. If they are not avail-

able, use a good quality 2-stroke oil rated FC underJASO classification.

Engine oil tank capacity 1.2 LFinal gear oil type SAE 10W-40Final gear oil capacity 130 ml

LE
P AY50W
1/5 P-02, 19



OIL PUMP

CLUTCH Unit: mm





2ndT Approx. 4.5 3.6N Approx. 3.0 2.4

Piston ring end gap 1st &2nd

T&N 0.08 – 0.18 0.80

Piston ring to groove clearance 1st & 2nd 0.01 – 0.05 —Piston pin bore 12.002 – 12.010 12.030Piston pin O.D. 11.996 – 12.000 11.980


ITEM SPECIFICATIONOil pump reduction ratio 30.000 (30/1)Oil pump discharge rate 0.8 – 1.0 ml


ITEM STANDARD LIMITClutch wheel I.D. 110.00 – 110.15 110.50Clutch shoe thickness 3.0 2.0Clutch engagement 4 000 ± 200 r/min —Clutch lock-up 5 600 ± 300 r/min —

SAM

2/5 P-02, 19

THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH + ENGINE COOLANT


CARBURETOR

ITEM STANDARD/SPECIFICATION LIMITThermostat valve opening temper-ature Approx. 65 °C —

Thermostat valve lift Over 3 mm at 80 °C —Radiator reservoir cap valve open-ing pressure 100 kPa (1.0 kgf/cm2) —

Engine coolant temp. switch operating temperature

ON Approx. 125 °C —OFF Approx. 118 °C —


—

Engine coolant including reserve 1 200 ml —

ITEM STANDARD LIMITReduction ratio Variable 2.975 – 1.033 —Final reduction ratio 16.271 (51/15 × 67/14) —Drive belt width 18.4 17.4Driven face spring free length 110 104.5

ITEM SPECIFICATIONCarburetor type KEIHIN PWS14Bore size 14 mmI.D. No. 35EAIdle r/min. 1 900 ± 200 r/minFloat height 5.1 ± 0.5 mmMain jet (M.J.) #62Jet needle (J.N.) N5GJ-2ndPilot jet (P.J.) #45Air screw (A.S.) 1 and 1/2 turns backThrottle cable play 2 – 4 mm

127

3/5 P-02, 19

ELECTRICAL Unit: mm

WATTAGE Unit: W


DENSO: W20FPRGap 0.6 – 0.7

Spark performance Over 8 at 1 atm.Ignition coil resistance

Secondary 4 – 10 kΩPlug cap –

B/W lead wire terminal

Generator coil resistance Charging 0.2 – 1.5 Ω Y – GroundPick-up 100 – 270 Ω R – Ground

Regulated voltage 13.5 – 15.5 V at 5 000 r/minGenerator Max. output 100 W at 5 000 r/minStarter relay resistance 50 – 90 ΩBattery Type

designation YT4L-BS



LO 35Brake light/Taillight 21/5Turn signal light 10Speedometer light 1.2 × 2Fuel meter light 1.2Turn signal indicator light 2Oil level indicator light 2Water temp. indicator light 2High beam indicator light 1.2Trunk light 2

4/5 P-02, 19


SUSPENSION Unit: mm

TIRE PRESSURE

ITEM STANDARD/SPECIFICATION LIMITBrake disc thickness Front 4.0 ± 0.2 3.5

Rear 4.0 ± 0.2 3.5Brake disc runout Front &

Rear — 0.30

Master cylinder bore Front 11.000 – 11.043 —Rear 12.000 – 12.043 —

Master cylinder piston diam. Front 10.957 – 10.984 —Rear 11.957 – 11.984 —

Brake caliper cylinder bore Front 30.230 – 30.306 —Rear 30.230 – 30.306 —

Brake caliper piston diam. Front 30.150 – 30.200 —Rear 30.150 – 30.200 —


Radial — 2.0Wheel axle runout Front — 0.25Wheel rim size Front J12 × MT3.50 —

Rear J13MC × MT3.50 —Tire size Front 120/70-12 51L —

Rear 130/60-13 M/C 53L —Tire type Front METZELER: ME 7 TEEN —

Rear METZELER: ME 7 TEEN —Tire tread depth Front — 1.6

Rear — 1.6

ITEM STANDARD LIMITFront fork stroke 77 —Front fork spring free length 124.7 122Rear wheel travel 60 —



FRONT 125 1.25 18 125 1.25 18REAR 175 1.75 25 230 2.30 33

LE
P
5/5 P-02, 19



Fuel tank capacity 6.8 LEngine oil type Use SUZUKI CCI SUPER OIL. If they are not avail-

able, use a good quality 2-stroke oil rated FC underJASO classification.

Engine oil tank capacity 1.2 LFinal gear oil type SAE 10W-40Final gear oil capacity 130 ml

SAM

128

JR50

1/4 P-03, 28



OIL PUMP


(0.0026 – 0.0030)0.120

(0.0047)Cylinder bore 41.000 – 41.015

(1.6142 – 1.6148)Measure at 20 mm (0.8 in) from the top surface.

41.065(1.6167)

Piston diam. 40.930 – 40.945(1.6114 – 1.6120)


(1.6094)



Piston ring free end gap

1stR Approx. 4.5 (0.18) 3.6

(0.14)

T Approx. 4.5 (0.18) 3.6(0.14)

2ndR Approx. 4.1 (0.16) 3.3

(0.13)

T Approx. 5.0 (0.20) 4.0(0.16)

Piston ring end gap 0.10 – 0.25(0.004 – 0.010)

0.75(0.030)

Piston ring to groove clearance 1st & 2nd 0.03 – 0.07(0.0012 – 0.0028) —

Piston pin bore 12.002 – 12.010 (0.4725 – 0.1728)

12.030(0.4736)

Piston pin O.D. 11.996 – 12.000 (0.4723 – 0.4724)

11.980(0.4717)


(0.6300 – 0.6304) 16.040


(0.12)Crank web to web width 32.0 ± 0.1

(1.260 ± 0.004) —


ITEM STANDARD LIMITOil pump reduction ratio 60.950 (53/20 × 23/1) —Oil pump discharge rate 0.8 – 1.1 ml

(0.027/0.028 – 0.037/0.039 US/lmp oz)for 5 minutes at 3 000 r/min

—

2/4 P-03, 28


TRANSMISSTION Unit: mm (in) Except ratio

DRIVE CHAIN Unit: mm (in)

CARBURETOR

ITEM STANDARD LIMITClutch release screw 1/4 turn back —Drive plate thickness 2.5 – 2.7

(0.10 – 0.11)2.2


(0.616 – 0.628)14.85


(0.006)Clutch engagement 2 500 – 2 900 r/min —Clutch lock-up 2 700 – 3 100 r/min —Clutch spring free length — 10.1

(0.4)

ITEM STANDARD LIMITPrimary reduction ratio 2.650 (53/20) —Final reduction ratio 2.153 (28/13) —Gear ratios 2.230 (29/13) —Shift fork to groove clearance 0.10 – 0.30

(0.004 – 0.012)0.50


(0.250 – 0.260) —


ITEM STANDARD LIMITDrive chain Type D.I.D.: DID 420 —

Links 78 —20-pitchlength — 259.0


(0.8 – 1.0) —

ITEM SPECIFICATIONCarburetor type MIKUNI VM12SCBore size 12 mmI.D. No 0445Idle r/min 1 700 ± 100 r/minFuel level 3.5 – 4.5 mm

(0.14 – 0.18 in)Float height 24.5 – 25.0 mm

(0.96 – 1.00 in)

LE
P
3/4 P-03, 28



ITEM SPECIFICATIONMain jet (M.J.) #56.3Jet needle (J.N.) 3D23-3rdNeedle jet (N.J.) E-6Pilot jet (P.J.) #15Air screw (A.S.) 1 and 1/4 turns outThrottle cable play 2 – 4 mm

(0.08 – 0.16 in)


DENSO: W14FPR-UL

Gap 0.6 – 0.7(0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Secondary 11 – 20 kΩ Plug cap –

GroundGenerator coil peak voltage More than 120 V : B/Y

: GroundGenerator coil resistance 100 – 160 Ω B/Y – Ground

ITEM STANDARD LIMITFront brake cable play 15 – 25

(0.6 – 1.0) —



Rear — 90.7(3.57)


Radial — 2.0(0.08)


Rear — 0.25(0.010)

Wheel rim size Front & Rear 1.40 × 10 —

Tire size Front & Rear 2.50-10 2PR —

Tire tread depth Front 4.0(0.16)

Rear 4.0(0.16)

SAM

4/4 P-03, 28


TIRE PRESSURE

FUEL + OIL


(2.8) —


169.0(6.65) Upper

192.5(7.58)

188.0(7.40) Lower



COLD INFLATIONTIRE PRESSURE kPa kg/cm2 psi

FRONT 150 1.50 22REAR 150 1.50 22



P-03, 28

Fuel tank capacity 2.0 L(0.5/0.4 US/lmp gal)

Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTORLUBRICANT or an equivalent good quality sys-thetic based 2-stroke engine oil rated FC under theJASO classification.

