2004_Service data_01E.book

Transcription

2004_Service data_01E.book
2004
STROKE
SERVICE DATA
99563-01040-01E
K4
FOREWORD
Among the 2004 SUZUKI motorcycles and vehicles with 4 & 2 stroke engines, many new models
have 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 motorcycles 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 the
individual 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 modifications will be provided to the national distributors through service bulletins, etc., so if you have any
inquiry, please contact your distributor.
E
L
A
S
P
M
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
CONTENTS
4 STROKE
AN250 ....................................................................................................... 1
AN400 ....................................................................................................... 3
AN650 ....................................................................................................... 5
AN650A .................................................................................................... 7
DL650 ...................................................................................................... 9
DL1000 .....................................................................................................12
DR200SE (E-03, 28, 33) ...........................................................................14
DR200SE (E-06, 24) .................................................................................16
DR650SE ..................................................................................................18
DR-Z110 ...................................................................................................20
DR-Z125/L ................................................................................................22
DR-Z250 (E-03, 28, 33) ............................................................................24
DR-Z250 (E-24) ........................................................................................26
DR-Z400/E (E-01, 03, 28, 33) ...................................................................28
DR-Z400E (E-24) ......................................................................................30
DR-Z400S .................................................................................................32
GS125T ....................................................................................................34
GS500/U/F/FU ..........................................................................................36
GSF600/U/Z/ZU ........................................................................................38
GSF600S/SU ............................................................................................40
GSF1200/Z ...............................................................................................42
GSF1200S ................................................................................................45
GSX600F ..................................................................................................47
GSX750F ..................................................................................................50
GSX1300R/RZ/RUD/RUF .........................................................................52
GSX1400/UD ............................................................................................55
GSX-R600/UE/UF .....................................................................................57
GSX-R750/UF ...........................................................................................60
GSX-R1000 ..............................................................................................62
GZ125/U ...................................................................................................65
GZ250 .......................................................................................................67
LS650 .......................................................................................................69
LT-160/F160 .............................................................................................71
LT-A400/F ................................................................................................73
LT-A500F .................................................................................................75
LT-F250 ....................................................................................................77
LT-F300F ..................................................................................................79
LT-F400F ..................................................................................................81
LT-F500F ..................................................................................................83
LT-V700F ..................................................................................................85
LT-Z250 ....................................................................................................87
LT-Z400 ....................................................................................................89
RM-Z250 ...................................................................................................91
RV125 .......................................................................................................93
SD110/S ...................................................................................................94
SV650/S/SU/U ..........................................................................................96
SV1000/UD/UF .........................................................................................98
SV1000SD/SF ........................................................................................101
UH125 .....................................................................................................103
UH150 .....................................................................................................105
VL125/U ..................................................................................................106
VL250 .....................................................................................................108
VL800/Z ..................................................................................................109
E
L
A
S
P
M
CONTENTS
VL1500 .................................................................................................. 111
VS800GL ............................................................................................... 113
VS1400GLP ........................................................................................... 116
VZ800 .................................................................................................... 118
VZ1600 .................................................................................................. 121
2 STROKE
A100X/XS .............................................................................................. 124
AY50 ...................................................................................................... 125
AY50W ................................................................................................... 126
JR50 ...................................................................................................... 128
JR80 ...................................................................................................... 129
LT50 ....................................................................................................... 130
LT80 ....................................................................................................... 131
LT-A50 ................................................................................................... 132
RM60 ..................................................................................................... 133
RM65 ..................................................................................................... 134
RM85/L .................................................................................................. 135
RM100 ................................................................................................... 137
RM125 ................................................................................................... 138
RM250 ................................................................................................... 139
E
L
A
S
P
M
COUNTRY AND AREA CODE
These may be some differences amoung models depending on specifications. If the service data differ, it is noted there by using the following codes.
The following codes stand for the applicable country(-ies) and area(-s).
CODE
E-01
E-02, P-02
E-03 P-03
E-06
P-09
E-13
E-17 P-17
E-19, P-19
P-21
E-24, P-24
COUNTRY OR AREA
General
U. K.
U. S. A. (Except for California)
South Africa
Colombia
Southeast Asia
Sweden
E. U.
Belgium
Australia
CODE
E-28, P-28
P-31
E-33, P-33
P-37
P-42
P-43
P-51
E-54, P-54
E-71, P-71
COUNTRY OR AREA
Canada
Philippines
California (U. S. A)
Brazil
Pakistan
Saudi Arabia
Korea
Isurael
Mexico
E
L
NOTE:
These service data are current as of APRIL 2004, and they are subject to change without
notice.
A
S
P
M
1
AN250
VALVE + VALVE GUIDE
ITEM
Valve diam.
Tappet clearance (when cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem deflection
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length
spring tension
Unit: mm
LIMIT
—
—
—
—
—
—
—
—
—
0.35
0.05
0.5
1.7
—
0.03
38.8
STANDARD
28.3
25.0
0.08 – 0.13
0.17 – 0.22
0.10 – 0.37
0.30 – 0.57
5.000 – 5.012
4.975 – 4.990
4.955 – 4.970
—
—
—
—
0.9 – 1.1
—
—
182 – 210 N
(18.2 – 21.0 kgf)
at length 31.5 mm
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
ITEM
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm shaft I.D.
Rocker arm shaft O.D.
Cylinder head distortion
IN. & EX.
IN. & EX.
Unit: mm
LIMIT
1050 kPa
(10.5 kgf/cm2)
0.120
73.090
STANDARD
1250 – 1650 kPa
(12.5 – 16.5 kgf/cm2)
0.04 – 0.05
73.000 – 73.015
72.955 – 72.970
Measure at 15 mm from the skirtend.
—
1st
R
9.3
2nd R
7.2
1st
0.10 – 0.30
2nd
0.35 – 0.50
1st
—
2nd
—
1st
1.01 – 1.04
2nd
1.01 – 1.04
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
19.002 – 19.008
18.996 – 19.000
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
Unit: mm
LIMIT
33.130
33.200
0.15
0.15
—
—
—
—
0.10
—
—
0.05
STANDARD
33.430 – 33.477
33.500 – 33.547
0.032 – 0.066
0.028 – 0.059
22.012 – 22.025
17.512 – 17.525
21.959 – 21.980
17.466 – 17.484
—
12.000 – 12.018
11.973 – 11.984
—
IN.
EX.
¬22
¬17.5
¬22
¬17.5
¬22
¬17.5
ITEM
Compression pressure
—
CAMSHAFT + CYLINDER HEAD
Cam height
CYLINDER + PISTON + PISTON RING
72.880
0.05
7.4
5.7
0.5
1.0
0.18
0.15
—
—
—
—
—
19.030
19.980
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Width between crankshaft webs
Crankshaft runout
Unit: mm
LIMIT
19.04
3.0
1.0
------0.08
STANDARD
19.006 – 19.014
—
0.10 – 0.75
21.95 – 22.00
59.9 – 60.1
—
OIL PUMP
ITEM
Oil pressure (at 60°C)
STANDARD
Above 80 kPa (0.8 kgf/cm2)
Below160 kPa (1.6 kgf/cm2)
at 3 000 r/min
LIMIT
—
CLUTCH
E
L
ITEM
Clutch wheel I.D.
Clutch shoe thickness
Engagement r/min
Lock-up r/min
1/7
A
S
TRANSMISSION
ITEM
Primary reduction ratio
Reduction ratio
Secondary reduction
Final reduction ratio
Drive V-belt width
Movable driven face spring free
length
Movable drive face roller O.D.
P
M
E-02, 19, 24, 38, 71
Unit: mm Except ratio
LIMIT
—
—
—
—
21.6
STANDARD
1.000
2.417 – 0.836
2.750
2.933
22.6
150
142.5
23.72 – 23.88
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor output voltage
Injector voltage
Ignition coil primary peak voltage
PAIR solenoid valve resistance
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2)
—
150 V and more (when cranking)
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Idle air screw opening
IAC valve resistance
Throttle cable play
—
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
NOTE
: G, : BI
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
SPECIFICATION
E-02, 19, 71, 24
14G0
31.2 mm
1600 – 2000 r/min
1500 ± 100 r/min
2 and 1/8 turns out
Approx. 3 – 9 Ω at 20 – 24 °C
2.0 – 4.0 mm
E38
14G1
←
←
←
←
←
←
STANDARD/SPECIFICATION
ITEM
Spark plug
: W
: Ground
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
—
Over 3.0 mm at 95 °C
20 °C
Approx. 2.58 kΩ
40 °C
Approx. 1.14 kΩ
80 °C
Approx. 0.28 kΩ
100 °C
Approx. 0.16 kΩ
107.9 – 137.3 kPa
(1.1 – 1.4 kgf/cm2)
ON
93 – 103 °C
OFF
87 – 97 °C
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reserve
Approx. 250 ml
tank side
Engine side
Approx. 1300 ml
—
E-02, 19, 24, 38, 71
—
—
—
—
—
—
—
—
Unit: mm
STANDARD/SPECIFICATION
NGK: CR7E
Type
DENSO: U22ESR-N
Gap
0.6 – 0.7
8.0 mm and over at 1 atm.
180 – 288 Ω
4.5 V and more
Primary
3–5Ω
Secondary
17 – 30 kΩ
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(When cold)
Generator Max. output
Regulated voltage
LIMIT
Approx.88 °C
ELECTRICAL
20 – 24 Ω at 20 °C
3/7
E-02, 19, 24, 38, 71
THERMOSTAT + RADIATOR + FAN + COOLANT
SPECIFICATION
10 – 18 Ω at 20 °C
35 ml and more
For 10 sec, at 300 kPa (3.0 kgf/cm2)
SPECIFICATION
180 – 280 Ω
4.5 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 0.6 kΩ
Opened
Approx. 3.8 kΩ
Closed
Approx. 0.6 V
Opened
Approx. 3.8 V
4.5 – 5.5 V
Approx. 1.14 kΩ at 40 °C
4.5 – 5.5 V
Approx. 1.14 kΩ at 40 °C
19.1 – 19.7 kΩ
Normal
1.3 V and less
Leaning
3.8 V and more
Battery voltage
2/7
THROTTLE BODY
FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
Unit: mm
LIMIT
135.5
2.0
—
—
STANDARD
135.0 – 135.2
3.0
2500 – 3100 rpm
4400 – 5400 rpm
150 V and more
0.2 – 0.6 Ω
Charging
NOTE
G-BI
: G, : BI
: W
: Ground
Y–Y
55 V and more at 5 000 r/min
Approx. 375 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
4/7
E-02, 19, 24, 38, 71
2
ITEM
Starter relay resistance
Battery
STANDARD/SPECIFICATION
3–6Ω
Type
designation
Capasity
HI
Headlight
LO
Meter
Ignition
Turn signal
Power source
Main
Fuse size
NOTE
ITEM
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diameter
Brake caliper cylinder bore
Brake caliper piston diameter
Unit: W
Headlight
HI
LO
Parking or position light
Brake light/Taillight
Taillight
Turn signal light
License light
Instrument panel light
Oil change indicator light
FI indicator light
Brake lock indicator light
High beam indicator light
Turn signal indicator light
Trunk light
Front
Rear
FT12A-BS
12 V 36 kC (10 Ah) /10 HR
15 A
15 A
10 A
10 A
15 A
10 A
30 A
WATTAGE
ITEM
BRAKE + WHEEL
E-02, 19, 71
35 × 2
35 × 2
5
21/5 × 2
21 × 4
5
1.7 × 3
1.7
1.7
1.7
1.7
1.7 × 2
5
STANDARD/SPECIFICATION
E-24
←
←
←
←
←
←
←
←
←
←
←
←
Wheel rim runout
E-38
←
←
Wheel axle runout
21 × 2
5
←
←
←
←
←
←
←
←
←
SUSPENSION
Wheel rim size
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Axial
Radial
Front
Rear
Front
Rear
Front
Solo riding
Front
Dual riding
Rear
Tire type
Tire tread depth
(Recommended depth)
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Transmission oil capacity
A
S
7/7
P
M
E-02, 19, 24, 38, 71
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
15.0 L
reserve
Fuel meter
Approx.
3.0 L
red zone
SAE 10W-40, API SF or SG
Oil change
1.9 L
Filter change
2.0 L
Overhaul
2.3 L
Oil change
190 ml
Overhaul
200 ml
NOTE
LIMIT
—
324
—
—
—
—
3rd
—
E-02, 19, 24, 38, 71
STANDARD
175 kPa
(1.75 kgf/cm2)
200 kPa
(2.00 kgf/cm2)
175 kPa
(1.75 kgf/cm2)
225 kPa
(2.25 kgf/cm2)
110/90-13M/C 55P
130/70-13M/C 63P
BRIDGESTONE HOOP B03G
—
—
—
E
L
Tire size
Fuel type
STANDARD
100
330.4
SUZUKI FORK OIL G-10 (#10)
284 ml
96
100
TIRE
Rear
FUEL + OIL
Unit: mm
LIMIT
4.0
5.0
0.30
—
—
—
—
—
—
—
—
2.0
2.0
0.25
0.25
—
—
Unit: mm
ITEM
Front fork stroke
Front fork spring free length
Front fork oil type
Front fork oil capacily (each leg)
Front fork oil level
Rear wheel travel
Rear shock absorber spring
adjuster
ITEM
Cold inflation tire pressure
5/7
STANDARD
4.5 ± 0.2
5.5 ± 0.2
—
11.000 – 11.043
14.000 – 14.043
10.957 – 10.984
13.957 – 13.984
33.960 – 34.010/22.650 – 22.700
25.400 – 25.450
33.878 – 33.928/22.568 – 22.618
25.318 – 25.368
—
—
—
—
13M/C × MT3.00
13M/C × MT3.50
Front
Rear
Front
Rear
Front
Rear
6/7
LIMIT
—
—
—
—
—
—
—
—
1.6 mm
2.0 mm
E-02, 19, 24, 38, 71
3
AN400
VALVE + VALVE GUIDE
ITEM
Valve diam.
Unit: mm (in)
LIMIT
STANDARD
––
EX.
Valve stem deflection
IN. & EX.
––
Valve stem runout
IN. & EX.
––
Valve head thickness
IN. & EX.
––
Valve stem end length
IN. & EX.
––
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
1.7
(0.07)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
––
Valve head radial runout
IN. & EX.
––
Valve spring free length
IN. & EX.
––
0.03
(0.001)
38.8
(1.53)
IN. & EX.
182 – 210 N
(18.2 – 21.0 kgf, 40.1 – 46.3 lbs)
at length 31.5 mm (1.24 in)
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
Valve spring tension
ITEM
Cam height
30.6
(1.20)
27.0
(1.06)
0.08 – 0.13
(0.003 – 0.005)
0.17 – 0.22
(0.007 – 0.009)
0.10 – 0.37
(0.004 – 0.015)
0.30 – 0.57
(0.012 – 0.022)
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
IN.
EX.
CAMSHAFT + CYLINDER HEAD
IN.
EX.
––
Camshaft journal oil clearance
––
¬22
¬17.5
––
Camshaft journal holder I.D.
––
¬22
¬17.5
––
Camshaft journal O.D.
––
¬22
¬17.5
––
Camshaft runout
––
Rocker arm shaft I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
Cylinder head distortion
Piston to cylinder clearance
860 – 900 kPa
(8.6 – 9.0 kgf/cm², 122 – 128 psi)
0.045 – 0.055
(0.0018 – 0.0022)
83.000 – 83.015
(3.2677 – 3.2683)
82.950 – 82.965 (3.2657 – 3.2663)
Measure at 15 mm (0.6 in) from the skirtend.
1st
R
Approx. 11.3 (0.44)
2nd
R
Approx. 7.7 (0.30)
0.20 –
(0.008 –
0.35 –
(0.014 –
1st
E
L
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
20.006 – 20.014
(0.7876 – 0.7880)
Conrod deflection
––
Conrod big end side clearance
0.10 – 0.75
(0.004 – 0.030)
21.95 – 22.00
(0.864 – 0.866)
59.9 – 60.1
(2.358 – 2.366)
Conrod big end width
Width between crankshaft webs
Crankshaft runout
P
M
E-02, 03, 19, 28, 33, 54
––
––
––
20.030
(0.789)
19.980
(0.787)
Unit: mm (in)
LIMIT
20.040
(0.789)
3.0
(0.12)
1.0
(0.04)
––
––
––
0.08
(0.003)
STANDARD
Above 80 kPa (0.8 kgf/cm², 11 psi)
Below 160 kPa (1.6 kgf/cm², 23 psi)
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
CLUTCH
ITEM
Clutch wheel I.D.
Clutch shoe thickness
Engagement r/min
Lock-up r/min
STANDARD
150.0 – 150.2
(5.906 – 5.913)
3.0
(0.12)
2 300 – 2 900 rpm
3 500 – 4 500 rpm
––
Unit: mm (in)
LIMIT
150.5
(5.925)
2.0
(0.08)
––
––
1st
––
––
2/8
ITEM
Primary reduction ratio
Reduction ratio
Secondary reduction
Final reduction ratio
Drive V-belt width
STANDARD
1.000
2.203 – 0.854
2.214
2.785
21.85
(0.86)
125
(4.92)
23.72 – 23.88
(0.93 – 0.94)
Movable driven face spring free
length
Movable drive face roller O.D.
Drive/Driven face wear
E-02, 03, 19, 28, 33, 54
Unit: mm (in)
LIMIT
616 kPa
(6.16 kgf/cm²,
88 psi)
0.120
(0.005)
83.085
(3.271)
82.880
(3.263)
0.05
(0.002)
9.0
(0.35)
6.2
(0.24)
0.70
(0.03)
1.0
(0.04)
0.18
(0.007)
0.15
(0.006)
E-02, 03, 19, 28, 33, 54
TRANSMISSION
Unit: mm (in) Except ratio
LIMIT
––
––
––
––
20.85
(0.82)
118.7
(4.67)
––
0.4
(0.02)
––
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
10 – 18 Ω at 20 °C (68 °F)
35 ml and more
For 10 sec, at 300 kPa (3.0 kgf/cm², 43 psi)
NOTE
––
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
––
––
FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor output voltage
Injector voltage
Ignition coil primary peak voltage
PAIR solenoid valve resistance
HO2 sensor resistance
HO2 sensor output voltage
3/8
0.35
0.014)
0.50
0.020)
2nd
––
––
––
0.05
(0.002)
STANDARD
2nd
Piston ring to groove clearance
LIMIT
––
––
Piston ring end gap
STANDARD
1.01 – 1.03
(0.0398 – 0.0406)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
0.97 – 0.99
(0.0382 – 0.0390)
0.97 – 0.99
(0.0382 – 0.0390)
20.002 – 20.008
(0.7874 – 0.7877)
19.992 – 20.000
(0.7871 – 0.7874)
––
0.10
(0.004)
––
ITEM
Compression pressure
Piston ring free end gap
1st
––
CYLINDER + PISTON + PISTON RING
Piston diam.
ITEM
Piston ring groove width
––
12.000 – 12.018
(0.472 – 0.473)
11.973 – 11.984
(0.471 – 0.472)
Cylinder distortion
1/8
––
––
Cylinder bore
––
Unit: mm (in)
LIMIT
33.130
(1.304)
33.000
(1.299)
0.15
(0.006)
0.15
(0.006)
STANDARD
33.430 – 33.477
(1.316 – 1.318)
33.300 – 33.347
(1.311 – 1.313)
0.032 – 0.066
(0.001 – 0.003)
0.028 – 0.059
(0.001 – 0.002)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.689 – 0.690)
21.959 – 21.980
(0.8645 – 0.8654)
17.466 – 17.484
(0.6876 – 0.6883)
SPECIFICATION
180 – 280 Ω
4.5 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 0.6 kΩ
Opened
Approx. 3.8 kΩ
Closed
Approx. 0.6 V
Opened
Approx. 3.8 V
4.5 – 5.5 V
Approx. 1.14 kΩ at 40 °C (104 °F)
4.5 – 5.5 V
Approx. 1.14 kΩ at 40 °C (104 °F)
19.1 – 19.7 kΩ
Normal
1.3 V and less
Leaning
3.8 V and more
Battery voltage
150 V and more (when cranking)
NOTE
: G, : BI
: W
: Ground
20 – 24 Ω at 20 °C (68 °F)
11.5 – 14.5 Ω at 23 °C (73.4 °F)
Idle speed
0.3 V and less
3 000 r/min
0.7 V and more
4/8
E-02, 03, 19, 28, 33, 54
4
THROTTLE BODY
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Idle air screw opening
IAC valve resistance
Throttle cable play
SPECIFICATION
E-02, 03, 19, 28, 54
15G0
37.2 mm (1.46 in)
1600 – 2000 r/min
1400 ± 100 r/min
2 turns out
Approx. 3 – 9 Ω at 20 – 24 °C (68 – 75 °F)
2.0 – 4.0 mm (0.08 – 0.16 in)
ITEM
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
E-33
15G1
←
←
←
←
←
←
STANDARD/SPECIFICATION
Approx. 375 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
Type
FT12A-BS
designation
Capasity
12 V 36 kC (10 Ah) /10 HR
HI
10 A
Headlight
LO
10 A
Meter
10 A
Ignition
10 A
Turn signal
15 A
Power source
10 A
Main
30 A
Fuse size
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
STANDARD/SPECIFICATION
LIMIT
Approx. 82 °C (180 °F) ± 1.5
––
Over 3.0 mm at 95 °C (203 °F)
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
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)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reserve
Approx. 250 ml
tank side
(8.45/8.80 US/Imp oz)
Approx.
1 300 ml
Engine side
(43.9/45.8 US/Imp oz)
––
––
––
––
––
WATTAGE
––
Parking or position light
Brake light/Taillight
Turn signal light
License light
Instrument panel light
Oil change indicator light
FI indicator light
Brake-lock indicator light
High beam indicator light
Turn signal indicator light
Trunk light
ELECTRICAL
ITEM
Spark plug
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
0.2 – 0.6 Ω
55 V and more at 5 000 r/min
Front
Brake disc runout
––
––
Rear
Axial
––
Radial
––
Front
––
Rear
––
Front
Rear
13M/C × MT3.00
13M/C × MT3.50
2.0
(0.08)
2.0
(0.08)
0.25
(0.01)
0.25
(0.01)
––
––
Rear
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diameter
Wheel rim runout
Wheel axle runout
Wheel rim size
A
S
11.000 – 11.043
(0.433 – 0.435)
14.000 – 14.043
(0.551 – 0.553)
10.957 – 10.984
(0.431 – 0.432)
13.957 – 13.984
(0.549 – 0.551)
33.960 – 34.010/22.650 – 22.700
(1.337 – 1.339/0.892 – 0.894)
25.400 – 25.450
(1.000 – 1.002)
33.878 – 33.928/22.568 – 22.618
(1.334 – 1.336/0.889 – 0.890)
25.318 – 25.368
(0.997 – 0.999)
Front
Front
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil type
Front fork oil capacily (each leg)
Front fork oil level
Rear wheel travel
Rear shock absorber spring
adjuster
STANDARD
100 (3.94)
330.4 (13.01)
SUZUKI FORK OIL G-10 (#10)
284 ml
96 (3.78)
100 (3.94)
4 and 1/2 turns out from softest
Standard
position (9 clicks)
Range
17 turns (34 clicks)
7/8
P
M
Unit: mm (in)
LIMIT
4.0
(0.16)
4.5
(0.18)
0.30
(0.01)
STANDARD/SPECIFICATION
E-02, 19, 54
E-03, 28, 33
35 × 2
←
35 × 2
←
5×2
21/5 × 2
←
21 × 4
←
5
←
1.7 × 3
←
1.7
←
1.7
←
1.7
←
1.7
←
1.7 × 2
←
5
←
E
L
E-02, 03, 19, 28, 33, 54
STANDARD
4.5 ± 0.2
(0.18 ± 0.008)
5.5 ± 0.2
(0.22 ± 0.008)
Rear
Master cylinder piston diameter
––
: W
: Ground
Y–Y
150 and more
Charging
BRAKE + WHEEL
Master cylinder bore
––
3–5Ω
17 – 30 kΩ
Primary
Secondary
5/8
ITEM
Brake disc thickness
––
HI
LO
G – BI
: G/W
: BI
4.5 V and more
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(When cold)
Headlight
Unit: mm (in)
NOTE
STANDARD/SPECIFICATION
NGK: CR7E
Type
DENSO: U22ESR-N
0.7 – 0.8
Gap
(0.28 – 0.03 in)
8.0 mm (0.31 in) and over at 1 atm.
180 – 288 Ω
Unit: W
ITEM
––
––
6/8
E-02, 03, 19, 28, 33, 54
TIRE
ITEM
Solo
riding
Front
Rear
Front
Rear
STANDARD
175 kPa
(1.75 kgf/cm², 25 psi)
200 kPa
(2.00 kgf/cm², 28 psi)
175 kPa
(1.75 kgf/cm², 25 psi)
225 kPa
(2.25 kgf/cm², 32 psi)
110/90-13 M/C 55P
130/70-13 M/C 63P
BRIDGESTONE HOOP B03G
BRIDGESTONE HOOP B02G
Front
––
Rear
––
Front
Rear
Cold inflation tire pressure
Dual
riding
––
Tire size
––
Tire type
Front
Rear
––
––
NOTE
Tire tread depth
(Recommended depth)
LIMIT
––
––
––
––
––
––
––
––
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
––
––
FUEL + OIL
––
Fuel type
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Transmission oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
13.0 L (13.7/11.4 US/Imp qt)
reserve
Fuel meter
Approx. 3.0 L
red zone
(3.17/2.64 US/Imp qt)
SAE 10W-40, API SF or SG
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)
Oil change
190 ml (6.42/6.69 US/Imp oz)
Overhaul
200 ml (6.76/7.04 US/Imp oz)
NOTE
Unit: mm (in)
LIMIT
––
324
(12.76)
––
––
––
––
––
––
E-02, 03, 19, 28, 33, 54
8/8
E-02, 03, 19, 28, 33, 54
5
AN650
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
Unit: mm (in)
LIMIT
STANDARD
29.5
(1.16)
25.0
(0.98)
0.10 – 0.20
(0.0039 – 0.0079)
0.20 – 0.30
(0.0079 – 0.0118)
0.010 – 0.040
(0.0004 – 0.0016)
0.030 – 0.060
(0.0012 – 0.0024)
4.500 – 4.515
(0.1772 – 0.1778)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
EX.
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
ITEM
Cam height
—
IN.
—
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length (IN. & EX.)
IN. & EX.
—
0.03
(0.001)
40.6
(1.60)
IN. & EX.
136 – 156 N
(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)
at length 33.4 mm (1.31 in)
15th pin
—
ITEM
Compression pressure
1 500 – 1 900 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi)
—
Piston to cylinder clearance
—
STANDARD
Compression pressure difference
Cylinder bore
Piston diam.
0.045 – 0.055
(0.0018 – 0.0022)
75.500 – 75.515
(2.9724 – 2.9730)
75.450 – 75.465
(2.9705 – 2.9711)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring end gap
1st
R
Approx. 11.6 (0.46)
2nd
RN
Approx. 8.6 (0.34)
0.20
(0.008
0.20
(0.008
1st
2nd
Piston ring to groove clearance
1st
E
L
Piston ring groove width
—
1.01
(0.040
1.01
(0.040
2.01
(0.079
1st
2nd
Oil
2nd
Piston pin bore
Piston pin O.D.
A
S
STANDARD
0.97 – 0.99
(0.038 – 0.039)
0.97 – 0.99
(0.038 – 0.039)
16.002 – 16.008
(0.6300 – 0.6302)
15.995 – 16.000
(0.6297 – 0.6299)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
STANDARD
16.010 –16.018
(0.6303 – 0.6306)
0.10 – 0.20
(0.004 – 0.008)
19.950 – 20.000
(0.7854 – 0.7874)
20.100 – 20.150
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
44.976 – 45.000
(1.7707 – 1.7717)
0.018 – 0.045
(0.0007 – 0.0018)
47.985 – 48.000
(1.8892 – 1.8898)
2.025 – 2.175
(0.0797 – 0.0856)
0.10 – 0.15
(0.0039 – 0.0059)
Crankshaft runout
P
M
E-02, 03, 19, 24, 28, 33
LIMIT
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
0.30
(0.012)
2/9
—
—
E-02, 03, 19, 24, 28, 33
CLUTCH
ITEM
Drive plate thickness
Driven plate thickness
Driven plate distortion
—
Clutch spring free length
Clutch plate concaved washer
height
Clutch engagement
Clutch lock-up
Unit: mm (in)
LIMIT
2.62
(0.103)
13.05
(0.514)
2.27
(0.089)
0.10
(0.004)
13.2
(0.520)
3.1
(0.12)
—
—
STANDARD
2.92 – 3.08
(0.115 – 0.121)
13.85 – 13.96
(0.545 – 0.550)
2.42 – 2.58
(0.095 – 0.102)
Drive plate claw width
13.9
(0.547)
—
1 500 – 2 100 r/min
3 200 – 3 800 r/min
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
STANDARD
Above 350 kPa (3.5 kgf/cm2)
Below 550 kPa (5.5 kgf/cm2)
at 3 000 r/min
LIMIT
Fuel pressure regulator operating
set pressure
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
More than 0.9 L (0.95/0.79 US/Imp qt)
For 30 sec, at 300 kPa (3.0 kgf/cm2, 43 psi)
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
—
—
FI/CVT-SENSORS
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
—
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor output voltage
Injector voltage
E-02, 03, 19, 24, 28, 33
75.380
(2.9677)
—
—
0.05
(0.002)
3/9
– 1.03
– 0.041)
– 1.03
– 0.041)
– 2.03
– 0.080)
—
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
– 0.30
– 0.012)
– 0.30
– 0.012)
—
2nd
Unit: mm (in)
LIMIT
1 200 kPa
(12 kgf/cm2,
171 psi)
200 kPa
(2.0 kgf/cm2,
28 psi)
0.120
(0.0047)
75.585
(2.9758)
0.10
(0.004)
9.3
(0.37)
6.9
(0.27)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
Piston ring free end gap
1st
—
0.10
(0.004)
—
0.10
(0.004)
—
CYLINDER + PISTON + PISTON RING
—
Valve head thickness
ITEM
Piston ring thickness
—
—
Valve seat width
1/9
Unit: mm (in)
LIMIT
35.10
(1.382)
33.70
(1.327)
0.150
(0.0059)
STANDARD
35.38 – 35.43
(1.393 – 1.395)
33.98 – 34.03
(1.338 – 1.340)
0.032– 0.066
(0.0013 – 0.0026)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 24.000
(0.9433 – 0.9449)
EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
Valve spring tension (IN. & EX.)
CAMSHAFT + CYLINDER HEAD
SPECIFICATION
0.9 – 1.7 kΩ
More than 0.5 V (When cranking)
150 – 300 Ω
More than 2.0 V (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.2 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 760 mmHg (100 kPa)
19.1 – 19.7 kΩ
Normal
Less than 1.4 V
Leaning
Less than 3.7 V
Battery voltage
4/9
NOTE
: B/Y, : Br
: Bl, : G
E-02, 03, 19, 24, 28, 33
6
ITEM
Ignition coil primary peak voltage
SPECIFICATION
NOTE
#1 : W/Bl,
: Ground
#2 : B/Y,
: Ground
More than 80 V (When cranking)
4 – 5 Ω at 23 °C (73.4 °F)
Idle speed
Less than 0.4 V
3 000 r/min
More than 0.6 V
PAIR 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 kΩ
st
Approx. 3.3 V
CVT primary pulley position sensor 1 : Idle speed
rd
output voltage
Approx. 1.3 V
3 : 3 000 r/min
Approx. 0.5 V
5th: 3 000 r/min
CVT secondary pulley revolution
400 – 600 Ω
sensor resistance
CVT secondary pulley revolution
More than 5 V at idle speed
sensor peak voltage
HO2 sensor resistance
HO2 sensor output voltage
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Eclectic fan thermo-switch operating temperature
Engine coolant type
: Y, : W
Engine coolant including reserve
STANDARD/SPECIFICATION
LIMIT
Approx. 88 °C (190 °F)
—
Over 8.0 mm (0.3 in) at 100 °C (212 °F)
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
—
—
—
—
—
110 kPa (1.1 kgf/cm²)
—
ON
93 – 103 °C
OFF
87 – 97 °C
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reverse
Approx. 250 ml
tank side
Engine side
Approx. 1 050 ml
—
—
—
—
—
THROTTLE BODY
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Synchronizing screw opening
IAC valve resistance
Throttle cable play
ELECTRICAL
SPECIFICATION
10GO
32 mm
1 300 – 1600 r/min
1 200 ± 100 r/min
1 and 1/2 turns out
Approx. 4 Ω at 20 – 24 °C (68 – 75 °F)
2.0 – 4.0 mm
(0.08 – 0.16 in)
Unit: mm (in)
ITEM
Firing order
Spark plug
Spark performance
CKP sensor peak voltage
Ignition coil resistance
STD/SPEC.
1·2
NGK: CR8E
Type
DENSO: U24ESR-N
0.7 – 0.8
Gap
(0.028 – 0.031)
Over 8.0 mm (0.3) at 1 atm.
More than 2.0 V
Primary
0.8 – 2.5 Ω
Secondary
8 – 18 kΩ
Ignition coil primary peak voltage
More than 80 V
Generator coil resistance
Generator no-load voltage
(When cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
5/9
Headlight
STD/SPEC.
15 A ..........E-03, 24, 28, 33
10A ...........E-02, 19
15 A
10 A
15 A
15 A
15 A
40 A
40 A
LO
HI
Fuel pump
Ignition
Turn signal
Fan motor
Main
CVT
Power
source
NOTE
ITEM
Brake disc thickness
Type
designation
Capacity
Unit: mm (in)
LIMIT
4.0
(0.16)
Rear
5.5 ± 0.2
(0.217 ± 0.008)
5.0
(0.20)
0.30
(0.012)
Front
12.700 – 12.743
(0.5000 – 0.5017)
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
12.657 – 12.684
(0.4983 – 0.4994)
25.400 – 25.450
(1.0000 – 1.0020)
27.000 – 27.050
(1.0630 – 1.0650)
25.318 – 25.368
(0.9968 – 0.9987)
26.918 – 26.968
(1.0598 – 1.0617)
DOT4
Front
—
Rear
Front
Unit: W
ITEM
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Instrument panel light
Engine coolant temp. indicator light
FI indicator light
Engine oil pressure indicator light
Brake-lock indicator light
High beam indicator light
Turn signal indicator light
Power mode indicator light
Drive indicator light
Gear position indicator light
Trunk light
E-02, 19
60 + 55
55
5×2
21/5 × 2
21 × 4
5
1.4 × 2
1.4
1.4
1.4 × 2
1.4
1.4
1.4 × 2
1.4
1.4
1.4 × 5
5
Brake caliper cylinder bore
E-03, 24, 28, 33
60 × 2
55 × 2
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Front
Rear
Brake caliper piston diameter
Front
Rear
Brake fluid type
Wheel rim runout
Axial
—
Radial
—
Wheel axle runout
Front
—
Rear
—
Wheel rim size
Front
Rear
15 M/C × MT3.50
14 M/C × MT4.50
SUSPENSION
Front fork oil type
Front fork oil capacity (each leg)
Front fork oil level
Rear wheel travel
STANDARD
110
(4.3)
—
SUZUKI FORK OIL G-10 (#10) or
an equivalent fork oil
458 ml
151
(5.9)
100
(3.9)
Rear shock absorber spring
adjuster
E-02, 03, 19, 24, 28, 33
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
Unit: mm (in)
ITEM
Front fork stroke
Front fork spring free length
7/9
E-02, 03, 19, 24, 28, 33
STANDARD
4.5 ± 0.2
(0.177 ± 0.008)
Rear
STD/SPEC.