P-03

Use SUZUKI CCI SUPER OIL. If they are not avail-able, use a good quality 2-stroke oil rated FC underJASO classification.

P-28

Engine oil tank capacity 0.3 L(0.3/0.3 US/lmp qt)

Transmission oil type SAE 10W-40Transmission oil capacity

Change450 ml

(0.5/0.4 US/lmp qt)

Overhaul500 ml

(0.5/0.4 US/lmp qt)

129

JR80

1/5 P-03, 28



OIL PUMP


(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 49.000 – 49.015


49.090 (1.9327)

Piston diam. 48.955 – 48.970 (1.9274 – 1.9279)


(1.9244)

Cylinder distortion — 0.05 (0.002)

Cylinder head distortion — 0.05 (0.002)

Piston ring free end gap 1st & 2nd T Approx. 4.5

(0.18) 3.6

(0.14)Piston ring end gap 0.15 – 0.35

(0.006 – 0.014)0.80

(0.031)Piston ring to groove clearance 1st & 2nd 0.03 – 0.07

(0.0012 – 0.0028) —

Piston pin bore 12.002 – 12.010 (0.4725 – 0.4728)

12.030 (0.4736)

Piston pin O.D. 11.995 – 12.000 (0.4722 – 0.4724)

11.980 (0.4717)


(0.6300 – 0.6304)16.040



(1.575 ± 0.004) —


ITEM SPECIFICATIONOil pump reduction ratio 6.461 (73/19 × 29/22 × 37/29)Oil pump discharge rate(Full open)

0.9 – 1.2 ml for 3 minutes at 2 000 r/min

2/5 P-03, 28





(0.4 – 0.6) —


2.6(0.10)

No. 2 2.92 – 3.08(0.11 – 0.12)

2.62(0.10)

Drive plate claw width No. 1 & 2 11.8 – 12.0(0.46 – 0.47)

11.0(0.43)




2nd 1.684 (32/19) —3rd 1.318 (29/22) —4th 1.083 (26/24) —Top 0.923 (24/26) —

Shift fork to groove clearance No. 1, 2 & 3

0.10 – 0.30(0.004 – 0.012)

0.50(0.020)

Shift fork groove width No. 1, 2 & 3

4.45 – 4.55(0.175 – 0.179) —

Shift fork thickness No. 1, 2 & 3

4.25 – 4.35(0.167 – 0.171) —

Countershaft length(Low to 2nd)

76.0 (2.992 )

—+ 0.1– 0+ 0.004– 0

ITEM STANDARD LIMITDrive chain Type D.I.D.: 428 —

Links 96 —

20-pitch length — 259.0(10.20)


LE
P
3/5 P-03, 28

CARBURETOR



ITEM SPECIFICATIONCarburetor type MIKUNI VM20SSBore size 20 mmI.D. No. 03410Idle r/min 1 500 ± 150 r/minFloat height 21.4 ± 1.0 mm (0.84 ± 0.04 in)Main jet (M.J.) #87.5Jet needle (J.N.) 4L27-3rdNeedle jet (N.J.) O-4Pilot jet (P.J.) #25Air screw (A.S.) 1 and 1/4turns outThrottle cable play 2 – 4 mm (0.08 – 0.16 in)

ITEM SPECIFICATION NOTESpark plug Type NGK: BR7ES

DENSO: W22ESR

Gap NGK: 0.7 – 0.8 (0.028 – 0.031)DENSO: 0.6 – 0.7 (0.024 – 0.028)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Secondary 25 – 35 kΩ Plug cap –

GroundGenerator coil resistance Primary 120 – 200 Ω B/R – B/W

Lighting 0.2 – 1.5 Ω Y/R – B/WIgnition coil primary peak voltage More than 140 V : B/Y

: Ground

ITEM STANDARD LIMITFront brake cable play 20 – 30

(0.8 – 1.2) —




Rear — 110.7(4.36)


Radial — 2.0(0.08)


Rear — 0.25(0.010)

SAM

4/5 P-03, 28


TIRE AIR PRESSURE

ITEM STANDARD LIMITTire size Front 2.50-14 4PR —

Rear 3.00-12 4PR —Wheel rim size Front 14 × 1.40 —

Rear 12 × 1.60 —Tire tread depth Front — 3.0

(0.12)

Rear — 3.0(0.12)


(3.9) —


315(12.4)


Compress inner tube without spring

Front fork oil type SUZUKI FORK OIL SS-08 (#10) or an equivalent fork oil

Front fork oil capacity (each leg) 83 ml(2.8/2.9 US/lmp oz)

Rear shock absorber spring pre-set length 2/5 —




kPa kgf/cm2 psi

FRONT 100 1.00 14REAR 125 1.25 18

130

5/5 P-03, 28


Fuel type Use only unleaded gasoline of at least 87 pumpoctane (R/2 + M/2) or 91 octane or higher rated bythe research method.Gasoline containing MTBE (MethyI Tertiary ButylEther), less than 10% ethanol, or less than 5%methanol with appropriate cosolvents and corrosioninhibitor is permissible.

P-03, 28


Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTORLUBRICANT or an equivalent good quality syn-thetic based 2-stroke engine oil rated FC under theJASO classification.

P-03

Use SUZUKI CCI SUPER OIL or an equivalentgood quality synthetic based 2-stroke oil rated FCunder the JASO classification.

For the others


Transmission oil type SAE 10W-40Transmission oil capacity Change 650 ml

(0.69/0.57 US/lmp qt)

Overhaul 700 ml(0.74/0.62 US/lmp qt)

LE
P LT50
1/3 P-01, 02, 37, 43, 71



OIL PUMP

CLUTCH Unit: mm





2ndR Approx. 4.5 3.6T Approx. 5.0 4.0

Piston ring end gap 0.10 – 0.25 0.75Piston ring to groove clearance 1st 0.020 – 0.060 —

2nd 0.020 – 0.060 —Piston pin bore 11.998 – 12.006 12.030Piston pin O.D. 11.996 – 12.000 11.980


ITEM STANDARDOil pump reduction ratio 60.95 (53/20 × 23/1)Oil pump discharge rate 0.8 – 1.1 ml


ITEM STANDARD LIMITClutch wheel I.D. 87.00 – 87.15 87.40Clutch shoe O.D. — No goove at

any partClutch engagement 2 600 ± 200 r/min —Clutch lock-up 3 500 ± 200 r/min —Clutch spring free length — Over 28.0

SAM

2/3 P-01, 02, 37, 43, 71

TRANSMISSTION

DRIVE CHAIN Unit: mm

CARBURETOR

ELECTRICAL Unit: mm

ITEM STANDARD LIMITPrimary reduction ratio 2.650 (53/20) —Final reduction ratio 3.364 (37/11) —Gear ratios 2.416 (29/12) —




ITEMSPECIFICATION

P-01, 02, 43, 71 P-37Carburetor type MIKUNI VM12SC ←Bore size 12 mm ←I.D. No. 04431 0444Idle r/min 1 550 ± 50 r/min ←Float height 24.5 – 25.0 mm ←Main jet (M.J.) #57.5 ←Jet needle (J.N.) 3E3-3rd ←Needle jet (N.J.) E-6 ←Pilot jet (P.J.) #15 ←Air screw (A.S.) 1 and 1/2 turns back ←Starter jet (G.S.) #50 ←Throttle cable play 3 – 5 mm ←

ITEM SPECIFICATION NOTESpark plug Type NGK: BPR4H

Gap 0.5 – 0.6Spark performance Over 8 at 1 atm.Ignition coil resistance B/Y – Ground

120 – 160 Ω

131

3/3 P-01, 02, 37, 43, 71


TIRE PRESSURE

FUEL + OIL

ITEM STANDARD LIMITParking brake lever free travel 5 —Brake drum I.D. Rear — 90.7Brake lining thickness — 1.5Steering angle Inside 35° —

Outside 21.5° —Turning radius Approx. 2 m —Toe-in 4.0 ± 1.5 —Camber 1° —Trail 10 —Kingpin inclination 10° —Caster 3° 30’ —Wheel rim runout Axial — 3.0

Radial — 3.0Tire size Front &

Rear 145/70-6 —

Tire tread depth Front & Rear — 4.0


FRONT 25 0.25 3.6REAR 25 0.25 3.6


higher. An unleaded gasoline is reccomended.Fuel tank capacity 1.5 LEngine oil type Use SUZUKI CCI SUPER OIL or an equivalent

good quality synthetic based 2-stroke oil rated FCunder the JASO classification.

Engine oil tank capacity 0.5 LTransmission oil type SAE 10W-40Transmission oil capacity Charge 500 ml

Overhaul 550 ml

LE
P LT80
1/4 P-02, 03, 19, 28



OIL PUMP


(0.0031 – 0.0035) 0.120

(0.0047)Cylinder bore 50.000 – 50.015


50.050 (1.9705)

Piston diam. 49.915 – 49.930(1.9652 – 1.9657)


(1.9638)



Piston ring free end gap 1st T Approx. 4.0 (0.16) 3.2 (0.13)

2nd T Approx. 4.0 (0.16) 3.2 (0.13)


0.80 (0.031)

Piston ring to groove clearance 1st 0.020 – 0.060(0.0008 – 0.0024) —

2nd 0.020 – 0.060(0.0008 – 0.0024) —

Piston pin bore 12.002 – 12.010(0.4725 – 0.4728)

12.030 (0.4736)

Piston pin O.D. 11.994 – 12.000(0.4722 – 0.4724)

11.980 (0.4717)


(0.6299 – 0.6302)16.040



(1.50 ± 0.004) —


ITEM SPECIFICATIONOil pump reduction ratio 6.500 (13/2)Oil pump discharge rate(Full open)

1.0 – 1.3 ml(0.03/0.04 – 0.04/0.05 US/lmp oz)


SAM

2/4 P-02, 03, 19, 28



CARBURETOR


(4.331 – 4.337) 110.50 (4.350)

Clutch shoe thickness 4.0(0.16)

2.5(0.10)

Clutch engagement 2 500 – 2 900 r/min —Clutch lock-up 3 000 – 3 600 r/min —Clutch spring free length — 34.2

(1.35)

ITEM STANDARD LIMITFinal reduction ratio Gears 7.197 (33/12 × 27/14 × 19/14) —

Chain 2.200 (22/10) —Gear ratios Variable, 2.341 – 0.851 —Drive belt width 17.6 – 18.6

(0.69 – 0.73)16.7

(0.66)Driven face spring free length 107.5

(4.23)102.1(4.02)

Drive chain Type RK520SMO —Links 36 —

ITEM SPECIFICATIONCarburetor type MIKUNI VM16SHBore size 16 mmI.D. No. 41B10Idle r/min 1 600 ± 150 r/minFloat height 18.5 ± 1.0 mm

(0.73 ± 0.04 in)Main jet (M.J.) #92.5Jet needle (J.N.) 3J17-2ndNeedle jet (N.J.) E-0Pilot jet (P.J.) #20Throttle cable play 3 – 5 mm

(0.12 – 0.20 in)

132

3/4 P-02, 03, 19, 28

ELECTRICAL


ITEM SPECIFICATION NOTESpark plug Type DENSO: W22FPR

NGK: BPR7HS

Gap 0.60 – 0.80(0.024 – 0.031)


Terminal


Generator coil resistance Charging 0.5 – 0.8 Ω W/R – GroundPrimary 139 – 207 Ω B/R – Ground

Generator no-load voltage More than 28 V (AC) at 5 000 r/minGenerator Max. output 30 W at 5 000 r/minStarter relay resistance 72 – 88 ΩBattery Type designation YTX5L-BS

Capacity 12 V 14.4 kC (4 Ah)/10 HRFuse size 5 ACircuit breaker 30 A


(0.59 – 0.98) —



Rear — 130.7(5.15)


Wheel rim size Front &Rear 8 × 5.5 AT —

Toe-in (with 60 kg load) 8(0.31) —

Turning radius 2.1 m (6.89 ft) —Camber 1° —Kingpin inclination 15° —Caster 3° —Trail 11.6

(0.46) —

Steering angle Inside 35° —Outside 27° 30’ —

Tire size Front AT19 × 7.00-8 —Rear AT19 × 7.00-8 —

4/4 P-02, 03, 19, 28


TIRE PRESSURE

VEHICLE LOAD CAPACITY: 60 kg (132 lbs)

FUEL + OIL

ITEM STANDARD LIMITTire tread depth Front — 4.0

(0.16)

Rear — 4.0(0.16)

ITEM STANDARD LIMIT NOTEFront suspension stroke 31

(1.22) —


Rear suspension stroke 55(2.17) —

Rear wheel travel 57.4(2.26) —


FRONT 15 0.15 2.2REAR 20 0.20 2.9



P-03, 28

Gasoline used should be graded 91 octane orhigher. An unleaded gasoline is recommended. For the others

Fuel tank capacity including reserve 6.0 L (1.58/1.32 US/lmp gal)

reserve 2.0 L (0.53/0.44 US/lmp gal)Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTOR

LUBRICANT or an equivalent good quality syn-thetic based 2-stroke engine oil rated FC under theJASO classification.

P-03

Use SUZUKI CCI SUPER OIL or an equivalentgood quality synthetic based 2-stroke oil rated FCunder the JASO classification.

For the others

Engine oil tank capacity 1.2 L (1.27/1.06 US/lmp qt)Transmission oil type SAE 10W-40Transmission oil capacity Change 80 ml (2.7/2.8 US/lmp oz)

Overhaul 80 – 90 ml(2.7/2.8 – 3.0/3.2 US/lmp oz)LE

P
LT-A50
1/4 P-02, 03, 19, 28




(0.0026 – 0.0030)0.120

(0.0047)Cylinder bore 41.000 – 41.015


41.065(1.6167)

Piston diam. 40.930 – 40.945(1.6114 – 1.6120)

Measure at 20 mm (0.8 in) from the top surface.40.880

(1.6094)



Piston ring free end gap

1stR Approx. 4.5 (0.18) 3.6

(0.14)

T Approx. 4.5 (0.18) 3.6(0.14)

2ndR Approx. 4.1 (0.16) 3.3

(0.13)

T Approx. 5.0 (0.20) 4.0(0.16)


0.80(0.031)

Piston ring to groove clearance 1st 0.020 – 0.060(0.0008 – 0.0024) —

2nd 0.020 – 0.060(0.0008 – 0.0024) —

Piston pin bore 12.002 – 12.010(0.4725 – 0.4728)

12.030(0.4736)

Piston pin O.D. 11.996 – 12.000(0.4723 – 0.4724)

11.980(0.4717)


(0.6300 – 0.6304) 16.040(0.6315)

Conrod deflection — 3.0(0.12)