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
6/9
Brake disc runout
Master cylinder bore
#1 : W/Bl,
: Ground
#2 : B/Y,
: Ground
G – BI
Y–Y
Approx. 500 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
BRAKE + WHEEL
Master cylinder piston diameter
10 A
WATTAGE
Headlight
P
M
: Bl, :G
More than 50 V at 5 000 r/min
E
L
E-02, 03, 19, 24, 28, 33
A
S
ITEM
Fuse size
150 – 300 Ω
0.1 – 1.0 Ω
CKP sensor
Charging
NOTE
2nd
8/9
LIMIT
—
341
(13.4)
—
—
—
—
—
E-02, 03, 19, 24, 28, 33
7
TIRE
ITEM
Cold inflation tire pressure
Solo
riding
Dual
riding
Tire size
STANDARD
225 kPa
(2.25 kgf/cm2, 33 psi)
Front
Tire tread depth
(Recommended depth)
—
250 kPa
(2.50 kgf/cm2, 36 psi)
225 kPa
(2.25 kgf/cm2, 33 psi)
280 kPa
(2.80 kgf/cm2, 41 psi)
120/70R15M/C 56H
160/60R14M/C 65H
BRIDGESTONE TH01F
BRIDGESTONE TH01R
Rear
Front
Rear
Front
Rear
Front
Rear
Tire type
LIMIT
Front
—
Rear
—
—
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
15.0 L
(4.0/3.3 US/lmp gal)
reserve
NOTE
E-03, 28, 33
The others
Fuel meter
Approx. 3.0 L
mark
(0.79/0.66 US/lmp gal)
flickering
Fuel meter
mark and
Approx. 1.5 L
LCD
(0.40/0.33 US/lmp gal)
flickering
Engine oil and transmission oil type
SAE 10W-40, API, SF or SG
Engine 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-5
Final gear oil capacity
Oil change
300 ml (10.1/10.6 US/lmp oz)
Overhaul
430 ml (14.5/15.1 US/lmp oz)
9/9
AN650A
ITEM
Valve diam.
Tappet clearance (when cold)
Valve guide to valve stem
clearance
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem deflection
stem runout
head thickness
seat width
head radial runout
spring free length (IN. & EX.)
spring tension (IN. & EX.)
STANDARD
29.5
25.0
0.10 – 0.20
0.20 – 0.30
0.010 – 0.040
0.030 – 0.060
4.500 – 4.515
4.475 – 4.490
4.455 – 4.470
—
—
—
0.9 – 1.1
—
—
136 – 156 N
(13.6 – 15.6 kgf)
at length 33.4 mm
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Cam chain pin (at arrow “3”)
Cylinder head distortion
STANDARD
35.38 – 35.43
33.98 – 34.03
0.032 – 0.066
24.012 – 24.025
23.959 – 23.980
—
15th pin
—
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
P
M
E-02, 03, 19, 24, 28, 33
A
S
VALVE + GUIDE
E
L
Unit: mm
LIMIT
—
—
—
—
—
—
—
—
—
0.35
0.05
0.5
—
0.03
40.6
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
—
Piston ring thickness
Unit: mm
LIMIT
35.10
33.70
0.150
—
—
0.10
—
0.10
STANDARD
1 500 – 1 900 kPa
(15.0 – 19.0 kgf/cm2)
Piston pin bore
Piston pin O.D.
—
0.045 – 0.055
75.500 – 75.515
75.450 – 75.465
Measure at 15 mm from the skirt end.
—
1st
R
Approx. 11.6
2nd RN
Approx. 8.6
1st
0.20 – 0.30
2nd
0.20 – 0.30
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
16.002 – 16.008
15.995 – 16.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
Crankshaft runout
STANDARD
16.010 –16.018
0.10 – 0.20
19.950 – 20.000
20.100 – 20.150
0.032 – 0.056
44.976 – 45.000
0.018 – 0.045
47.985 – 48.000
2.025 – 2.175
0.10 – 0.15
—
Unit: mm
LIMIT
1 200 kPa
(12 kgf/cm2)
200 kPa
(2.0 kgf/cm2)
0.120
75.585
75.380
0.10
9.3
6.9
0.50
0.50
0.180
0.150
—
—
—
—
—
16.030
15.980
Unit: mm
LIMIT
16.040
0.30
—
—
0.080
—
0.080
—
—
—
0.05
OIL PUMP
ITEM
Oil pressure (at 60 °C)
1/7
E-02, 19
STANDARD
Above 350 kPa (3.5 kgf/cm2)
Below 550 kPa (5.5 kgf/cm2)
at 3 000 r/min
2/7
LIMIT
—
E-02, 19
8
CLUTCH
ITEM
Drive plate thickness
Drive plate claw width
Driven plate No. 2 thickness
Driven plate distortion
Clutch spring free length
Clutch plate concaved washer
height
Clutch engagement
Clutch lock-up
STANDARD
2.92 – 3.08
13.85 – 13.96
2.42 – 2.58
—
13.9
Unit: mm
LIMIT
2.62
13.05
2.27
0.10
13.2
3.2
3.1
1 500 – 2 100 r/min
3 200 – 3 800 r/min
—
—
SPECIFICATION
11 – 13 Ω at 20 °C
More than 0.9 L
for 30 sec, at 300 kPa (3.0 kgf/cm2)
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2)
—
Fuel pressure regulator operating
set pressure
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor output voltage
Injector voltage
Ignition coil primary peak voltage
SPECIFICATION
0.9 – 1.7 kΩ
More than 0.5 V (When cranking)
150 – 300 Ω
More than 2.0 V (When cranking)
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.2 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C
4.5 – 5.5 V
Approx. 3.6 V at 100 kPa (760 mmHg)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Leaning
3.7 – 4.4 V
Battery voltage
More than 80 V (When cranking)
3/7
Type
Gap
Spark performance
CKP sensor peak voltage
Ignition coil resistance
Primary
Secondary
More than 80 V
Generator no-load voltage
(When cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Fuse size
150 – 300 Ω
0.1 – 1.0 Ω
CKP sensor
Charging
: Bl, : G
NOTE
400 – 600 Ω
More than 5 V at idle speed
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Synchronizing screw opening
IAC valve resistance
Throttle cable play
: Y, : W
SPECIFICATION
10GO
32 mm
1 300 – 1600 r/min
1 200 ± 100 r/min
1-1/2 turns out
Approx. 4 Ω at 20 – 24 °C
2.0 – 4.0 mm
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Eclectic fan thermo-switch operating temperature
Engine coolant type
: B, : B/Br
: B, : B/Br
P
M
#1 : W/Bl,
: Ground
#2 : B/Y,
: Ground
G – BI
Y–Y
Approx. 500 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
Approx. 88 °C
20 °C
50 °C
80 °C
110 °C
Over 8.0 mm at 100 °C
Approx. 2.45 kΩ
Approx. 0.811 kΩ
Approx. 0.318 kΩ
Approx. 0.142 kΩ
—
—
—
—
—
—
110 kPa (1.1 kgf/cm²)
—
—
—
4/7
—
—
—
E-02, 19
Unit: W
ITEM
Headlight
LIMIT
ON
93 – 103 °C
OFF
87 – 97 °C
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reverse
Approx. 250 ml
tank side
Engine side
Approx. 1 350 ml
WATTAGE
NOTE
: Bl, :G
STANDARD/SPECIFICATION
E
L
Engine coolant including reserve
#1 : W/Bl,
: Ground
#2 : B/Y,
: Ground
More than 50 V at 5 000 r/min
Type
designation
Capacity
Head- LO
light
HI
Fuel pump
Ignition
Turn signal
Fan motor
Main
CVT
Power
source
ABS
Compressed
Extended
1st: Idle speed
3rd : 3 000 r/min
5th: 3 000 r/min
CVT secondary pulley revolution
sensor resistance
CVT secondary pulley revolution
sensor peak voltage
E-02, 19
STD/SPEC.
1·2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8
Over 8.0 at 1 atm.
More than 2.0 V
0.8 – 2.5 Ω
8 – 18 kΩ
Ignition coil primary peak voltage
Generator coil resistance
: B/Y, : Br
Unit: mm
ITEM
Firing order
Spark plug
NOTE
A
S
ELECTRICAL
PAIR solenoid valve resistance
CVT primary pulley position sensor
SPECIFICATION
4 – 5 Ω at 23 °C
Less than 0.4 V
More than 0.6 V
20 – 24 Ω at 20 °C
1.9 – 2.3 kΩ
0.2 – 1.0 kΩ
Approx. 3.3 V
Approx. 1.3 V
Approx. 0.5 V
THROTTLE BODY
—
FI/CVT-SENSORS
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
Idle speed
3 000 r/min
CVT primary pulley position sensor
output voltage
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
ITEM
HO2 sensor resistance
HO2 sensor output voltage
STD/SPEC.
60 + 55
55
5×2
21/5 × 2
21 × 4
5
1.4 × 2
1.4
1.4
1.4
1.4
1.4
1.4 × 2
1.4
1.4
1.4 × 5
1.4
5
HI
LO
Parking/Position light
Brake light/Taillight
Turn signal light
License light
Instrument panel light
Engine coolant temp. indicator light
FI indicator light
Engine oil pressure indicator light
Brake-lock indicator light
High beam indicator light
Turn signal indicator light
Power mode indicator light
Drive indicator light
Gear position indicator light
ABS warning indicator light
Trunk light
FTX14-BS
BRAKE + WHEEL
12 V 43.2 kC (12 Ah)/10 HR
15 A
15 A
10 A
15 A
15 A
15 A
40 A
40 A
ITEM
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diameter
Brake caliper cylinder bore
10 A
15 A × 2
Brake caliper piston diameter
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
5/7
E-02, 19
Unit: mm
STANDARD
4.5 ± 0.2
Front
Rear
5.5 ± 0.2
—
12.700 – 12.743
12.700 – 12.743
12.657 – 12.684
12.657 – 12.684
25.400 – 25.450
27.000 – 27.050
25.318 – 25.368
26.918 – 26.968
DOT 4
—
—
—
—
15 M/C × MT3.50
14 M/C × MT4.50
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Axial
Radial
Front
Rear
Front
Rear
6/7
LIMIT
4.0
5.0
0.30
—
—
—
—
—
—
—
—
—
2.0
2.0
0.25
0.25
—
—
E-02, 19
9
SUSPENSION
Unit: mm
ITEM
Inner tube outside diameter
STANDARD
41
LIMIT
—
Front fork stroke
Front fork spring free length
Front fork oil type
110
—
SUZUKI FORK OIL G-10 (#10) or
an equivalent fork oil
458 ml
151
100
—
341
2nd
—
Front fork oil capacity (each leg)
Front fork oil level
Rear wheel travel
Rear shock absorber spring
adjuster
—
—
—
—
TIRE
ITEM
Cold inflation tire pressure
Solo
riding
Dual
riding
Tire size
Tire type
Tire tread depth
(Recommended depth)
STANDARD
225 kPa (2.25 kgf/cm2)
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
LIMIT
—
250 kPa (2.50 kgf/cm2)
225 kPa (2.25 kgf/cm2)
280 kPa (2.80 kgf/cm2)
120/70R 15M/C 56H
160/60R 14M/C 65H
BRIDGESTONE TH01F
BRIDGESTONE TH01R
—
—
—
—
—
—
—
—
—
1.6 mm
2.0 mm
FUEL + OIL
ITEM
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank capacity
Including
15.0 L
reserve
Fuel meter
mark
Approx. 3.0 L
flickering
Fuel meter
mark and
Approx. 1.5 L
LCD
flickering
Engine oil and transmission oil type
SAE 10W-40, API SF or SG
Engine oil capacity
Oil change
2.6 L
Filter change
2.9 L
Overhaul
3.4 L
Transmission oil capacity
Oil change
360 ml
Overhaul
400 ml
Final gear oil type
Hypoid gear oil SAE #90 API grade GL-5
Final gear oil capacity
Oil change
300 ml
Overhaul
430 ml
NOTE
Fuel type
7/7
DL650
ITEM
Valve diam.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
Unit: mm (in)
LIMIT
STANDARD
31
(1.2)
25.5
(1.0)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1772 – 0.1776)
4.465 – 4.480
(0.1758 – 0.1764)
4.455 – 4.470
(0.1754 – 0.1760)
IN.
EX.
P
M
E-02, 19
A
S
VALVE + GUIDE
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
Cam height
IN.
Camshaft journal oil clearance
IN. & EX.
—
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
—
0.10
(0.004)
—
0.05
(0.002)
—
16th pin
—
—
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
36.8
(1.45)
39.8
(1.57)
4.2 – 4.8 kgf
(9.26 – 10.58 lbs)
at length 29.9 mm (1.18 in)
17.0 – 19.6 kgf
(37.48 – 43.21 lbs)
at length 33.4 mm (1.31 in)
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
Compression pressure difference
—
Piston to cylinder clearance
Cylinder bore
Piston diam.
0.055 – 0.065
(0.0022 – 0.0026)
81.000 – 81.015
(3.1890 – 3.1896)
80.950 – 80.955
(3.1870 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
—
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
—
1st
Approx. 9.5 (0.37)
2nd
Approx. 11 (0.43)
1st
2nd
0.20 – 0.35
(0.008 – 0.014)
0.20 – 0.35
(0.008 – 0.0014)
1st
—
2nd
—
1st
1.21 – 1.23
(0.0476 – 0.0484)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
2nd
Oil
1/9
Unit: mm (in)
LIMIT
35.18
(1.3850)
33.18
(1.3063)
0.150
(0.0059)
STANDARD
35.48 – 35.53
(1.3968 – 1.3988)
33.48 – 33.53
(1.3181 – 1.3201)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
Camshaft journal holder I.D.
Valve head thickness
OUTER
ITEM
—
Valve seat width
INNER
CAMSHAFT + CYLINDER HEAD
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
Valve spring tension
(IN. & EX.)
E
L
E-02, 03, 19, 24, 28, 33
E-19
2/9
Unit: mm (in)
LIMIT
1 100 kPa
(11 kgf/cm2,
156 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.120
(0.0047)
Nicks or
Scratches
80.88
(3.184)
0.05
(0.002)
7.6
(0.30)
8.8
(0.35)
0.70
(0.028)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
E-02, 03, 19, 24, 28, 33
E-19
10
ITEM
Piston ring thickness
STANDARD
1.17 – 1.19
(0.0461 – 0.0469)
0.97 – 0.99
(0.0382 – 0.0390)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7871 – 0.7874)
1st
2nd
Piston pin bore
Piston pin O.D.
LIMIT
—
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.5
(0.02)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.170 – 0.320
(0.0067 – 0.0126)
20.95 – 21.00
(0.825 – 0.827)
42.17 – 42.22
(1.660 – 1.662)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4960)
0.002 – 0.029
(0.0001 – 0.0011)
41.985 – 42.000
(1.6529 – 1.6535)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
—
—
Drive plate claw width
No. 1 & No. 2
Driven plate distortion
0.05
(0.002)
Fuel pressure regulator operating set
pressure
LIMIT
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
PAIR solenoid valve resistance
ITEM
Thermostat valve opening temperature
Thermostat valve lift
ECT sensor resistance
—
—
2.62
(0.103)
12.9
(0.507)
0.10
(0.004)
50.5
(1.99)
53.1
(2.09)
Radiator cap valve opening pressure
Cooling fan thermo-switch operating
temperature
A
S
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
Min. 168 ml (5.7/5.9 US/lmp oz)
for 10 sec. at 300 kPa (30 kgf/cm², 43 psi)
Engine coolant including reserve
SPECIFICATION
130 – 240 Ω
3.7 V (When cranking) and more
4.5 – 5.5 V
P
M
—
STANDARD
NOTE
—
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
40 °C
Approx.
1.148 kΩ
(104 °F)
60 °C
Approx.
0.587 kΩ
(140 °F)
80 °C
Approx.
0.322 kΩ
(176 °F)
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
OFF→ON
Approx. 98 °C (208 °F)
ON→OFF
Approx. 92 °C (198 °F)
Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio
of 50:50.
Reserve
Approx. 250 ml
tank side
(0.53/0.44 US/lmp qt)
Engine
Approx. 1650 ml
side
(3.49/2.90 US/lmp qt)
—
ITEM
Firing order
Spark plug
Type
Gap
Spark performance
CKP sensor resistance
Ignition coil resistance
SPECIFICATION
1.2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8 mm
(0.028 – 0.031 in)
Over 8 mm (0.3 in) at 1 atm.
130 – 240 Ω
2–5Ω
Primary
Secondary
G/B –
B/Br
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Leaning 65°
3.7 – 4.4 V
1.0 V and more (From 1st to Top)
Battery voltage
4.5 – 5.5 V
Closed
Approx. 0.58 kΩ
Opened
Approx. 4.38 kΩ
Closed
Approx. 0.58 V
Opened
Approx. 4.40 V
7 – 14 Ω
20 – 24 kΩ at 20 °C (68 °F)
P/W –
B/Br
Br/W –
B/Br
Y–B
Y–
B/Br
THROTTLE BODY
SPECIFICATION
27 G0 (Others), 27 G1 (For E-33)
39 mm
1 800 – 2 400 r/min at 25 °C (77 °F)
1 300 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
E-02, 03, 19, 24, 28, 33
E-19
CKP sensor peak voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When cold)
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Fuel
Ignition
Fan motor
Signal
Main
—
—
—
—
—
—
—
—
—
—
E-02, 03, 19, 24, 28, 33
E-19
ELECTRICAL
NOTE
NOTE
W–G
Approx. 2.7 V at idle speed
5/9
—
Approx. 88 °C (190 °F)
4/9
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
ITEM
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
—
20 – 30
(0.79 – 1.18)
25
(0.98)
E
L
Engine coolant type
E-02, 03, 19, 24, 28, 33
E-19
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
116 links
—
—
—
—
319.4
(12.57)
THERMOSTAT + RADIATOR + FAN + COOLANT
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Links
20-pitch
length
Gearshift lever height
Unit: mm (in)
LIMIT
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turns back
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
3/9
D.I.D.525V8
—
—
—
Clutch spring free length
Type
Drive chain slack (on side-stand)
0.080
(0.0031)
CLUTCH
No. 1 & No. 2
Shift fork thickness
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
STANDARD
Above 100 kPa (1.0 kgf/cm², 14 psi)
Below 400 kPa (4.0 kgf/cm², 57 psi)
at 3 000 r/min
Clutch release screw
Drive plate thickness
Shift fork groove width
0.080
(0.0031)
—
ITEM
Clutch cable play
Shift fork to groove clearance
Drive chain
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
2.088 (71/34)
3.133 (47/15)
2.461 (32/13)
1.777 (32/18)
1.380 (29/21)
1.125 (27/24)
0.961 (25/26)
0.851 (23/27)
0.1 – 0.3
(0.004 – 0.012)
5.5 – 5.6
(0.217 – 0.220)
5.3 – 5.4
(0.209 – 0.213)
Low
2nd
3rd
4th
5th
Top
20.030
(0.7886)
19.98
(0.7866)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
24 – 37 kΩ
3.7 V and more
Unit: mm (in)
NOTE
W–G
tap –
tap
tap –
Plug cap
When
cranking
150 V and more
0.2 – 0.7 Ω
Approx. 375 W at 5 000 r/min
60 V (AC) and more at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX12-BS
12 V 36.0 kC (10 Ah)/10 HR
15 A
15 A
10 A
10 A
15 A
15 A
30 A
WATTAGE
Unit: W
SPECIFICATION
E-03, 24, 28, 33
Others
12 V 60/55 W × 2 (H4)
←
12 V 5 W × 2
12 V 21/5 W × 2
←
12 V 21 W
←
12 V 5 W
←
LED
←
LED
←
LED
←
LED
←
LED
←
ITEM
Headlight
Position/Parking light
Brake light/Taillight
Turn signal light
License light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure/Coolant temp./Fuel injection warning
6/9
E-02, 03, 19, 24, 28, 33
E-19
11
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
STANDARD
15 – 25 (0.59 – 0.98)
5
(0.20)
5
(0.20)
Front
Rear
Brake disc runout
Master cylinder bore
—
15.870 –
(0.6248 –
14.000 –
(0.5512 –
15.827 –
(0.6231 –
13.957 –
(0.5495 –
30.230 –
(1.1902 –
38.180 –
(1.5031 –
30.150 –
(1.1870 –
38.098 –
(1.4999 –
DOT 4
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Wheel rim runout
15.913
0.6265)
14.043
0.5529)
15.854
0.6242)
13.984
0.5506)
30.306
1.1931)
38.256
1.5061)
30.200
1.1890)
38.148
1.5019)
Axial
—
Radial
—
Wheel rim size
Front
Rear
19 M/C × MT2.50
17 M/C × MT4.00
Wheel axle runout
Front
—
Rear
—
Unit: mm (in)
LIMIT
—
4.5
(0.18)
4.5
(0.18)
0.3
(0.012)
—
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Front
—
Rear
—
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
—
Tire type
—
—
Front
Rear
Front
Rear
STD/SPEC.
225 kPa
(2.25 kgf/cm², 33 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
225 kPa
(2.25 kgf/cm², 33 psi)
280 kPa
(2.80 kgf/cm², 41 psi)
110/80 R19 M/C (59 H)
150/70 R17 M/C (69 H)
BRIDGESTONE: TW101 F
BRIDGESTONE: TW152 F
Front
Tire tread depth
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
SUSPENSION
ITEM
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork spring free length
Front fork oil level (without spring,
outer tube fully compressed)
Front fork spring adjuster
Front fork oil type
Front fork oil capacity (each leg)
Rear shock absorber spring
adjuster
Rear shock absorber damping
force adjuster
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
A
S
E-02, 03, 19, 24, 28, 33
E-19
—
435 (17.1)
143 (5.63)
—
3 groove from Top/Spring adjuster height 9 mm
(0.35 in)
SUZUKI FORK OIL SS-08 or
equivalent fork oil
524 ml
(17.7/18.5 US/Imp oz)
—
2 groove from bottom
—
Rebound
1 turn back from stiffest position
1 and 1/2 turns back from
stiffest position
150 mm
(5.9 in)
—
E
L
P
M
E-02, 03, 19, 24, 28, 33
E-19
STD/SPEC.
NOTE
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Gasoline used should be graded 91 octane or
Others
higher. An unleaded gasoline is recommended.
22 L (5.8/4.8 US/lmp gal)
SAE 10W-40, API SF or SG
2 300 ml
Change
(2.4/2.0 US/lmp qt)
2 700 ml
Filter change
(2.9/2.4 US/lmp qt)
3 100 ml
Overhaul
(3.3/2.7 US/lmp qt)
9/9
—
Unit: mm (in)
LIMIT
STD/SPEC.
150
(5.9)
444.1 (17.5)
Front fork stroke
Swingarm pivot shaft runout
FUEL + OIL
—
—
Rear wheel travel
7/9
LIMIT
8/9
—
—
E-02, 19, 24
E-03, 28, 33
—
0.3
(0.01)
E-02, 03, 19, 24, 28, 33
E-19
12
DL1000
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
36
(1.42)
33
(1.30)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Unit: mm (in)
ITEM
Cam height
—
STANDARD
36.28 – 36.32
(1.428 – 1.430)
35.68 – 35.72
(1.405 – 1.406)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8650 – 0.8659)
IN.
EX.
—
—
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam drive idle gear/sprocket thrust
clearance
Cylinder head distortion
—
—
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
39.6
(1.56)
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
at length 35.6 mm (1.40 in)
Valve spring tension
CAMSHAFT + CYLINDER HEAD
LIMIT
ITEM
Compression pressure
(Automatic de-comp. actuated)
Cylinder bore
Piston diam.
0.15 – 0.29
(0.006 – 0.011)
—
—
0.05
(0.002)
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm², 142 – 199 psi)
—
0.015 – 0.025
(0.0006 – 0.0010)
98.000 – 98.015
(3.8583 – 3.8589)
97.980 – 97.995
(3.8575 – 3.8581)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion
—
Piston ring end gap
1st
Approx. 8.8 (0.35)
2nd
Approx. 10.1 (0.40)
0.15 – 0.35
(0.006 – 0.014)
0.30 – 0.45
(0.012 – 0.018)
1st
2nd
Piston ring to groove clearance
RN
1st
—
E
L
2nd
ITEM
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore I.D.
Piston pin O.D.
P
M
E-02, 03, 19, 24, 28, 33
A
S
STANDARD
0.93 – 0.95
(0.0366 – 0.0374)
1.55 – 1.57
(0.0610 – 0.0618)
1.01 – 1.03
(0.0398 – 0.0406)
2.51 – 2.53
(0.0988 – 0.0996)
0.86 – 0.91
(0.034 – 0.036)
1.38 – 1.40
(0.054 – 0.055)
0.97 – 0.99
(0.038 – 0.039)
22.002 – 22.008
(0.8662 – 0.8665)
21.992 – 22.000
(0.8658 – 0.8661)
LIMIT
—
—
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft journa l holder width
Crankshaft journa l width
Crankshaft runout
—
3/10
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm²,
114 psi)
200 kPa
(2 kgf/cm², 28 psi)
0.12
(0.0047)
Nicks or
Scratches
97.880
(3.8535)
0.05
(0.002)
7.0
(0.28)
8.1
(0.32)
0.5
(0.02)
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
E-02, 03, 19, 24, 28, 33
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
STANDARD
Above 400 kPa (4.0 kgf/cm², 57 psi)
Below 700 kPa (7.0 kgf/cm², 100 psi)
at 3 000 r/min
LIMIT
—
—
—
—
CLUTCH
Unit: mm (in)
ITEM
Drive plate thickness
—
—
22.030
(0.8673)
21.980
(0.8654)
LIMIT
22.040
(0.8677)
0.50
(0.020)
—
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
13.85 – 13.96
(0.545 – 0.550)
13.90 – 14.00
(0.547 – 0.551)
No. 1
No. 2 and 3
Drive plate claw width
No.1
No. 2 and 3
Driven plate distortion
—
61.5 – 62.5
(2.42 – 2.46)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
Unit: mm (in)
STANDARD
22.010 – 22.018
(0.8665 – 0.8668)
0.17 – 0.32
(0.007 – 0.013)
21.95 – 22.00
(0.864 – 0.866)
44.17 – 44.22
(1.739 – 1.741)
0.040 – 0.064
(0.0016 – 0.0025)
44.976 – 45.000
(1.7707 – 1.7717)
0.002 – 0.029
(0.0008 – 0.0011)
47.985 – 48.000
(1.8892 – 1.8898)
25.2 – 25.4
(0.99 – 1.00)
25.50 – 25.55
(1.004 – 1.006)
—
2/10
Clutch spring free length
CONROD + CRANKSHAFT
—
0.10
(0.004)
—
Compression pressure difference
Piston ring free end gap
1/10
—
CYLINDER + PISTON + PISTON RING
Piston to cylinder clearance
—
LIMIT
35.98
(1.417)
35.38
(1.393)
0.150
(0.0059)
Clutch master cylinder bore
Clutch master cylinder piston diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
0.10
(0.004)
59.4
(2.34)
—
—
—
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
0.05
(0.004)
E-02, 03, 19, 24, 28, 33
THERMOSTAT + RADIATOR + FAN
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Cooling fan therON→OFF
moswitch operating
ON→OFF
temperature
Engine coolant temperature sensor resistance
20 °C
(68 °F)
40 °C
(104 °F)
60 °C
(140 °F)
80 °C
(176 °F)
STANDARD
86.5 – 89.5 °C
(188 – 193 °F)
Over 8 mm (0.31 in) at 100 °C (212 °F)
110 kPa
(1.1 kgf/cm², 15.6 psi)
Approx. 105 °C (221 °F)
LIMIT
Approx. 100 °C (212 °F)
—
Approx. 2.45 kΩ
—
Approx. 1.148 kΩ
—
Approx. 0.587 kΩ
—
Approx. 0.322 kΩ
—
4/10
—
—
—
—
E-02, 03, 19, 24, 28, 33
13
DRIVE TRAIN
Unit: mm (in) Expect ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio
STANDARD
1.838 (57/31)
2.411 (41/17)
3.000 (36/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
0.913 (21/23)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK525SMOZ7
112 links, ENDLESS
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Type
Links
Drive chain
20-pitch length
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
20 – 30
(0.8 – 1.2)
25
(1.0)
Drive chain slack
Gearshift lever height
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
12 – 18 Ω at 20 °C (68 °F)
Approx. 1.2 L (1.3/1.1 US/lmp qt)
for 1 minute at 300 kPa (3.0 kgf/cm², 43 psi)
NOTE
FI-SENSORS
ITEM
CMP sensor output voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor reisitance
IAT sensor input volatage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
Heated oxygen sensor output voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
SPECIFICATION
More than 3.7 V
130 – 240 Ω
More than 3.7 V (When cranking)
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.3 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 4.0 V at 760 mmHg (100 kPa)
19.1 – 19.7 kΩ
Approx. 0.4 – 1.4 V
More than 1.0 V (From 1st to top)
Battery voltage
More than 150 V (When cranking)
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.3 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.8 – 7.2 Ω
Less than 0.4 V at idle speed
(After warming up)
4 – 5 Ω at 23 °C (73.4 °F)
20 – 24 Ω at 20 °C (68 °F)
NOTE
European
markets
THROTTLE BODY
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
5/10
Ignition timing
Firing order
Spark plug
SPECIFICATION
4° B.T.D.C. at 1 200 r/min
1·2
NGK: CR8EK
Denso: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Crankshaft position sensor resistance
Ignition coil resistance
Crankshaft position sensor peak
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
HI
Headlight
LO
Turn signal
Ignition
Fan motor
Meter
Main
P
M
Unit: mm (in)
ITEM
130 – 240 Ω
2–5Ω
24 – 37 kΩ
Primary
Secondary
E
L
E-02, 03, 19, 24, 28, 33
A
S
ELECTRICAL
NOTE
Bl – G
tap – tap
tap – Plug cap
More than 3.7 V
When cranking
More than 150 V
0.2 – 0.5 Ω
Approx. 400 W at 5 000 r/min
When cranking
Y–Y
SPECIFICATION
06G3 (For E-02, 19), 06G4 (For E-33), 06G5 (For E-03, 24, 28)
45 mm
1 500 – 2 100 r/min at 25 °C (77 °F)
1 200 ± 100 r/min/Warmed engine
2.0 – 4.0 r/min
(0.08 – 0.16 in)
6/10
WATTAGE
Unit: W
SPECIFICATION
ITEM
Headlight
Position/Parking light
Brake light/Taillight
Turn signal light
License light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure/Coolant temp./Fuel
injection warning
E-03, 24, 28, 33
12 V 21/5 W × 2
12 V 21 W
12 V 5 W
LED
LED
LED
LED
Others
←
12 V 5 W × 2
←
←
←
←
←
←
←
LED
←
12 V 60/55 W × 2 (H4)
BRAKE + WHEEL
ITEM
Rear brake pedal height
More than 75 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
Brake disc thickness
FTX14-BS
STANDARD
20 – 30
(0.8 – 1.2)
5.0 ± 0.2
(0.197 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
12 V 43.2 kC (12 Ah)/10 HR
15 A
15 A
15 A
10 A
15 A
10 A
30 A
Brake disc runout
(Front & Rear)
Master cylinder bore
—
15.870
(0.6248
14.000
(0.5512
15.827
(0.6231
13.957
(0.5495
30.230
(1.1902
38.180
(1.5031
30.150
(1.1870
38.098
(1.4999
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Rear
Rear
Wheel rim runout
(Front & Rear)
7/10
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
– 15.913
– 0.6265)
– 14.043
– 0.5529)
– 15.854
– 0.6242)
– 13.984
– 0.5506)
– 30.306
– 1.1931)
– 38.230
– 1.5051)
– 30.200
– 1.1890)
– 38.148
– 1.5019)
Axial
—
Radial
—
8/10
Unit: mm (in)
LIMIT
—
4.5
(0.18)
4.5
(0.18)
0.30
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
E-02, 03, 19, 24, 28, 33
14
ITEM
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
STANDARD
Front
LIMIT
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
—
Rear
—
Front
Rear
Front
Rear
Front
Rear
19M/C × MT 2.50
17M/C × MT 4.00
110/80R19M/C 59H
150/70R17M/C 69H
BRIDGESTONE: TW101 F
BRIDGESTONE: TW152 F
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring,
inner tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Rear shock absorber spring
adjuster
Rear shock absorber damping
force adjuster
Rear wheel travel
STANDARD
160
(6.3)
433.6
(17.07)
140.0
(5.51)
SUZUKI FORK OIL SS-08 or an equivalent fork oil
496.0 ml
(16.76/17.46 US/lmp oz)
3rd groove from top
2nd groove from bottom
Rebound
ITEM
Fuel type
Fuel tank
Engine oil type
Engine oil capacity
Unit: mm (in)
LIMIT
Brake fluid type
Engine coolant type
—
424
(16.7)
Engien coolant
—
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
17 L
(4.5/3.7 US/lmp gal)
SAE 10W-40, API SF or SG
2 700 ml
Change
(2.9/2.4 US/lmp qt)
2 900 ml
Filter change
(3.1/2.6 US/lmp qt)
3 300 ml
Overhaul
(3.5/2.9 US/lmp qt)
DOT 4
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reserve
Approx. 250 ml
tank side
(0.3/0.2 US/lmp qt)
Approx.
1 950 ml
Engine side
(2.1/1.7 US/lmp qt)
NOTE
E-03, 28, 33
The others
—
—
7/8 turn out from stiffest position
Swingarm pivot shaft runput
FUEL + OIL + ENGINE COOLANT
—
159
(6.3)
—
—
0.3
(0.01)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
250
250
SOLO RIDING
kgf/cm²
2.50
2.50
psi
36
36
kPa
250
280
DUAL RIDING
kgf/cm²
2.50
2.80
9/10
psi
36
41
A
S
Unit: mm (in)
ITEM
Valve diam.
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance (when cold)
Valve guide to valve stem
clearance
P
M
E-02, 03, 19, 24, 28, 33
DR200SE (E-03, 28, 33)
VALVE + GUIDE
IN. & EX.
IN.
EX.
E
L
LIMIT
—
10/10
E-02, 03, 19, 24, 28, 33
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
IN.
EX.
—
—
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
Rocker arm shaft O.D.
IN. & EX.
EX.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
Cylinder head distortion
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
Cylinder head cover distortion
Valve head thickness
Valve stem O.D.
IN.
Valve seat width
IN. & EX.
0.9 – 1.1
(0.04 – 0.05)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
OUTER
Valve spring tension
(IN. & EX.)
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
at length 32.5 mm (1.28 in)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
at length 36.0 mm (1.42 in)
INNER
OUTER
—
—
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1/7
E-03, 28, 33
12.018
0.4731)
11.995
0.4722)
1 400 kPa
(14 kgf/cm2, 199 psi)
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
1st
R
Approx. 7.5 (0.30)
2nd
R
Approx. 9.4 (0.37)
2nd
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
1st
—
2nd
—
1st
2/7
—
—
—
0.05
(0.002)
0.05
(0.002)
STANDARD
Cylinder distortion
—
0.10
(0.004)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm2,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
E-03, 28, 33
15
ITEM
Piston ring groove width
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
—
16.030
(0.6311)
15.980
(0.6291)
1 pc.
5 pcs.
Driven plate distortion
—
Clutch spring free length
—
—
ITEM
Spark plug
Type
Gap
Spark performance
Signal coil resitance
Ignition coil resistance
LIMIT
2 – 6Ω
Secondary
20 – 30 kΩ
—
Headlight
Unit: mm (in)
NOTE
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
SPECIFICATION
60
55
21/5
21
3.4
3.4
1.7
3.4
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
—
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(G.S.)
(P.S.)
#125
#
#25
PRE-SET
2 – 4 mm (0.08 – 0.16 in)
E-33
←
←
42AE
←
←
←
←
←
←
←
←
←
←
E-03, 28, 33
Unit: mm (in)
ITEM
Brake lever play
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Rear
—
Brake lining thickness
Rear
—
Brake disc thickness
Front
3.5 ± 0.2
(0.138 ± 0.008)
Brake disc runout
Front
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
12.700 –
(0.5000 –
12.657 –
(0.4983 –
33.960 –
(1.3370 –
33.878 –
(1.3338 –
Wheel rim runout
Axial
—
Radial
—
Front
—
Wheel axle runout
Wheel rim size
Tire tread depth
E-03, 28, 33
4/7
BRAKE + WHEEL
Tire size
5/7
—
SPECIFICATION
E-03, 28
MIKUNI BST31SS
31 mm
42AC
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#
5D77
P
M
Unit: W
ITEM
—
—
—
319.4
(12.57)
E
L
2.6
(0.10)
Generator coil resistance
Charging
0.1 – 1.5 Ω
Generator no-load voltage
More than 60 V (AC) at 5 000 r/min
Generator Max. output
150 W at 5 000 r/min
Regulated voltage
13.0 – 16.0 V at 5 000 r/min
Starter relay resistance
2–6Ω
Battery
Type designation
YTX7L-BS
Capacity
12 V 21.6 kC (6 Ah)/10 HR
Fuse size
20 A
WATTAGE
—
—
A
S
Primary
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
Throttle cable play
E-03, 28, 33
SPECIFICATION
DENSO: X24ESR-U
NGK: CR8EA
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140 Ω
—
25 – 40
(1.0 – 1.6)
ITEM
—
0.10
(0.004)
31.0
(1.22)
3/7
ELECTRICAL
Type
Links
20-pitch
length
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
CARBURETOR
—
Unit: mm (in)
Clutch plate thickness
No.1, 2, 3
Drive chain slack
LIMIT
—
Clutch release screw
Shift fork thickness
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
STANDARD
2.000 (30/15)
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
STANDARD
10 – 15
(0.4 – 0.6)
1/4@turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
No.1, 2, 3
Drive chain
—
ITEM
Clutch lever play
Shift fork groove width
Unit: mm (in)
0.08
(0.003)
CLUTCH
STANDARD
3.157 (60/19)
3.000 (45/15)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
D.I.D. 520VC5
112 links
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
TRANSMISSTION + DRIVE CHAIN
12.743
0.5017)
12.684
0.4994)
34.010
1.3390)
33.928
1.3357)
Rear
—
Front
Rear
Front
Rear
J21 × 1.60
J18 × 2.15
70/100-21 44P or 70/100-21 M/C 44P
100/90-18 56P or 100/90-18 M/C 56P
Front
—
Rear
—
6/7
LIMIT
—
—
—
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
3.0
(0.12)
3.0
(0.12)
E-03, 28, 33
16
SUSPENSION
ITEM
Front fork stroke
STANDARD
205
(8.1)
LIMIT
—
561
(22.1)
179.5
(7.07)
231
(9.1)
205
(8.1)
—
—
—
0.6
(0.02)
Front fork spring free length
Front fork oil level
Rear shock absorber spring
pre-set length
Rear wheel travel
Swingarm pivot shaft runout
Unit: mm (in)
NOTE
—
—
TIRE PRESSUER
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
150
175
SOLO RIDING
kgf/cm2
1.50
1.75
psi
22
25
kPa
150
200
DUAL RIDING
kgf/cm2
1.50
2.00
psi
22
29
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
13.0 L
(3.4/2.9 US/lmp qt)
12.5 L
(3.3/2.7 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
850 ml
Change
(0.90/0.75 US/lmp qt)
950 ml
Filter change
(1.00/0.84 US/lmp qt)
1
100 ml
Overhaul
(1.2/1.0 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
7/7
Valve guide to valve stem
clearance
A
S
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance (when cold)
E-33
IN. & EX.
IN.
EX.
E
L
P
M
Unit: mm (in)
ITEM
Valve diam.
E-03, 28
E-03, 28, 33
DR200SE (E-06, 24)
VALVE + GUIDE
NOTE
LIMIT
—
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
34.174 – 34.218
(1.3454 – 1.3472)
33.804 – 33.848
(1.3309 – 1.3326)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
IN.
EX.
—
—
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
Rocker arm shaft O.D.
IN. & EX.
EX.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2146 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
Cylinder head distortion
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
Cylinder head cover distortion
Valve head thickness
Valve stem O.D.
IN.
Valve seat width
IN. & EX.
0.9 – 1.1
(0.04 – 0.05)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
OUTER
Valve spring tension
(IN. & EX.)
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
at length 32.5 mm (1.28 in)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
at length 36.0 mm (1.42 in)
INNER
OUTER
—
—
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
1/7
E-06, 24
12.018
0.4731)
11.995
0.4722)
1 400 kPa
(14 kgf/cm2, 199 psi)
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 15 mm (0.59 in) from the skirt end.
—
1st
R
Approx. 7.5 (0.30)
2nd
R
Approx. 9.4 (0.37)
2nd
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
1st
—
2nd
—
1st
2/7
—
—
—
0.05
(0.002)
0.05
(0.002)
STANDARD
Cylinder distortion
—
0.10
(0.004)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
LIMIT
33.870
(1.3335)
33.500
(1.3189)
0.150
(0.0059)
Unit: mm (in)
LIMIT
980 kPa
(9.8 kgf/cm2,
139 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
6.0
(0.24)
7.5
(0.30)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
E-06, 24
17
ITEM
Piston ring groove width
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.01 – 2.03
(0.079 – 0.080)
0.970 – 0.990
(0.038 – 0.039)
1.170 – 1.190
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.996 – 16.000
(0.6298 – 0.6299)
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
—
16.030
(0.6311)
15.980
(0.6291)
STANDARD
2.000 (30/15)
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
LIMIT
—
—
Unit: mm (in)
Clutch plate thickness
1 pc.
5 pcs.
Driven plate distortion
—
Clutch spring free length
—
LIMIT
—
ITEM
Spark performance
Signal coil resitance
Ignition coil resistance
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Valve seat
Starter jet
Pilot screw
Throttle cable play
Primary
0.14 – 0.18 Ω
Secondary
15 – 18 kΩ
Signal coil peak voltage
3.0 – 4.6 V
Ignition coil primary peak voltage
125 – 195 V
Generator coil resistance
Charging
0.1 – 1.5 Ω
Generator no-load voltage
More than 70 V (AC) at 5 000 r/min
Regulated voltage
13.0 – 16.0 V at 5 000 r/min
Starter relay resistance
2–6Ω
Battery
Type designation
YTX7L-BS
Capacity
12 V 21.6 kC (6 Ah)/10 HR
Standard
1.32 at 20 °C (68 °F)
electrolyte S.G.
Fuse size
20 A
Headlight
SPECIFICATION
60
55
21/5
HI
LO
Brake light/Taillight
Turn signal light
(For South Africa)
Speedometer light
Turn signal indicator light
(Fpr South Afriaca)
High beam indicator light
Neutral indicator light
4/7
E-06, 24
Unit: mm (in)
ITEM
Brake lever play
STANDARD
0.1 – 0.3
(0.004 – 0.010)
20 – 30
(0.8 – 1.2)
2.5
(0.10)
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Rear
LIMIT
—
—
—
—
Brake lining thickness
Rear
—
Brake disc thickness
Front
3.5 ± 0.2
(0.138 ± 0.008)
Brake disc runout
Front
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
12.700 –
(0.5000 –
12.657 –
(0.4983 –
33.960 –
(1.3370 –
33.878 –
(1.3338 –
Wheel rim runout
Axial
—
Radial
—
Front
—
Unit: W
ITEM
(M.J.)
(M.A.J)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(V.S.)
(G.S.)
(P.S.)
BRAKE + WHEEL
Wheel axle runout
WATTAGE
—
—
—
319.4
(12.57)
SPECIFICATION
MIKUNI BST31SS
31 mm
42AA
1 500 ± 100 r/min
13.0 ± 1.0 mm (0.51 ± 0.04 in)
#122.5
0.8 mm
5D26-3rd
P-5
#125
#40
1.5 mm
#25
1 and 1/2 turns out
3 – 6 mm (0.1 – 0.2 in)
P
M
G – Bl
Terminal –
Terminal
Plug cap –
Terminal
G/W –
Bl/Y
White –
Ground
—
—
—
E
L
E-06, 24
A
S
—
—
CARBURETOR
0.10
(0.004)
31.0
(1.22)
Unit: mm (in)
NOTE
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
25 – 40
(1.0 – 1.6)
—
SPECIFICATION
7°B.T.D.C. Below at 1 500 r/min
DENSO: X24ESR-U
Type
NGK: CR8EA
0.6 – 0.7
Gap
(0.024 – 0.028)
Over 8 mm (0.3) at 1 atm.
100 – 140 Ω
Ignition timing
Spark plug
Type
Links
20-pitch
length
2.6
(0.10)
3/7
ELECTRICAL
No.1, 2, 3
Drive chain slack
0.08
(0.003)
Clutch release screw
Shift fork thickness
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.00
(0.039)
—
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.9 – 3.1
(0.114 – 0.122)
2.95 – 3.15
(0.116 – 0.124)
No.1, 2, 3
Drive chain
—
ITEM
Clutch lever play
Shift fork groove width
Unit: mm (in)
—
CLUTCH
STANDARD
3.157 (60/19)
3.916 (47/12)
3.000 (33/11)
1.933 (29/15)
1.437 (23/16)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.20 – 0.21)
4.8 – 4.9
(0.18 – 0.19)
D.I.D. 520VC5
112 links, ENDLESS
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
TRANSMISSTION + DRIVE CHAIN
12.743
0.5017)
12.684
0.4994)
34.010
1.3390)
33.928
1.3357)
Rear
—
Tire size
Front
Rear
70/100-21 44M
90/100-18 54M
Tire tread depth
Front
—
Rear
—
21
1.7
130.7
(5.15)
1.5
(0.06)
3.0
(0.12)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
40
(0.16)
4.0
(0.16)
2
SUSPENSION
2
2
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring
pre-set length
Rear wheel travel
Swingarm pivot shaft runout
5/7
E-06, 24
STANDARD
205
(8.1)
LIMIT
—
561
(22.1)
179.5
(7.07)
231
(9.1)
205
(8.1)
—
—
0.6
(0.02)
6/7
Unit: mm (in)
NOTE
—
—
—
E-06, 24
18
TIRE PRESSUER
E-24
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
100
100
SOLO RIDING
kgf/cm2
1.0
1.0
psi
15
15
kPa
100
100
SOLO RIDING
kgf/cm2
1.0
1.0
psi
15
15
E-06
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
100
100
DUAL RIDING
kgf/cm2
1.0
1.0
psi
15
15
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or
higher. An unleaded gasoline is recommended.
13.0 L
(3.4/2.9 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
950 ml
Change
(1.0/0.8 US/lmp qt)
1 050 ml
Filter change
(1.1/0.9 US/lmp qt)
1 200 ml
Overhaul
(1.3/1.1 US/lmp qt)
Fork oil #10
309 ml
(10.4/10.9 US/lmp oz)
DOT 4
7/7
DR650SE
ITEM
STANDARD
33
(1.3)
28
(1.1)
0.08 – 0.13
(0.003 – 0.005)
0.17 – 0.22
(0.0067 – 0.0087)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance
(when engine is cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
—
5.500
(0.2165
5.475
(0.2156
5.455
(0.2148
EX.
– 5.512
– 0.2170)
– 5.490
– 0.2161)
– 5.470
– 0.2154)
Valve stem runout
P
M
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
Unit: mm (in)
LIMIT
—
—
—
0.35
(0.014)
Right &
Center
Camshaft journal holder I.D.
Right &
Center
Left
Left
Camshaft journal O.D.
Right &
Center
Left
—
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
34.4
(1.35)
38.1
(1.50)
OUTER
Camshaft journal oil clearance
Camshaft runout
IN. & EX.
INNER
IN.
—
—
12.000
(0.4724
11.973
(0.4714
—
Cylinder head cover distortion
—
Cylinder bore
Piston diam.
—
—
—
—
—
0.05
(0.002)
0.05
(0.002)
Unit: mm (in)
—
0.05
(0.002)
10.8
(0.43)
9.1
(0.36)
0.50
(0.039)
1.00
(0.039)
1st
R
Approx. 13.5 (0.53)
2nd
R
Approx. 11.4 (0.45)
1st
2nd
Compression pressure
(Automatic decomp. actuated)
—
LIMIT
0.120
(0.0047)
Nicks or
Scratches
Cylinder distortion
Piston ring free end gap
—
STANDARD
0.020 – 0.030
(0.0008 – 0.0012)
100.000 – 100.015
(3.9371 – 3.9376)
99.975 – 99.990
(3.9360 – 3.9366)
Measure at 21 mm (0.8 in) from the skirt end.
—
E-03, 24, 28, 33
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Unit: mm (in)
LIMIT
33.410
(1.3154)
33.400
(1.3150)
0.150
(0.0059)
0.150
(0.0059)
0.10
(0.004)
—
Cylinder head distortion
Piston ring end gap
1/8
STANDARD
33.710 – 33.750
(1.3272 – 1.3287)
33.700 – 33.740
(1.3268 – 1.3283)
0.032 – 0.066
(0.0013 – 0.0026)
0.028 – 0.059
(0.0011 – 0.0023)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.6894 – 0.6900)
21.959 – 21.980
(0.8645 – 0.8654)
17.466 – 17.484
(0.6877 – 0.6883)
EX.
—
0.9 – 1.1
(0.035 – 0.043)
—
Cam height
—
IN. & EX.
5.9 – 6.7 kg
(13.0 – 14.8 lbs)
at length 27.5 mm (1.1 in)
13.8 – 15.8 kg
(30.4 – 34.8 lbs)
at length 31.0 mm (1.2 in)
ITEM
—
Valve seat width
OUTER
CAMSHAFT + CYLINDER HEAD
—
0.05
(0.002)
0.5
(0.02)
2.7
(0.11)
Valve spring tension (IN. & EX.)
E
L
E-06, 24
A
S
VALVE + GUIDE
Valve diam.
NOTE
0.30 – 0.45
(0.012 – 0.018)
0.45 – 0.60
(0.018 – 0.024)
Approx. 850 kPa
2
(8.5 kg/cm , 120 psi)
2/8
99.880
(3.9323)
—
E-03, 24, 28, 33
19
ITEM
Piston ring to groove clearance
Piston ring groove width
STANDARD
1st
—
2nd
—
1.230 – 1.250
(0.048 – 0.049)
1.210 – 1.230
(0.047 – 0.048)
2.810 – 2.830
(0.110 – 0.111)
1.170 – 1.190
(0.0461 – 0.0469)
1.150 – 1.170
(0.0453 – 0.0461)
23.002 – 23.008
(0.9056 – 0.9058)
22.996 – 23.000
(0.9054 – 0.9055)
1st
2nd
Oil
Piston ring thickness
LIMIT
0.180
(0.0071)
0.150
(0.0059)
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
Conrod big end side clearance
0.10
(0.004
24.95
(0.982
Conrod big end width
Crankshaft runout
Crank web to web width
– 0.65
– 0.026)
– 25.00
– 0.984)
—
—
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
STANDARD
10 – 15
(0.4 – 0.6)
2.9 – 3.1
(0.11 – 0.12)
No. 1 &
No. 2
Driven plate distortion
—
Clutch spring free length
—
—
—
DRIVE TRAIN
—
ITEM
Primary reduction ratio
Final reduction ratio
23.030
(0.9067)
22.980
(0.9047)
Unit: mm (in)
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.00
(0.039)
2.800 (42/15)
Shift fork thickness
—
—
0.05
(0.002)
71.0 ± 0.1
(2.795 ± 0.004)
—
Drive chain
Type
Links
20-pitch length
Drive chain slack
STANDARD
1.633 (61/28 × 30/20 × 15/30)
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
3/8
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(S.J.)
(P.S.)
Throttle cable play
(pulling cable)
E-03, 28
MIKUNI
BST40SS
40 mm
32E1
1 500 ± 100 r/min
14.7 ± 1.0 mm
(0.58 ± 0.04 in)
#
6F23
A
S
SPECIFICATION
E-33
E-24
←
←
←
32E6
←
←
32E3
←
Spark plug
←
#95
#
#40
PRE-SET
←
#140
6F19-3rd
Y-5
←
#42.5
←
PRE-SET
(1.0 turn back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
←
←
Gap
Spark performance
Ignition coil resistance
Primary
Secondary
Generator coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuse size
Main
Headlight (H)
Headlight (L)
23 – 25 kΩ
Charging
0.5 – 0.9 Ω
Power
0.1 – 0.2 Ω
source
Pick-up
170 – 256 Ω
More than 75 V (AC) at 5 000 r/min
Approx. 200 W at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
3–5Ω
YTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
NOTE
4/8
Unit: W
SPECIFICATION
E-03, 24, 28, 33
60
55
ITEM
Headlight
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
License light
21/5
21
1.7
2
2
2
5
BRAKE + WHEEL
Unit: mm (in)
STANDARD
5
(0.2)
4.0 ± 0.2
(0.157 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
ITEM
Rear brake pedal height
Brake disc thickness
Front
Rear
Brake disc runout
Master cylinder bore
—
12.700
(0.5000
12.700
(0.5000
12.657
(0.4983
12.657
(0.4983
27.000
(1.0630
30.23
(1.1902
26.90
(1.0591
30.16
(1.1874
Front
Rear
B – B/W
Plug cap –
Plug cap
Y–Y
E-03, 24, 28, 33
WATTAGE
Unit: mm (in)
Type
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
B–W
Front
Bl – G
Rear
Brake caliper piston diam.
Front
Rear
Wheel rim runout
Axial
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
—
Radial
—
Front
—
Rear
—
1.320 at 20 °C (68 °F)
Wheel axle runout
30 A
10 A
10 A
5/8
—
—
319.4
(12.57)
—
E
L
P
M
←
←
←
←
←
←
SPECIFICATION
ND.: U31ESR-N
N.G.K.: CR10E
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
0.07 – 0.12 Ω
—
—
—
←
ITEM
—
—
—
—
—
—
0.50
(0.020)
LIMIT
—
E-03, 24, 28, 33
ELECTRICAL
—
30 – 45
(1.2 – 1.8)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
—
2.733 (41/15)
2.416 (29/12)
1.625 (26/16)
1.238 (26/21)
1.000 (21/21)
0.826 (19/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.200)
4.8 – 4.9
(0.189 – 0.193)
DAIDO: D.I.D. 525V9
110
Shift fork groove width
—
2.6
(0.10)
0.10
(0.004)
33.0
(1.30)
Unit: mm (in) Except ratio
LIMIT
—
STANDARD
2.178 (61/28)
E-03, 28,
33
E-24
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Unit: mm (in)
LIMIT
E-03, 24, 28, 33
6/8
12.743
0.5017)
12.743
0.5017)
12.684
0.4994)
12.684
0.4994)
27.050
1.0650)
30.28
1.1921)
26.95
1.0610)
30.18
1.1882)
LIMIT
—
3.5
(0.14)
4.0
(0.16)
0.30
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
E-03, 24, 28, 33
20
STANDARD
21 × 1.85
17M/C × MT2.50
90/90-21M/C 54S
120/90-17M/C 64S
ITEM
Tire rim size
Front
Rear
Front
Rear
Tire size
Tire tread depth
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
FUEL + OIL
LIMIT
ITEM
—
—
—
—
3.0
(0.12)
3.0
(0.12)
Fuel type
Unit: mm (in)
STANDARD
260
(10.2)
220
(8.7)
LIMIT
—
NOTE
—
Low seat
—
548
(21.6)
164
(6.5)
150
(5.9)
247.5
(9.74)
260
(10.2)
220
(8.7)
—
—
0.3
(0.01)
Front fork spring free length
Front fork oil level
Rear shock absorber spring
pre-set length
Rear wheel travel
Swingarm pivot shaft runout
—
Engine oil type
Engine oil capacity
Low seat
—
Front fork oil type
Front fork oil capacity (each leg)
—
—
Fuel tank capacity
Low seat
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the reserch method.
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
12 L
(3.2/2.6 US/Imp gal)
Including
reserve
13 L
(3.4/2.9 US/Imp gal)
Only
3.0 L
reserve
(0.8/0.7 US/Imp gal)
SAE 10W-40, API SF or SG
Oil
2 300 ml
change
(2.4/2.0 US/lmp qt)
Oil and
2 400 ml
filter change
(2.5/2.1 US/lmp qt)
Engine
2 600 ml
overhaul
(2.7/2.3 US/lmp qt)
Fork oil #10
565 ml
(19.1/19.9 US/lmp oz)
563 ml
(19.0/19.8 US/Imp oz)
DOT 4
NOTE
E-03, 28, 33
E-24
E-33
Others
Low seat
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
150
175
SOLO RIDING
kgf/cm2
1.50
1.75
psi
22
25
kPa
175
200
7/8
A
S
ENGINE TOP END
Cam height
Camshaft chain 20-link length
Rocker arm inside diameter
Rocker arm shaft diameter
Cylinder compression
—
0.04 – 0.08
(0.0016 – 0.0031)
0.04 – 0.08
(0.0016 – 0.0031)
0.85 – 1.15
(0.0335 – 0.0453)
1.15 – 1.45
(0.0453 – 0.0571)
IN.
EX.
Valve head thickness
IN.
EX.
Valve stem bend
Valve stem diameter
TIR 0.01 (0.0004) or less
IN.
EX.
Valve guide inside diameter
IN. & EX.
Valve/valve guide clearance
(Wobble method)
IN.
EX.
Valve seat cutting angle
Valve seat width
Valve seat surface outside diameter
IN. & EX.
IN.
EX.
Valve spring free length
Cylinder inside diameter
E
L
P
M
Unit: mm (in)
STANDARD
28.984 – 29.164
IN.
(1.1411 – 1.1482)
29.021 – 29.201
EX.
(1.1426 – 1.1496)
127.00 – 127.48
(5.000 – 5.014)
10.000 – 10.015
(0.3937 – 0.3943)
9.980 – 9.995
(0.3929 – 0.3935)
Usable range
865 – 1 320 kPa
(8.8 – 13.5 kgf/cm2, 125 – 192 psi)
at 5 kicks
Cylinder head warp
Valve clearance
psi
25
29
E-03, 24, 28, 33
DR-Z110
ITEM
DUAL RIDING
kgf/cm2
1.75
2.00
4.475 – 4.490
(0.1762 – 0.1768)
4.462 – 4.472
(0.1757 – 0.1761)
4.500 – 4.512
(0.1772 – 0.1776)
0.02 – 0.07
(0.0008 – 0.0028)
0.06 – 0.11
(0.002 – 0.004)
45°, 32°, 60°, 67.5°
0.80 – 1.15
(0.0315 – 0.0453)
22.9 – 23.1
(0.902 – 0.909)
19.9 – 20.1
(0.784 – 0.791)
36.75
(1.447)
52.997 – 53.009
(2.0865 – 2.0870)
LIMIT
28.88
(1.137)
28.92
(1.139)
128.9
(5.075)
10.05
(0.396)
9.95
(0.392)
ITEM
Piston outside diameter
Piston/cylinder clearance
Oversize piston and rings
Piston ring/groove clearance
Top
Second
Piston ring groove width
Top
Second
—
0.05
(0.002)
8/8
Piston ring thickness
Piston ring end gap
Top &
Second
—
Top
—
Second
0.5
(0.02)
0.5
(0.02)
TIR 0.05
(0.002)
4.46
(0.176)
4.44
(0.175)
4.55
(0.179)
0.12
(0.0047)
0.19
(0.007)
—
—
—
Oil
Piston pin diameter
Piston pin hole inside diameter
Connecting rod small end inside
diameter
STANDARD
52.981 – 52.993
(2.0859 – 2.0863)
0.010 – 0.022
(0.0004 – 0.0009)
+0.50 (0.0197), +1.0 (0.0394)
0.02 – 0.06
(0.0008 – 0.0024)
0.01 – 0.05
(0.0004 – 0.0020)
0.81 – 0.83
(0.0319 – 0.0327)
0.80 – 0.82
(0.0315 – 0.0323)
0.77 – 0.79
(0.0303 – 0.0311)
0.15 – 0.30
(0.0059 – 0.0118)
0.30 – 0.45
(0.0118 – 0.0177)
0.10 – 0.60
(0.0039 – 0.0236)
12.995 – 13.000
(0.5116 – 0.5118)
13.001 – 13.007
(0.5118 – 0.5121)
13.003 – 13.014
(0.5119 – 0.5124)
CRANKSHAFT/TRANSMISSION
ITEM
Connecting rod big end radial
clearance
Connecting rod big end side clearance
Crankshaft runout
STANDARD
0.006 – 0.020
(0.0002 – 0.0008)
0.1 – 0.2
(0.004 – 0.008)
Less than 0.03 mm (0.001 in) TIR
Shift fork ear thickness
3.9 – 4.0
(0.154 – 0.157)
4.05 – 4.15
(0.159 – 0.163)
4.9 – 5.0
(0.193 – 0.197)
5.05 – 5.20
(0.199 – 0.205)
—
35.5
(1.40)
53.10
(2.091)
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
1/5
P-03, 21, 24, 28
E-03, 24, 28, 33
2/5
LIMIT
52.83
(2.080)
—
—
0.16
(0.0063)
0.15
(0.0059)
0.90
(0.035)
0.90
(0.035)
0.7
(0.028)
0.6
(0.024)
0.8
(0.032)
0.9
(0.035)
12.96
(0.5102)
13.07
(0.5146)
13.05
(0.5138)
Unit: mm (in)
LIMIT
0.07
(0.0028)
0.4
(0.016)
0.08
(0.003)
3.8
(0.15)
4.3
(0.17)
4.8
(0.19)
5.3
(0.21)
P-03, 21, 24, 28
21
CLUTCH
Unit: mm (in)
ITEM
Primary clutch housing inside
diameter
Primary clutch shoe groove depth
Secondary clutch friction plate
thickness
Secondary clutch friction plate
warp
Secondary clutch steel plate warp
LIMIT
104.0 – 104.2
(4.094 – 4.102)
104.5
(4.114)
1.0
(0.04)
0.5
(0.02)
3.1 – 3.3
(0.12 – 0.13)
2.9
(0.11)
0.2 mm (0.008 in) or less
0.3
(0.01)
0.15 mm (0.006 in) or less
0.3
(0.01)
20.35
(0.80)
15.92
(0.6268)
16.04
(0.6315)
Exciter coil resistance
Unit: mm (in)
BRAKES
LIMIT
—
—
259
(10.20)
ITEM
Brake lever free play
Brake pedal free play
Brake shoe lining thickness
Clutch spring free length
22.04
(0.87)
15.941 – 15.968
(0.6276 – 0.6287)
16.000 – 16.018
(0.6299 – 0.6306)
Kick shaft diameter
Kick gear inside diameter
FINAL DRIVE
ITEM
Drive chain
STANDARD
DAIDO: D.I.D. 420MBK1
86 links
254.0 – 254.6
(10.00 – 10.02)
0–5
(0 – 0.2)
49.1 – 49.3
(1.93 – 1.94)
126.24
(4.97)
Type
Links
20-link length
Drive chain slack
Engline sprocket diameter
Rear sprocket diameter
Rear sprocket warp
Less than 0.4 mm (0.016 in)
FUEL SYSTEM
STANDARD
2 – 3 (0.08 – 0.12)
KEIHIN PB18
#80
NCFA
3.0
#38/38
1 and ¼ turns out
1 250 – 1 350 r/min (rpm)
Rear tire
Tire air pressure
10.7 ± 2 (0.42 ± 0.08)
High quality foam air filter oil
—
—
A
S
Unit: mm (in)
STANDARD
Axial
0.5 mm (0.02 in) or less
Radial
0.8 mm (0.03 in) or less
Front
(/100 mm)
Rear
(/110 mm)
Size
Make
Type
Size
Make
Type
Front &
Rear
0.1 (0.004)
0.1 (0.004)
2.50-14MC 4PR
CHENG SHIN
C803
3.00-12 4PR
CHENG SHIN
C803
100 kPa
(1.0 kgf/cm2, 14 psi)
Engine oil type
Engine oil viscosity
Engine oil capacity
Engine oil level
LIMIT
2
(0.08)
2
(0.08)
0.2
(0.008)
0.2
(0.008)
—
—
—
—
—
—
—
—
Unit: mm (in)
STANDARD
SS-8 or SAE 10W-20
163 ± 2.5 ml
(5.51 ± 0.08 US oz)
89 ± 2 (3.50 ± 0.08)
from top of inner tube
439.7
(17.31)
LIMIT
—
—
—
430.9
(16.96)
Unit: mm (in)
STANDARD
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
When engine is
1.1 L (1.2 US qt)
completely dry
When filter is
1.0 L (1.1 US qt)
removed
When filter is
0.9 L (1.0 US qt)
not removed
Between upper and lower level lines
5/5
LIMIT
—
—
—
—
—
—
P-03, 21, 24, 28
0.19 – 0.23 Ω
2.5 – 3.7 kΩ
0.2 – 1.0 Ω
0.1 – 0.8 Ω
NGK CR6HSA
0.6 – 0.7 (0.024 – 0.028)
100 V or above
4.6 V or above
15 V or above
type
gap
NOTE
Bl/Y – Ground
—
—
—
W – Ground
Y – Ground
—
—
—
—
—
Unit: mm (in)
Brake shoe spring free length
Front
Front
Rear
Brake drum inside diameter
Front
Rear
Brake camshaft diameter
Front
Rear
Brake camshaft hole inside diameter
Front
STANDARD
4 – 5 (0.16 – 0.20)
20 – 30 (0.79 – 1.18)
2.10 – 3.00
(0.08 – 0.12)
3.85 – 4.15
(0.152 – 0.163)
30.8 – 31.2
(1.213 – 1.228)
32.5
(1.280)
90.000 – 90.087
(3.543 – 3.547)
110.000 – 110.087
(4.331 – 4.334)
11.957 – 11.984
(0.471 – 0.472)
14.957 – 14.984
(0.589 – 0.590)
12.000 – 12.027
(0.472 – 0.474)
15.000 – 15.027
(0.591 – 0.592)
80 – 90°
E
L
Rear
P
M
P-03, 21, 24, 28
ENGINE OIL
ITEM
Primary
winding
resistance
Secondary winding
resistance
Rear
LIMIT
—
—
—
—
—
—
—
—
—
SUSPENSIONS
ITEM
Front fork oil viscosity
Front fork oil capacity
(completely dry)
Front fork oil level
(fully compressed, spring removed)
Front fork spring free length
Unit: mm (in)
STANDARD
50 – 200 Ω
0.7 (0.028)
Ignition coil (primary) peak voltage
Pickup coil peak voltage
Exciter coil peak voltage
—
48.4
(1.91)
125.4
(4.94)
0.5
(0.020)
3.0 ± 1 (0.12 ± 0.04)
WHEELS/TIRES
Front tire
Spark plug
Brake cam lever angle
3/5
Axle runout
ITEM
Pickup coil resistance
Air gap
Ignition coil
Unit: mm (in)
ITEM
Throttole grip free play
Carburetor type
Main jet
Jet needle
Throttle valve cutaway
Pilot jet
Air screw
Idle speed
Servise fuel level (below the bottom
edge of carburetor body)
Float height
Air cleaner element oil
ITEM
Wheel rim runout (Front & Rear)
ELECTRICAL SYSTEM
STANDARD
4/5
LIMIT
—
—
1.2
(0.05)
2.0
(0.08)
32.6
(1.28)
34.1
(1.34)
90.75
(3.57)
110.75
(4.36)
11.88
(0.468)
14.88
(0.586)
12.15
(0.478)
15.15
(0.596)
—
P-03, 21, 24, 28
22
DR-Z125/L
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
30
(1.2)
26
(1.0)
0.08 – 0.13
(0.003 – 0.005)
0.13 – 0.18
(0.005 – 0.007)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
—
INNER
—
OUTER
Valve spring tension
(IN. & EX.)
INNER
OUTER
—
76 – 90 N
(7.8 – 9.2 kgf, 17.2 – 20.3 lbs)
at length 32.5 mm (1.28 in)
186 – 219 N
(18.9 – 22.3 kgf, 41.7 – 49.2 lbs)
at length 36.0 mm (1.42 in)
1/8
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring end gap
—
1st
R
2nd
R
7.0
(0.28)
8.5
Approx.
(0.33)
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
Approx.
1st
2nd
Piston ring to groove clearance
1st
—
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
Camshaft runout
—
—
1.21 – 1.23
(0.047 – 0.048)
1.21 – 1.23
(0.047 – 0.048)
2.51 – 2.53
(0.099 – 0.100)
1.175 – 1.190
(0.0463 – 0.0469)
1.170 – 1.190
(0.0461 – 0.0469)
14.002 – 14.008
(0.5513 – 0.5515)
13.994 – 14.002
(0.5509 – 0.5513)
3/8
IN. & EX.
IN. & EX.
IN. & EX.
Cylinder head distortion
—
12.018
0.4731)
11.995
0.4722)
—
Cylinder head cover distortion
—
LIMIT
32.83
(1.29)
0.150
(0.0059)
—
—
0.10
(0.004)
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
Rocker arm shaft O.D.
—
IN. & EX.
IN. & EX.
Rocker arm I.D.
—
STANDARD
33.13 – 33.17
(1.304 – 1.306)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
IN. & EX.
Camshaft journal oil clearance
—
—
—
—
0.05
(0.002)
0.05
(0.002)
0.35
(0.014)
0.05
(0.002)
0.5
(0.014)
2.5
(0.10)
—
0.03
(0.001)
36.0
(1.42)
39.3
(1.55)
—
E
L
—
A
S
Cylinder distortion
Piston ring free end gap
Cam height
—
P
M
Unit: mm (in)
STANDARD
1 200 – 1 600 kPa
(12 – 16 kgf/cm2, 171 – 228 psi)
0.020 – 0.030
(0.0008 – 0.0012)
57.000 – 57.015
(2.2440 – 2.2447)
56.975 – 56.990
(2.2431 – 2.2437)
Measure at 12 mm (0.5 in) from the skirt end.
Unit: mm (in)
ITEM
E-28, 33
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
CAMSHAFT + CYLINDER HEAD
LIMIT
LIMIT
1 000 kPa
(10 kgf/cm2, 142 psi)
0.120
(0.0047)
57.110
(2.2484)
56.880
(2.2394)
0.05
(0.002)
5.6
(0.22)
6.8
(0.27)
0.5
(0.02)
0.5
(0.02)
0.18
(0.007)
0.15
(0.006)
2/8
E-28, 33
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Unit: mm (in)
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
15.95 – 16.00
(0.628 – 0.630)
53.0 ± 0.1
(2.09 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
LIMIT
14.040
(0.5528)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
STANDARD
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
CLUTCH
Drive plate thickness
—
Drive plate claw width
—
Driven plate distortion
—
Clutch spring free length
—
Unit: mm (in)
ITEM
Clutch lever play
—
LIMIT
STANDARD
10 – 15
(0.4 – 0.6)
2.90 – 3.10
(0.114 – 0.122)
11.8 – 12.0
(0.46 – 0.47)
—
32.6
(1.28)
LIMIT
—
2.60
(0.102)
11.5
(0.45)
0.10
(0.004)
31.0
(1.22)
—
14.030
(0.5524)
13.980
(0.5504)
E-28, 33
4/8
E-28, 33
23
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Unit: mm (in) Except ratio
STANDARD
3.470 (59/17)
3.642 (51/14)
4.071 (57/14)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.196 – 0.201)
5.5 – 5.6
(0.217 – 0.224)
4.8 – 4.9
(0.189 – 0.193)
5.3 – 5.4
(0.209 – 0.213)
DR-Z125
DR-Z125L
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
No. 1
No. 2
Shift fork thickness
No. 1
No. 2
Countershaft length
(Low to 2nd)
88.0
Drive chain
Type
Links
(3.46
+0.004
-0
)
D.I.D. 428HG
122
130
DR-Z125
DR-Z125L
20-pitch
length
Drive chain slack
+0.1
-0
—
35 – 45
(1.4 – 1.8)
–5 – 5
(–0.2 – 0.2)
25 – 40
Gearshift lever height
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.02)
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Throttle cable play
ELECTRICAL
ITEM
—
Spark plug
SPECIFICATION
DENSO: X24ESR-U
NGK: DR8EA
0.6 – 0.8 mm
Gap
(0.024 – 0.031 in)
Over 8 mm (0.3 in) at 1 atm.