SAM

2/4 P-02, 03, 19, 28

OIL PUMP


TRANSMISSTION


CARBURETOR

ITEM SPECIFICATIONOil pump reduction ratio 60.95 (53/20 × 23/1)Oil pump discharge rate 0.6 – 0.8 ml

(0.020/0.021 – 0.027/0.030 US/lmp oz)for 5 minutes at 2 000 r/min


(3.425 – 3.431)87.50

(3.445)Clutch shoe thickness — No goove at

any partClutch engagement 2 200 – 2 600 r/min —Clutch lock-up 2 500 – 2 900 r/min —

ITEM STANDARD LIMITPrimary reduction ratio 2.650 (53/20) —Final reduction ratio 3.700 (37/10) —Gear ratios 2.416 (29/12) —




(0.8 – 1.2) —

ITEM SPECIFICATIONCarburetor type MIKUNI VM12SCBore size 12 mmI.D. No. 43F0Idle r/min 1 800 ± 100 r/minFloat height 24.5 – 25.0 mm

(0.96 – 0.98 in)Main jet (M.J.) #55Jet needle (J.N.) 3E3-4thNeedle jet (N.J.) E-6Pilot jet (P.J.) #15Air screw (A.S.) 1 and 1/8 turns outThrottle cable play 3 – 5 mm

(0.12 – 0.20 in)

133

3/4 P-02, 03, 19, 28



TIRE PRESSURE

VEHICLE LOAD CAPACITY: 38 kg (841 lbs)

ITEM SPECIFICATION NOTESpark plug Type NGK: BPR4H

Gap 0.50 – 0.60(0.020 – 0.024)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Secondary 13 – 20 Ω Plug cap –

TerminalGenerator coil resistance Primary 100 – 160 Ω B/Y – GroundIgnition coil primary peak voltage More than 100 V : B/Y

: Ground

ITEM STANDARD LIMITFront brake lever play 3 – 7

(0.12 – 0.28) —

Rear brake lever play 4 – 6(0.16 – 0.24) —


Rear — 110.7(4.36)


Wheel rim size Front & Rear 7 × 6.0 AT —

Toe-in (with 30 kg load) 1.5 ± 3(0.06 ± 0.12) —

Turning radius 2.0 m(6.6 ft) —

Camber 0° —Caster 3° —Trail 10

(0.39) —

Steering angle Inside 33° 40’ —Outside 24° —

Tire size Front AT16 × 8.00-7 —Rear AT16 × 8.00-7 –


Rear — 4.0(0.16)


FRONT 20 0.20 2.9REAR 20 0.20 2.9

4/4 P-02, 03, 19, 28


FUEL + OIL

ITEM STANDARD LIMITFront suspension stroke 31

(1.22) —


Rear suspension stroke 31(1.22) —




P-03, 28


For the others


Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTORLUBRICANT or an equivalent good quality syn-thetic based 2-stroke engine oil rated FC under theJASO classification.

P-03

Use SUZUKI CCI SUPER OIL. If they are not avail-able, use a good quality 2-stroke engine oil ratedFC under the JASO classification.

For the others


Transmission oil type SAE 10W-40Transmission oil capacity Charge 500 ml

(0.53/0.44 US/lmp qt)

Overhaul 550 ml(0.58/0.48 US/lmp qt)

LE
P RM60
1/4 P-03, 24, 28

ENGINE TOP END Unit: mm

ENGINE BOTTOM END/TRANSMISSION Unit: mm

ITEM STANDARD LIMITCylinder compression (Usable range)

770 – 1 200 kPa(7.7 – 12 kgf/cm2, 109 – 171 psi)

—

Cylinder head warp — 0.03Cylinder inside diameter 43.000 – 43.015 43.10Piston diameter 42.965 – 42.980 42.83Piston/cylinder clearance 0.030 – 0.040 —Piston ring/groove clearance 0.02 – 0.06 0.16Piston ring groove width 1.01 – 1.03 1.10Piston ring thickness 0.97 – 0.99 0.90Piston ring end gap 0.15 – 0.35 0.70Piston pin diameter 11.995 – 12.000 11.96Piston pin hole diameter 12.000 – 12.006 12.07Small end inside diameter 16.002 – 16.013 16.05

ITEM STANDARD LIMITTransmission oil grade SE class —Transmission oil viscosity SAE 10W-30 or 10W-40 —Transmission oil amount 0.6 L —Connecting rod bend and twist Not more than 0.03 mm/100 mm 0.2 mm/100 mmConnecting rod big end radial clearance 0.021 – 0.033 0.08

Connecting rod big end side clear-ance 0.35 – 0.45 0.7

Crankshaft runout Not more than 0.03 mm 0.10Transmission gear backlash 0.02 – 0.19 0.26Shift fork finger thickness 3.9 – 4.0 3.8Gear shift fork groove width 4.05 – 4.15 4.25Shift fork guide pin diameter 5.9 – 6.0 5.85Shift drum groove width 6.05 – 6.20 6.25

SAM

2/4 P-03, 24, 28

ENGINE RIGHT SIDE Unit: mm

FINAL DRIVE Unit: mm

FUEL SYSTEM Unit: mm

COOLING SYSTEM

ITEM STANDARD LIMITClutch lever free play 2 – 3 —Clutch spring free length 26.6 25.3Friction plate thickness 3.1 – 3.3 2.9Friction plate/clutch housing clear-ance 0.35 – 0.60 0.9

Friction and steel plate warp Not more than 0.15 mm 0.3

ITEM STANDARD LIMITDrive chain Type DAIDO: D.I.D. 420M —

Links 104 links —20-link length 254.0 259

Drive chain slack 15 – 30 Less than 15 mmMore than 35 mm

Engine sprocket diameter 44.71 – 44.91 mm/13T 44.0Rear sprocket diameter 170.3 – 170.8 mm/44T 170Rear sprocket warp under 0.4 mm 0.5

ITEM STANDARD LIMITThrottole grip free play 2 – 3 —Carburetor type MIKUNI VM24SS —Main jet #200 —Needle jet N-8 —Throttle valve cutaway 2.0 —Jet needle 5I14-3 —Jet needle clip position 3rd groove from the top —Pilot jet #30Servise fuel level 1.5 ± 1 —Bore center 26 —Float height 21.1 ± 2 —Air cleaner element oil 2-stroke racing oil or

high-quality foam-air filter oil —

Reed valve warp — 0.2

ITEM STANDARDCoolant type Permanent type antifreeze for aluminum engines and radiatorsCoolant color GreenCoolant mixed ratio Soft water 50%, coolant 50%Coolant total amount 0.5 LRadiator cap relief pressure 95 – 125 kPa

(0.95 – 1.25 kgf/cm2, 14 – 18 psi)

134

3/4 P-03, 24, 28

ELECTRICAL SYSTEM Unit: mm

BRAKES Unit: mm

WHEELS/TIRES Unit: mm

ITEM STANDARD NOTEIgnition timing 18.5° BTDC at 6 000 r/min (rpm)Ignition coil 3 needle

arcing dis-tance

7 mm or more

Primary winding

resistance0.25 – 0.37 Ω

Second-ary wind-

ing resistance

2.5 – 3.7 kΩ

Spark plug Type NGK B9EG (AS)(CN)(EU) BR9EGGap 0.5 – 0.6

ITEM STANDARD LIMITBrake lever free play 4 – 5 —Brake pedal position Adjustable (to suit rider) —Brake pedal play 20 – 30 —Brake cam lever angle 80 – 90° —Brake shoe lining thickness 2.1 – 3.0 1.2Brake shoe spring free length Front 30.8 – 31.2 32.8