Primary
0.1 – 0.8 Ω
Secondary
13 – 18 kΩ
Charging
13 – 22 Ω
Pick-up coil
140 – 230 Ω
More than 2.0 V
More than 150 V
NOTE
Type
—
—
—
Spark performance
Ignition coil resistance
—
Generator coil resistance
—
—
—
259.0
(10.20)
SPECIFICATION
E-03, 28
#102.5
5HGM74-1
N-6M
#2.5
#17.5
PRE-SET
(2 and µ turns back)
2.0 – 4.0 mm (0.08 – 0.16 in)
ITEM
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Pick-up coil peak voltage
Ignition coil primary peak voltage
W/Bl – B/W
Plug cap – W/Bl
Y – Y/R
G – B/W
: G, : B/W
: B/W, : W/Bl
—
—
CARBURETOR
SPECIFICATION
E-33, 28
MIKUNI
VM20SS
20 mm (0.8 in)
08G
1 700 ± 100 r/min
18.9 ± 1.0 mm (0.74 ± 0.04 in)
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
5/8
Unit: mm (in)
ITEM
Brake lever play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Brake caliper cylinder bore
11.000 –
(0.4331 –
10.957 –
(0.4314 –
30.230 –
(1.1902 –
30.150 –
(1.1870 –
DOT 4
Front
Front
Brake caliper piston diam.
Front
Brake fluid type
Wheel rim runout
Axial
Wheel axle runout
Front
Rear
Front
Rear
Tire tread depth
—
Front
Master cylinder piston diam.
Tire size
STANDARD/SPECIFICATION
15 – 25
DR-Z125
(0.6 – 1.0)
0.1 – 0.3
DR-Z125
(0.004 – 0.012)
20 – 30
(0.8 – 1.2)
–10 – 0
(–0.4 – 0)
Rear
—
3.5 ± 0.2
Front
(0.14 ± 0.008)
Front
Master cylinder bore
Wheel rim size
P
M
E-28, 33
A
S
BRAKE + WHEEL
11.043
0.4348)
10.984
0.4324)
30.306
1.1931)
30.200
1.1890)
—
Radial
—
Front
—
Rear
—
DR-Z125
DR-Z125L
DR-Z125
DR-Z125L
DR-Z125
DR-Z125L
DR-Z125
DR-Z125L
J17 × 1.40
J19 × 1.40
J14 × 1.60
J16 × 1.60
70/100-17 40M
70/100-19 42M
90/100-14 49M
90/100-16 52M
Front
—
Rear
—
7/8
E
L
LIMIT
—
—
—
—
110.7
3.0
(0.12)
0.30
(0.012)
—
—
6/8
E-28, 33
SUSPENSION
Unit: mm (in)
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear shock absorber spring
pre-set length
Rear wheel travel
Swingarm pivot shaft runout
STANDARD/SPECIFICATION
180 (7.1)
—
173.0 (6.81)
SUZUKI FORK OIL SS-08 (#10) or
an equivalent fork oli
172 ml (4.3/4.5 US/lmp oz)
DR-Z125
240.5 (9.47)
DR-Z125L
241.1 (9.49)
DR-Z125
160 (6.3)
DR-Z125L
170 (6.7)
—
LIMIT
—
587 (23.1)
—
—
—
—
—
—
0.6 (0.02)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
100
105
1.0
1.0
14
14
—
FUEL + OIL
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
E-28, 33
ITEM
Fuel type
Fuel tank including
Engine oil type
Engine oil capacity
reserve
reserve
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
6.6 L (1.7/1.5 US/lmp qt)
1.7 L (0.4/0.4 US/lmp qt)
SAE 10W-40, API SF or SG
Change
850 ml (0.9/0.7 US/lmp qt)
Filter
950 ml (1.0/0.8 US/lmp qt)
change
Overhaul
1 100 ml (1.2/1.0 US/lmp qt)
8/8
NOTE
E-28, 33
24
DR-Z250 (E-03, 28, 33)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
28.5
(1.12)
25.0
(0.98)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
LIMIT
—
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
—
—
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
EX.
4.500 – 4.512
(0.1772 – 0.1776)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
Valve head radial runout
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
OUTER
Valve spring tension
(IN. & EX.)
INNER
OUTER
Piston to cylinder clearance
Cylinder bore
—
—
—
48 – 58 N
(4.8 – 5.8 kgf, 10.6 – 12.8 lbs)
at length 29.9 mm (1.18 in)
133 – 153 N
(13.3 – 15.3 kgf, 29.3 – 33.7 lbs)
at length 33.4 mm (1.32 in)
—
1 300 kPa
(13 kgf/cm2, 185 psi)
0.015 – 0.025
(0.0006 – 0.0010)
73.000 – 73.015
(2.8740 – 2.8746)
72.980 – 72.995
(2.8732 – 2.8738)
Measure at 15 mm (0.6 in) from the skirt end.
Piston diam.
Cylinder distortion
—
Piston ring free end gap
Cam height
STANDARD
35.32 –
(1.391 –
35.22 –
(1.387 –
IN.
EX.
1/7
1st & 2nd
1st & 2nd
A
S
STANDARD
19.006 – 19.014
(0.7483 – 0.7486)
Conrod deflection
—
Conrod big end side clearance
Crank web to web width
Crankshaft runout
1st & 2nd
Piston pin O.D.
E
L
ITEM
Shift fork to groove clearance
Shift fork groove width
Drive chain
20-pitch length
—
STANDARD
1.571 (33/21)
Above 50 kPa (0.5 kgf/cm2, 7.1 psi)
Below 150 kPa (1.5 kgf/cm2, 21.3 psi)
at 3 000 r/min
LIMIT
—
—
Drive chain slack
LIMIT
910 kPa
(9.1 kgf/cm2,
129 psi)
0.120
(0.0047)
Nicks or
scratches
72.880
(2.8693)
0.05
(0.002)
6.1
(0.24)
6.2
(0.25)
0.50
(0.02)
0.180
(0.007)
—
—
—
19.030
(0.7492)
18.980
(0.7472)
E-03, 28, 33
STANDARD
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
D.I.D. 520V2
112
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
Shift fork thickness
—
0.08
(0.003)
1.01 – 1.03
(0.040 – 0.041)
2.01 – 2.03
(0.079 – 0.080)
0.97 – 0.99
(0.038 – 0.039)
19.002 – 19.008
(0.7481 – 0.7483)
18.992 – 19.000
(0.7477 – 0.7480)
2/7
—
30 – 45
(1.2 – 1.8)
LIMIT
0.5
(0.02)
—
—
—
—
319.4
(12.57)
—
CARBURETOR
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
CLUTCH
—
Unit: mm (in)
ITEM
Clutch lever play
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
Drive plate thickness
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
—
LIMIT
—
2.62
(0.103)
12.9
(0.51)
0.10
(0.004)
39.0
(1.54)
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
(pulling cable)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
SPECIFICATION
E-03, 28
E-33
TM28SS
BSR32
28 mm
32 mm
13E3
13E4
1 600 ± 100 r/min
1 500 ± 100 r/min
14.2 ± 1.0 mm
13.0 ± 1.0 mm
(0.56 ± 0.04 in)
(0.51 ± 0.04 in)
#127.5
#
6FN3-3rd
5DH46
P-6M
#37.5
#
1 and 1/4 turns back
PRE-SET
2.0 – 4.0 mm
←
(0.08 – 0.16 in)
ELECTRICAL
Unit: mm (in)
ITEM
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
Piston pin bore
P
M
LIMIT
19.040
(0.7496)
3.0
(0.12)
1.0
(0.04)
0.10 – 0.55
(0.004 – 0.022)
19.95 – 20.00
(0.785 – 0.787)
64.0 ± 0.1
(2.52 ± 0.004)
Conrod big end width
0.08 – 0.20
(0.003 – 0.008)
Oil
Unit: mm (in)
ITEM
Conrod small end I.D.
Approx. 7.7 (0.31)
Piston ring groove width
E-03, 28, 33
CONROD + CRANKSHAFT
Approx. 7.6 (0.30)
R
Piston ring to groove clearance
—
LIMIT
35.02
(1.379)
34.92
(1.375)
35.36
1.392)
35.26
1.388)
R
1st & 2nd
Unit: mm (in)
ITEM
1st
2nd
Piston ring end gap
—
—
Unit: mm (in)
STANDARD
Piston ring thickness
CAMSHAFT + CYLINDER HEAD
0.10
(0.004)
—
0.05
(0.002)
—
ITEM
Compression pressure
—
—
INNER
—
17th pin
CYLINDER + PISTON + PISTON RING
—
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
Valve spring free length
(IN. & EX.)
LIMIT
0.150
(0.0059)
Cam chain pin (at arrow “3”)
Cylinder head distortion
IN. & EX.
IN.
STANDARD
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
Camshaft runout
—
Valve stem deflection
Valve stem O.D.
ITEM
Camshaft journal oil clearance
Unit: mm (in) Except ratio
STANDARD
3.190 (67/21)
3.769 (49/13)
2.416 (29/12)
1.733 (26/15)
1.333 (24/18)
1.111 (20/18)
0.952 (20/21)
0.826 (19/23)
Low
2nd
3rd
4th
5th
Top
3/7
LIMIT
—
—
—
—
—
—
—
—
E-03, 28, 33
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
0.1 – 1.5 Ω
Primary
Secondary
Ignition coil primary peak voltage
Generator coil resistance
Charging
Signal coil
Pick-up coil
12 – 20 kΩ
More than 150 V
0.7 – 1.5 Ω
0.1 – 1.2 Ω
390 – 620 Ω
4/7
NOTE
Terminal –
Ground
Plug cap –
Terminal
: B/W, : W/Bl
Y–Y
W–B
G – Bl
E-03, 28, 33
25
ITEM
Pickup coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
SPECIFICATION
More than 5 V
More than 1.2 V
NOTE
: G, : Bl
: W, : B
ITEM
Wheel rim runout
More than 75 V (AC) at 5 000 r/min
Wheel axle runout
14.0 – 15.5 V at 5 000 r/min
3–5Ω
FTZ5L-BS
12 V 16.2 kC (4.5 Ah)/10 HR
10 A
WATTAGE
Wheel rim size
Unit: W
ITEM
SPECIFICATION
35
5
Headlight
Taillight
STANDARD/SPECIFICATION
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
J21 × 1.60
J18 × 2.15
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Front
Rear
BRAKE + WHEEL
Unit: mm (in)
ITEM
Brake lever play
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.0 ± 0.2
Front
(0.118 ± 0.008)
4.0
± 0.2
Rear
(0.157 ± 0.008)
Rear brake pedal height
Brake disc thickness
Brake disc runout
—
Master cylinder bore
11.000 –
(0.4331 –
14.000 –
(0.5512 –
10.957 –
(0.4314 –
13.957 –
(0.5495 –
27.000 –
(1.0630 –
30.230 –
(1.1902 –
26.900 –
(1.0591 –
30.160 –
(1.1874 –
DOT 4
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
11.043
0.4348)
14.043
0.5529)
10.984
0.4324)
13.984
0.5506)
27.050
1.0650)
30.280
1.1921)
26.950
1.0610)
30.180
1.1882)
Front
Rear
Tire tread depth
Front
—
Rear
—
—
2.5
(0.098)
3.5
(0.138)
0.3
(0.012)
ITEM
Front fork stroke
Front fork oil level
—
Front fork oil type
Front fork oil capacity
(each leg)
Front fork damping force adjuster
—
—
—
—
Rear shock absorber gas
pressure
Rear shock absorber spring
pre-set length
Rear shock absorber damping
force adjuster
—
Rear wheel travel
—
—
100/100-18 59M
SUSPENSION
Front fork spring free length
—
STANDARD/SPECIFICATION
100 kPa
(1.00 kgf/cm2, 14 psi)
100 kPa
(1.00 kgf/cm2, 14 psi)
80/100-21 51M
Tire size
LIMIT
—
E
L
A
S
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
including
reserve
reserve
SPECIFICATION
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2).
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
10.5 L
(2.8/2.3 US/Imp gal)
2.4 L
(0.6/0.5 US/Imp gal)
SAE 10W-40, API SF or SG
1 100 ml
Change
(1.2/1.0 US/Imp qt)
1 200 ml
Filter change
(1.3/1.1 US/Imp qt)
1
600 ml
Overhaul
(1.7/1.4 US/Imp qt)
7/7
P
M
E-03, 28, 33
NOTE
E-03, 28, 33
LIMIT
—
—
—
—
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
Unit: mm (in)
STANDARD/SPECIFICATION
280
(11.0)
502.6
(19.79)
143
(5.6)
SUZUKI fork oil SS-07 or an equivalent fork oil
526 ml
(17.8/18.5 US/Imp oz)
Rebound
8 clicks turns back
Compression
7 clicks turns back
1 000 kPa
(10 kgf/cm2, 142 psi)
269.4
(10.6)
Rebound
3 turns back
Compression
1 and 1/4 turns back
285
(11.2)
Swingarm pivot shaft runout
5/7
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
6/7
—
LIMIT
—
492
(19.4)
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
E-03, 28, 33
26
DR-Z250 (E-24)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
28.5
(1.12)
25.0
(0.98)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
LIMIT
—
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
—
—
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
EX.
4.500 – 4.512
(0.1772 – 0.1776)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
Valve head radial runout
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
OUTER
Valve spring tension
(IN. & EX.)
INNER
OUTER
Piston to cylinder clearance
Cylinder bore
—
—
—
48 – 58 N
(4.8 – 5.8 kgf, 10.6 – 12.8 lbs)
at length 29.9 mm (1.18 in)
133 – 153 N
(13.3 – 15.3 kgf, 29.3 – 33.7 lbs)
at length 33.4 mm (1.32 in)
1 300 kPa
(13 kgf/cm2, 185 psi)
0.015 – 0.025
(0.0006 – 0.0010)
73.000 – 73.015
(2.8740 – 2.8746)
72.980 – 72.995
(2.8732 – 2.8738)
Measure at 15 mm (0.6 in) from the skirt end.
Piston diam.
Cylinder distortion
—
Piston ring free end gap
—
Cam height
STANDARD
35.32 –
(1.391 –
35.22 –
(1.387 –
IN.
EX.
1/7
1st & 2nd
1st & 2nd
A
S
STANDARD
19.006 – 19.014
(0.7483 – 0.7486)
Conrod deflection
—
Conrod big end side clearance
Crank web to web width
Crankshaft runout
1st & 2nd
Piston pin O.D.
E
L
P
M
ITEM
Shift fork to groove clearance
Shift fork groove width
Drive chain
20-pitch length
—
—
STANDARD
1.571 (33/21)
Above 50 kPa (0.5 kgf/cm2, 7.1 psi)
Below 150 kPa (1.5 kgf/cm2, 21.3 psi)
at 3 000 r/min
LIMIT
—
72.880
(2.8693)
0.05
(0.002)
6.1
(0.24)
6.2
(0.25)
0.50
(0.02)
0.180
(0.007)
—
—
—
19.030
(0.7492)
18.980
(0.7472)
E-24
STANDARD
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
D.I.D. 520V2
108
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
—
0.08
(0.003)
1.01 – 1.03
(0.040 – 0.041)
2.01 – 2.03
(0.079 – 0.080)
0.97 – 0.99
(0.038 – 0.039)
19.002 – 19.008
(0.7481 – 0.7483)
18.992 – 19.000
(0.7477 – 0.7480)
LIMIT
910 kPa
(9.1 kgf/cm2,
129 psi)
0.120
(0.0047)
Nicks or
scratches
2/7
Shift fork thickness
—
Drive chain slack
30 – 45
(1.2 – 1.8)
LIMIT
0.5
(0.02)
—
—
—
—
319.4
(12.57)
—
CARBURETOR
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
CLUTCH
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
—
Unit: mm (in)
ITEM
Clutch lever play
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
Drive plate thickness
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
—
LIMIT
—
2.62
(0.103)
12.9
(0.51)
0.10
(0.004)
39.0
(1.54)
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
(pulling cable)
SPECIFICATION
TRANSMISSION + DRIVE CHAIN
TM28SS
28 mm
13E3
1 600 ± 100 r/min
14.2 ± 1.0 mm
(0.56 ± 0.04 in)
#127.5
6FN3-3rd
P-6M
#37.5
1 and 1/4 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
ELECTRICAL
Unit: mm (in)
ITEM
Spark plug
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
Piston pin bore
LIMIT
19.040
(0.7496)
3.0
(0.12)
1.0
(0.04)
0.10 – 0.55
(0.004 – 0.022)
19.95 – 20.00
(0.785 – 0.787)
64.0 ± 0.1
(2.52 ± 0.004)
Conrod big end width
0.08 – 0.20
(0.003 – 0.008)
Oil
Unit: mm (in)
ITEM
Conrod small end I.D.
Approx. 7.7 (0.31)
Piston ring groove width
E-24
CONROD + CRANKSHAFT
Approx. 7.6 (0.30)
R
Piston ring to groove clearance
—
LIMIT
35.02
(1.379)
34.92
(1.375)
35.36
1.392)
35.26
1.388)
R
1st & 2nd
Unit: mm (in)
ITEM
1st
2nd
Piston ring end gap
—
—
Unit: mm (in)
STANDARD
Piston ring thickness
CAMSHAFT + CYLINDER HEAD
0.10
(0.004)
—
0.05
(0.002)
—
ITEM
Compression pressure
—
—
INNER
—
17th pin
CYLINDER + PISTON + PISTON RING
—
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
Valve spring free length
(IN. & EX.)
LIMIT
0.150
(0.0059)
Cam chain pin (at arrow “3”)
Cylinder head distortion
IN. & EX.
IN.
STANDARD
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
Camshaft runout
—
Valve stem deflection
Valve stem O.D.
ITEM
Camshaft journal oil clearance
Type
Unit: mm (in) Except ratio
STANDARD
3.190 (67/21)
3.000 (42/14)
2.416 (29/12)
1.733 (26/15)
1.333 (24/18)
1.111 (20/18)
0.952 (20/21)
0.826 (19/23)
Low
2nd
3rd
4th
5th
Top
3/7
Gap
LIMIT
—
—
—
—
—
—
—
—
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
E-24
SPECIFICATION
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
Primary
0.1 – 1.5 Ω
Secondary
12 – 20 kΩ
Charging
Signal coil
Pick-up coil
More than 150 V
0.7 – 1.5 Ω
0.1 – 1.2 Ω
390 – 620 Ω
4/7
NOTE
Terminal –
Ground
Plug cap –
Terminal
: B/W, : W/Bl
Y–Y
W–B
G – Bl
E-24
27
ITEM
Pickup coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
SPECIFICATION
More than 5 V
More than 1.2 V
NOTE
: G, : Bl
: W, : B
ITEM
Brake caliper cylinder bore
More than 75 V (AC) at 5 000 r/min
Brake caliper piston diam.
14.0 – 15.5 V at 5 000 r/min
3–5Ω
FTZ5L-BS
12 V 16.2 kC (4.5 Ah)/10 HR
10 A
Brake fluid type
Wheel rim runout
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
60
55
21/5
21
LED
2
2
2
5
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
Turn signal indicator light
High beam indicator light
License plate light
BRAKE + WHEEL
Wheel axle runout
Wheel rim size
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.5 ± 0.2
Front
(0.138 ± 0.008)
4.0
± 0.2
Rear
(0.157 ± 0.008)
Rear brake pedal height
Brake disc thickness
Brake disc runout
—
Master cylinder bore
12.700 –
(0.5000 –
14.000 –
(0.5512 –
12.657 –
(0.4983 –
13.957 –
(0.5495 –
Front
Rear
Master cylinder piston diam.
Front
Rear
12.743
0.5017)
14.043
0.5529)
12.684
0.4994)
13.984
0.5506)
ITEM
Cold inflation tire pressure
(Solo riding)
Tire size
—
Tire type
Rear wheel travel
Tire tread depth
ITEM
Front fork stroke
—
Front fork spring free length
—
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
including
reserve
reserve
Front fork oil type
Front fork oil capacity
(each leg)
Front fork damping force adjuster
P
M
LIMIT
—
—
—
—
—
—
0.3
(0.01)
SPECIFICATION
Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
10.5 L
(2.8/2.3 US/Imp gal)
2.4 L
(0.6/0.5 US/Imp gal)
SAE 10W-40, API SF or SG
1 100 ml
Change
(1.2/1.0 US/Imp qt)
1 200 ml
Filter change
(1.3/1.1 US/Imp qt)
1 600 ml
Overhaul
(1.7/1.4 US/Imp qt)
NOTE
7/7
—
Front
Rear
J21 × 1.60
J18 × 2.15
Front
STANDARD/SPECIFICATION
150 kPa
(1.50 kgf/cm2, 22 psi)
150 kPa
(1.50 kgf/cm2, 22 psi)
3.00-21 51P
4.60-18 63P
DUNLOP: D903F
DUNLOP: D903
Front
—
Rear
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
E-24
LIMIT
—
—
—
—
—
—
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
Unit: mm (in)
STANDARD/SPECIFICATION
280
(11.0)
502.6
(19.79)
143
(5.6)
SUZUKI fork oil SS-07 or an equivalent fork oil
526 ml
(17.8/18.5 US/Imp oz)
Rebound
8 clicks turns back
Compression
7 clicks turns back
E
L
Front fork oil level
—
FUEL + OIL
Fuel type
—
Rear
SUSPENSION
—
A
S
Swingarm pivot shaft runout
Front
Front
Rear
Front
Rear
—
3.0
(0.118)
3.5
(0.138)
0.3
(0.012)
E-24
STANDARD/SPECIFICATION
1 000 kPa
(10 kgf/cm2, 142 psi)
269.4
(10.6)
Rebound
3 turns back
Compression
1 and 1/4 turns back
285
(11.2)
—
—
Rear
LIMIT
5/7
ITEM
Rear shock absorber gas
pressure
Rear shock absorber spring
pre-set length
Rear shock absorber damping
force adjuster
Axial
Radial
LIMIT
TIRE
Unit: mm (in)
ITEM
Brake lever play
STANDARD/SPECIFICATION
27.000 – 27.050
(1.0630 – 1.0650)
30.230 – 30.280
Rear
(1.1902 – 1.1921)
26.900 – 26.950
Front
(1.0591 – 1.0610)
30.160 – 30.180
Rear
(1.1874 – 1.1882)
DOT 4
Front
6/7
LIMIT
—
492
(19.4)
—
—
—
—
—
E-24
28
DR-Z400/E (E-01, 03, 28, 33)
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
CAMSHAFT + CYLINDER HEAD
Cam height
—
E-01, 03,
28
—
—
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Camshaft runout
Valve stem O.D.
IN.
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
0.05
(0.002)
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)
32.6
(1.28)
36.3
(1.43)
—
OUTER
Valve spring tension
(IN. & EX.)
INNER
OUTER
—
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
at length 30.9 mm (1.22 in)
ITEM
Compression pressure
(Automatic de-comp. actuated)
Except for DR-Z400
Piston to cylinder clearance
Cylinder bore
—
Piston diam.
—
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
ITEM
Conrod small end I.D.
LIMIT
—
—
—
—
—
Unit: mm (in)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
Conrod big end side clearance
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
—
0.120
(0.0047)
Nicks or
scratches
—
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
2nd
6.9
Approx. (0.27)
11.5
Approx. (0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
1st
—
2nd
—
1st
R
2nd
R
1st
2/9
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
CLUTCH
Unit: mm (in)
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
—
Clutch spring free length
—
TRANSMISSTION + DRIVE CHAIN
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
—
Drive chain
—
0.08
(0.003)
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch
length
—
Drive chain slack
40 – 50
(1.6 – 2.0)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm2, 5.7 psi)
Below 140 kPa (1.4 kgf/cm2, 19.9 psi)
at 3 000 r/min
3/9
LIMIT
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Shift fork thickness
89.880
(3.5386)
E-01, 03
E-01, 03, 28, 33
—
20.030
(0.7886)
19.980
(0.7866)
LIMIT
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
P
M
—
Unit: mm (in)
1 000 kPa
(10.0 kgf/cm2, 142 psi)
E
L
E-01, 03
E-01, 03, 28, 33
CONROD + CRANKSHAFT
—
STANDARD
Cylinder distortion
Piston ring to groove clearance
STANDARD
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
—
0 – 0.1
(0 – 0.004)
—
CYLINDER + PISTON + PISTON RING
Piston ring end gap
ITEM
Piston ring groove width
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
15th pin
De-compression cable play
(DR-Z400)
Piston ring free end gap
1/9
—
—
Cylinder head cover distortion
IN. & EX.
INNER
IN. & EX.
LIMIT
36.610
(1.4413)
36.580
(1.4402)
36.190
(1.4248)
35.490
(1.3972)
0.150
(0.0059)
—
Valve head thickness
Valve spring free length
(IN. & EX.)
EX.
EX.
—
IN. & EX.
IN.
E-33
—
IN. & EX.
Valve stem runout
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
36.490 – 36.540
(1.4366 – 1.4386)
35.790 – 35.840
(1.4091 – 1.4110)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
IN.
—
Valve stem deflection
EX.
Unit: mm (in)
ITEM
LIMIT
LIMIT
—
—
—
—
—
—
—
0.5
(0.020)
—
—
—
—
319.4
(12.57)
—
LIMIT
—
—
E-01, 03
E-01, 03, 28, 33
4/9
E-01, 03
E-01, 03, 28, 33
29
CARBURETOR
BRAKE + WHEEL
SPECIFICATION
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Slow jet
Slow air jet
Air jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
Throttle cable play
(pulling cable)
Pilot jet
Pilot air jet
(P. J.)
(P.A.J.)
DR-Z400
E-01
E-03, 28
KEIHIN
←
FCR39H
39 mm
←
(1.5 in)
29F0
29F1
1 800 ± 100
←
r/min
9.0 ± 1.0
mm
←
(0.35 ± 0.04
in)
#165
#142
OBDXP-4th
←
2.9 mm
←
(0.11 in)
#45
←
#60
←
#90
←
1 and ½
←
turns back
2 – 4 mm
(0.08 – 0.16
←
in)
—
—
—
—
E-01
DR-Z400E
E-03, 28
←
←
←
←
29F3
29F4
←
←
←
←
E-33
MIKUNI
BSR36
36 mm
(1.4 in)
29F2
1 600 ±
100 r/min
13.0 ± 1.0
mm
(0.51 ± 0.04
in)
#
5DH56
#165
←
#142
←
←
←
←
←
←
←
←
←
←
←
—
—
—
2 and ½
turns back
←
←
←
—
—
—
—
Engine coolant capacity
Brake disc thickness
Rear
—
Master cylinder bore
Master cylinder piston diam.
Front
Rear
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Wheel rim runout
#
#
LIMIT
Wheel rim size
Axial
—
Radial
—
Front
—
—
Front
Rear
1.60 × 21
2.15 × 18
ITEM
Cold inflation tire pressure
(Solo riding)
Front
P
M
E-01, 03
E-01, 03, 28, 33
A
S
STANDARD/SPECIFICATION
288
(11.3)
Front fork spring free length
510.6
(20.1)
Front fork oil level
122
(without spring)
(4.8)
Front fork oil type
SUZUKI FORK OIL SS-05 or
an equivalent fork oli
Front fork oil capacity
720 ml
(each leg)
(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)
Rear shock absorber spring
258.0
pre-set length
(10.2)
Rear shock absorber damping
Rebound
13th clicks turn back
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
10th clicks turn back
Rear wheel travel
295
(11.6)
Swingarm pivot shaft runout
—
Unit: mm (in)
LIMIT
—
Front
—
Rear
—
6/9
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
Over 8 mm (0.3 in) at 1 atm.
Primary
0.1 – 1.0 Ω
Secondary
12 – 20 kΩ
—
—
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
More than 150 V (: B/W, : B/Y)
Charging
0.50 – 1.25 Ω
Signal coil
0.05 – 0.20 Ω
Pick-up coil
390 – 600 Ω
Pick-up coil peak voltage
More than 10.0 V (: Bl, : G)
More than 5.0 V (: Bl, : G)
Signal coil peak voltage
More than 1.0 V (: B, : W)
More than 1.4 V (: B, : W)
Generator no-load voltage
More than 55 V (AC) at 5 000 r/min
(When engine is cold)
(Y – Y)
More than 75 V (AC) at 5 000 r/min
(Y – Y)
Regulated voltage
12.5 – 14.0 V at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
Generator Max. output
150 W at 5 000 r/min
200 W at 5 000 r/min
Starter relay resistance
3–5Ω
Battery
Type designation
YT7B-BS
Capacity
12 V 21.6 kC (6 Ah)/10 HR
Ignition coil primary peak voltage
Generator coil resistance
WATTAGE
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
Unit: mm (in)
NOTE
Terminal –
Ground
Plug cap –
Terminal
Y–Y
B–W
G – Bl
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400
DR-Z400E
DR-Z400E
DR-Z400E
SPECIFICATION
35
LED
Taillight
E-01, 03
E-01, 03, 28, 33
LIMIT
Unit: W
ITEM
Headlight
7/9
—
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
E-01, 03
E-01, 03, 28, 33
ELECTRICAL
500
(19.7)
—
STANDARD/SPECIFICATION
100 kPa
(1.0 kgf/cm2, 14 psi)
100 kPa
(1.0 kgf/cm2, 14 psi)
80/100-21 51M
110/100-18 64M
E
L
Front
Rear
Tire tread depth
ITEM
Front fork stroke
LIMIT
TIRE
Tire size
SUSPENSION
11.043
0.4348)
12.743
0.5017)
10.984
0.4324)
12.684
0.4994)
27.050
1.0650)
27.050
1.0650)
26.950
1.0610)
26.950
1.0610)
Rear
Rear
5/9
11.000 –
(0.4331 –
12.700 –
(0.5000 –
10.957 –
(0.4314 –
12.657 –
(0.4983 –
27.000 –
(1.0630 –
27.000 –
(1.0630 –
26.900 –
(1.0591 –
26.900 –
(1.0591 –
DOT 4
Front
Rear
Wheel axle runout
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 250 ml
(1.3/1.1 US/lmp qt)
Front
STANDARD/SPECIFICATION
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Brake disc runout
Brake caliper cylinder bore
RADIATOR + ENGINE COOLANT
ITEM
Radiator cap valve opening pressure
Engine coolant type
Unit: mm (in)
ITEM
Rear brake pedal height
8/9
E-01, 03
E-01, 03, 28, 33
30
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
10.0 L
(2.6/2.2 US/lmp qt)
2.3 L
(0.6/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
1 700 ml
Change
(1.8/1.5 US/lmp qt)
1 800 ml
Filter change
(1.9/1.6 US/lmp qt)
1 900 ml
Overhaul
(2.0/1.7 US/lmp qt)
9/9
DR-Z400E (E-24)
IN.
IN.
EX.
IN.
EX.
Valve stem deflection
Valve guide I.D.
P
M
LIMIT
—
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
0.05
(0.002)
0.5
(0.02)
EX.
—
Valve head thickness
—
IN. & EX.
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
INNER
OUTER
—
15th pin
—
—
CYLINDER + PISTON + PISTON RING
—
0.9 – 1.1
(0.035 – 0.043)
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
at length 30.9 mm (1.22 in)
Cam chain pin (at arrow “3”)
Cylinder head distortion
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
—
—
Piston ring end gap
Piston ring to groove clearance
—
2nd
6.9
Approx. (0.27)
11.5
Approx. (0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
1st
—
1st
R
2nd
R
1st
2nd
—
Piston ring groove width
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
1st
2nd
Oil
1/8
E-24
2/8
—
—
Unit: mm (in)
STANDARD
1 000 kPa
(10.0 kgf/cm2, 142 psi)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
LIMIT
36.610
(1.4413)
36.580
(1.4402)
0.150
(0.0059)
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
—
—
IN. & EX.
OUTER
IN. & EX.
Cylinder head cover distortion
Valve seat width
Valve spring tension
(IN. & EX.)
EX.
Camshaft journal holder I.D.
—
STANDARD
36.910 – 36.960
(1.4531 – 1.4551)
36.880 – 36.930
(1.4520 – 1.4539)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
IN.
—
IN. & EX.
IN. & EX.
Cam height
Camshaft journal oil clearance
0.35
(0.014)
Valve stem runout
Unit: mm (in)
ITEM
—
—
IN.
CAMSHAFT + CYLINDER HEAD
—
IN. & EX.
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
Valve stem O.D.
E
L
E-01, 03
E-01, 03, 28, 33
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
EX.
Valve guide to valve stem
clearance
E-01
Unit: mm (in)
ITEM
Tappet clearance (when cold)
E-03, 28
A
S
VALVE + GUIDE
Valve diam.
NOTE
LIMIT
—
0.120
(0.0047)
Nicks or
scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
—
E-24
31
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
CONROD + CRANKSHAFT
TRANSMISSTION + DRIVE CHAIN
LIMIT
—
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
Conrod big end side clearance
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
20.030
(0.7886)
19.980
(0.7866)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm2, 5.7 psi)
Below 140 kPa (1.4 kgf/cm2, 19.9 psi)
at 3 000 r/min
LIMIT
—
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
—
Clutch spring free length
—
ITEM
Carburetor type
Bore size
ITEM
Radiator cap valve opening pressure
Engine coolant type
Engine coolant capacity
Rear brake pedal height
Front
Rear
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Brake disc runout
Master cylinder bore
—
12.700 –
(0.5000 –
12.700 –
(0.5000 –
12.657 –
(0.4983 –
12.657 –
(0.4983 –
27.000 –
(1.0630 –
27.000 –
(1.0630 –
26.900 –
(1.0591 –
26.900 –
(1.0591 –
DOT 4
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Slow jet
Slow air jet
Air jet
Pilot screw
Throttle cable play
(pulling cable)
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
Axial
—
Radial
—
Front
—
12.743
0.5017)
12.743
0.5017)
12.684
0.4994)
12.684
0.4994)
27.050
1.0650)
27.050
1.0650)
26.950
1.0610)
26.950
1.0610)
Rear
—
Front
Rear
1.60 × 21
2.15 × 18
5/8
—
—
319.4
(12.57)
—
(S.J.)
(S.A.J.)
(A.J.)
(P.S.)
E
L
P
M
4/8
E-24
TIRE
ITEM
Cold infation tire pressure
(Solo riding)
LIMIT
Front
Rear
STANDARD/SPECIFICATION
125 kPa
(1.25 kgf/cm2, 18 psi)
125 kPa
(1.25 kgf/cm2, 18 psi)
80/100-21 51P or 80/100-21 M/C 51P
120/90-18 65P or 120/90-18 M/C 65P
Tire size
Front
Rear
Tire tread depth
Front
—
Rear
—
Unit: mm (in)
ITEM
Brake lever play
Brake disc thickness
(M.J.)
(J.N.)
(N.J.)
LIMIT
A
S
BRAKE + WHEEL
Main jet
Jet needle
Needle jet
E-24
STANDARD/SPECIFICATION
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 250 ml
(1.3/1.1 US/lmp qt)
—
—
SPECIFICATION
KEIHIN FCR39H
39 mm
(1.5 in)
29F6
1 800 ± 100 r/min
9.0 ± 1.0 mm
(0.35 ± 0.04 in)
#165
OBDXP-4th
2.9 mm
(0.11 in)
#45
#60
#90
2 and ¾ turns back
2 – 4 mm
(0.08 – 0.16 in)
I.D. No.
Idle r/min
Float height
—
3/8
RADIATOR + ENGINE COOLANT
40 – 50
(1.6 – 2.0)
LIMIT
—
—
—
—
—
—
—
0.5
(0.020)
CARBURETOR
Unit: mm (in)
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
—
Drive chain slack
0.08
(0.003)
ITEM
Clutch lever play
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch
length
Drive chain
—
—
CLUTCH
Shift fork groove width
Shift fork thickness
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
STANDARD
2.960 (74/25)
3.357 (47/14)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
—
Unit: mm (in)
ITEM
Conrod small end I.D.
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
LIMIT
—
SUSPENSION
—
ITEM
Front fork stroke
STANDARD/SPECIFICATION
288
(11.3)
Front fork spring free length
510.6
(20.1)
Front fork oil level
122
(without spring)
(4.8)
Front fork oil type
SUZUKI FORK OIL SS-05 or
an equivalent fork oli
Front fork oil capacity
720 ml
(each leg)
(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)
Rear shock absorber spring
258.0
pre-set length
(10.2)
Rear shock absorber damping
Rebound
13th clicks turn back
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
10th clicks turn back
Rear wheel travel
295
(11.6)
Swingarm pivot shaft runout
—
2.5
(0.098)
4.0
(0.16)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
E-24
6/8
LIMIT
—
—
—
—
4.0
(0.16)
4.0
(0.16)
Unit: mm (in)
LIMIT
—
500
(19.7)
—
—
—
—
—
—
—
—
0.3
(0.01)
E-24
32
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
Over 8 mm (0.3 in) at 1 atm.
0.1 – 1.0 Ω
Primary
Secondary
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(When engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery
Type designation
Capacity
12 – 20 kΩ
More than 150 V
0.50 – 1.25 Ω
0.05 – 0.20 Ω
390 – 600 Ω
More than 5.0 V
More than 1.4 V
Charging
Signal coil
Pick-up coil
More than 75 V (AC) at 5 000 r/min
Unit: mm (in)
NOTE
FUEL + OIL
ITEM
Fuel type
Fuel tank including
Terminal –
Ground
Plug cap –
Terminal
: B/W, : B/Y
Y–Y
B–W
G – Bl
: Bl, : G
: B, : W
reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
10.0 L
(2.6/2.2 US/lmp qt)
2.3 L
(0.6/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
1 700 ml
Change
(1.8/1.5 US/lmp qt)
1 800 ml
Filter change
(1.9/1.6 US/lmp qt)
1 900 ml
Overhaul
(2.0/1.7 US/lmp qt)
NOTE
Y–Y
13.5 – 15.0 V at 5 000 r/min
200 W at 5 000 r/min
3–5Ω
YT7B-BS
12 V 21.6 kC (6 Ah)/10 HR
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
60
55
21/5
21
LED
2
2
2
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
High beam indicator light
Turn signal indicator light
7/8
DR-Z400S
Unit: mm (in)
ITEM
Valve diam.
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0079)
0.20 – 0.30
(0.0079 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
P
M
E-24
A
S
VALVE + GUIDE
IN. & EX.
—
5.000
(0.1969
4.975
(0.1959
4.955
(0.1951
IN. & EX.
IN.
EX.
Valve stem runout
IN. & EX.
Valve head thickness
– 5.012
– 0.1973)
– 4.990
– 0.1965)
– 4.970
– 0.1957)
—
—
IN. & EX.
IN. & EX.
—
Camshaft runout
15th pin
—
Cylinder head cover distortion
—
—
—
0.05
(0.002)
0.5
(0.02)
IN. & EX.
—
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
OUTER
Cam chain pin (at arrow “3”)
Cylinder head distortion
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
—
—
Piston ring end gap
Piston ring to groove clearance
—
2nd
6.9
Approx. (0.27)
11.5
Approx. (0.45)
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
1st
—
1st
R
2nd
R
1st
2nd
—
Piston ring groove width
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
1st
2nd
Oil
1/8
E-03, 28, 33
2/8
—
—
Unit: mm (in)
STANDARD
950 kPa
(9.5 kgf/cm2, 135 psi)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
LIMIT
36.190
(1.4248)
35.490
(1.3972)
0.150
(0.0059)
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
—
—
Valve head radial runout
INNER
IN. & EX.
—
—
—
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
0.9 – 1.1
(0.035 – 0.043)
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
at length 27.4 mm (1.08 in)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
at length 30.9 mm (1.22 in)
STANDARD
36.490 – 36.540
(1.4366 – 1.4386)
35.790 – 35.840
(1.4091 – 1.4110)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
IN.
Camshaft journal O.D.
IN. & EX.
OUTER
Cam height
—
0.35
(0.014)
E-24
Unit: mm (in)
ITEM
—
—
8/8
CAMSHAFT + CYLINDER HEAD
LIMIT
Valve seat width
Valve spring tension
(IN. & EX.)
E
L
LIMIT
—
0.120
(0.0047)
Nicks or
scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
—
E-03, 28, 33
33
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
CONROD + CRANKSHAFT
LIMIT
—
—
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
ITEM
Conrod small end I.D.
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
Conrod big end side clearance
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
—
OIL PUMP
ITEM
Oil pressure reduction ratio
Oil pressure (at 60°C, 140°F)
STANDARD
2.220 (74/25 × 20/16 × 12/20)
Above 40 kPa (0.4 kgf/cm2, 5.7 psi)
Below 140 kPa (1.4 kgf/cm2, 19.9 psi)
at 3 000 r/min
CLUTCH
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
—
Clutch spring free length
—
3/8
Engine coolant type
Engine coolant capacity
—
Cold inflation tire pressure
(Dual riding)
Front
—
12.700
(0.5000
12.700
(0.5000
12.657
(0.4983
12.657
(0.4983
27.000
(1.0630
27.000
(1.0630
26.900
(1.0591
26.900
(1.0591
DOT 4
Front
Front
Rear
Front
Rear
Front
Rear
– 12.743
– 0.5017)
– 12.743
– 0.5017)
– 12.684
– 0.4994)
– 12.684
– 0.4994)
– 27.050
– 1.0650)
– 27.050
– 1.0650)
– 26.950
– 1.0610)
– 26.950
– 1.0610)
Axial
—
Radial
—
5/8
3.0
(0.118)
4.0
(0.16)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
E-03, 28, 33
Tire type
Tire tread depth
←
←
←
←
←
←
←
←
4/8
E-03, 28, 33
STANDARD/SPECIFICATION
Front
—
Rear
—
Front
Rear
1.60 × 21
2.15 × 18
Front
Front
Rear
Tire size
E-33
←
←
29FC
←
#
#135
PRE-SET
2 – 4 mm
(0.08 – 0.16 in)
Rear
Unit: mm (in)
Rear
Brake fluid type
Wheel rim runout
ITEM
Wheel axle runout
ITEM
Cold inflation tire pressure
(Solo riding)
—
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.A.J.)
(P.S.)
E
L
TIRE
Rear
Brake caliper piston diam.
Main jet
Jet needle
Needle jet
Pilot jet
Pilot air jet
Pilot screw
Throttle cable play
(pulling cable)
—
—
—
SPECIFICATION
E-03, 28
MIKUNI BSR36
36 mm (1.4 in)
29FB
1 500 ± 100 r/min
130 ± 1.0 mm
(0.5 ± 0.04 in)
#
5DH37
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
—
—
LIMIT
—
—
319.4
(12.57)
40 – 50
(1.6 – 2.0)
ITEM
Wheel rim size
STANDARD/SPECIFICATION
0.1 – 0.3
(0.004 – 0.010)
5
(0.2)
3.5 ± 0.2
(0.138 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
—
—
CARBURETOR
—
—
LIMIT
—
—
—
—
—
—
—
0.5
(0.020)
—
Drive chain slack
P
M
LIMIT
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch
length
Drive chain
—
—
—
Brake disc runout
Brake caliper cylinder bore
Shift fork groove width
Shift fork thickness
Approx. 75 °C (167 °F)
Rear brake pedal height
Master cylinder piston diam.
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
STANDARD
2.960 (74/25)
2.933 (44/15)
2.285 (32/14)
1.733 (26/15)
1.375 (22/16)
1.090 (24/22)
0.863 (19/22)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
4.6 – 4.7
(0.181 – 0.185)
RK520KZO
112
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Over 6 mm (0.24 in) at 90°C (194 °F)
OFF→ON
Approx. 117 °C (243 °F)
ON→OFF
Approx. 100 °C (212 °F)
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
OFF→ON
Approx. 96 °C (205 °F)
ON→OFF
Approx. 91 °C (196 °F)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 250 ml (1.3/1.1 US/lmp qt)
ITEM
Brake lever play
Master cylinder bore
—
A
S
STANDARD/SPECIFICATION
BRAKE + WHEEL
Brake disc thickness
LIMIT
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
E-03, 28, 33
THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
—
Unit: mm (in)
ITEM
Clutch cable play
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temp. switch operating temperature
LIMIT
—
TRANSMISSTION + DRIVE CHAIN
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
125 kPa
(1.25 kgf/cm2, 18 psi)
150 kPa
(1.50 kgf/cm2, 22 psi)
125 kPa
(1.25 kgf/cm2, 18 psi)
175 kPa
(1.75 kgf/cm2, 25 psi)
80/100-21 51P or 80/100-21 M/C 51P
120/90-18 65P or 120/90-18 M/C 65P
BRIDGESTONE TRAIL WING-41
BRIDGESTONE TRAIL WING-42
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
STANDARD/SPECIFICATION
288
(11.3)
Front fork spring free length
573.2
(22.57)
Front fork oil level
129
(without spring)
(5.07)
Front fork oil type
SUZUKI FORK OIL SS-05 or
an equivalent fork oli
Front fork oil capacity (each leg)
710 ml
(24.0/25.0 US/lmp oz)
Front fork damping force adjuster
Rebound
16th clicks turn back
Compression
13th clicks turn back
Rear shock absorber gas pressure
900 kPa
(9.0 kgf/cm2, 128 psi)
Rear shock absorber spring
258.0
pre-set length
(10.2)
Rear shock absorber damping
Rebound
13th clicks turn back
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
10th clicks turn back
Rear wheel travel
295
(11.6)
Swingarm pivot shaft runout
—
6/8
LIMIT
0.25
(0.010)
0.25
(0.010)
—
—
LIMIT
—
—
—
—
—
—
—
—
3.0
(0.12)
3.0
(0.12)
Unit: mm (in)
LIMIT
—
561
(22.1)
—
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
E-03, 28, 33
34
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
Over 8 mm (0.3 in) at 1 atm.
Primary
0.1 – 1.0 Ω
Secondary
12 – 20 kΩ
More than 150 V
0.50 – 1.25 Ω
0.05 – 0.20 Ω
390 – 600 Ω
More than 5.0 V
More than 1.4 V
Charging
Signal coil
Pick-up coil
Pick-up coil peak voltage
Signal coil peak voltage
Generator no-load voltage
(When engine is cold)
Regulated voltage
Generator Max. output
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
More than 75 V (AC) at 5 000 r/min
Unit: mm (in)
NOTE
ITEM
Fuel type
Terminal –
Ground
Plug cap –
Terminal
: B/W, : B/Y
Y–Y
B–W
G – Bl
: Bl, : G
: B, : W
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
Y–Y
13.5 – 15.0 V at 5 000 r/min
200 W at 5 000 r/min
3–5Ω
YT7B-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
WATTAGE
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
9.5 L
(2.5/2.1 US/lmp qt)
10.0 L
(2.6/2.2 US/lmp qt)
2.3 L
(0.6/0.5 US/lmp qt)
SAE 10W-40, API SF or SG
1 700 ml
Change
(1.8/1.5 US/lmp qt)
1 800 ml
Filter change
(1.9/1.6 US/lmp qt)
1 900 ml
Overhaul
(2.0/1.7 US/lmp qt)
NOTE
E-03, 28, 33
E-33
The others
Unit: W
SPECIFICATION
E-03, 28, 33
60
55
ITEM
Headlight
HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
21/5
21
LED
LED
LED
LED
LED
Turn signal indicator light
High beam indicator light
Water temp. indicator light
7/8
GS125T
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve guide I.D.
Valve stem O.D.
stem deflection
stem runout
head thickness
stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
STANDARD
25.5
22.5
0.04 – 0.07
0.13 – 0.18
0.010 – 0.037
0.037 – 0.057
5.00 – 5.12
4.975 – 4.990
4.955 – 4.970
—
—
—
—
—
0.58 – 1.00
—
—
—
38.1 – 43.9 N
(3.9 – 4.5 kgf)
at length 26.8 mm
89.6 – 103.0 N
(9.1 – 10.5 kgf)
at length 29.8 mm
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
STANDARD
33.65 – 33.69
33.30 – 33.34
0.019 – 0.045
22.012 – 22.025
21.993 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
1/6
E
L
P
M
E-03, 28, 33
A
S
VALVE + GUIDE
Valve
Valve
Valve
Valve
FUEL + OIL
Unit: mm
LIMIT
—
—
—
—
—
—
—
—
—
0.35
0.05
0.5
1.54
1.54
—
0.03
31.3
33.6
ITEM
Compression pressure
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
—
CONROD + CRANKSHAFT
P-31
E-03, 28, 33
CYLINDER + PISTON + PISTON RING
—
Unit: mm
LIMIT
33.35
33.00
0.150
—
—
0.10
—
—
0.05
0.05
8/8
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
0.04 – 0.05
57.000 – 57.015
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
1st
1R
Approx. 7.2
2nd
2R
Approx. 5.8
1st
0.20 – 0.32
2nd
0.20 – 0.32
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
14.002 – 14.008
13.992 – 14.000
STANDARD
14.006 – 14.014
—
—
15.95 – 16.00
52.90 – 53.10
—
Unit: mm
LIMIT
800 kPa
(8 kgf/cm2,
114 psi)
0.12
57.090
56.880
0.05
5.7
4.6
0.7
0.7
0.18
0.15
—
—
—
—
—
14.030
13.980
Unit: mm
LIMIT
14.04
3.0
1.0
—
—
0.08
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C)
STANDARD
2.000 (30/15)
Above 10 kPa (0.1 kgf/cm2)
Below 30 kPa (0.3 kgf/cm2)
at 3 000 r/min
2/6
LIMIT
—
—
P-31
35
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Countershaft length
(Low to 2nd)
Drive chain
Type
Links
20-pitch
length
Drive chain slack
ITEM
Spark plug
0.1
88.0 +– 0.2
—
RK428FDZ
116
—
—
—
259.0
25 – 35
—
Gap
3/6
ITEM
Front brake cable play
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
Front
Rear
150 V and more
150 V and more
190 – 300 Ω
210 – 350 Ω
∞Ω
8 V and more
Exciting coil resistance
Pick-up coil resistance
Pick-up coil peak voltage
Generator no-load voltage
(when engine is cold)
Regulated voltage
Generator Max. output
Battery
Type designation
Capacity
Standard electrolyte
S.G
Fuse size
20 V
1.280 at 20 °C
15 A
HI
LO
E
L
P
M
—
—
0.6
STANDARD/SPECIFICATION
35
35
5
21/5
10
1.7
1.7
1.7
1.7
1.7
4/6
P-31
v
Unit: mm
LIMIT
—
477
—
—
—
94
—
tap – tap
Plug cap –
tap
Y–Y
Ground – Y
: B/R,
: Ground
: Ground,
: W/Bl
B/R – Ground
G – Bl
G – Ground
: Bl, : B/W
Unit: W
Headlight
STANDARD
110
487
—
MUSHAKU TOP 46# or an equivalent fork oil
143 ml
2nd
NOTE
14.5 – 15.0 V at 5 000 r/min
120 W and more at 5 000 r/min
CB4L-B
12 V 14.4 kC (4 Ah)/10 HR
ITEM
Unit: mm
LIMIT
—
—
—
130.7
130.7
2.0
2.0
0.25
0.25
—
—
—
—
—
—
1.6
1.6
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear shock absorber spring
adjuster
Rear wheel travel
Swingarm pivot shaft runout
Exciting coil peak voltage
Ignition coil primary peak voltage
WATTAGE
STANDARD/SPECIFICATION
15 – 25
20 – 30
0
—
—
—
—
—
—
18 × 1.40
18 × 1.60
2.75-18 42P
3.00-18 47P
TAIYO TYRE
TAIYO TYRE
—
—
Front
Rear
Axial
Radial
Front
Rear
0.5 – 1.5 Ω
∞Ω
Generator coil resistance
P-31
A
S
BRAKE + WHEEL
14 – 19 kΩ
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
SPECIFICATION
MIKUNI BS26SS
26 mm
054J
1500 ± 100 r/min
17.1 ± 0.5 mm
#110
4DH41-2nd
P-0
# 105
# 12.5
1.25
2 and 5/8 turns out
2.0 – 4.0 mm
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.A.J.)
(P.S.)
Primary
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
Over 8 mm at 1 atm.
0.1 – 0.7 Ω
Secondary
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot air screw
Pilot screw
Throttle cable play
Type
Spark performance
Ignition coil resistance
Unit: mm Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
—
—
—
—
STANDARD
3.470 (59/17)
3.071 (43/14)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.913 (21/23)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
No. 1 & 2
No. 3
No. 1 & 2
No. 3
ELECTRICAL
Unit: mm
LIMIT
—
—
2.6
11.0
0.10
29.5
STANDARD
10 – 15
1/4 turn back
2.9 – 3.1
11.8 – 12.0
—
31.0
FUEL + OIL
ITEM
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline type is recommended.
Fuel tank capacity including reserve
12.0 L
reserve
2.3 L
Engine oil type
SAE 10W-40, API SF or SG
Engine oil capacity
Change
850 ml
Filter change
950 ml
Overhaul
1 300 ml
NOTE
Fuel type
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
SOLO RIDING
kPa
kgf/cm2
150
1.50
200
2.00
5/6
DUAL RIDING
kPa
kgf/cm2
150
1.50
225
2.25
P-31
6/6
P-31
36
GS500/U/F/FU
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Valve lift
IN.
EX.
Tappet clearance (when cold)
Valve guide to valve stem
clearance
Unit: mm (in)
LIMIT
STANDARD
39
(1.5)
32
(1.3)
8.5
(0.33)
8.0
(0.31)
0.03 – 0.08
(0.001 – 0.003)
0.025 – 0.055
(0.0010 – 0.0022)
0.040 – 0.070
(0.0016 – 0.0028)
IN. & EX.
IN.
EX.
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
—
IN.
EX.
—
—
—
—
—
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
—
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
CYLINDER + PISTON + PISTON RING
—
ITEM
Compression pressure
EX.
7.000 – 7.015
(0.2756 – 0.2762)
6.960 – 6.975
(0.2740 – 0.2746)
6.945 – 6.960
(0.2734 – 0.2740)
—
Compression pressure difference
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
Valve seat width
IN. & EX.
Valve head radial runout
IN. & EX.
Valve spring free length
(IN. & EX.)
IN.
—
0.05
(0.002)
0.5
(0.02)
Cylinder bore
1.0 – 1.2
(0.04 – 0.05)
—
Piston diam.
—
0.03
(0.001)
35.6
(1.40)
40.6
(1.60)
INNER
—
OUTER
Valve spring tension
(IN. & EX.)
—
10.9 – 12.5 kgf
(24.0 – 27.6 lbs)
at length 31.0 mm (1.22 in)
20.3 – 23.3 kgf
(44.8 – 51.4 lbs)
at length 35.0 mm (1.38 in)
INNER
OUTER
—
Piston to cylinder clearance
Piston ring end gap
—
Piston ring to groove clearance
ITEM
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
STANDARD
1.21 – 1.23
(0.047 – 0.048)
1.21 – 1.23
(0.047 – 0.048)
2.51 – 2.53
(0.099 – 0.100)
1.17 – 1.19
(0.046 – 0.047)
1.17 – 1.19
(0.046 – 0.047)
18.002 – 18.008
(0.7087 – 0.7090)
17.995 – 18.000
(0.7085 – 0.7087)
—
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing
thickness
Crankshaft runout
Balancer journal oil clearance
Balancer journal O.D.
Balancer spring free length
—
Drive plate claw width
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.3
(0.012)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
2.850
(0.1122)
0.05
(0.002)
0.080
(0.0031)
—
0.020
(0.0008
31.984
(1.2592
– 0.044
– 0.0017)
– 32.000
– 1.2598)
N
Approx. 7.0 (0.28)
N
Approx. 11.0 (0.43)
2nd
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
1st
—
2nd
—
1st
Driven plate distortion
—
Clutch spring free length
—
Shift fork groove width
Shift fork thickness
Countershaft length
(Low to 2nd)
Drive chain
114.7
4.516
Type
Links
14.9
(0.59)
STANDARD
1.879 (76/28 × 27/39)
Above 200 kPa (2.0 kgf/cm2, 28 psi)
Below 500 kPa (5.0 kgf/cm2, 71 psi)
at 3 000 r/min
LIMIT
—
+ 0.1
- 0
+ 0.004
- 0
20-pitch length
Drive chain slack
—
20 – 30
(0.8 – 1.2)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.5
(0.020)
—
—
—
D.I.D.: DID520VM
110
—
—
—
STANDARD
2.714 (76/28)
2.437 (39/16)
2.461 (32/13)
1.777 (32/18)
1.380 (29/21)
1.125 (27/24)
0.961 (25/26)
0.851 (23/27)
0.1 – 0.3
(0.004 – 0.012)
5.5 – 5.6
(0.217 – 0.220)
5.3 – 5.4
(0.209 – 0.213)
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
0.10
(0.004)
5.6
(0.22)
8.8
(0.35)
0.70
(0.028)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
2.62
(0.103)
15.0
(0.59)
0.10
(0.004)
60.8
(2.39)
TRANSMISSION + DRIVE CHAIN
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
73.880
(2.9087)
Unit: mm (in)
LIMIT
STANDARD
10 – 15
(0.4 – 0.6)
1/4 – 1/2 turn back
2.92 – 3.08
(0.115 – 0.121)
15.8 – 16.0
(0.62 – 0.63)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 144 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
74.080
(2.9165)
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
2/8
ITEM
Clutch lever play
—
18.030
(0.7098)
17.980
(0.7079)
STANDARD
18.006 – 18.014
(0.7089 – 0.7092)
0.1 – 0.2
(0.004 – 0.008)
22.95 – 23.00
(0.904 – 0.906)
23.10 – 23.15
(0.909 – 0.911)
0.024 – 0.048
(0.0009 – 0.0019)
33.976 – 34.000
(1.3376 – 1.3386)
0.020 – 0.044
(0.0008 – 0.0017)
31.976 – 32.000
(1.2589 – 1.2598)
2.950 – 2.975
(0.1161 – 0.1171)
1st
2nd
CLUTCH
Clutch release screw
Drive plate thickness
—
CONROD + CRANKSHAFT + BALANCER
—
P
M
LIMIT
—
—
0.050 – 0.060
(0.0020 – 0.0024)
74.000 – 74.015
(2.9134 – 2.9140)
73.945 – 73.960
(2.9112 – 2.9118)
Measure at 15 mm (0.6 in) from the skirt end.
E
L
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
1/8
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
Cylinder distortion
Piston ring free end gap
—
0.10
(0.004)
—
0.10
(0.004)
18th pin
Valve stem deflection
Valve stem O.D.
—
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
Unit: mm (in)
LIMIT
35.80
(1.409)
35.80
(1.409)
0.150
(0.0060)
STANDARD
36.090 – 36.130
(1.4208 – 1.4224)
36.090 – 36.130
(1.4208 – 1.4224)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
—
319.4
(12.57)
—
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
3/8
—
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
4/8
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
37
CARBURETOR
ELECTRICAL
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
ITEM
SPECIFICATION
GS500 P-02, 19, 24, 54
GS500U P-19
GS500F P-02, 19, 24, 54
GS500FU P-19
MIKUNI
←
BSR34
34 mm
←
01DN
01DP
1 200 ±100 r/min
←
13.0 ± 1.0 mm
←
#130
#135
5DH57-3rd
←
P-5M
←
#105
←
#17.5
←
3 turns back
←
2.0 – 4.0 mm
←
(0.08 – 0.16 in)
Ignition timing
Firing order
Spark plug
Gap
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
100 V and more
←
←
01DU
←
←
←
5DH60
←
←
←
←
ITEM
Rear brake pedal height
Brake disc thickness
Front
Rear
Brake disc runout
Master cylinder bore
12.700
(0.5000
12.700
(0.5000
12.630
(0.4972
12.657
(0.4983
30.230
(1.1902
38.180
(1.5031
30.150
(1.1870
38.098
(1.4999
Front
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Wheel rim runout
—
– 12.725
– 0.5010)
– 12.743
– 0.5017)
– 12.670
– 0.4988)
– 12.684
– 0.4994)
– 30.306
– 1.1931)
– 38.256
– 1.5061)
– 30.200
– 1.1890)
– 38.148
– 1.5019)
—
—
E
L
P-03, 28, 33
←
←
←
32/3 cp
←
←
←
←
←
←
←
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
6/8
SUSPENSION
ITEM
Front fork stroke
Unit: mm (in)
LIMIT
STANDARD
120
(4.7)
343
(13.5)
110
(4.3)
Fork oil #10
380 ml
(12.8/13.4 US/lmp oz)
36.9
(1.45)
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity
(each leg)
Front fork inner tube O.D.
—
336
(13.2)
—
—
—
—
Rear shock absorber spring
adjuster
Rear wheel travel
4th position among 7
115
(4.5)
—
Swingarm pivot shaft runout
—
0.3
(0.01)
—
—
—
—
Radial
—
Wheel axle runout
Front
—
Rear
—
Wheel rim size
Front
Rear
Front
Rear
17 × MT3.00, 17M/C × MT3.00
17 × MT3.50, 17M/C × MT3.50
110/70-17M/C 54H
130/70-17M/C 62H
Front
—
Rear
—
TIRE PRESSURE
—
COLD INFLATION TIRE PRESSURE
—
FRONT
REAR
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
ITEM
Fuel type
Fuel tank including reserve
reserve
Brake fluid type
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
kPa
225
250
SOLO RIDING
kgf/cm2
2.25
2.50
psi
33
36
kPa
225
280
DUAL RIDING
kgf/cm2
2.25
2.80
psi
33
41
FUEL + OIL
Engine oil type
Engine oil capacity
7/8
SPECIFICATION
GS500F/FU
P-02, 19, 24, 54
←
←
5
←
←
←
←
←
←
←
←
GS500/U
P-02, 09, 19, 24, 54
60
55
4
21/5
21
1.7
1.7
1.7
1.7
1.7
1.7
—
—
Tire tread depth
20 A
P
M
4.0
(0.16)
5.5
(0.22)
0.30
(0.012)
Axial
Tire size
HI
LO
Position light
Brake light/Taillight
Turn signal light
Tachometer light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure indicator light
Unit: mm (in)
LIMIT
—
Rear
Master cylinder piston diam.
ITEM
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
STANDARD
55
(2.2)
4.5 ± 0.2
(0.177 ± 0.008)
6.0 ± 0.2
(0.236 ± 0.008)
1.28 at 20 °C (68 °F)
Unit: W
Headlight
A
S
BRAKE + WHEEL
Approx. 200 W at 5 000 r/min
More than 75 V (AC) at 5 000 r/min
13.5 – 15.5 V at 5 000 r/min
3–5Ω
CB10L-B2
12 V 39.6 kC (11 Ah)/10 HR
WATTAGE
←
5/8
Terminal –
Terminal
Plug cap –
Terminal
Probe: Br
Probe: B/Bl
Probe:
W or B/Y
Probe:
Ground
1.8 V and more
Generator Max. output
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuse size
GS500F P-33
#105
#
PRE-SET (3 turns back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
3–6Ω
18 – 30 kΩ
Ignition coil primary peak voltage
SPECIFICATION
GS500 P-09, 28
GS500F P-03, 28
MIKUNI
BSR34
34 mm
01DS
1 200 ± 100 r/min
13.0 ± 1.0 mm
#
5DH91
Primary
Secondary
Signal generator peak voltage
CARBURETOR
ITEM
Type
Spark performance
Signal generator resistance
Ignition coil resistance
Unit: mm (in)
NOTE
P-03, 28, 33
Others
SPECIFICATION
5° B.T.D.C. at 1 200 r/min
12° B.T.D.C. at 1 200 r/min
L·R
DENSO: X24EPR-U9
NGK: DPR8EA-9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
250 – 420 Ω
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octaneor 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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
19 L
(5.0/4.2 US/lmp gal)
20 L
(5.3/4.4 US/lmp gal)
4.3 L
(1.1/0.9 US/lmp gal)
SAE 10W-40, API SF or SG
2 600 ml
Change
(2.7/2.3 US/lmp qt)
2 900 ml
Filter change
(3.1/2.6 US/lmp qt)
3 200 ml
Overhaul
(3.4/2.8 US/lmp qt)
DOT 4
8/8
NOTE
P-03, 28, 33
Others
P-33
Others
P-02, 09, 19, 24, 28, 54
P-19
P-02, 03, 19, 24, 28, 33, 54
P-19
38
GSF600/U/Z/ZU
VALVE + GUIDE
ITEM
Valve diameter
STANDARD
23
(0.9)
20
(0.8)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
—
5.000
(0.1969
4.965
(0.1955
4.955
(0.1950
IN.
EX.
– 5.012
– 0.1973)
– 4.980
– 0.1961)
– 4.970
– 0.1957)
Valve stem runout
IN. & EX.
—
Valve face thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
Unit: mm (in)
LIMIT
—
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
0.35
(0.014)
Cylinder head distortion
—
0.03
(0.001)
35.0
(1.38)
38.4
(1.51)
INNER
OUTER
55 – 65 N
(5.6 – 6.6 kgf, 12.3 – 14.6 lbs)
at length 28 mm (1.10 in)
126 – 147 N
(12.8 – 15.0 kgf, 28.2 – 33.1 lbs)
at length 31.5 mm (1.24 in)
ITEM
Compression pressure
STANDARD
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
—
Piston to cylinder clearance
Cylinder bore
Piston diameter
—
Cylinder distortion
—
Piston ring free end gap
0.040 – 0.050
(0.0016 – 0.0020)
62.600 – 62.615
(2.4646 – 2.4652)
62.555 – 62.570
(2.4628 – 2.4634)
Measure at 15 mm (0.6) from the skirt end.
—
1st
R
Approx. 6.7 (0.26)
2nd
RN
Approx. 7.0 (0.28)
1st
E
L
Piston ring to groove clearance
A
S
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft thrust bearing thickness
Left side
Right side
STANDARD
18.010 –18.018
(0.7091 – 0.7094)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
33.976 – 34.000
(1.3376 – 1.3386)
0.020 – 0.044
(0.0008 – 0.0017)
31.976 – 32.000
(1.2589 – 1.2598)
0.04 – 0.09
(0.002 – 0.004)
2.350 – 2.500
(0.0925 – 0.0984)
2.425 – 2.450
(0.0955 – 0.0965)
Crankshaft runout
—
LIMIT
—
—
1st
—
—
2/8
CLUTCH
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
15.9 – 16.0
(0.626 – 0.630)
—
—
Clutch drive plate claw width
—
Clutch drive plate distortion
—
Clutch spring free length
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
—
—
0.080
(0.0031)
—
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
0.080
(0.0031)
—
No. 2
Gearshift fork thickness
—
—
No. 1&
No. 3
No. 2
Drive chain
—
0.05
(0.002)
STANDARD
1.744 (75/43)
3.133 (47/15)
3.083 (37/12)
2.062 (33/16)
1.647 (28/17)
1.400 (28/20)
1.227 (27/22)
1.095 (23/21)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
5.0 – 5.1
(0.197 – 0.201)
4.6 – 4.7
(0.181 – 0.185)
4.8 – 4.9
(0.189 – 0.193)
RKFS50SMOZ1
112 links
1st (Low)
2nd
3rd
4th
5th
6th (Top)
Gearshift fork to groove clearance No. 1, No. 2
& No. 3
Gearshift fork groove width
No. 1&
No. 3
Type
Links
20-pitch
length
—
Drive chain slack
25 – 35
(0.98 – 1.38)
55 (2.2)
Gearshift lever height
STANDARD
1.898 (75/43 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
3/8
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2,
114 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.120
(0.0047)
62.690
(2.4681)
62.480
(2.4598)
0.20
(0.008)
5.4
(0.21)
5.6
(0.22)
0.5
(0.02)
0.7
(0.03)
0.180
(0.007)
0.150
(0.006)
E-02, 19, P-37
E-19
E-02, 19
E-19
Clutch release screw
Clutch drive plate thickness
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
0.1 – 0.3
(0.004 – 0.012)
0.3 – 0.5
(0.012 – 0.020)
2nd
P
M
E-02, 19, P-37
E-19
E-02, 19
E-19
STANDARD
1.02 – 1.04
(0.040 – 0.041)
0.81 – 0.83
(0.032 – 0.033)
1.51 – 1.53
(0.059 – 0.060)
0.97 – 0.99
(0.038 – 0.039)
0.77 – 0.79
(0.030 – 0.031)
18.002 – 18.008
(0.7087 – 0.7090)
17.996 – 18.000
(0.7085 – 0.7086)
1st
—
0.20
(0.008)
—
2nd
ITEM
Piston ring groove width
—
CYLINDER + PISTON + PISTON RING
Piston ring end gap
1/8
– 12.018
– 0.4731)
– 11.984
– 0.4718)
Compression pressure difference
—
Valve spring tension (IN. & EX.)
—
0.10
(0.004)
—
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
0.9 – 1.1
(0.035 – 0.043)
—
24th pin
12.000
(0.4724
11.973
(0.4714
—
IN. & EX.
—
—
—
—
IN. & EX.
INNER
IN.
—
Unit: mm (in)
LIMIT
32.83
(1.2925)
32.55
(1.2815)
0.150
(0.0059)
STANDARD
33.13 – 33.17
(1.3043 – 1.3059)
32.85 – 32.89
(1.2933 – 1.2949)
0.032– 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
—
Valve seat width
OUTER
ITEM
Cam height
—
Valve head radial runout
Valve spring free length (IN. & EX.)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
—
319.4
(12.57)
—
—
LIMIT
—
—
E-02, 19, P-37
E-19
E-02, 19
E-19
4/8
E-02, 19, P-37
E-19
E-02, 19
E-19
39
CARBURETOR
ITEM
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle Valve
Pilot jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(Th.V)
(P.J.)
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
SPECIFICATION
E-02, 19
E-19 (U-type)
P-37
KEIHIN CVR32SS
←
←
32 mm
←
←
31FA
31FB
31F9
1 200 ± 100 r/min
←
←
17.0 ± 1.0 mm
←
←
(0.67 ± 0.04 in)
#92
←
#98
N1QH
←
N1QJ
¬ 3.4
←
←
11°
←
←
#35
←
#38
PRE-SET
PRE-SET
PRE-SET
(1 and 3/8 turns back) (1 and 1/2 turns back) (1 and 3/4 turns back)
2.0 – 4.0 mm
←
←
(0.08 – 0.16 in)
0.5 – 1.0 mm
←
←
(0.02 – 0.04 in)
ELECTRICAL
ITEM
Ignition timing
Firing order
Spark plug
SPECIFICATION
4° B.T.D.C. at 1 200 r/min
1·2·4·3
NGK: CR9EK
DENSO: U27ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Pickup coil resistance
Signal generator peak voltage
Ignition coil resistance
Primary
Secondary
Ignition coil primary peak
voltage
Generator
Unit: mm (in)
NOTE
Approx. 135 – 200 Ω
Tester range:
(× 100 Ω)
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
Spark plug cap – Spark plug cap
Approx. 30 – 40 kΩ
Tester range:
(× 1 Ω)
Tester range:
(× 1 kΩ)
Generator Maximum output
Regulated voltage
Starter relay resistance
Type
designation
Capacity
Standard
electrolyte S.G.