Rear 32 – 33 34.5Brake drum inside diameter Front &

Rear 90.000 – 90.087 90.75

Brake camshaft hole inside diame-ter 12.000 – 12.027 12.18

Brake camshaft diameter 11.957 – 11.984 11.83

ITEM STANDARD LIMITWheel rim runout Axial Under 0.5 mm 2

Radial Under 0.8 mm 2Axle runout/100 mm Front &

Rear Under 0.10 mm 0.2

Tire size Front 60/100-14 —Rear 80/100-12 —

Tire type Front DUNLOP K195 —Rear DUNLOP K195 —


100 kPa(1.0 kgf/cm2, 14 psi) —

4/4 P-03, 24, 28

SUSPENSIONS Unit: mm

ITEM STANDARD LIMITFront Air pressure Atmospheric pressure 40 kPa

(0.4 kgf/cm2, 6 psi)Front fork oil viscosity SHOWA SS-8 or SAE 5W-20 —Front fork oil capacity(completely dry) 181 ± 2.5 ml —

Front fork oil level(fully compressed, spring removed) 132 ± 5

(Adjustable range)

100 – 165Front fork spring free length 487.9 478Rear shock absorber spring adjust-ing sleeve position —

(Adjustable range)1 – 5

LE
P RM65
1/4 E-03, 21, 24, 28




755 – 1 177 kPa(7.70 – 12.0 kgf/cm2, 109 – 171 psi)

—

Cylinder head warp — 0.03Cylinder inside diameter (15 mm below from the cylinder top end) 44.500 – 44.515 44.64

Piston diameter 44.460 – 44.475 44.31Piston/cylinder clearance 0.042 – 0.052 —Piston ring/groove clearance Top &

Second 0.02 – 0.06 0.16

Piston ring groove width Top & Second 1.01 – 1.03 1.11

Piston ring thickness Top & Second 0.97 – 0.99 0.90

Piston ring end gap Top & Second 0.15 – 0.35 0.65

Piston pin diameter 11.995 – 12.000 11.96Piston pin hole diameter 12.001 – 12.011 12.08Small end inside diameter 16.002 – 16.013 16.05

ITEM STANDARD LIMITTransmission oil type API SE, SF or SG


Transmission oil viscosity SAE 10W-40 —Transmission oil capacity 0.5 L —Connecting rod bend Not more than 0.05 mm/100 mm 0.2 mm/100 mmConnecting rod twist Not more than 0.05 mm/100 mm 0.2 mm/100 mmConnecting rod big end radial clearance 0.025 – 0.037 0.09


Crankshaft runout Not more than 0.03 mm 0.05Shift fork ear thickness 3.90 – 4.00 3.80Gear shift fork groove width 4.05 – 4.15 4.25Shift fork guide pin diameter 5.90 – 6.00 5.80Shift drum groove width 6.05 – 6.20 6.25

SAM

2/4 E-03, 21, 24, 28




ITEM STANDARD LIMITClutch lever free play 2 – 3 —Friction plate thickness 3.1 – 3.3 2.9Steel plate thickness 1.47 – 1.73 1.37Friction plate warp Not more than 0.2 mm 0.3Steel plate warp Not more than 0.15 mm 0.3Clutch spring free length 28.1 26.7Friction plate/clutch housing clear-ance 0.3 – 0.6 0.9

ITEM STANDARD LIMITDrive chain Type DAIDO: D.I.D. 420MBK1 —

Links 110 links —20-link length 254.0 – 254.6 259

Drive chain slack 44 – 54 44 mm or less59 mm or more

Engine sprocket diameter 44.70 – 44.90/13T 44.0Rear sprocket diameter 182.38 – 182.88/47T 182.1Rear sprocket warp under 0.4 mm 0.5

ITEM STANDARD LIMITThrottole grip free play and cable 2 – 3 —Carburetor type MIKUNI VM24SS —Main jet #190 —Throttle valve cutaway #1.5 —Jet needle WY-3 —Jet needle clip position 4th groove from the top —Needle jet O-0 —Slow jet #25Air screw 1 and 1/2 (turns out) —Main air jet 0.8 (Pressed in) —Servise fuel level (below the bottom edge of the carburetor body) 0.5 ± 1 —

Float height 21.1 ± 1 —Air cleaner element oil High quality foam air filter oil —Reed valve warp — 0.5

135

3/4 E-03, 21, 24, 28

COOLING SYSTEM


BRAKES Unit: mm

ITEM STANDARDCoolant type Permanent type antifreeze for aluminum engines and radiatorsCoolant color GreenCoolant mixed ratio Soft water 50%, coolant 50%Coolant total amount 0.4 LRadiator cap relief pressure 108 – 137 kPa

(1.1 – 1.4 kgf/cm2, 16 – 20 psi)

ITEM STANDARD NOTEStator coil resistance 214 Ω ± 20% : B/R

: B/WIgnition timing 20.5° BTDC at 6 000 r/min (rpm)Ignition coil 3 needle arcing

distance 7 mm or more

Primary winding resistance 0.31 Ω ± 15% (at 20 °C)

Secondary winding resistance 3.1 kΩ ± 15% (at 20 °C)

Spark plug Type NGK BR10EG (US) B10EGGap 0.5 – 0.6

C.D.I. unit Ignition coil primary peak voltage 115 V or above : Ground

: OStator coil primary

peak voltage 100 V or above : B/R: B/W

ITEM STANDARD LIMITBrake lever free play Adjustable (to suit rider) —Brake fliud type DOT 3 or DOT 4 —Brake pad lining thickness Front &

Rear 4.5 0.7

Brake disc thickness Front & Rear 2.80 – 3.20 2.5

Brake disc runout Front & Rear Not more than 0.15 mm 0.3

4/4 E-03, 21, 24, 28



ITEM STANDARD LIMITWheel rim runout (Axial & Radial) Front &

Rear 1.0 mm or less 2

Axle runout/100 mm Front & Rear 0.1 0.2


98 kPa(1.0 kgf/cm2, 14 psi) —


Tire type Front DUNLOP D755F, Tube —Rear DUNLOP D755, Tube —

ITEM STANDARD LIMITFront fork oil viscosity SS-8 or 10W-20 —Front fork oil capacity(completely dry) 252 ± 2.5 ml —

Front fork oil level(fully compressed, spring removed) 132 ± 2

(from top of inner tube)(Adjustable

range)98 – 142

Front fork spring free length 497.1 487.2Rear shock absorber spring pre-load adjustment(Adjusting nut position from the center of the upper mounting hole)

76.4(Adjustable

range)72.4 – 80.4

Rear shock spring free length 211.1 197.3Reservoir gas pressure 980 kPa

(10 kgf/cm2, 142 psi) —

Tie-rod sleeve outside diameter 17.989 – 18.000 17.96Rocker arm mounting bolt runout under 0.1 mm 0.2

LE
P RM85/L
1/5 P-03, 28




RADIATOR


(0.0016 – 0.0020)0.120

(0.0047)Cylinder bore 48.000 – 48.015

(1.8898 – 1.8904)Measure 15 mm (0.59 in) from the top surface.

Nicks or scratches

Piston diam. 47.955 – 47.970(1.8880 – 1.8886)

Measure 16 mm (0.63 in) from the skirt end.47.880

(1.8850)



Piston ring free end gap N Approx. 4.0 (0.16) 3.2(0.13)

Piston ring to groove clearance 0.020 – 0.060 (0.008 – 0.0024)


0.80(0.031)

Piston pin bore 14.002 – 14.008(0.5513 – 0.5515)

14.030(0.5524)

Piston pin O.D. 13.995 – 14.000(0.5510 – 0.5512)

13.980(0.5504)

Reed valve clearance — 0.2(0.008)


(0.7088 – 0.7091)18.040

(0.7102)Crank web to web width 44.9 – 45.1

(1.767 – 1.775) —



(0.4 – 0.6) —


2.4(0.094)



ITEM STANDARD LIMITRadiator cap valve opening pres-sure

110 kPa(1.1 kgf/cm2, 16 psi) —

SAM

2/5 P-03, 28



CARBURETOR

ITEM STANDARD LIMITPrimary reduction ratio 3.444 (62/18) —Final reduction ratio 3.357 (47/14) RM85 —

3.615 (47/13) RM85L —Gear ratios Low 2.545 (28/11) —

2nd 1.933 (29/15) —3rd 1.571 (22/14) —4th 1.333 (20/15) —5th 1.166 (21/18) —Top 1.045 (23/22) —