HI
Headlight
LO
Turn signal
Ignition
Meter
Main
Fuse size
Headlight
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
License plate light
Brake disc thickness
Brake caliper piston diameter
Wheel rim runout
A
S
E
L
Wheel axle runout
Wheel rim size
—
Axial
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
Front
—
Rear
—
Front
Rear
17 M/C × MT3.50
17 M/C × MT4.50
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Front fork inner tube O.D.
Rear wheel travel
Swingarm pivot shaft runout
P
M
Rear
Radial
STANDARD
130 (5.1)
366.1 (14.41)
114 (4.5)
SUZUKI FORK OIL #10 or an equivalent fork oil
508 ml (17.2/17.9 US/lmp oz)
41 (1.6)
126 (5.0)
—
Front
Front
Rear
—
Front
Front
—
Master cylinder piston diameter
LIMIT
15.870
(0.6248
12.700
(0.5000
15.827
(0.6231
12.657
(0.4983
DOT 4
–
–
–
–
–
–
–
–
15.913
0.6264)
12.743
0.5017)
15.854
0.6242)
12.684
0.4994)
6/8
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
—
—
—
—
—
E-02, 19, P-37
E-19
E-02, 19
E-19
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
—
—
LIMIT
—
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Rear
38.180 – 38.256
(1.5031 – 1.5061)
30.150 – 30.200
(1.1870 – 1.1890)
38.098 – 38.148
(1.5000 – 1.5019)
Rear
STANDARD
50 (2.0)
Rear
E-02, 19, P-37
E-19
E-02, 19
E-19
STANDARD
30.230 – 30.306
(1.1902 – 1.1931)
Front
A
A
A
A
A
A
Unit: mm (in)
ITEM
Rear brake pedal height
Brake fluid type
ITEM
Brake caliper cylinder bore
10
10
15
10
10
30
BRAKE + WHEEL
DENSO
5/8
1.320 at 20 °C (68 °F)
SPECIFICATION
60
55
5
21/5 × 2
21 × 4
LED
LED
LED × 2
LED
LED
LED
5
HI
LO
Limit: 4.5 (0.18)
More than 550 W at 5 000 r/min
13.6 – 14.4 V at 5 000 r/min
3–6Ω
12 V 28.8 kC (8 Ah)/10 HR
Unit: W
ITEM
Master cylinder bore
Limit: 14.0 (0.55)
NOTE
FTX9-BS
WATTAGE
Brake disc runout
More than 140 V
Slip ring
O.D.
Brush
length
SPECIFICATION
Battery
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
20 L (5.3/4.4 US/lmp gal)
reserve
NOTE
Reserve only
4.5 L (1.2/1.0 US/lmp gal)
SAE 10W-40, API, SF or SG
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)
Unit: mm (in)
LIMIT
—
358 (14.1)
—
—
—
—
—
0.3 (0.01)
TIRE
ITEM
Cold inflation tire pressure
(Solo/Dual riding)
STANDARD
225 kPa
(2.25 kgf/cm2, 33 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
Front
Rear
Tire size
Tire type
Tire tread depth
(Recommended depth)
Front
Rear
Front
Rear
120/60 ZR17 M/C (55W)
160/60 ZR17 M/C (69W)
BRIDGESTONE BT56F
BRIDGESTONE BT56R
Front
—
Rear
—
7/8
LIMIT
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
E-02, 19, P-37
E-19
E-02, 19
E-19
8/8
E-02, 19, P-37
E-19
E-02, 19
E-19
40
GSF600S/SU
VALVE + GUIDE
ITEM
Valve diameter
STANDARD
23
(0.9)
20
(0.8)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
IN. & EX.
—
5.000
(0.1969
4.965
(0.1955
4.955
(0.1950
IN. & EX.
IN.
EX.
– 5.012
– 0.1973)
– 4.980
– 0.1961)
– 4.970
– 0.1957)
Unit: mm (in)
LIMIT
—
—
—
—
0.35
(0.014)
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
—
0.03
(0.001)
35.0
(1.38)
38.4
(1.51)
Valve spring tension (IN. & EX.)
5.6 – 6.6 kgf
(12.3 – 14.6 lbs)
at length 28 mm (1.10 in)
12.8 – 15.0 kgf
(28.2 – 33.1 lbs)
at length 31.5 mm (1.24 in)
INNER
OUTER
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Rocker arm I.D.
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft thrust bearing thickness
Left side
Right side
STANDARD
18.010 –18.018
(0.7091 – 0.7094)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
33.976 – 34.000
(1.3376 – 1.3386)
0.020 – 0.044
(0.0008 – 0.0017)
31.976 – 32.000
(1.2589 – 1.2598)
0.04 – 0.09
(0.002 – 0.004)
2.350 – 2.500
(0.0925 – 0.0984)
2.425 – 2.450
(0.0955 – 0.0965)
Crankshaft runout
—
—
—
Piston to cylinder clearance
Cylinder bore
Piston diameter
STANDARD
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
0.040 – 0.050
(0.0016 – 0.0020)
62.600 – 62.615
(2.4646 – 2.4652)
62.555 – 62.570
(2.4628 – 2.4634)
Measure at 15 mm (0.6 in) from the skirt end.
—
Piston ring free end gap
1st
R
Approx. 6.7 (0.26)
2nd
RN
Approx. 7.0 (0.28)
2nd
0.1 – 0.3
(0.004 – 0.012)
0.3 – 0.5
(0.012 – 0.020)
1st
—
2nd
—
1st
E
L
P
M
2/9
CLUTCH
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
15.9 – 16.0
(0.626 – 0.630)
—
—
Clutch drive plate claw width
—
Clutch drive plate distortion
—
Clutch spring free length
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
—
—
0.080
(0.0031)
—
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
0.080
(0.0031)
—
No. 2
Gearshift fork thickness
—
—
No. 1&
No. 3
No. 2
Drive chain
—
0.05
(0.002)
STANDARD
1.744 (75/43)
3.133 (47/15)
3.083 (37/12)
2.062 (33/16)
1.647 (28/17)
1.400 (28/20)
1.227 (27/22)
1.095 (23/21)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
5.0 – 5.1
(0.197 – 0.201)
4.6 – 4.7
(0.181 – 0.185)
4.8 – 4.9
(0.189 – 0.193)
RKFS50SMOZ1
112 links
1st (Low)
2nd
3rd
4th
5th
6th (Top)
Gearshift fork to groove clearance No. 1, No. 2
& No. 3
Gearshift fork groove width
No. 1&
No. 3
Type
Links
20-pitch
length
—
Drive chain slack
25 – 35
(0.98 – 1.38)
55 (2.2)
Gearshift lever height
STANDARD
1.898 (75/43 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi))
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
3/9
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2,
114 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.120
(0.0047)
62.690
(2.4681)
62.480
(2.4598)
0.20
(0.008)
5.4
(0.21)
5.6
(0.22)
0.5
(0.02)
0.7
(0.03)
0.180
(0.007)
0.150
(0.006)
E-02, 03, 19, 28, 33
E-19
Clutch release screw
Clutch drive plate thickness
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
—
0.20
(0.008)
—
Cylinder distortion
—
LIMIT
—
—
—
A
S
CONROD + CRANKSHAFT
IN. & EX.
– 12.018
– 0.4731)
– 11.984
– 0.4718)
Compression pressure difference
E-02, 03, 19, 28, 33
E-19
STANDARD
1.02 – 1.04
(0.040 – 0.041)
0.81 – 0.83
(0.032 – 0.033)
1.51 – 1.53
(0.059 – 0.060)
0.97 – 0.99
(0.038 – 0.039)
0.77 – 0.79
(0.030 – 0.031)
18.002 – 18.008
(0.7087 – 0.7090)
17.996 – 18.000
(0.7085 – 0.7086)
24th pin
12.000
(0.4724
11.973
(0.4714
IN. & EX.
ITEM
Compression pressure
Piston ring to groove clearance
ITEM
Piston ring groove width
—
0.10
(0.004)
—
CYLINDER + PISTON + PISTON RING
Piston ring end gap
1/9
—
—
—
Valve stem end length
—
IN. & EX.
Cylinder head distortion
—
—
Camshaft journal O.D.
—
IN. & EX.
INNER
IN. & EX.
IN. & EX.
Rocker arm shaft O.D.
Valve face thickness
OUTER
Camshaft journal oil clearance
Camshaft journal holder I.D.
—
—
Valve spring free length (IN. & EX.)
IN.
—
Unit: mm (in)
LIMIT
32.83
(1.2925)
32.55
(1.2815)
0.150
(0.0059)
STANDARD
33.13 – 33.17
(1.3043 – 1.3059)
32.85 – 32.89
(1.2933 – 1.2949)
0.032– 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
IN. & EX.
IN. & EX.
ITEM
Cam height
—
Valve stem runout
Valve head radial runout
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
—
319.4
(12.57)
—
—
LIMIT
—
—
E-02, 03, 19, 28, 33
E-19
4/9
E-02, 03, 19, 28, 33
E-19
41
CARBURETOR
ELECTRICAL
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle Valve
Pilot jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(Th.V)
(P.J.)
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
SPECIFICATION
E-02, 19
E-03, 28
KEIHIN CVR32SS
←
32 mm
←
31FA
31F7
1 200 ± 100 r/min
←
17.0 ± 1.0 mm
←
(0.67 ± 0.04 in)
#92
←
N1QH
N1QL
¬ 3.4
←
11°
←
#35
←
PRE-SET
PRE-SET
(1 and 3/8 turns back)
(1 and 7/8 turns back)
2.0 – 4.0 mm
←
(0.08 – 0.16 in)
0.5 – 1.0 mm
←
(0.02 – 0.04 in)
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle Valve
Pilot jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(Th.V)
(P.J.)
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
SPECIFICATION
E-19 (U-type)
E-33
KEIHIN CVR32SS
←
32 mm
←
31FB
31F8
1 200 ± 100 r/min
←
17.0 ± 1.0 mm
←
(0.67 ± 0.04)
#92
←
N1QH
N1QL
¬ 3.4
←
11°
←
#35
←
PRE-SET
PRE-SET
(1 and 1/2 turns back)
(1 and 7/8 turns back)
2.0 – 4.0 mm
←
(0.08 – 0.16 in)
0.5 – 1.0 mm
←
(0.02 – 0.04 in)
5/9
Headlight
E-03, 28, 33
60
51
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
License plate light
A
S
21/5 × 2
21 × 4
LED
LED
LED × 2
LED
LED
LED
5
SPECIFICATION
The other countries
←
←
5
←
←
←
←
←
←
←
←
←
BRAKE + WHEEL
Gap
Signal generator peak voltage
Ignition coil resistance
Brake disc thickness
STANDARD
50 (2.0)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Ignition coil primary peak
voltage
Generator
Generator Maximum output
Regulated voltage
Starter relay resistance
Battery
Fuse size
Rear
Brake disc runout
Master cylinder bore
—
—
Rear
15.870 – 15.913
(0.6248 – 0.6264)
12.700 – 12.743
(0.5000 – 0.5017)
15.827 – 15.854
(0.6231 – 0.6242)
12.657 – 12.684
(0.4983 – 0.4994)
30.230 – 30.306
(1.1902 – 1.1931)
38.180 – 38.256
(1.5031 – 1.5061)
30.150 – 30.200
(1.1870 – 1.1890)
38.098 – 38.148
(1.5000 – 1.5019)
Axial
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
Front
Rear
Master cylinder piston diameter
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diameter
Wheel rim runout
Wheel axle runout
Front
Radial
—
Front
—
Rear
—
7/9
Tester range:
(× 100 Ω)
Approx. 135 – 200 Ω
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
Spark plug cap – Spark plug cap
Approx. 30 – 40 kΩ
Primary
6/9
ITEM
Wheel rim size
STANDARD
17 M/C × MT3.50
17 M/C × MT4.50
Front
Rear
Front fork spring free length
Front fork oil level
Rear wheel travel
Swingarm pivot shaft runout
DENSO
E-02, 03, 19, 28, 33
E-19
SUSPENSION
ITEM
Front fork stroke
Tester range:
(× 1 Ω)
Tester range:
(× 1 kΩ)
More than 140 V
Slip ring O.D.
Limit: 14.0 (0.55)
Brush length
Limit: 4.5 (0.18)
More than 550 W at 5 000 r/min
13.6 – 14.4 V at 5 000 r/min
3–6Ω
Type
FTX9-BS
designation
Capacity
12 V 28.8 kC (8 Ah)/10 HR
Standard
1.320 at 20 °C (68 °F)
electrolyte S.G.
HI
10 A
Headlight
LO
10 A
Turn signal
15 A
Ignition
10 A
Meter
10 A
Main
30 A
E
L
LIMIT
—
—
Unit: mm (in)
STANDARD
130 (5.1)
LIMIT
—
—
116 (4.6)
356 (14.0)
—
112 (4.4)
—
126 (5.0)
—
—
0.3 (0.01)
NOTE
E-03, 28, 33
The other
countries
TIRE
ITEM
Cold inflation tire pressure
(Solo/Dual riding)
LIMIT
—
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
NOTE
E-03, 28, 33
The other
countries
1·2·4·3
NGK: CR9EK
DENSO: U27ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Secondary
P
M
Unit: mm (in)
ITEM
Rear brake pedal height
Type
Spark performance
Pickup coil resistance
Unit: W
ITEM
SPECIFICATION
4° B.T.D.C. at 1 200 r/min
10° B.T.D.C. at 1 200 r/min
Firing order
Spark plug
E-02, 03, 19, 28, 33
E-19
WATTAGE
Unit: mm (in)
ITEM
Ignition timing
STANDARD
225 kPa
(2.25 kgf/cm2, 33 psi)
Front
Front
Rear
Front
Rear
250 kPa
(2.50 kgf/cm2, 36 psi)
120/60 ZR17 M/C (55W)
160/60 ZR17 M/C (69W)
BRIDGESTONE BT56F
BRIDGESTONE BT56R
Front
—
Rear
—
Rear
Tire size
Tire type
Tire tread depth
(Recommended depth)
LIMIT
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
—
—
—
—
—
—
—
E-02, 03, 19, 28, 33
E-19
8/9
E-02, 03, 19, 28, 33
E-19
42
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
19 L (5.0/4.2 US/lmp gal)
Including
reserve
20 L (5.3/4.4 US/lmp gal)
Reserve only
4.5 L (1.2/1.0 US/lmp gal)
SAE 10W-40, API, SF or SG
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)
Fork oil #10
506 ml (17.1/17.8 US/lmp oz)
510 ml (17.2/18.0 US/lmp oz)
Brake fluid type
GSF1200/Z
IN.
IN.
EX.
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
E-33
The other
countries
E-03, 28, 33
The other
countries
IN. & EX.
—
5.000
(0.1969
4.965
(0.1955
4.945
(0.1947
IN. & EX.
IN.
EX.
P
M
– 5.012
– 0.1973)
– 4.980
– 0.1961)
– 4.960
– 0.1953)
Unit: mm (in)
LIMIT
—
IN. & EX.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
24th pin
12.000
(0.4724
11.973
(0.4714
—
—
Cylinder head distortion
– 12.018
– 0.4731)
– 11.984
– 0.4718)
IN. & EX.
—
Valve stem end length
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 250 kPa
(12.5 kgf/cm2, 178 psi)
Compression pressure difference
Piston-to-cylinder clearance
Cylinder bore
Piston diameter
—
0.040 – 0.070
(0.0016 – 0.0028)
79.000 – 79.015
(3.1102 – 3.1108)
78.945 – 78.960
(3.1081 – 3.1087)
Measure 15 mm (0.6 in) from the skirt end.
Cylinder distortion
—
—
Piston ring free end gap
—
Piston ring end gap
Piston-ring to piston-ring-groove
clearance
E-02, 03, 19
E-02,19
1st
R
Approx. 10 (0.39)
2nd
RN
Approx. 12 (0.47)
2nd
0.20 – 0.35
(0.008 – 0.014)
0.35 – 0.50
(0.014 – 0.020)
1st
—
2nd
—
1st
2/9
Unit: mm (in)
LIMIT
33.28
(1.3102)
32.35
(1.2736)
0.150
(0.0059)
—
—
0.10
(0.004)
—
—
—
0.20
(0.008)
—
—
Valve face thickness
1/9
IN.
—
0.35
(0.014)
STANDARD
33.58 – 33.62
(1.3220 – 1.3236)
32.65 – 32.69
(1.2854 – 1.2870)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
Camshaft journal oil clearance
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
OUTER
Cam height
Camshaft journal holder I.D.
—
53 – 65 N
(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)
at length 28 mm (1.10 in)
131 – 151 N
(13.1 – 15.1 kgf, 28.9 – 33.3 lbs)
at length 31.5 mm (1.24 in)
ITEM
—
IN. & EX.
INNER
CAMSHAFT + CYLINDER HEAD
—
Valve stem runout
Valve spring tension
(IN. & EX.)
E
L
E-02, 03, 19, 28, 33
E-19
STANDARD
28.5
(1.12)
25
(1.0)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
EX.
Valve-guide to valve-stem clearance
The other
countries
A
S
VALVE + GUIDE
Valve clearance (when cold)
E-03, 28, 33
DOT 4
9/9
ITEM
Valve diameter
NOTE
Unit: mm (in)
LIMIT
875 kPa
(8.75 kgf/cm2 , 124 psi)
200 kPa
(2 kgf/cm2 , 28 psi)
0.120
(0.0047)
79.080
(3.1134)
78.880
(3.1055)
0.20
(0.008)
8.0
(0.31)
9.6
(0.38)
0.5
(0.02)
1.0
(0.04)
0.180
(0.007)
0.150
(0.006)
E-02, 03, 19
E-02,19
43
ITEM
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.01 – 1.03
(0.040 – 0.041)
2.01 – 2.03
(0.079 – 0.080)
0.975 – 0.990
(0.0384 – 0.0390)
0.970 – 0.990
(0.038 – 0.039)
20.002 – 20.008
(0.7875 – 0.7877)
19.996 – 20.000
(0.7872 – 0.7874)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft thrust bearing thickness
Left side
Right side
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4961)
0.020 – 0.044
(0.0008 – 0.0017)
35.976 – 36.000
(1.4164 – 1.4173)
0.04 – 0.08
(0.0016 – 0.0031)
2.360 – 2.520
(0.0929 – 0.0992)
2.420 – 2.440
(0.0953 – 0.0961)
Crankshaft runout
OIL PUMP
LIMIT
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C,140°F)
—
—
—
—
CLUTCH
—
ITEM
Clutch drive plate thickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
Clutch drive plate claw width
—
Clutch driven plate distortion
—
20.030
(0.7886)
19.980
(0.7866)
Clutch spring free height
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.01)
14.000 –
(0.5511 –
13.957 –
(0.5495 –
35.700 –
(1.4055 –
35.650 –
(1.4035 –
Clutch master cylinder piston diam.
Clutch release cylinder bore
—
Clutch release cylinder piston
diam.
—
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
0.080
(0.0031)
1st (low)
2nd
3rd
4th
5th (top)
Gearshift-fork to gearshift-forkgroove clearance
Gearshift fork groove width
—
—
—
—
Gearshift fork thickness
Drive chain
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch
length
E
L
Drive chain slack
Gearshift lever height
3/9
A
S
CARBURETOR
SPECIFICATION
E-02, 19
MIKUNI BSR36SS
36 mm
32F0
1 200 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#
5C70-3rd
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th. V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
P
M
E-02, 03, 19
E-02,19
#100
#
3 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min.
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th. V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
5/9
ITEM
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
20 – 30
(0.8 – 1.2)
55
(2.2)
—
—
—
—
319.4
(12.57)
—
—
E-02, 03, 19
E-02,19
Ignition timing
Firing order
Spark plug
SPECIFICATION
7° B.T.D.C. at 1 200 r/min
1•2•4•3
NGK: JR9B
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Pickup coil resistance
Signal generator peak voltage
Ignition coil resistance
Primary
Unit: mm (in)
NOTE
Approx. 130 – 200 Ω
Tester range:
(× 100 Ω)
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
Spark plug cap – Spark plug cap
Approx. 30 – 40 kΩ
More than 140 V
Tester range:
(× 1 Ω)
Tester range:
(× 1 kΩ)
Slip ring
O.D.
Brush
length
Limit: 14.0 (0.55)
DENSO
Limit: 4.5 (0.18)
More than 550 W at 5 000 r/min
13.5 – 15 V at 5 000 r/min
3–5Ω
YTX12-BS
12 V 36.0 kC (10 Ah)/10HR
1.320 at 20 °C (68 °F)
HI
LO
10 A
10 A
Turn signal
Ignition
Meter
Main
E-02, 03, 19
E-02,19
—
ELECTRICAL
Generator maximum output
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
Standard
electrolyte S.G.
Fuse size
Headlight
#100
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
STANDARD
1.565 (72/46)
3.000 (45/15)
2.384 (31/13)
1.631 (31/19)
1.250 (25/20)
1.045 (23/22)
0.913 (21/23)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK GB50GSVZ3
110 links
—
v
Secondary
SPECIFICATION
E-03
MIKUNI BSR36SS
36 mm
32F1
1 300 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#
5C71
Unit: mm (in)
LIMIT
2.62
(0.103)
13.0
(0.51)
0.10
(0.004)
3.1
(0.12)
4/9
Ignition coil primary peak voltage
Generator
CARBURETOR
—
14.043
0.5529)
13.984
0.5506)
35.762
1.4079)
35.675
1.4045)
TRANSMISSION + DRIVE CHAIN
0.080
(0.0031)
LIMIT
—
—
Clutch master cylinder bore
0.05
(0.002)
—
STANDARD
1.703 (72/46 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
15 A
10 A
10 A
30 A
6/9
E-02, 03, 19
E-02,19
44
WATTAGE
Unit: W
SPECIFICATION
ITEM
E-03
60
55
Headlight
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
License plate light
E-02, 19
←
←
5
←
←
←
←
←
←
←
←
←
21/5 × 2
21 × 4
LED
LED
LED × 2
LED
LED
LED
5
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
STANDARD
55
(2.2)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
Brake disc runout
Master cylinder bore
—
Front
Rear
Master cylinder piston diameter
Front
Rear
Brake caliper cylinder bore
Leading
Front
Trailing
Rear
Brake caliper piston diameter
Leading
Front
Trailing
Rear
Wheel rim runout
15.870 – 15.913
(0.6248 – 0.6264)
12.700 – 12.743
(0.5000 – 0.5017)
15.827 – 15.854
(0.6231 – 0.6242)
12.657 – 12.684
(0.4983 – 0.4994)
24.000 – 24.076
(0.9449 – 0.9479)
27.000 – 27.076
(1.0630 – 1.0660)
38.180 – 38.256
(1.5031 – 1.5061)
23.925 – 23.975
(0.9419 – 0.9439)
26.920 – 26.970
(1.0598 – 1.0618)
38.098 – 38.148
(1.4999 – 1.5019)
Axial
—
Radial
—
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method. Gasoline containing MTBE
(MethyI Tertiary ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including
20 L (5.3/4.4 US/lmp gal)
reserve
Reserve
4.4 L
only
(1.2/1.0 US/lmp gal)
SAE 10W-40, API SF or SG
3 300 ml
Change
(3.5/2.9 US/lmp qt)
Filter
3 500 ml
change
(3.7/3.1 US/lmp qt)
4 600 ml
Overhaul
(4.9/4.0 US/lmp qt)
Fork oil SS-08 or equivalent fork oil
507 ml
(17.1/17.9 US/Imp oz)
DOT 4
9/9
STANDARD
Front
—
Rear
—
Front
Rear
17 M/C × MT3.50
17 M/C × MT5.50
SUSPENSION
ITEM
Front fork stroke
STANDARD
130
(5.1)
LIMIT
—
366
(14.4)
107
(4.2)
125
(4.9)
—
—
0.3
(0.01)
Front fork spring free length
Front fork oil level
Rear wheel travel
Unit: mm (in)
LIMIT
—
Swingarm pivot shaft runout
LIMIT
0.25
(0.010)
0.25
(0.010)
—
—
Unit: mm (in)
NOTE
—
—
TIRE
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
ITEM
Cold inflation tire pressure
(Solo/Dual riding)
Tire size
Front
Rear
Front
Rear
Tire type
—
Tire tread depth
(Recommended depth)
—
STANDARD
250 kPa
(2.50 kgf/cm2, 36 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
120/70 ZR17 M/C (58W)
180/55 ZR17 M/C (73W)
MACADAM 90XM
MACADAM 90XM
Front
Rear
—
—
Front
—
Rear
—
LIMIT
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
—
—
—
—
E
L
—
—
2.0
(0.08)
2.0
(0.08)
A
S
FUEL + OIL
Fuel type
Wheel rim size
P
M
E-02, 03, 19
E-02,19
7/9
ITEM
Wheel axle runout
NOTE
E-03
E-02, 19
E-02, 03, 19
E-02,19
8/9
E-02, 03, 19
E-02,19
45
GSF1200S
VALVE + GUIDE
ITEM
Valve diameter
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve-guide to valve-stem
clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
Unit: mm (in)
LIMIT
STANDARD
28.5
(1.12)
25
(1.0)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
—
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
0.35
(0.014)
Cylinder head distortion
Valve face thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
—
—
OUTER
—
Valve spring tension
(IN. & EX.)
INNER
OUTER
53 – 65 N
(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)
at length 28 mm (1.10 in)
131 – 151 N
(13.1 – 15.1 kgf, 28.9 – 33.3 lbs)
at length 31.5 mm (1.24 in)
ITEM
Compression pressure
Cylinder bore
Piston diameter
—
0.040 – 0.070
(0.0016 – 0.0028)
79.000 – 79.015
(3.1102 – 3.1108)
78.945 – 78.960
(3.1081 – 3.1087)
Measure 15 mm (0.6 in) from the skirt end.
Cylinder distortion
—
—
Piston ring free end gap
—
A
S
—
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
—
1.01 – 1.03
(0.040 – 0.041)
1.01 – 1.03
(0.040 – 0.041)
2.01 – 2.03
(0.079 – 0.080)
0.975 – 0.990
(0.0384 – 0.0390)
0.970 – 0.990
(0.038 – 0.039)
20.002 – 20.008
(0.7875 – 0.7877)
19.996 – 20.000
(0.7872 – 0.7874)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft thrust bearing
thickness
Left side
Right side
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4961)
0.020 – 0.044
(0.0008 – 0.0017)
35.976 – 36.000
(1.4164 – 1.4173)
0.04 – 0.08
(0.0016 – 0.0031)
2.360 – 2.520
(0.0929 – 0.0992)
2.420 – 2.440
(0.0953 – 0.0961)
Crankshaft runout
—
1st
R
Approx. 10 (0.39)
2nd
RN
Approx. 12 (0.47)
0.20 – 0.35
(0.008 – 0.014)
0.35 – 0.50
(0.014 – 0.020)
1st
E
L
P
M
LIMIT
0.180
(0.007)
0.150
(0.006)
2/9
Unit: mm(in)
LIMIT
875 kPa
(8.75 kgf/cm2, 124 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
79.080
(3.1134)
78.880
(3.1055)
0.20
(0.008)
8.0
(0.31)
9.6
(0.38)
0.5
(0.02)
1.0
(0.04)
E-02, 03, 19, 24, 28, 33
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
STANDARD
1.703 (72/46 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
LIMIT
—
—
—
—
CLUTCH
—
ITEM
Clutch drive plate thickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
—
Clutch drive plate claw width
—
—
Clutch driven plate distortion
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.01)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
Clutch spring free height
14.000 –
(0.5511 –
13.957 –
(0.5495 –
35.700 –
(1.4055 –
35.650 –
(1.4035 –
Clutch master cylinder piston
diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
14.043
0.5529)
13.984
0.5506)
35.762
1.4079)
35.675
1.4045)
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
1st (low)
2nd
3rd
4th
5th (top)
Gearshift-fork to gearshift-forkgroove clearance
Gearshift fork groove width
Gearshift fork thickness
Drive chain
0.05
(0.002)
STANDARD
1.565 (72/46)
3.000 (45/15)
2.384 (31/13)
1.631 (31/19)
1.250 (25/20)
1.045 (23/22)
0.913 (21/23)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK GB50GSVZ3
110 links
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch length
—
20 – 30
(0.8 – 1.2)
55
(2.2)
Gearshift lever height
E-02, 03, 19, 24, 28, 33
Unit: mm (in)
LIMIT
2.62
(0.103)
13.0
(0.51)
0.10
(0.004)
3.1
(0.12)
—
Clutch master cylinder bore
Drive chain slack
3/9
—
0.20
(0.008)
STANDARD
1 250 kPa
(12.5 kgf/cm2, 178 psi)
Compression pressure difference
Piston-to-cylinder clearance
E-02, 03, 19, 24, 28, 33
STANDARD
1st
—
—
2nd
ITEM
Piston-ring to piston-ring-groove
clearance
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
Piston ring end gap
1/9
—
0.10
(0.004)
—
—
—
INNER
24th pin
12.000
(0.4724
11.973
(0.4714
—
IN. & EX.
IN. & EX.
—
—
—
Valve stem runout
Valve spring free length
(IN. & EX.)
IN.
—
Unit: mm (in)
LIMIT
33.28
(1.3102)
32.35
(1.2736)
0.150
(0.0059)
STANDARD
33.58 – 33.62
(1.3220 – 1.3236)
32.65 – 32.69
(1.2854 – 1.2870)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
—
– 5.012
– 0.1973)
– 4.980
– 0.1961)
– 4.960
– 0.1953)
Valve head radial runout
ITEM
Cam height
—
—
5.000
(0.1969
4.965
(0.1955
4.945
(0.1947
CAMSHAFT + CYLINDER HEAD
4/9
—
—
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.57)
—
—
E-02, 03, 19, 24, 28, 33
46
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th. V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
ELECTRICAL
SPECIFICATION
E-02, 19, 24
MIKUNI BSR36SS
36 mm
32F0
1 200 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#
5C70-3rd
ITEM
E-03, 28
←
←
32F1
1 300 ± 100 r/min
Ignition timing
Firing order
Spark plug
Gap
←
5C71-1st
←
←
←
PRE-SET
#100
#
3 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
Signal generator peak voltage
Ignition coil resistance
Ignition coil primary peak
voltage
Generator
←
←
Generator maximum output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuse size
HI
Headlight
LO
Turn signal
Ignition
Meter
Main
SPECIFICATION
E-33
MIKUNI BSR36SS
36 mm
32F2
1 300 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#
5C71-1st
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th. V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play
(pulling cable)
Starter (enricher) plunger cable
play
P
M
A
S
Unit: W
SPECIFICATION
E-03, 24, 28, 33
The other countries
60 + 51
←
51
←
5
21/5 × 2
←
21 × 4
←
LED
←
LED
←
LED × 2
←
LED
←
LED
←
LED
←
5
←
ITEM
Headlight
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
License plate light
BRAKE + WHEEL
ITEM
Rear brake pedal height
Tester range:
(× 1 Ω)
Tester range:
(× 1 kΩ)
More than 140 V
Slip ring O.D.
Limit: 14.0 (0.55)
Brush length
Limit: 4.5 (0.18)
More than 550 W at 5 000 r/min
13.5 – 15 V at 5 000 r/min
3–5Ω
YTX12-BS
12 V 36.0 kC (10 Ah)/10HR
DENSO
1.320 at 20 °C (68 °F)
10
10
15
10
10
30
A
A
A
A
A
A
Front
Brake disc runout
—
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
—
Front
Rear
Front
Rear
Brake caliper cylinder bore
Leading
Front
Trailing
Rear
Brake caliper piston diameter
Leading
Front
Trailing
Rear
7/9
ITEM
Wheel rim runout
Wheel axle runout
Wheel rim size
6/9
15.870 – 15.913
(0.6248 – 0.6264)
12.700 – 12.743
(0.5000 – 0.5017)
15.827 – 15.854
(0.6231 – 0.6242)
12.657 – 12.684
(0.4983 – 0.4994)
24.000 – 24.076
(0.9449 – 0.9479)
27.000 – 27.076
(1.0630 – 1.0660)
38.180 – 38.256
(1.5031 – 1.5061)
23.925 – 23.975
(0.9419 – 0.9439)
26.920 – 26.970
(1.0598 – 1.0618)
38.098 – 38.148
(1.4999 – 1.5019)
STANDARD
—
Radial
—
Front
—
Rear
—
Front
Rear
17 M/C × MT3.50
17 M/C × MT5.50
ITEM
Front fork stroke
LIMIT
—
366
(14.4)
370
(14.6)
E-03, 28, 33
—
E-03, 28, 33
—
The other
countries
Front fork oil level
Rear wheel travel
Swingarm pivot shaft runout
ITEM
Cold inflation tire pressure
(Solo/Dual riding)
Tire size
—
—
Front
Rear
—
—
—
—
TIRE
Tire type
Tire tread depth
(Recommended depth)
Unit: mm (in)
NOTE
STANDARD
130
(5.1)
Front fork spring free length
—
—
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
SUSPENSION
—
—
E-02, 03, 19, 24, 28, 33
Axial
Unit: mm (in)
LIMIT
STANDARD
55
(2.2)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Rear
Master cylinder piston diameter
Tester range:
(× 100 Ω)
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
Spark plug cap – Spark plug cap
Approx. 30 – 40 kΩ
E
L
E-02, 03, 19, 24, 28, 33
WATTAGE
Master cylinder bore
Approx. 130 – 200 Ω
# 100
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
5/9
Brake disc thickness
Primary
Secondary
CARBURETOR
ITEM
Type
Spark performance
Pickup coil resistance
←
Unit: mm (in)
NOTE
SPECIFICATION
7° B.T.D.C. at 1 200 r/min
1•2•4•3
NGK: JR9B
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Front
Rear
Front
Rear
107
(4.2)
105
(4.1)
125
(4.9)
—
—
0.3
(0.01)
The other
countries
STANDARD
250 kPa
(2.50 kgf/cm2, 36 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
120/70ZR17M/C (58W)
180/55ZR17M/C (73W)
MICHELIN MACADAM 100X B
MICHELIN MACADAM 100X
Front
—
Rear
—
LIMIT
—
—
—
—
—
—
1.6 mm
(0.06 in)
2.0 mm
(0.08 in)
—
—
E-02, 03, 19, 24, 28, 33
8/9
E-02, 03, 19, 24, 28, 33
47
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane or 91 octane (R/2 + M/2) or higher rated by
the Research Method.
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
19 L
(5.0/4.2 US/lmp gal)
Including
reserve
20 L
(5.2/4.4 US/lmp gal)
Reserve
4.4 L
only
(1.2/1.0 US/lmp gal)
SAE 10W-40, API SF or SG
3 300 ml
Change
(3.5/2.9 US/lmp qt)
Filter
3 500 ml
change
(3.7/3.1 US/lmp qt)
4 600 ml
Overhaul
(4.9/4.0 US/lmp qt)
Fork oil SS-08 or equivalent fork oil
507 ml
(17.1/17.9 US/lmp oz)
509 ml
(17.2/17.9 US/Imp oz)
DOT 4
9/9
GSX600F
E-03, 28, 33
The other
countries
E-33
The other
countries
E-03, 28, 33
The other
countries
E
L
P
M
E-02, 03, 19, 24, 28, 33
A
S
VALVE + GUIDE
ITEM
Valve diameter
NOTE
STANDARD
Unit: mm (in)
LIMIT
CAMSHAFT + CYLINDER HEAD
ITEM
STANDARD
—
Camshaft journal oil clearance
IN. & EX.
EX.
23
(1.9)
20
(0.8)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
—
Camshaft journal holder I.D.
IN. & EX.
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Camshaft journal O.D.
IN. & EX.
Valve guide I.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
Valve stem O.D.
IN.
5.000 – 5.012
(0.1969 – 0.1973)
4.965 – 4.980
(0.1955 – 0.1961)
4.955 – 4.970
(0.1950 – 0.1957)
—
Cam chain pin (at arrow “3”)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide-to-valve stem
clearance
IN.
EX.
Valve stem runout
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
0.03
(0.001)
35.0
(1.38)
38.4
(1.51)
OUTER
—
5.6 – 6.6 kgf
(12.3 – 14.6 lbs)
at length 28 mm (1.10 in)
12.8 – 15.0 kgf
(28.2 – 33.1 lbs)
at length 31.5 mm (1.24 in)
INNER
OUTER
Others
24th pin
12.000
(0.4724
11.973
(0.4714
Cylinder head distortion
STANDARD
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
Compression pressure difference
Piston-to-cylinder clearance
Cylinder bore
Piston diameter
—
Cylinder distortion
Piston ring end gap
Piston ring-to-piston ring groove
clearance
—
0.040 – 0.050
(0.0016 – 0.0020)
62.600 – 62.615
(2.4646 – 2.4652)
62.555 – 52.570
(2.4628 – 2.4634)
Measure at 15 mm (0.6 in) from the skirt end.
—
1st
R
Approx. 6.7 (0.26)
2nd
RN
Approx. 7.0 (0.28)
2nd
0.1 – 0.3
(0.004 – 0.012)
0.3 – 0.5
(0.012 – 0.020)
1st
—
2nd
—
1st
2/9
—
—
0.10
(0.004)
—
—
—
0.20
(0.008)
—
ITEM
Compression pressure
—
E-02, 03, 19, 28, 33
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
Piston ring free end gap
1/9
32.38 – 32.42
(1.2748 – 1.2764)
33.13 – 33.17
(1.3043 – 1.3059)
32.10 – 32.14
(1.2638 – 1.2654)
32.85 – 32.89
(1.2933 – 1.2949)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
—
—
IN. & EX.
Valve spring tension
(IN. & EX.)
E-18
EX.
—
Valve stem end length
—
Others
—
Valve face thickness
—
E-18
IN.
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
IN. & EX.
Cam height
Unit: mm (in)
LIMIT
32.08
(1.2630)
32.83
(1.2925)
31.80
(1.2520)
32.55
(1.2815)
0.150
(0.0059)
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
62.690
(2.4681)
62.480
(2.4598)
0.20
(0.008)
5.4
(0.21)
5.6
(0.22)
0.5
(0.02)
0.7
(0.03)
0.180
(0.007)
0.150
(0.006)
E-02, 03, 19, 28, 33
48
ITEM
Piston ring groove width
2nd
Oil
Piston ring thickness
1st
2nd
Piston pim bore
Piston pin O.D.
1.02 – 1.04
(0.040 – 0.041)
0.81 – 0.83
(0.032 – 0.033)
1.51 – 1.53
(0.059 – 0.060)
0.97 – 0.99
(0.038 – 0.039)
0.77 – 0.79
(0.030 – 0.031)
18.002 – 18.008
(0.7087 – 0.7090)
17.996 – 18.000
(0.7085 – 0.7086)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft jounal width
—
Clutch release screw
Clutch drive plate thickness
—
No. 2
18.030
(0.7098)
17.980
(0.7079)
Clutch drive plate distortion
—
Clutch spring free length
—
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
TRANSMISSION + DRIVE CHAIN
—
—
0.080
(0.0031)
1st (low)
2nd
3rd
4th
5th
6th (top)
Gearshift fork-to-gearshift fork
groove clearance
Gearshift fork groove width
—
Gearshift fork thickness
—
1.898 (75/43 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
Caburetor type
Bore size
I.D. No.
Idle r/min
Float height
Drive chain
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th.V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play (pulling cable)
Starter (enricher) plunger cable
play
LIMIT
—
Drive chain slack
A
S
E-33
←
←
19E4
1 300 ± 100 r/min
P
M
←
←
←
←
←
←
←
Caburetor type
Bore size
I.D. No.
Idle r/min
Float height
ITEM
Ignition timing
4° B.T.D.C. at 1 200 r/min
10° B.T.D.C. at 1 200 r/min
Firing order
Spark plug
Gap
Spark performance
Pickup coil resistance
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th.V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play (pulling cable)
5/9
Primary
More than 1.0 V
tap – tap
Approx. 2 – 4 kΩ
Spark plug cap – Spark plug cap
Approx. 30 – 40 kΩ
More than 140 V
Slip ring
O.D.
Brush
length
E-02, 03, 19, 28, 33
—
—
—
—
319.4
(12.57)
—
—
Unit: mm (in)
NOTE
E-03, 28, 33
The other
countries
Tester range:
(× 100 Ω)
Tester range:
(× 1 Ω)
Tester range:
(× 1 Ω)
Limit: 14.0 (0.55)
DENSO
Limit: 4.5 (0.18)
Approx. 550 W at 5 000 r/min
13.6 – 14.4 V at 5 000 r/min
3–6Ω
YTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
1.320 at 20 °C (68 °F)
15
10
15
10
15
10
10
30
Turn signal
Ignition
Meter
Main
#110
#
3 and 1/4 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
Starter (enricher) plunger cable
play
Approx. 135 – 200 Ω
Secondary
Ignition coil primary peak voltage
Generator
—
1·2·4·3
NGK: CR9EK
DENSO: U27ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Signal generator peak voltage
Ignition coil resistance
—
E-02, 03, 19, 28, 33
STD/SPEC.
Generator maximaum output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuze size
HI
Headlight
LO
MIKUNI BSR32SS
32 mm
19E6
1 200 ± 100 r/min
13.0 ± 0.5 mm
(0.51 ± 0.02 in)
No. 1&4: #
No. 2&3: #
5DH53- 3rd
20 – 30
(0.79 – 1.18)
54
(2.1)
ELECTRICAL
CABURETOR
STD/SPEC.
E-02, 19
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
4/9
←
←
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
—
E
L
—
#110
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
ITEM
No. 1 &
No. 3
Type
Links
20-pitch
length
E-02, 03, 19, 28, 33
E-03, 28
MIKUNI BSR32SS
32 mm
19E3
1 200 ± 100 r/min
13.0 ± 0.5 mm
(0.51 ± 0.02 in)
Nos. 1&4: #
Nos. 2&3: #
5DH30-54
No. 1, No. 2
& No. 3
No. 1 &
No. 3
No. 2
0.05
(0.002)
STD/SPEC.
ITEM
1.744 (75/43)
3.133 (47/15)
3.083 (37/12)
2.062 (33/16)
1.647 (28/17)
1.400 (28/20)
1.227 (27/22)
1.095 (23/21)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
5.0 – 5.1
(0.197 – 0.201)
4.6 – 4.7
(0.181 – 0.185)
4.8 – 4.9
(0.189 – 0.193)
RK50SMOZ1
118 links
Gearshift lever height
3/9
CABURETOR
STANDARD
No. 2
—
STANDARD
No. 1 &
No. 2
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
No. 1
Clutch drive plate claw width
0.080
(0.0031)
—
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
3.42 – 3.58
(0.135 – 0.141)
15.9 – 16.0
(0.626 – 0.630)
—
—
Unit: mm (in)
LIMIT
STANDARD
—
STANDARD
18.010 – 18.018
(0.7091 – 0.7094)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 34.000
(1.3376 – 1.3386)
0.020 – 0.044
(0.0008 – 0.0017)
31.976 – 32.000
(1.2589 – 1.2598)
0.04 – 0.09
(0.002 – 0.004)
24.00 – 24.05
(0.945 – 0.947)
Crankshaft runout
ITEM
Clutch cable play
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
CLUTCH
LIMIT
STANDARD
1st
6/9
A
A
A
A
A
A
A
A
E-03, 28, 33
Others
E-03, 28, 33
Others
E-02, 03, 19, 28, 33
49
WATTAGE
Unit: W
ITEM
Headlight
E-03, 28, 33
60 × 2
55 × 2
5
21/5 × 2
21 × 4
1.7 × 2
1.7
1.7
1.4 × 2
1.4
1.4
1.4
5
HI
LO
Parking or position light
Brake light/taillight
Turn signal light
Speedometer light
Tachometer light
Fuel meter light
Turn signal indicator lights
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
License plate light
SPECIFICATION
The other countries
55
55
←
←
←
←
←
←
←
←
←
←
←
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
54
(2.1)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
Brake disc runout
Master cylinder bore
Front
Rear
Master cylinder piston diameter
Front
Rear
Brake caliper cylinder bore
Front
Brake caliper piston diameter
Front
Rear
Rear
7/9
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Fuel fork oil type
Front fork oil capacity (each leg)
Brake fluid type
Tire size
Tire tread depth
Tire type
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
– 14.043
– 0.5529)
– 12.743
– 0.5017)
– 13.984
– 0.5506)
– 12.684
– 0.4994)
– 30.306
– 1.1931)
– 38.256
– 1.5061)
– 30.200
– 1.1890)
– 38.148
– 1.5019)
—
Radial
—
Front
—
Rear
—
Front
Rear
Front
Rear
17M/C × MT 3.50
17M/C × MT 4.50
120/70 ZR17 M/C (58 W)
150/70 ZR17 M/C (69 W)
Front
—
Rear
—
Front
Rear
MICHELIN MACADAM 100X B
MICHELIN MACADAM 100X
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear wheel travel
—
—
LIMIT
STANDARD
Swingarm pivot shaft runout
130
(5.1)
—
—
361
(14.2)
108
(4.3)
142
(5.6)
—
—
0.3
(0.01)
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
—
—
Unit: mm (in)
NOTE
—
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
—
—
kPa
225
250
SOLO RIDING
kgf/cm2
2.25
2.50
psi
33
36
kPa
225
250
DUAL RIDING
kgf/cm2
2.25
2.50
psi
33
36
—
—
—
E
L
P
M
E-02, 03, 19, 28, 33
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octone or
higher. An unleaded gasoline is recommended.
18.5 L
(4.9/4.1 US/lmp gal)
Including
reserve
20 L
(5.3/4.4 US/lmp gal)
5.0 L
Reserve only
(1.3/1.1 US/lmp gal)
SAE 10W-40, API, SF or SG
3 300 ml
Change
(3.5/2.9 US/lmp qt)
3 500 ml
Filter change
(3.7/3.1 US/lmp qt)
4 700 ml
Overhaul
(5.0/4.1 US/lmp qt)
Fork oil #10
499 ml
(16.9/17.6 US/lmp oz)
DOT 4
9/9
STD/SPEC.
Axial
—
A
S
FUEL + OIL
Fuel type
Wheel rim size
—
—
14.000
(0.5512
12.700
(0.5000
13.957
(0.5495
12.657
(0.4983
30.230
(1.1902
38.180
(1.5031
30.150
(1.1870
38.098
(1.5000
Wheel axle runout
Unit: mm (in)
LIMIT
STD/SPEC.
ITEM
Wheel rim runout
NOTE
E-03, 28, 33
The other
countries
E-33
The other
countries
E-02, 03, 19, 28, 33
8/9
E-02, 03, 19, 28, 33
50
GSX750F
VALVE + GUIDE
ITEM
Valve diameter
STANDARD
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide-to-valve stem
clearance
IN.
EX.
27
(1.1)
24
(0.9)
0.10 – 0.15
(0.004 – 0.006)
0.18 – 0.23
(0.007 – 0.009)
0.020 – 0.047
(0.0008 – 0.0019)
0.040 – 0.067
(0.0016 – 0.0026)
Unit: mm (in)
LIMIT
—
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
Cam chain pin (at arrow “3”)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
0.35
(0.014)
IN. & EX.
—
EX.
5.000 – 5.012
(0.1969 – 0.1973)
4.965 – 4.980
(0.1955 – 0.1961)
4.945 – 4.960
(0.1947 – 0.1953)
Valve stem runout
IN. & EX.
—
Valve face thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.3
(0.09)
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
0.03
(0.001)
33.9
(1.33)
37.3
(1.47)
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
INNER
—
OUTER
—
6.0 – 6.8 kgf
(13.2 – 15.0 lbs)
at length 28 mm (1.10 in)
15.4 – 17.8 kgf
(34.0 – 39.2 lbs)
at length 31.5 mm (1.24 in)
INNER
OUTER
32.66
(1.2858
32.65
(1.2854
0.032
(0.0013
22.012
(0.8666
21.959
(0.8645
EX.
IN. & EX.
24th pin
12.000
(0.4724
11.973
(0.4714
Cylinder head distortion
2nd
Oil
Piston ring thickness
1st
ITEM
Compression pressure
2nd
Piston pim bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust clearance
Crankshaft jounal width
STANDARD
18.010 – 18.018
(0.7091 – 0.7094)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
33.976 – 34.000
(1.3376 – 1.3386)
0.020 – 0.044
(0.0008 – 0.0017)
31.976 – 32.000
(1.2589 – 1.2598)
0.06 – 0.11
(0.002 – 0.004)
24.00 – 24.05
(0.945 – 0.947)
Crankshaft runout
—
STD/SPEC.
1.898 (75/43 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi)
at 3 000 r/min
3/9
—
0.20
(0.008)
Piston-to-cylinder clearance
Cylinder bore
Piston diameter
—
0.055 – 0.065
(0.0022 – 0.0026)
70.000 – 70.015
(2.7559 – 2.7565)
69.940 – 69.955
(2.7535 – 2.7541)
Measure at 15 mm (0.6) from the skirt end.
—
—
Piston ring free end gap
—
LIMIT
—
—
1st
R
Approx. 7.0 (0.28)
2nd
RN
Approx. 10.5 (0.41)
0.10
(0.004
0.25
(0.010
1st
E
L
—
1st
—
—
2/9
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
3.42 – 3.58
(0.135 – 0.141)
15.9 – 16.0
(0.626 – 0.630)
No. 1
No. 2
—
Clutch drive plate claw width
18.030
(0.7098)
17.980
(0.7079)
Clutch drive plate distortion
—
Clutch spring free length
—
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
TRANSMISSION + DRIVE CHAIN
—
0.080
(0.0031)
—
0.080
(0.0031)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
1st (low)
2nd
3rd
4th
5th
6th (top)
Gearshift fork-to-gearshift fork
groove clearance
Gearshift fork groove width
STD/SPEC.
1.744 (75/43)
3.000 (45/15)
3.083 (37/12)
2.062 (33/16)
1.647 (28/17)
1.400 (28/20)
1.227 (27/22)
1.095 (23/21)
0.1 – 0.3
(0.004 – 0.012)
4.8 – 4.9
(0.189 – 0.193)
5.0 – 5.1
(0.197 – 0.201)
4.6 – 4.7
(0.181 – 0.185)
4.8 – 4.9
(0.189 – 0.193)
RK50SMOZ1
116 links
No. 1, No. 2
& No. 3
No. 1 &
No. 3
No. 2
—
—
No. 1 &
No. 2
Gearshift fork thickness
No. 1 &
No. 3
No. 2
—
0.05
(0.002)
Drive chain
LIMIT
—
Drive chain slack
Type
Links
20-pitch
length
—
20 – 30
(0.79 – 1.18)
55
(2.17)
Gearshift lever height
—
E-02, 03, 19, 24, 28, 33
P-37
4/9
—
70.075
(2.7589)
69.880
(2.7512)
0.20
(0.008)
5.6
(0.22)
8.4
(0.33)
0.5
(0.02)
0.7
(0.03)
0.180
(0.007)
0.150
(0.006)
E-02, 03, 19, 24, 28, 33
P-37
CLUTCH
—
—
– 0.25
– 0.010)
– 0.40
– 0.016)
2nd
P
M
Clutch release screw
Clutch drive plate thickness
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
200 kPa
(2 kgf/cm2, 28 psi)
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
Compression pressure difference
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
—
STANDARD
Cylinder distortion
A
S
1.01 – 1.04
(0.040 – 0.041)
1.004 – 1.027
(0.0395 – 0.0404)
1.51 – 1.53
(0.059 – 0.060)
0.97 – 0.99
(0.038 – 0.039)
0.97 – 0.99
(0.038 – 0.039)
18.002 – 18.008
(0.7087 – 0.7090)
17.992 – 18.000
(0.7083 – 0.7086)
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
E-02, 03, 19, 24, 28, 33
P-37
STANDARD
—
0.10
(0.004)
—
—
2nd
1st
—
—
Piston ring-to-piston ring groove
clearance
ITEM
Piston ring groove width
– 32.71
– 1.2878)
– 32.70
– 1.2874)
– 0.066
– 0.0026)
– 22.025
– 0.8671)
– 21.980
– 0.8654)
—
—
Piston ring end gap
1/9
Unit: mm (in)
LIMIT
32.36
(1.2740)
32.35
(1.2736)
0.150
(0.0059)
STANDARD
IN.
—
Valve guide I.D.
IN.
ITEM
Cam height
—
Valve stem deflection
Valve stem O.D.
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
—
319.4
(12.57)
—
—
E-02, 03, 19, 24, 28, 33
P-37
51
CABURETOR
ELECTRICAL
Caburetor type
Bore size
I.D. No.
Engine idle speed
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
ITEM
SPECIFICATION
ITEM
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Throttle cable play (pulling cable)
Starter (enricher) plunger cable
play
E-24
MIKUNI BSR36
36 mm
08F0
1 200 ± 100 r/min
13.0 ± 0.5 mm
(0.51 ± 0.02 in)
#117.5
5DF20-52-3
P-0
#100
#15
No.1&4: 2 turns back
No. 2&3 : 1 and 1/2 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
E-02, 19
←
←
08F6
←
Firing order
Spark plug
Gap
←
5DF25-3
P-0M
←
#12.5
Ignition coil primary peak voltage
Generator
3 and 1/2 turns back
←
Caburetor type
Bore size
Engine idle speed
Idle r/min
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th.V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
Throttle cable play (pulling cable)
E-33
←
←
08F4
←
←
#100
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
Starter (enricher) plunger cable
play
HI
LO
60 × 2
55 × 2
5
21/5 × 2
21 × 4
1.7 × 2
1.7
1.7
5
1.4 × 2
1.4
1.4
1.4
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Fuel meter light
License plate light
Turn signal indicator light
High beam indicator light
Neutral position indicator light
Oil pressure indicator light
A
S
55
55
←
←
←
←
←
←
←
←
←
←
←
ITEM
Rear brake pedal height
STD/SPEC.
55
(2.17)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
Brake disc runout
Master cylinder bore
—
14.000
(0.5512
12.700
(0.5000
13.957
(0.5495
12.657
(0.4983
30.230
(1.1902
38.180
(1.5031
30.150
(1.1870
38.098
(1.5000
Front
Rear
Master cylinder piston diameter
1.320 at 20 °C (68 °F)
15
10
15
10
10
15
10
30
A
A
A
A
A
A
A
A
E-03, 24, 28, 33
Others
E-03, 24, 28, 33
Others
P
M
Axial
—
Radial
—
Wheel axle runout
Front
—
ITEM
Wheel rim runout
Wheel rim size
Tire size
Tire tread depth
6/9
E-02, 03, 19, 24, 28, 33
P-37
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
STD/SPEC.
Rear
—
Front
Rear
Front
Rear
17M/C × MT 3.50
17M/C × MT 4.50
120/70 ZR17 M/C (58 W)
150/70 ZR17 M/C (69 W)
Front
—
Rear
—
SUSPENSION
BRAKE + WHEEL
Brake disc thickness
Approx. 550 W at 5 000 r/min
13.6 – 14.4 V at 5 000 r/min
3–6Ω
YTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
E
L
E-02, 03, 19, 24, 28, 33
P-37
Unit: W
Headlight
DENSO
Limit: 4.5 (0.18)
←
SPECIFICATION
E-03, 24, 28, 33
The other countries
ITEM
Limit: 14.0 (0.55)
←
5/9
WATTAGE
More than 140 V
Ignition
Turn signal
Meter
Main
←
5DF22-53
←
←
←
←
tap – tap
Spark plug cap –
Spark plug cap
Approx. 30 – 40 kΩ
Slip ring
O.D.
Brush
length
Generator maximaum output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuse size
HI
Headlight
LO
←
SPECIFICATION
E-03, 28
MIKUNI BSR36
36 mm
08F3
1 200 ± 100 r/min
13.0 ± 0.5 mm
(0.51 ± 0.02 in)
#
5DF21-53
Primary
Secondary
CABURETOR
ITEM
1·2·4·3
NGK: CR9EK
DENSO: U27ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Approx. 135 – 200 Ω
More than 1.0 V
Approx. 2 – 4 kΩ
Type
Spark performance
Pickup coil resistance
Signal generator peak voltage
Ignition coil resistance
←
Unit: mm (in)
NOTE
SPECIFICATION
Front
Rear
Brake caliper cylinder bore
Front
Brake caliper piston diameter
Front
Rear
Rear
– 14.043
– 0.5529)
– 12.743
– 0.5017)
– 13.984
– 0.5506)
– 12.684
– 0.4994)
– 30.306
– 1.1931)
– 38.256
– 1.5061)
– 30.200
– 1.1890)
– 38.148
– 1.5019)
Unit: mm (in)
LIMIT
—
4.0
(0.16)
4.5
(0.18)
0.30
(0.012)
—
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork damping force adjuster
Rear shock absorber gas pressure
(N2 gas)
Rear shock absorber damping
force adjuster
—
359
(14.13)
—
—
—
—
—
Rear wheel travel
—
Swingarm pivot shaft runout
E-03, 33
The other
countries
—
At punch mark
(About 1 and 3/4
turns out)
158.5
(6.24)
160
(6.30)
142
(5.6)
—
Unit: mm (in)
NOTE
—
Rebound
3/4
1 000 kPa
(10 kgf/cm2, 142 psi)
1/4
Rebound
2/4
Rear shock absorber spring set
length
—
—
E-03, 33
—
The other
countries
—
0.3
(0.01)
—
—
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
7/9
LIMIT
130
(5.1)
367
(14.45)
102
(4.0)
Compression
—
—
STD/SPEC.
E-02, 03, 19, 24, 28, 33
P-37
kPa
225
250
SOLO RIDING
kgf/cm2
2.25
2.50
8/9
psi
33
36
kPa
225
250
DUAL RIDING
kgf/cm2
2.25
2.50
psi
33
36
E-02, 03, 19, 24, 28, 33
P-37
52
FUEL + OILs
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
Fuel fork oil type
Front fork oil capacity (each leg)
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octone or
higher. An unleaded gasoline is recommended.
18.5 L
(4.9/4.1 US/lmp gal)
Including
reserve
20.0 L
(5.3/4.4 US/lmp gal)
5.0 L
Reserve only
(1.3/1.1 US/lmp gal)
SAE 10W-40, API, SF or SG
3 300 ml
Oil change
(3.5/2.9 US/lmp qt)
Oil and filter
3 500 ml
change
(3.7/3.1 US/lmp qt)
Engine
4 700 ml
overhaul
(5.0/4.1 US/lmp qt)
Fork oil #10
513 ml
(17.3/18.1 US/lmp oz)
DOT 4
9/9
NOTE
E-03, 28, 33
The other
countries
E-33
The other
countries
A
S
ITEM
Valve diam.
33
(1.30)
27.5
(1.08)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.490
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
Unit: mm (in)
LIMIT
STD/SPEC.
IN.
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
P
M
E-02, 03, 19, 24, 28, 33
P-37
GSX1300R/RZ/RUD/RUF
VALVE + GUIDE
E
L
—
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
—
EX.
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
—
0.10
(0.004)
—
0.20
(0.008)
—
15th pin
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
ITEM
Compression pressure
—
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Cylinder bore
Valve head radial runout
IN. & EX.
—
Piston diam.
Valve spring free length
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
35.1
(1.38)
45.2
(1.77)
3.1 – 3.5 kgf
(6.83 – 7.72 lbs)
at length 33.1 mm (1.30 in)
15.5 – 17.9 kgf
(34.17 – 39.46 lbs)
at length 36.6 mm (1.44 in)
Piston to cylinder clearance
1 200 – 1 600 kPa
(12 – 16 kgf/cm2, 17 – 228 psi)
—
0.020 – 0.030
(0.0008 – 0.0012)
81.000 – 81.015
(3.1890 – 3.1896)
80.975 – 80.990
(3.1880 – 3.1886)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
—
—
STD/SPEC.
Compression pressure difference
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
—
1st
R
Approx. 7.3 (0.29)
2nd
RN
Approx. 11.4 (0.45)
1st
R
2nd
RN
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.08)
1st
—
2nd
—
1st
1.21 – 1.23
(0.0476 – 0.0484)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
2nd
Oil
1/9
—
CYLINDER + PISTON + PISTON RING
IN. & EX.
OUTER
– 36.848
– 1.4506)
– 35.548
– 1.3995)
– 0.066
– 0.0026)
– 24.025
– 0.9459)
– 23.980
– 0.9441)
—
Valve stem runout
INNER
36.780
(1.4480
35.480
(1.3968
0.032
(0.0013
24.012
(0.9454
23.959
(0.9433
IN.
—
Valve stem deflection
Valve spring tension
(IN. & EX.)
Unit: mm (in)
LIMIT
36.48
(1.436)
35.18
(1.385)
0.150
(0.0059)
STD/SPEC.
E-02, 03, 19, 24, 28, 33, P-37
E-19
2/9
Unit: mm (in)
LIMIT
900 kPa
(9 kgf/cm2 , 128 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
Nicks or
Scratches
80.880
(3.1842)
0.20
(0.008)
5.8
(0.23)
9.1
(0.36)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
E-02, 03, 19, 24, 28, 33, P-37
E-19
53
ITEM
Piston ring thickness
STD/SPEC.
1.17 – 1.19
(0.0461 – 0.0469)
0.97 – 0.99
(0.0382 – 0.0390)
20.002 – 20.008
(0.7857 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
1st
2nd
Piston pin bore
Piston pin O.D.
LIMIT
—
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing
thickness
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
STD/SPEC.
Right side
Left side
Crankshaft thrust clearance
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
20.95 – 21.00
(0.825 – 0.827)
21.10 – 21.15
(0.831 – 0.833)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4960)
0.016 – 0.040
(0.0006 – 0.0016)
39.976 – 40.000
(1.5734 – 1.5748)
2.425 – 2.450
(0.0955 – 0.0965)
2.350 – 2.500
(0.0925 – 0.0984)
0.055 – 0.110
(0.0022 – 0.0043)
Crankshaft runout
—
—
ITEM
Oil pressure (at 60°C, 140°F)
Shift fork groove width
—
Shift fork thickness
—
Drive chain
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
13.85 – 13.96
(0.542 – 0.550)
13.90 – 14.00
(0.547 – 0.551)
No. 1
No. 1
No. 2
3/9
LIMIT
ITEM
Thermostat valve opening
temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening preessure
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
Type
Links
20-pitch
length
P
M
A
S
—
—
ITEM
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
Heated oxygen sensor output voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
VCSV resistance
Intake air control valve operating
rpm
—
THROTTLE BODY
STD/SPEC.
LIMIT
—
Over 8 mm (0.31 in) at 95 °C (203 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
50 °C
Approx.
0.811 kΩ
(122 °F)
80 °C
Approx.
0.318
kΩ
(176 °F)
110 °C
Approx.
0.142
kΩ
(230 °F)
130 °C
Approx. 0.088 kΩ
(226 °F)
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
OFF→ON
Approx. 105 °C (221 °F)
ON→OFF
Approx. 100 °C (212 °F)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reserve
Approx. 250 ml (0.3/0.2 US/lmp qt)
tank side
Engine side Approx. 2 700 ml (2.9/2.4 US/lmp qt)
—
—
—
—
—
—
—
—
—
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.57)
—
E
L
E-02, 03, 19, 24, 28, 33, P-37
E-19
Approx. 82 °C (179.6 °F)
—
20 – 30
(0.79 – 1.18)
50 – 60
(1.97 – 2.36)
—
THERMOSTAT + RADIATOR + FAN + COOLANT
—
STD/SPEC.
1.596 (83/52)
2.352 (40/17)
2.615 (34/13)
1.937 (31/16)
1.526 (29/19)
1.285 (27/21)
1.136 (25/22)
1.043 (24/23)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK GB50GSVZ3
112 links
Gearshift lever height
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
STD/SPEC.
No. 2
Drive plate claw width
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Drive chain slack (on side-stand)
STD/SPEC.
Above 200 kPa (2.0 kgf/cm2, 43 psi)
Below 500 kPa (5.0 kgf/cm2, 71 psi)
at 3 000 r/min
—
DRIVE TRAIN
0.05
(0.002)
CLUTCH
ITEM
Drive plate thickness
Clutch release cylinder piston
diam.
Clutch fluid type
—
OIL PUMP
28.96
(1.140)
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
Brake fluid DOT 4
Clutch master cylinder piston
diam.
Clutch release cylinder bore
—
—
0.080
(0.0031)
LIMIT
0.10
(0.004)
27.6
(1.09)
—
Clutch master cylinder bore
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
0.080
(0.0031)
—
STD/SPEC.
Clutch spring free hength
—
20.030
(0.7886)
19.980
(0.7866)
CONROD + CRANKSHAFT
ITEM
Driven plate distortion
4/9
—
—
E-02, 03, 19, 24, 28, 33, P-37
E-19
STD/SPEC.
4.5 – 5.5 V
2.2 – 2.7 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 100 kPa (760 mmHg)
60 – 64 kΩ
Approx. 2.5 V
More than 0.6 V (From 1st to top without neutral)
Battery voltage
More than 80 V (When cranking)
NOTE
Iess than 0.4 V at 1 150 rpm (After warming up)
For E-02,19
4 – 5 kΩ at 23 °C (73.4 °F)
16 – 24 kΩ at 20 °C (68 °F)
36 – 44 Ω
Opening
Above 2 500 rpm
Closing
Below 2 200 rpm
ITEM
Fast idle r/min
Idle r/min
Throttle cable play
STD/SPEC.
3 500 r/min (After warming up)
1 150 ± 100 r/min
2.0 – 4.0 mm
(0.08 – 0.16 in)
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
STD/SPEC.
11 – 16 Ω at 20 °C (68 °F)
Approx. 1 200 ml (1.3/1.1 US/Imp oz) /30 sec.
at 300 kPa (3.0 kgf/cm2, 43 psi)
NOTE
—
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
—
—
ELECTRICAL
ITEM
Firing order
Spark plug
1·2·4·3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
180 – 280 Ω
More than 3 V
Type
Gap
FI SENSORS + INTAKE AIR CONTROL VALVE
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
STD/SPEC.
0.9 – 1.3 kΩ
More than 0.7 V
180 – 280 Ω
More than 3 V
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.3 kΩ
Opened
Approx. 4.5 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
2.3 – 2.6 kΩ at 20 °C (68 °F)
5/9
NOTE
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
1.0 – 1.6 Ω
Primary
Secondary
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When cold)
Regulated voltage
Starter relay resistance
E-02, 03, 19, 24, 28, 33, P-37
E-19
Unit: mm (in)
NOTE
STD/SPEC.
10 – 16.5 kΩ
G – BI
Terminal –
Terminal
Plug cap –
Terminal
More than 80 V
0.2 – 0.4 Ω
Approx. 400 W at 5 00 r/min
More than 65 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–5Ω
6/9
E-02, 03, 19, 24, 28, 33, P-37
E-19
54
ITEM
Battery
Fuse size
NOTE
STD/SPEC.
Type
designation
Capacity
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
ITEM
Master cylinder piston diam.
YT12A-BS
12 V 36 kC (10 Ah)/10 HR
15 A
15 A
15 A
15 A
10 A
10 A
30 A
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
WATTAGE
Unit: W
STD/SPEC.
ITEM
Headlight
E-03, 24, 28, 33
65 + 55W
55 W
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Tachometer light
Speedometer light
Fuel meter light
Engine coolant temp. meter light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure indicator light
FI indicator light
Fuel level indicator light
Engine coolant temp. indicator light
21/5 W × 2
21 W × 4
5W
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
LED
BRAKE + WHEEL
55 – 65
(2.2 – 2.6)
4.8 – 5.2
(0.189 – 0.205)
4.8 – 5.2
(0.189 – 0.205)
Front
Brake disc runout
15.870 –
(0.6248 –
12.700 –
(0.5000 –
Front
Rear
7/9
Front fork spring free length
Front fork oil level (without spring,
outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Front fork damping force
adjuster
Rear shock absorber spring
pre-set length
Rear shock absorber damping
force adjuster
Rear wheel travel
15.913
0.6265)
12.743
0.5017)
Fuel tank capacity
Engine oil type
Engine oil capacity
Front
Rear
17 M/C × MT 3.50
17 M/C × MT 6.00
Wheel axle runout
Front
—
Rear
—
Front
Tire size
Front
Rear
Front
Rear
A
S
Tire type
E
L
Tire tread depth
(Recommended depth)
P
M
Unit: mm (in)
LIMIT
—
240
(9.4)
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
—
STD/SPEC.
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
19 L
(50/4.2 US/lmp gal)
Including
reserve
21L
(5.5/4.6 US/lmp gal)
SAE 10W-40, API SF or SG
3.1 L
Change
(3.3/2.7 US/lmp qt)
3.3 L
Filter change
(3.5/2.9 US/lmp qt)
4.0 L
Overhaul
(4.2/3.5 US/lmp qt)
9/9
Rear
—
120
(4.7)
245.1
(9.65)
98
(3.9)
SUZUKI FORK OIL L01 or an equivalent fork oil
480 ml
(16.2/16.9 US/Imp oz)
5th groove from top
Rebound
3 turns back
Compression
9 turns back
183
(7.20)
Rebound
11 turns back
Compression
8 turns back
140
(5.5)
290 kPa
(2.90 kgf/cm2, 42 psi)
290 kPa
(2.90 kgf/cm2, 42 psi)
290 kPa
(2.90 kgf/cm2, 42 psi)
290 kPa
(2.90 kgf/cm2, 42 psi)
120/70ZR17M/C (58W)
190/50ZR17M/C (73W)
BRIDGESTONE: BT56F J
BRIDGESTONE: BT56R J
Front
NOTE
E-03, 28, 33
The others
E-33
The others
E-02, 03, 19, 24, 28, 33, P-37
E-19
Front
—
Rear
—
8/9
—
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
Unit: mm (in)
LIMIT
STD/SPEC.
Cold inflation tire pressure
(Dual riding)
—
FUEL + OIL
ITEM
Wheel rim size
Rear
4.5
(0.177)
4.5
(0.177)
0.30
(0.012)
STD/SPEC.
Swingarm pivot shaft runout
Fuel type
—
—
ITEM
Cold inflation tire pressure
(Solo riding)
E-02, 03, 19, 24, 28, 33, P-37
E-19
SUSPENSION
ITEM
Front fork stroke
Axial
Radial
—
—
15.827 – 15.854
(0.6231 – 0.6242)
12.657 – 12.684
(0.4983 – 0.4994)
24.000 – 24.076
Leading
(0.9449 – 0.9479)
27.000 – 27.076
Trailing
(1.0630 – 1.0660)
38.180 – 38.256
(1.5031 – 1.5061)
23.925 – 23.975
Leading
(0.9419 – 0.9439)
26.920 – 26.970
Trailing
(1.0598 – 1.0618)
38.098 – 38.148
(1.4999 – 1.5019)
DOT 4
TIRE
LIMIT
STD/SPEC.
Rear
Master cylinder bore
Brake fluid type
Wheel rim runout
Unit: mm (in)
ITEM
Rear brake pedal height
Brake disc thickness
Rear
The other countries
←
←
5W
←
←
←
←
←
←
←
←
←
←
←
←
←
←
LIMIT
STD/SPEC.
Front
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
E-02, 03, 19, 24, 28, 33, P-37
E-19
55
GSX1400/UD
VALVE + GUIDE
ITEM
STD/SPEC.
Valve diam.
Unit: mm (in)
LIMIT
EX.
28.5
(1.12)
25
(0.98)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1772 – 0.1776)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
INNER
—
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
Valve head thickness
Valve spring free length
(IN. & EX.)