Shift fork to groove clearance No. 1, No. 2 & No. 3

0.05 – 0.25(0.002 – 0.010)

0.45(0.018)


No. 2 & No. 3

4.45 – 4.55(0.175 – 0.179) —


No. 2 & No. 3

4.30 – 4.40(0.169 – 0.173) —

ITEM STANDARD LIMITDrive chain Type D.I.D. 428G2 —

Links118 RM85 —112 RM85L —

20-pitch length — 259


(1.6 – 2.0) —

ITEM SPECIFICATIONCarburetor type KEIHIN PE28Bore size 28 mmI.D. No. 03B1 Float height 19.0 ± 0.5 mm (0.75 ± 0.02 in)Main jet (M.J.) #125Jet needle (J.N.) 24NAAH-3rdSlow jet (S.J.) #50Air screw (P.A.S.) 2 turns outThrottle cable play 2 – 4 mm (0.08 – 0.16 in) at the throttle grip

136

3/5 P-03, 28



ITEM SPECIFICATION NOTESpark plug Type NGK: BR10ES

Gap 0.7 – 0.8(0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.Ignition coil resistance Primary 0.2 – 1.0 Ω W/Bl – Ground


Magneto coil resistance 100 – 160 Ω B/R – R/W140 – 230 Ω R/W – B/W240 – 380 Ω B/R – B/W

Ignition coil primary peak voltage More than 200 V : Ground : W\Bl

ITEM STANDARD LIMITBrake lever play 5 – 20

(0.20 – 0.79) —

Brake disk thickness Front 2.8 – 3.2(0.110 – 0.126)

2.5(0.10)

Rear 2.85 – 3.15(0.112 – 0.124)

2.5(0.10)

Brake disk runout — 0.30(0.012)


Rear 12.700 – 12.743(0.5000 – 0.5017) —


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.076(1.0630 – 1.0660) —


Rear 26.920 – 26.970(1.0600 – 1.0618) —


Radial — 2.0(0.08)


Rear — 0.25(0.010)

4/5 P-03, 28


TIRE PRESSURE

ITEM STANDARD LIMITTire size

Front70/100-17 40M RM85 —70/100-19 42M RM85L —

Rear90/100-14 49M RM85 —90/100-16 52M RM85L —


(10.8) —


Front fork spring rate (each leg) 2.6 N/mm (0.26 kgf/mm) —Front fork oil level 115

(4.53) —

Front fork damping force adjuster Rebound 1 and 1/8 turns out —Compres-

sion 7 clicks out —

Front fork air pressure 0 kPa(0 kgf/cm2, 0 psi) —

Rear shock absorber gas pressure 1 000 kPa(10 kgf/cm2, 142 psi) —


RM85: 2 mm (0.08 in) compressed from springfree length

RM85L: 5.5 mm (0.22 in) compressed from springfree length

—

Rear shock absorber damping force adjuster Rebound RM85: 1 and 1/2 turns out

RM85L: 1 and 1/4 turns out —

Compression 1 and 3/4 turns out —Rear shock absorber spring rate RM85: 48 N/mm (4.8 kgf/mm)

RM85L: 50 N/mm (5.0 kgf/mm) —



Front & Rear 70 – 110 kPa(0.7 – 1.1 kgf/cm2, 10 – 16 psi)

LE
P
5/5 P-03, 28

FUEL + OIL + COOLANTITEM SPECIFICATION NOTE

Fuel type Unleaded gasoline minumum 95 octane (RON)Fuel tank capacity 5.0 L

(1.3/1.1 US/Imp gal)Engine oil type MOTUL 800 2T or

equivalent Two Cycle Racing LubricantEngine coolant type Use an anti-freeze & Summer engine coolant com-

patible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50.

Engine coolant tank capacity 570 ml(1.20/1.00 US/Imp pt)

Transmission oil type SAE 10W-40Transmission oil capacity Change 550 ml

(1.16/0.97 US/Imp pt)

Overhaul 650 ml(1.37/1.14 US/Imp pt)

Brake fluid type DOT 4Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oilFront fork oil capacity (each leg) 357 ml

(12.07/12.57 US/Imp oz)Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-15

or an equivalent rear suspension oilRear shock absorber oil capacity 150 ml

(5.07/5.28 US/Imp oz)

SAM

137

RM100

1/4 E-03, 24, 28





825 – 1 280 kPa(8.4 – 13.0 kgf/cm2, 119 – 185 psi)

—

Cylinder head warp — 0.03Cylinder inside diameter 52.505 – 52.520 52.60Piston diameter 52.435 – 52.450 52.29Piston/cylinder clearance 0.065 – 0.075 —Piston ring/groove clearance Top 0.040 – 0.080 0.18

Second 0.020 – 0.060 0.16Piston ring groove width Top 1.03 – 1.05 1.13

Second 1.01 – 1.03 1.11Piston ring thickness Top &

Second 0.97 – 0.99 0.90

Piston ring end gap Top & Second 0.30 – 0.50 0.80

ITEM STANDARD LIMITTransmission oil type API SE, SF or SG


Transmission oil viscosity SAE 10W-40 —Transmission oil level in middle of level gauge —Transmission oil capacity 0.65 L —Connecting rod big end radial clearance 0.023 – 0.035 0.08


Crankshaft runout TIR 0.03 or less TIR 0.08Shift fork ear thickness 3.9 – 4.0 3.8Gear shift fork groove width 4.05 – 4.15 4.3Shift fork guide pin diameter 5.9 – 6.0 5.8Shift drum groove width 6.05 – 6.20 6.3

ITEM STANDARD LIMITClutch lever free play 2 – 3 —Friction plate thickness 2.8 – 2.9 2.7Friction and steel plate warp 0.15 or less 0.3Clutch spring free length 35.0 34.0

2/4 E-03, 24, 28



COOLING SYSTEM

ITEM STANDARD LIMITDrive chain Type DAIDO: D.I.D. 420DS —

Links 124 links, Endless —20-link length 254.0 259

Drive chain slack60 – 70

Too tight less than 54 mm

Too loose more than 69 mm

Rear sprocket warp 0.4 or less 0.5

ITEM STANDARD LIMITThrottole grip free play and cable 2 – 3 —Carburetor type KEIHIN PWK28 —Main jet #138 —Main air jet #60 —Throttle valve cutaway #3.5 —Jet needle NAPF —Jet needle clip position 4th groove from the top —Pilot jet (Slow jet) #45 —Air screw 1 and 3/8 —Starter jet #62 —Servise fuel level(below the float bowl mating sur-face)

1.0 ± 1 —

Float height 19 ± 1 —Air cleaner element oil High quality foam air filter oil —Reed valve warp — 0.2

ITEM STANDARDCoolant type Permanent type antifreeze (soft water and ethylene glycol plus corro-

sion and rust inhibitor chemicals for aluminum engines and radiators)Coolant color GreenCoolant mixed ratio Soft water 50%, coolant 50%Coolant freezing point –35 °C (–31 °F)Coolant total amount 0.67 LRadiator cap relief pressure 93 – 123 kPa

(0.95 – 1.25 kgf/cm2, 14 – 18 psi)

LE
P
3/4 E-03, 24, 28


BRAKES Unit: mm


ITEM STANDARD NOTEMagneto output voltage 16 V or more —Pickup coil air gap 0.4 – 0.6 —Pickup coil resistance 396 – 594 Ω —Pickup coil peak voltage 4.0 V or more —Ignition coil 3 needle

arcing dis-tance

6 mm or more —

Primary winding

resistance0.36 – 0.48 Ω —

Second-ary wind-

ing resistance

5.4 – 7.4 kΩ —

Peak volt-age 110 V or more —

Spark plug gap 0.7 – 0.8 —Spark plug resistance 3.75 – 6.25 kΩ —Magneto stator coil resistance 288 – 432 Ω —

ITEM STANDARD LIMITBrake lever free play Adjustable (to suit rider) —Brake pad lining thickness Front &

Rear 4.0 1

Brake disc thickness Front & Rear 2.85 – 3.15 2.5

Brake disc runout Front & Rear 0.12 or less 0.3

Brake fliud type DOT 4 —

ITEM STANDARD LIMITWheel rim runout (Axial & Radial) Front &

Rear 1.0 or less 2

Axle runout/100 mm Front & Rear 0.10 or less 0.2

Tire air pressure Front & Rear 100 kPa (1.0 kgf/cm2, 14 psi) —

Tire size Front 70/100-19, 70/100-19 42M (EU) —Rear 90/100-16, 90/100-16 52M (EU) —

Tire type Front BRIDGESTONE M61DUNLOP D752 (EU) —

Rear BRIDGESTONE M58DUNLOP D752 (EU) —

SAM

4/4 E-03, 24, 28


ITEM STANDARD LIMITFront fork air pressure Atmospheric pressure —Front fork compression damping adjustment 6 clicks —

Front fork oil viscosity KAYABA 01 or SAE 5W —Front fork oil capacity 321 ± 4 ml —Front fork oil level(fully compressed, spring removed) 90 ± 2

(Adjustable range)

75 – 115Front fork spring free length 430 422Rear shock absorber compression damper setting (upper) 2nd position

(Adjustable range)4 clicks

Rear shock absorber rebound damper setting (lower) 11th click from fully clockwise position

(Adjustable range)

20 clicksRear shock absorber standard adjusting nut position 76 —

Rear shock absorber nut adjusting range 63 – 95 —

Rear shock absorber standard spring set length 244.5 —

Rear shock absorber oil type KYB K-2C (SAE 5W or Bel-Ray SE2 #40) —Rear shock absorber oil total amount 161 ml —

Rear shock absorber gas pressure 980 kPa(10 kgf/cm2, 142 psi) —

Rear shock absorber spring free length 256 250

138

RM125

1/5 000, E-03, 28

CYLINDER + PISTON + PISTON RING

CONROD + CRANKSHAFT


(0.0012 – 0.0016)0.120

(0.0047)Cylinder bore 54.000 – 54.015


—

Piston diam. 53.965 – 53.980(2.1246 – 2.1252)

Measure 19 mm (0.75 in) from the skirt end.53.880

(2.1213)



Piston ring free end gap Approx. 4.3 (0.17) 3.4(0.13)


0.80(0.031)

Piston ring to groove clearance 0.045 – 0.060(0.0018 – 0.0024) —

Piston pin bore 15.002 – 15.008(0.5905 – 0.5907)

15.030(0.5917)

Piston pin O.D. 14.995 – 15.000(0.5904 – 0.5906)

14.980(0.5898)


(0.7481 – 0.7485)19.040



(0.0118 – 0.0315) 1.0

Crank web to web width 53.9 – 54.1(2.12 – 2.13) —


2/5 000, E-03, 28

CLUTCH

RADIATOR

TRANSMISSION

DRIVE CHAIN


(0.40 – 0.60) —

Drive plate thickness No. 1, 2 2.72 – 2.88(0.107 – 0.113)

2.42(0.094)

Drive plate claw width No. 1, 2 13.85 – 13.96(0.545 – 0.550)

13.05(0.514)



37.8(1.49)

ITEM STANDARD LIMITRadiator cap valve release pressure

95 – 125 kPa(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi) —


2nd 1.687 (27/16) —3rd 1.444 (26/18) —4th 1.200 (24/20) —5th 1.052 (20/19) —Top 0.950 (19/20) —

Shift fork to groove clearance No. 1, 2 & 3 0.05 – 0.25(0.002 – 0.010)

0.45(0.018)

Shift fork groove width No. 1, 2 & 3 4.95 – 5.05(0.195 – 0.200) —

Shift fork thickness No. 1, 2 & 3 4.80 – 4.90(0.190 – 0.193) —

ITEM STANDARD LIMITDrive chain Type D.I.D. 520DMA2 —

Links 114 —

20-pitch length — 323.8(12.7)

Drive chain slack 40 – 50(1.6 – 2.0)

LE
P
3/5 000, E-03, 28

CARBURETOR

ELECTRICAL

BRAKE + WHEEL

ITEMSPECIFICATION

USA, 000 OthersCarburetor type TMX38S ←Bore size 38 mm ←I.D. No. 36F4 36F5Float height 8.7 ± 1.0 mm (0.34 ± 0.04 in) ←Main jet (M.J.) #390 #460Jet needle (J.N.) 6CHY16-62-3rd 6CHY17-62-4thPilot jet (P.J.) #42.5 #42.5Cut-away (C.A.) 5.0 5.0Air screw (A.S.) 1 and 1/2 turns out 1 and 1/2 turns outThrottle cable play 2 – 4 mm

(0.08 – 0.16 in) at the throttle grip

ITEM SPECIFICATION NOTEIgnition timing 5° B.T.D.C. at 1 000 r/minSpark plug Type NGK: R6918B-8

Gap 0.55 – 0.65(0.022 – 0.026)

Spark performance Over 8 (0.3) at 1 atm.Pick-up coil resistance 75 – 125 Ω R – GPick-up peak voltage 3 V and more G – RExciter peak voltage 30 V and more R/W –

B/RIgnition coil resistance Primary 0.15 – 0.45 Ω W/Bl – B/W

Secondary 12 – 21 kΩ Plug cap – W/BlIgnition coil primary peak voltage 210 V and more B/W –

W/BlExciter coil resistance 18 – 30 Ω R/W – B/R

ITEM STANDARD LIMITBrake lever adjuster length 11 – 15

(0.4 – 0.6) —

Rear brake pedal height 0 – 10(0 – 0.4) —


2.5(0.10)

Rear 4.0 ± 0.2(0.157 ± 0.008)

3.5(0.14)

Brake disc runout Front & Rear — 0.30


(0.4331 – 0.4348) —

Rear 12.700 – 12.743(0.5000 – 0.5017) —

SAM

4/5 000, E-03, 28

SUSPENSION

ITEM STANDARD LIMITMaster cylinder piston diam. Front 10.957 – 10.984

(0.4314 – 0.4324) —

Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.050(1.0630 – 1.0650) —


Rear 26.900 – 26.950(1.0598 – 1.0617) —

Brake fluid type DOT4Wheel rim runout Axial — 2.0

(0.08)

Radial — 2.0(0.08)

Wheel rim size Front 1.60 × 21Rear 1.85 × 19


Rear — 0.25(0.010)



(12.2) —

Front fork spring free length

494 ± 2.4(19.45 ± 0.09) 487 (19.17)

Front fork damping force adjuster

Rebound MAX-11 clicksturns back —

Compres-sion

MAX-9 clicksturns back —


Front fork spring rate 4.2 N/mm(0.42 kgf/mm) —

Rear shock absorber gas pressure 981 kPa(9.8 kgf/cm2, 139.5 psi) —

Rear shock absorber spring set length 6.7 (0.26) —

6.7 mm compressed from spring free length

Rear shock absorber spring rate 50 N/mm(5 kgf/mm) —

139

5/5 000, E-03, 28

TIRE PRESSURE


ITEM STANDARD LIMIT NOTERear shock absorber damping force adjuster

Rebound MAX-11 clicks turns back —

Compres-sion (High speed)

MAX-2 and 1/8 turns back —

Compres-sion (Low speed)

MAX-8 clicks turns back —



Front & Rear 70 – 110 kPa(0.7 – 1.1 kgf/cm2, 10 – 16 psi)


octane (R/2 + M/2 method).E-03, 28

Use only unleaded gasoline of at least 95 octane(Research method).

The others

Fuel tank capacity 8.0 L(2.1/1.8 US/Imp gal)

Engine oil type SUZUKI CCI SUPER 2-CYCLE MOTOR LUBURICANT or equivalent Two Cycle Racing Lubricant E-03

MOTUL 800 2T FACTORY LINE OFF ROAD

or equivalent Two Cycle Racing LubricantThe others

Fuel and engine oil mixture ratio 30 : 1Transmission oil type SAE 10W-40Transmission oil capacity Change 750 ml

(0.8/0.7 US/Imp qt)

Overhaul 800 ml(0.9/0.8 US/Imp qt)

Front fork oil type SUZUKI fork oil SS-05 or an equivalent fork oilFront fork oil capacity(each leg)

373 ml(12.6/13.1 US/Imp oz)

Outer tube oil quantity

180 ml(6.08/6.33 US/lmp oz)

Damper rod oil quantity

Engine coolant type Use an anti-freeze & summer engine coolant com-patible with aluminum radiator, mixed with distilledwater only, at the ratio of 50:50.

Engine coolant capacity 1 100 ml(1.2/1.0 US/Imp qt)

Rear shock absorber oil type SUZUKI rear suspension oil SS-25 or an equivalent suspension oil

Rear shock absorber oil capacity 380 ml(12.8/13.4 US/Imp oz)
LE
P
RM250
1/5 000, E-03, 28



ITEM STD/SPEC. LIMITPiston to cylinder clearance 0.045 – 0.055

(0.0018 – 0.0022)0.120

(0.0047)Cylinder bore 66.400 – 66.415


Nicks or scratches

Piston diam. 66.350 – 66.365(2.6122 – 2.6128)

Measure 25.5 mm (1.00 in) from the skirt end.66.280

(2.6100)



Piston ring free end gap 1st & 2nd R Approx. 8.4 (0.33) 6.7

(0.26)Piston ring end gap 1st & 2nd 0.30 – 0.45

(0.012 – 0.018)0.50

(0.02)Piston ring to groove clearance 1st & 2nd 0.020 – 0.060

(0.0008 – 0.0024) —

Piston pin bore 18.002 – 18.008(0.7087 – 0.7090)

18.030(0.7098)

Piston pin O.D. 17.995 – 18.000(0.7085 – 0.7087)

17.980(0.7079)


(0.9056 – 0.9059)23.040


(0.12)Conrod big end side clearance — 1.0

(0.04)Crank web to web width 59.9 – 60.1

(2.358 – 2.366) —


SAM

2/5 000, E-03, 28


RADIATOR + COOLANT

TRANSMISSION + DRIVE CHAIN

ITEM STD/SPEC. LIMITClutch lever play 10 – 15

(0.40 – 0.60) —


2.77(0.109)


13.05(0.514)



37.8(1.49)

ITEM STD/SPEC. LIMITRadiator cap valve release pres-sure

95 – 125 kPa(0.95 – 1.25 kgf/cm2, 14 – 18 psi) —

Engine coolant type Use a anti-freeze & Summer coolant compatiblewith aluminum radiator, mixed with distilled wateronly, at the ratio of 50:50.

—

Engine coolant capacity 1100 ml(1.2/1.0 US/Imp qt) —


2nd 1.470 (25/17) —3rd 1.210 (23/19) —4th 1.000 (21/21) —Top 0.869 (20/23) —

Shift fork to groove clearance 0.10 – 0.30 mm(0.004 – 0.012 in)

0.50 mm(0.020 in)

Shift fork groove width 4.80 – 4.90 mm(0.189 – 0.193 in) —

Shift fork thickness 4.60 – 4.70 mm(0.181 – 0.185 in) —

Drive chain Type DAIDO: D.I.D. 520DMA2 —Links 114 links —

20-pitch length — 323.8 mm(12.75 in)

Drive chain slack 40 – 50 mm(1.6 – 2.0 in) —

Gearshift lever height 0 – 5 mm below(0 – 0.2 in) —

140

3/5 000, E-03, 28

CARBURETOR

ELECTRICAL


ITEM STD/SPEC.Carburetor type KEIHIN PWK38SBore size 39 mm (1.54 in)I.D. No. 37F7Float height 6.5 ± 1.0 mm (0.26 ± 0.04 in)Main jet (M.J.) #172Jet needle (J.N.) NEDH-4thCut-away (C.A.) #7Slow jet (S.J.) #50Air screw (A.S.) 1 and 1/2 turns outPower jet (PW.J.) #55Throttle cable play 2 – 4 mm (0.08 – 0.16 in) at the throttle grip

ITEM STD/SPEC. NOTESpark plug Type NGK: BR8EG

Gap 0.5 – 0.6 mm(0.020 – 0.024 in)

Ignition coil resistance Primary 0.17 – 0.46 Ω W/Bl – B/WSecondary 13 – 20 kΩ W/Bl – Plug cap

Magneto coil resistance 78 – 122 G – R28 – 46 R/W – B/R

ITEM STD/SPEC. LIMITRear brake pedal height 0 – 10 mm below

(0 – 0.39 in) —


2.5(0.10)

Rear 3.8 – 4.2(0.15 – 0.17)

3.5(0.14)

Brake disc runout Front & Rear — 0.30


(0.4331 – 0.4348) —

Rear 12.700 – 12.743(0.5000 – 0.5017)


Rear 12.657 – 12.684(0.4983 – 0.4994) —


Rear 27.000 – 27.050(1.0630 – 1.0650) —

4/5 000, E-03, 28

TIRE

SUSPENSION

ITEM STD/SPEC. LIMITBrake caliper piston diam. Front 26.930 – 26.950

(1.0602 – 1.0610) —

Rear 26.918 – 26.968(1.0598 – 1.0617) —


(0.08)

Radial — 2.0(0.08)

Wheel rim size Front 21 × 1.60 —Rear 19 × 2.15 —


Rear — 0.25(0.010)

ITEM STD/SPEC. LIMITTire air pressure Front 70 – 110 kPa

(0.7 – 1.1 kgf/cm2, 10 – 16 psi) —

Rear 70 – 110 kPa(0.7 – 1.1 kgf/cm2, 10 – 16 psi) —


Tire tread depth(Recomend depth) — 4.0 mm

(0.16 in)

— 4.0 mm(0.16 in)

ITEM STD/SPEC. LIMITFront fork stroke 310 mm

(12.2 in) —

Front fork spring free length 494 mm(19.45 in)

487 mm(19.17 in)

Front fork spring rate 4.4 N/mm(0.44 kgf/mm) —

Front fork oil type SUZUKI FORK OIL SS-05 or an equivalent fork oil —Front fork oil capacity (each leg) OUTER: 362 ml (12.24/12.75 US/Imp oz)

— INNER: 180 ml (6.08/6.34 US/Imp oz)

Front fork damping force adjuster Compression 6 clicks turns back —Rebound 13 clicks tuns back —


Rear shock absorber gas pressure 981 kPa(9.8 kgf/cm2, 139.5 psi) —

Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 or an equivalent rear suspension oil —

Rear shock absorber oil capacity 380 ml (12.84/13.38 US/Imp oz) —LE
P
5/5 000, E-03, 28

FUEL + OIL

ITEM STD/SPEC. LIMITRear shock absorber spring set length

258 mm(10.16 in) —

Rear shock absorber spring rate 52 N/mm(5.2 kgf/mm) —


Rebound 11 clicks turns back —Compression (High speed) 1 and 7/8 turns back —

Compression(Low speed) 7 clicks turns back —

Rear wheel travel 310 mm(12.2 in) —

Swingarm pivot shaft runout — 0.3 mm(0.01 in)


octane (R/2 + M/2 method).For Canada

Use only unleaded gasoline of at least 95 octane(Research method).

For other countries

Fuel tank capacity 8.0 L(2.1/1.8 US/Imp gal)

Engine oil type MOTUL 800 2T FACTORY LINE OFF ROAD or equivalent Two Cycle Racing Lubricant

Fuel and engine oil mixture ratio 30:1Transmission oil type SAE 10W-40Transmission oil capacity Change 750 ml

(0.8/0.7 US/Imp qt)

Overhaul 850 ml(0.9/0.7 US/Imp qt)

SAM

Prepared by

March, 2004

Part No. 99563-01040-01E

140SAMPLE

20

04

STROKE

SE

RV

ICE

DA

TA

K4

9 9 5 6 3 - 0 1 0 4 0 - 0 1 E

SAMPLE

2004 service data 01e - serviceinfo mc info/2004_service data_manual.pdf · among the 2004 suzuki...

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