OUTER
Valve spring tension
(IN. & EX.)
—
49 – 59 N
(4.9 – 5.9 kgf, 10.8 – 13.0 lbs)
at length 29.9 mm (1.18 in)
136 – 156 N
(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)
at length 33.4 mm (1.31 in)
INNER
OUTER
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
—
35.28
(1.389
34.18
(1.346
0.032
(0.0013
24.012
(0.9454
23.959
(0.9433
IN.
—
EX.
—
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
24th pin
—
ITEM
Compression pressure
STD/SPEC.
1 180 kPa
(11.8 kgf/cm2, 168 psi)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
0.015 – 0.025
(0.0006 – 0.0010)
81.000 – 81.015
(3.1890 – 3.1896)
80.980 – 80.995
(3.1881 – 3.1888)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
—
Piston ring free end gap
1st
N
Approx. 9.5 (0.37)
2nd
2N
Approx. 11.0 (0.43)
1st
N
2nd
2N
—
Piston ring end gap
—
0.08
(0.003
0.18
(0.007
1st
—
E
L
1.21 – 1.23
(0.0476 – 0.0484)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
1st
Oil
A
S
1.175 – 1.190
(0.0463 – 0.0469)
0.970 – 0.990
(0.0382 – 0.0390)
18.002 – 18.008
(0.7087 – 0.7090)
17.996 – 18.000
(0.7085 – 0.7087)
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STD/SPEC.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing
thickness
Right side
Left side
Crankshaft thrust clearance
18.010 – 18.018
(0.7091 – 0.7094)
0.10 – 0.20
(0.004 – 0.008)
20.950 – 21.000
(0.8248 – 0.8268)
21.100 – 21.150
(0.8307 – 0.8327)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4961)
0.016 – 0.040
(0.0006 – 0.0016)
39.976 – 40.000
(1.5734 – 1.5748)
2.425 – 2.450
(0.0955 – 0.0965)
2.430 – 2.585
(0.0957 – 0.1018)
0.055 – 0.110
(0.0022 – 0.0043)
Crankshaft runout
P
M
E-02, 19, 24
E-19
—
LIMIT
—
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.012)
—
2/9
ITEM
Drive plate thickness
Drive plate claw width
STD/SPEC.
No. 1, 2
and 3
No. 1, 2
and 3
3.22 – 3.38
(0.127 – 0.133)
13.7 – 13.8
(0.5394 – 0.5433)
Driven plate distortion
—
Clutch spring free length
28.96
(1.140)
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
Brake fluid DOT 4
Clutch master cylinder bore
Clutch master cylinder piston
diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
Clutch fluid type
—
0.080
(0.0031)
—
—
—
—
0.05
(0.002)
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STD/SPEC.
1.509 (83/55)
2.277 (41/18)
2.916 (35/12)
1.937 (31/16)
1.526 (29/19)
1.285 (27/21)
1.136 (25/22)
1.000 (24/24)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RKGB50GSVZ3
116 links
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
LIMIT
Drive chain
—
Type
Links
20-pitch
length
—
Drive chain slack (on side-stand)
20 – 30
(0.79 – 1.18)
30 – 40
(1.2 – 1.6)
Gearshift lever height
3/9
80.880
(3.1842)
0.20
(0.008)
7.6
(0.30)
8.8
(0.35)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
Unit: mm (in)
LIMIT
2.92
(0.115)
12.9
(0.5079)
0.10
(0.004)
27.6
(1.087)
—
—
—
—
—
—
0.080
(0.0031)
OIL PUMP
STD/SPEC.
300 – 600 kPa
(3.0 – 6.0 kgf/cm2, 43 – 85 psi)
at 3 000 r/min
Unit: mm (in)
LIMIT
880 kPa
(8.8 kgf/cm2 , 125 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
Nicks or
Scratches
E-02, 19, 24
E-19
CLUTCH
Shift fork thickness
ITEM
Oil pressure (at 60°C, 140°F)
– 0.20
– 0.008)
– 0.30
– 0.012)
—
2nd
STD/SPEC.
—
0.10
(0.004)
—
0.20
(0.008)
CYLINDER + PISTON + PISTON RING
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
Piston ring groove width
1st
—
—
2nd
ITEM
Piston ring thickness
– 35.33
– 1.391)
– 34.22
– 1.347)
– 0.066
– 0.0026)
– 24.025
– 0.9459)
– 23.980
– 0.9441)
—
Piston ring to groove clearance
1/9
Unit: mm (in)
LIMIT
34.98
(1.377)
33.88
(1.334)
0.150
(0.0059)
STD/SPEC.
E-02, 19, 24
E-19
4/9
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.57)
—
—
E-02, 19, 24
E-19
56
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
ELECTRICAL
NOTE
STD/SPEC.
ITEM
12 – 18 Ω at 20 °C (68 °F)
Approx. 1.2 L (1.3/1.1 US/Imp qt) /30 sec.
Firing order
Spark plug
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
NOTE
STD/SPEC.
More than 3.7 V
134 – 202 Ω
More than 2.7 V
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.3 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 61.3 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
TP sensor output voltage
EOT sensor input voltage
EOT sensor resistance
IAT sensor input voltage
IAT sensor resistance
Approx. 2.6 kΩ at 20 °C (68 °F)
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
W–W
Terminal –
Terminal
Generator coil resistance
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
34 mm
42F0
1 100 ± 100 r/min
1 500 – 1 700 r/min (When engine is cold)
2.0 – 4.0 mm
(0.08 – 0.16 in)
P
M
E-02, 19, 24
E-19
A
S
WATTAGE
Unit: W
ITEM
STD/SPEC.
60 W
HI
LO
55 W
5 W (Except for E-24)
21/5 W × 2
21 W × 4
LED
LED
LED
LED
LED
LED
LED
Parking or position light
Brake light/Taillight
Turn signal light
Speedometer light
Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
FI indicator light
Oil pressure indicator light
BRAKE + WHEEL
Brake disc thickness
STD/SPEC.
35 – 45
(1.4 – 1.8)
4.8 – 5.2
(0.189 – 0.205)
5.3 – 5.7
(0.209 – 0.224)
Front
Rear
Brake disc runout
Master cylinder bore
—
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
ITEM
Wheel rim runout
15.870 – 15.913
(0.6248 – 0.6265)
12.700 – 12.743
(0.5000 – 0.5017)
15.827 – 15.854
(0.6231 – 0.6242)
12.657 – 12.684
(0.4983 – 0.4994)
24.000 – 24.076
Leading
(0.9449 – 0.9479)
27.000 – 27.076
Trailing
(1.0630 – 1.0660)
38.180 – 38.230
(1.5031 – 1.5051)
23.925 – 23.975
Leading
(0.9419 – 0.9439)
26.920 – 26.970
Trailing
(1.0598 – 1.0618)
38.115 – 38.148
(1.5006 – 1.5019)
DOT 4
7/9
25 – 40 kΩ
14.0 – 15.5 V at 5 000 r/min
3–5Ω
More than 0.6 V (From 1st to top without neutral)
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
10 A
10 A
15 A
10 A
10 A
10 A
30 A
6/9
E-02, 19, 24
E-19
STD/SPEC.
Axial
—
—
Front
Rear
17 M/C × MT 3.50
17 M/C × MT 6.00
Wheel axle runout
Front
—
Rear
—
TIRE
LIMIT
—
4.5
(0.177)
5.0
(0.197)
0.30
(0.012)
—
—
STD/SPEC.
Front
Rear
Front
Rear
250 kPa
(2.50 kgf/cm2, 36 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
290 kPa
(2.90 kgf/cm2, 42 psi)
120/70ZR17M/C (58 W)
190/50ZR17M/C (73 W)
BRIDGESTONE: BT020F F
BRIDGESTONE: BT020R
Front
—
Rear
—
Front
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
Tire type
Tire tread depth
(Recommended depth)
: Y : Bl
Terminal –
Terminal
Plug cap –
Plug cap
W/Bl
No. 1 & 4 :
: O/W
:
No. 2 & 3 : B
O/W
0.2 – 1.0 Ω
Radial
ITEM
Cold inflation tire pressure
(Solo riding)
Unit: mm (in)
NOTE
More than 60 V (AC) at 5 000 r/min
Wheel rim size
Unit: mm (in)
ITEM
Rear brake pedal height
Secondary
E
L
STD/SPEC.
5/9
2–4Ω
More than 150 V
4.5 – 5.5 V
Approx. 4.0 V at 100 kPa (760 mmHg)
60 – 64 kΩ
Approx. 3.8 V
More than 0.6 V (From 1st to Top)
Battery voltage
More than 150 V (When cranking)
4.5 – 5.5 V
Closed
Approx. 0.8 kΩ
Opened
Approx. 3.9 kΩ
Closed
Approx. 0.8 V
Opened
Approx. 4.0 V
Approx. 4.8 – 7.2 Ω
ITEM
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
Primary
Ignition coil primary peak voltage
THROTTLE BODY
Headlight
1·2·4·3
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
134 – 202 Ω
More than 2.7 V
Type
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR
ITEM
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
STD/SPEC.
LIMIT
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
Unit: mm (in)
LIMIT
—
—
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
—
—
—
—
—
—
—
—
—
E-02, 19, 24
E-19
8/9
E-02, 19, 24
E-19
57
SUSPENSION
ITEM
Front fork stroke
Unit: mm (in)
LIMIT
STD/SPEC.
Front fork spring adjuster
Front fork damping force
adjuster
130
(5.12)
322.6
(12.70)
108
(4.25)
SUZUKI FORK OIL L01 or an equivalent fork oil
644 ml
(21.76/22.68 US/Imp oz)
5th groove from top
Rebound
8 clicks out from stiffest position
Compression 7 clicks out from stiffest position
Rear shock absorber spring
adjuster
Rear shock absorber damping
force adjuster
Rebound
Compression
Front fork spring free length
Front fork oil level (without spring,
outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
1.5
Swingarm pivot shaft runout
—
—
—
—
—
—
—
—
—
2
Rear wheel travel
—
316
(12.44)
123
(4.8)
—
—
0.3
(0.01)
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
STD/SPEC.
Gasoline used should be graded 95 octane or
higher. An unleaded gasoline is recommended.
Including
22 L
reserve
(5.8/4.8 US/lmp gal)
SAE 10W-40, API, SF or SG
4 200 ml
Change
(4.4/3.7 US/lmp qt)
4 800 ml
Filter change
(5.1/4.2 US/lmp qt)
5
700 ml
Overhaul
(6.0/5.0 US/lmp qt)
9/9
GSX-R600/UE/UF
ITEM
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
P
M
Unit: mm (in)
LIMIT
STANDARD
27.2
(1.07)
22.0
(0.87)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1772 – 0.1776)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
IN.
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
—
Cam height
IN.
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
—
0.10
(0.004)
—
0.20
(0.008)
—
12th pin
—
—
—
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN.
—
EX.
—
0.03
(0.001)
36.2
(1.43)
36.0
(1.42)
155 – 179 N
(15.8 – 18.3 kgf, 34.8 – 40.3 lbs)
at length 32.55 mm (1.28 in)
146 – 168 N
(14.9 – 17.1 kgf, 32.8 – 37.7 lbs)
at length 32.55 mm (1.28 in)
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
STANDARD
1 100 – 1 500 kPa
(11 – 15 kgf/cm², 156 – 213 psi)
Compression pressure
difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
0.025 – 0.035
(0.0010 – 0.0014)
67.000 – 67.015
(2.6378 – 2.6384)
66.985 – 66.970
(2.6372 – 2.6366)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
—
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
—
1st
T
Approx 5.5 (0.22)
2nd
T
Approx 10.0 (0.39)
1st
T
2nd
T
0.06 – 0.21
(0.002 – 0.008)
0.06 – 0.18
(0.002 – 0.007)
1st
—
2nd
—
1st
1.01 – 1.03
(0.0398 – 0.0406)
0.81 – 0.83
(0.0319 – 0.0327)
1.51 – 1.53
(0.0594 – 0.0602)
2nd
Oil
1/10
Unit: mm (in)
LIMIT
36.28
(1.428)
34.98
(1.377)
0.150
(0.0059)
STANDARD
36.58 – 36.63
(1.440 – 1.442)
35.28 – 35.33
(1.389 – 1.391)
0.032 – 0.066
(0.0013 – 0.0026)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
EX.
Camshaft journal oil clearance
IN. & EX.
EX.
ITEM
—
Valve seat width
IN.
CAMSHAFT + CYLINDER HEAD
—
0.25
(0.001)
0.05
(0.002)
0.5
(0.02)
Valve spring tension
E
L
E-02, 19, 24
E-19
A
S
VALVE + VALVE GUIDE
Valve diam.
NOTE
E-02, 03, 19, 24, 28, 33
E-19
E-19
2/10
Unit: mm (in)
LIMIT
900 kPa
(9 kgf/cm²,
128 psi)
200 kPa
(2 kgf/cm²,
28 psi)
0.120
(0.0047)
Nicks or
Scratches
66.880
(2.6331)
0.02
(0.008)
4.4
(0.17)
8.0
(0.31)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
E-02, 03, 19, 24, 28, 33
E-19
E-19
58
ITEM
Piston ring thickness
STANDARD
0.97 – 0.99
(0.0382 – 0.0390)
0.77 – 0.79
(0.0303 – 0.0311)
14.002 – 14.008
(0.5513 – 0.5515)
13.995 – 14.000
(0.5510 – 0.5512)
1st
2nd
Piston pin bore I.D.
Piston pin O.D.
LIMIT
CLUTCH
ITEM
Clutch lever play
—
—
14.030
(0.5524)
13.980
(0.5504)
Clutch release screw
Drive plate thickness
No. 1, 2 and 3
Drive plate claw width
No. 1, 2 and 3
Driven plate distortion
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Unit: mm (in)
LIMIT
14.040
(0.5528)
0.30
(0.012)
STANDARD
14.010 – 14.018
(0.5516 – 0.5519)
0.10 – 0.15
(0.004 – 0.006)
19.95 – 20.00
(0.7854 – 0.7874)
20.10 – 20.15
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
30.976 – 31.000
(1.2195 – 1.2205)
0.016 – 0.040
(0.0006 – 0.0016)
29.976 – 30.000
(1.1802 – 1.1811)
2.425 – 2.450
(0.0955 – 0.0965)
2.350 – 2.500
(0.0925 – 0.0984)
0.055 – 0.110
(0.0022 – 0.0043)
Right side
Left side
Crankshaft thrust clearance
Crankshaft runout
—
—
—
0.080
(0.0031)
—
Shift fork-to-groove clearance
—
Shift fork groove width
—
Shift fork thickness
—
Drive chain
STANDARD
200 – 500 kPa
(2.0 – 5.0 kgf/cm², 28 – 71 psi)
at 3 000 r/min
LIMIT
Engine coolant type
Engine coolant
20-pitch length
Gearshift lever height
E
L
P
M
E-02, 03, 19, 24, 28, 33
E-19
E-19
A
S
STANDARD/SPECIFICATION
NOTE
Approx. 88 °C (190 °F)
—
8 mm (0.31 in) and over at 100 °C (212 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
50 °C
Approx.
0.811 kΩ
(122 °F)
80 °C
Approx.
0.318 kΩ
(176 °F)
110 °C
Approx.
0.142 kΩ
(230 °F)
93 – 123 kPa
(0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)
OFF→ON
Approx. 105 °C (221 °F)
ON→OFF
Approx. 100 °C (212 °F)
Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of
50:50.
Reservoir
Approx. 250 ml
tank side
(0.3/0.2 US/lmp qt)
Engine
Approx. 2 700 ml
side
(2.9/2.4 US/lmp qt)
—
—
SPECIFICATION
Approx. 12 Ω at 20 °C (68 °F)
168 ml (5.7/5.9 US/lmp oz) and more/10 sec.
E-02, 03, 19, 24, 28, 33
E-19
E-19
4/10
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
ITEM
CMP sensor resistance
CMP sensor peak voltage
SPECIFICATION
0.9 – 1.7 kΩ
NOTE
0.7 V and more
When
cranking
CKP sensor resistance
CKP sensor peak voltage
142 – 194 Ω
When
cranking
0.5 V and more
—
—
—
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
—
TP sensor output voltage
—
—
—
—
—
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel discharge amount
Fuel pressure regulator operating set
pressure
Unit: mm (in) Except ratio
STANDARD
LIMIT
1.926 (79/41)
—
2.812 (45/16)
—
2.785 (39/14)
—
2.052 (39/19)
—
1.681 (37/22)
—
1.450 (29/20)
—
1.304 (30/23)
—
1.181 (26/22)
—
0.10 – 0.30
0.50
(0.004 – 0.012)
(0.020)
5.0 – 5.1
—
(0.197 – 0.201)
4.8 – 4.9
—
(0.189 – 0.193)
RK525SMOZ7
—
110 links
—
336.5
—
(13.25)
20 – 30
—
(0.8 – 1.2)
60 – 70
—
(2.4 – 2.8)
—
THERMOSTAT + RADIATOR + FAN + COOLANT
Radiator cap valve opening
pressure
Cooling fan thermo-switch
operating temperature
Type
Links
Drive chain slack (on side-stand)
3/10
ITEM
Thermostat valve opening
temperature
Thermostat valve lift
ECT sensor resistance
Low
2nd
3rd
4th
5th
Top
0.05
(0.002)
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
54.15
(2.132)
TRANSMISSION + DRIVE CHAIN
0.080
(0.0031)
—
—
2.62
(0.103)
12.90
(0.5079)
0.10
(0.004)
51.5
(2.028)
—
Clutch spring free length
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Unit: mm (in)
LIMIT
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn out
2.92 – 3.08
(0.115 – 0.121)
13.70 – 13.80
(0.5394 – 0.5433)
4.5 – 5.5 V
Approx. 2.7 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.4 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.4 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 760 mmHg (100 kPa)
16.5 – 22.3 kΩ
Normal
0.4 – 1.4 V
Leaning
NOTE
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
0.6 V and more
Injector voltage
Ignition coil primary peak voltage
Battery voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
PAIR control solenoid valve resistance
When
leaning 65°
From 1st to
Top
3.7 – 4.4 V
GP switch voltage
When
cranking
85 V and more
4.5 – 5.5 V
Closed
Approx. 0.6 kΩ
Opened
Approx. 4.5 kΩ
Closed
Approx. 0.6 V
Opened
Approx. 4.5 V
Approx. 7 Ω
18 – 22 Ω (at 20 °C/68 °F – 30 °C/86 °F)
THROTTLE BODY
ITEM
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
5/10
E-02, 03, 19, 24, 28, 33
E-19
E-19
SPECIFICATION
38 mm
29G10 (For E-33), 29G00 (For the others)
1 300 ± 100 r/min
1 500 – 2 000 r/min (When cold engine)
2.0 – 4.0 mm
(0.08 – 0.16 in)
6/10
E-02, 03, 19, 24, 28, 33
E-19
E-19
59
ELECTRICAL
ITEM
Firing order
Spark plug
Type
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Secondary
Terminal –
Terminal
Plug cap –
Terminal
10.8 – 16.2 kΩ
85 V and more
0.2 – 0.9 Ω
65 V and more at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–5Ω
0.6 V and more (From 1st to top without neutral)
FTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
10 A
10 A
10 A
15 A
10 A
10 A
30 A
LO
Unit: W
ITEM
HI
LO
Position light
Brake light/Taillight
Turn signal light
License plate light
Combination meter light
Turn signal indicator light
High beam indicator light
Neutral indicator light
FI indicator light/Oil pressure indicator
light/Engine coolant temp. indicator
light
Fuel level indicator light
Engine RPM indicator light
STANDARD/SPECIFICATION
E-03, 24, 28, 33
Others
60/55 W
←
55/55 W
55 W
5W
LED
←
18 W × 4
←
5W
←
LED
←
LED
←
LED
←
LED
←
Brake disc thickness
Front
Rear
Brake disc runout
Front
Rear
Front
Front
Rear
E
L
Brake caliper piston diam
Front
Rear
7/10
Wheel rim size
Wheel axle runout
A
S
STANDARD
DOT 4
LIMIT
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
—
—
Front
Rear
17 M/C × MT 3.50
17 M/C × MT 5.50
Front
—
Rear
P
M
E-02, 03, 19, 24, 28, 33
E-19
E-19
—
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
STANDARD
250 kPa
(2.50 kgf/cm², 36 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
120/70 ZR17 M/C (58 W)
180/55 ZR17 M/C (73 W)
DUNLOP: D218F
BRIDGESTONE: BT014F SF
DUNLOP:D218
BRIDGESTONE: BT014R F
Front
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
Tire type
Front
Rear
Front
Rear
Tire tread depth
(Recommended depth)
Front
—
Rear
—
LIMIT
—
—
—
—
—
—
E-03, 28, 33
Others
E-03, 28, 33
Others
1.6
(0.06)
2.0
(0.08)
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring,
outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork inner tube outside diam.
Front fork spring adjuster
Front fork damping force adjuster
Rear shock absorber spring pre-set
length
Rear shock absorber damping force
adjuster
19.050 – 19.093
(0.7500 – 0.7517)
14.000 – 14.043
(0.5512 – 0.5529)
19.007 – 19.034
(0.7483 – 0.7494)
13.957 – 13.984
(0.5495 – 0.5506)
30.230 – 30.306
Leading
(1.1902 – 1.1931)
33.960 – 34.036
Trailing
(1.3370 – 1.3400)
38.180 – 38.230
(1.5031 – 1.5051)
30.230 – 30.306
Leading
(1.1902 – 1.1931)
33.960 – 34.036
Trailing
(1.3370 – 1.3400)
38.080 – 38.130
(1.4992 – 1.5012)
Rear wheel travel
—
—
—
—
—
—
—
—
—
—
E-02, 03, 19, 24, 28, 33
E-19
E-19
8/10
STANDARD
120
(4.72)
244.6
(9.63)
102
(4.02)
SUZUKI FORK OIL SS-05 or an equivalent fork oil
479 ml
(16.2/16.9 US/Imp oz)
43
(1.69)
4 th groove from top
Rebound
1 and 3/4 turns out from stiffest position
Compression 1 and 3/4 turns out from stiffest position
195.9
(7.71)
Rebound
2 turns out from stiffest position
Compression 1 and 3/4 turns out from stiffest position
130
(5.1)
Swingarm pivot shaft runout
—
Unit: mm (in)
LIMIT
—
239
(9.41)
—
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
FUEL + OIL
ITEM
Fuel type
Engine oil type
Engine oil capacity
9/10
—
5.0
(0.20)
4.5
(0.18)
0.30
(0.012)
SUSPENSION
Fuel tank capacity
E-02, 03, 19, 24, 28, 33
E-19
E-19
Unit: mm (in)
LIMIT
—
Master cylinder bore
Brake caliper cylinder bore
Radial
←
←
STANDARD
60 – 70
(2.4 – 2.8)
5.3 – 5.7
(0.209 – 0.224)
4.8 – 5.2
(0.189 – 0.205)
Rear
Axial
←
LED
LED
ITEM
Rear brake pedal height
Master cylinder piston diam
ITEM
Brake fluid type
Wheel rim runout
LED
BRAKE + WHEEL
E-03, 24,
28, 33
E-02, 19
15 A
Signal
Ignition
Fuel
Fan
Main
WATTAGE
Headlight
1.3 – 1.9 Ω
Primary
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load performance
(when engine is cold)
Regulated voltage (charging output)
Starter relay resistance
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
Unit: mm (in)
NOTE
SPECIFICATION
1.2.4.3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
142 – 194 Ω
0.5 V and more
SPECIFICATION
NOTE
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Gasoline used should be graded 91 octane or
Others
higher. An unleaded gasoline is recommended.
16.5 L
E-33
(4.4/3.6
US/lmp
gal)
Including
reserve
17 L
Others
(4.5/3.7 US/lmp gal)
Fuel level
Approx. 1.7 L
indicator light
(1.8/1.5 US/lmp qt)
lighting
SAE 10 W-40, API, SF or SG
2.8 L
(3.0/2.5 US/lmp qt)
3.1 L
Filter change
(3.3/2.7 US/lmp qt)
3.6 L
Overhaul
(3.8/3.2 US/lmp qt)
Change
10/10
E-02, 03, 19, 24, 28, 33
E-19
E-19
60
GSX-R750/UF
VALVE + VALVE GUIDE
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
Valve stem deflection
Unit: mm (in)
LIMIT
STANDARD
29.0
(1.14)
24.0
(0.94)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1575 – 0.1580)
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
ITEM
Compression pressure
—
Compression pressure difference
Piston-to-cylinder clearance
—
—
Cylinder bore
—
Piston diam.
—
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
35.6
(1.40)
IN. & EX.
137 – 157 N
(14.0 – 16.0 kgf, 30.9 – 35.3 lbs)
at length 32.55 mm (1.28 in)
ITEM
Cam height
STANDARD
36.78 – 36.83
(1.448 – 1.450)
35.28 – 35.33
(1.389 – 1.391)
35.28 – 35.33
(1.389 – 1.391)
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
ITEM
Conrod small end I.D.
STANDARD
15.010 – 15.018
(0.5909 – 0.5913)
0.10 – 0.20
(0.004 – 0.008)
19.95 – 20.00
(0.7854 – 0.7874)
20.10 – 20.15
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
32.976 – 33.000
(1.2983 – 1.2992)
0.016 – 0.040
(0.0006 – 0.0016)
31.976 – 32.000
(1.2589 – 1.2598)
2.425 – 2.450
(0.0955 – 0.0965)
2.350 – 2.500
(0.0925 – 0.0984)
0.055 – 0.110
(0.0022 – 0.0043)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness Right side
Left side
Crankshaft thrust clearance
Crankshaft runout
Piston ring end gap
1st
R
Approx 8.2 (0.32)
2nd
RN
Approx 7.8 (0.31)
1st
R
0.06 – 0.21
(0.002 – 0.008)
0.06 – 0.18
(0.002 – 0.007)
2nd
Piston ring to groove clearance
RN
1st
Piston ring groove width
Unit: mm (in)
LIMIT
36.48
(1.436)
34.98
(1.377)
0.150
(0.0059)
—
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore I.D.
—
E
L
Piston pin O.D.
—
P
M
Unit: mm (in)
LIMIT
15.040
(0.5921)
0.30
(0.012)
—
—
0.080
(0.0031)
STANDARD
1.857 (78/42)
2.529 (43/17)
2.785 (39/14)
2.052 (39/19)
1.681 (37/22)
1.450 (29/20)
1.304 (30/23)
1.181 (26/22)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK525ROZ5
110 links
Low
2nd
3rd
4th
5th
Top
Shift fork-to-groove clearance
Shift fork groove width
Shift fork thickness
—
Drive chain
—
—
—
—
0.05
(0.002)
STANDARD
100 – 400 kPa
(1.0 – 4.0 kgf/cm², 14 – 57 psi)
at 3 000 r/min
LIMIT
Type
Links
20-pitch length
—
—
—
—
15.030
(0.5917)
14.980
(0.5898)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
336.5
(13.25)
20 – 30
(0.8 – 1.2)
60 – 70
(4 – 8)
Gearshift lever height
71.880
(2.8299)
—
—
Drive chain slack (on side-stand)
0.120
(0.0047)
Nicks or
Scratches
E-02, 13, 19, 24, 28, 33
E-19
TRANSMISSION + DRIVE CHAIN
—
0.080
(0.0031)
1.01 – 1.03
(0.0398 – 0.0406)
0.81 – 0.83
(0.0319 – 0.0327)
1.51 – 1.53
(0.0594 – 0.0602)
0.97 – 0.99
(0.0382 – 0.0390)
0.77 – 0.79
(0.0303 – 0.0311)
15.002 – 15.008
(0.5906 – 0.5909)
14.995 – 15.000
(0.5904 – 0.5906)
2/9
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Unit: mm (in)
LIMIT
0.02
(0.008)
6.5
(0.26)
6.2
(0.24)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
—
2nd
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
1 100 – 1 500 kPa
(11 – 15 kgf/cm², 156 – 213 psi)
—
0.030 – 0.040
(0.0012 – 0.0016)
72.000 – 72.015
(2.8346 – 2.8352)
71.965 – 71.980
(2.8209 – 2.8339)
Measure at 15 mm (0.6 in) from the skirt end.
—
Piston ring free end gap
—
A
S
CONROD + CRANKSHAFT
—
Cylinder distortion
E-02, 13, 19, 24, 28, 33
E-19
1/9
14th pin
CYLINDER + PISTON + PISTON RING
—
—
CAMSHAFT + CYLINDER HEAD
LIMIT
0.10
(0.004)
—
0.20
(0.008)
—
—
Valve stem runout
Valve spring tension
STANDARD
Cam chain pin (at arrow “3”)
Cylinder head distortion
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
ITEM
Camshaft runout
—
—
—
THERMOSTAT + RADIATOR + FAN + COOLANT
CLUTCH
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
No. 1, 2 and 3
Drive plate claw width
No. 1, 2 and 3
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn out
2.92 – 3.08
(0.115 – 0.121)
13.70 – 13.80
(0.5394 – 0.5433)
Driven plate distortion
—
Clutch spring free length
55.11
(2.170)
—
Unit: mm (in)
LIMIT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
ECT sensor resistance
—
—
2.62
(0.103)
12.90
(0.5079)
0.10
(0.004)
52.4
(2.063)
Radiator cap valve opening pressure
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant
3/9
E-02, 13, 19, 24, 28, 33
E-19
STANDARD/SPECIFICATION
NOTE
Approx. 88 °C (190 °F)
—
8 mm (0.31 in) and over at 100 °C (212 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
50 °C
Approx. 0.811 kΩ
(122 °F)
80 °C
Approx. 0.318 kΩ
(176 °F)
110 °C
Approx. 0.142 kΩ
(230 °F)
108 – 137 kPa
(1.08 – 1.37 kgf/cm², 15.4 – 19.5 psi)
OFF→ON
Approx. 105 °C (221 °F)
ON→OFF
Approx. 100 °C (212 °F)
Use an antifreeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Reservoir
Approx. 250 ml
tank side
(0.3/0.2 US/lmp qt)
Engine
Approx. 2 900 ml
side
(3.1 – 2.6 US/lmp qt)
—
4/9
—
—
—
—
—
—
—
—
—
—
E-02, 13, 19, 24, 28, 33
E-19
61
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel discharge amount
Fuel pressure regulator operating
set pressure
THROTTLE BODY
SPECIFICATION
Approx. 12 Ω at 20 °C (68 °F)
168 ml (5.7/5.9 US/lmp OZ) and more/10 sec.
NOTE
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
ITEM
CMP sensor resistance
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
SPECIFICATION
0.9 – 1.7 kΩ
0.7 V and more
142 – 194 Ω
0.5 V and more
4.5 – 5.5 V
Approx. 2.7 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.4 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.4 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 3.6 V at 760 mmHg (100 kPa)
16.5 – 22.3 kΩ
Normal
0.4 – 1.4 V
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
Leaning
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
PAIR control solenoid valve resistance
Closed
Opened
Closed
Opened
ITEM
ITEM
Bore size
Headlight
HI
I.D. No.
LO
Idle r/min
Position
Fast idle light
r/min
Brake
light/Taillight
Throttle
cable play
Turn signal light
License plate light
ELECTRICAL
Combination meter light
ITEM light
Turn signal indicator
Firingbeam
orderindicator light
High
Spark
plug
Neutral indicator light
FI indicator light/Oil pressure indicator light/Engine coolant temp.
indicator light
Sparklevel
performance
Fuel
indicator light
CKP sensor
Engine
RPMresistance
indicator light
CKP sensor peak voltage
Ignition coil+resistance
BRAKE
WHEEL
ITEM
Rear brake pedal height
Ignition coil primary peak voltage
Brake
disc coil
thickness
Generator
resistance
Generator no-load voltage
(when engine is cold)
Regulated
Brake
disc voltage
runout
Starter relay resistance
GP switch
voltage
Master
cylinder
bore
Battery
Type designation
Capacity
Master
cylinder
piston
diam
Fuse size
HI
Headlight
LO
Signal
Brake caliper cylinder bore
Ignition
Fuel
Fan
Main
Brake caliper piston diam
Brake fluid type
ELECTRICAL
ITEM
When cranking
When cranking
Firing order
Spark plug
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
When
leaning 65°
From 1st to Top
3.7 – 4.4 V
When cranking
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
P
M
A
S
Unit: W
STANDARD/SPECIFICATION
SPECIFICATION
E-03, 24, 28, 33
Others
42 mm
55
W (For E-33), 30G0 (For the others)
←
30G1
60/55 W
←
1 200 ± 100 r/min
5W
1 500 – 2 000 r/min (When cold engine)
LED
←
2.0 – 4.0 mm
(0.08 – 0.16 in)
18 W × 4
←
5W
←
Unit: mm (in)
LED
←
SPECIFICATION
NOTE
LED
←
LED 1.2.4.3
←
NGK:
CR9E
Type
LED DENSO: U27ESR-N
←
Primary
Secondary
Front
0.7 – 0.8
LED
(0.028 – 0.031)
Over
8
(0.3)
at 1 atm.
LED
LED142 – 194 Ω
0.5 V and more
←
←
←
Terminal
– (in)
Unit: mm
Terminal
LIMIT
Plug
cap –
Terminal
—
1.3 – 1.9 Ω
STANDARD
10.8
60 – 70– 16.2 kΩ
– 2.8)
85(2.4
V and
more
5.3Ω– 5.7
0.2 –(0.209
0.9
– 0.224)
at –55.2
000 r/min
4.8
Rear 65 V (AC) and more
(0.189 – 0.205)
14.0 – 15.5 V at 5 000 r/min
3 –—5 Ω
0.6
V and more (From19.050
1st to top
without neutral)
– 19.093
Front
(0.7500 – 0.7517)
YT12A-BS
14.000
–
14.043
Rear
(0.5512
– 0.5529)
12 V 36.0 kC
(10 Ah)/10
HR
19.018
– 19.034
15
A –
Front
(0.7487
0.7494)
10
A
13.957 – 13.984
Rear
10 A – 0.5506)
(0.5495
10
A 30.230 – 30.306
Leading
15 A (1.1902 – 1.1931)
Front
33.960 – 34.036
Trailing 10 A (1.3370
– 1.3400)
10
A – 38.230
38.180
Rear
30 A – 1.5051)
(1.5031
30.150 – 30.200
Leading
(1.1870 – 1.1890)
Front
33.884
– 33.934
Trailing
(1.3340 – 1.3360)
38.060
–
38.093
Rear
(1.4984 – 1.4997)
DOT 4
6/9
7/9
5.0
(0.20)
4.5
(0.18)
0.30
(0.012)
—
WATTAGE ITEM
Wheel rim runout
ITEM
Headlight
HI
LO
Wheel rim
size
Position
light
Brake light/Taillight
Wheelsignal
axle runout
Turn
light
License plate light
Combination meter light
Turn signal indicator light
TIRE
High beam indicator light
ITEM
Neutral indicator
light
Cold
inflation
tire pressure
FI
indicator
light/Oil
pressure indi(Solo light/Engine
riding)
cator
coolant temp.
indicator light
Fuel level indicator light
Cold inflation
tire pressure
Engine
RPM indicator
light
(Dual riding)
BRAKE + WHEEL
ITEM
Tire size
Rear brake pedal height
Tire type
Brake disc thickness
Brake
discdepth
runout
Tire tread
(Recommended depth)
Master cylinder bore
—
E-03, 24,
— 28, 33
E-02, 19
—
Master cylinder piston diam
—
Brake caliper cylinder bore
—
—
—
Brake caliper piston diam
—
—
—
E-02, 13, 19, 24, 28, 33
E-19
Primary
1.3 – 1.9 Ω
Secondary
10.8 – 16.2 kΩ
Brake fluid type
Terminal –
Terminal
Plug cap –
Terminal
85 V and more
0.2 – 0.9 Ω
65 V (AC) and more at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–5Ω
0.6 V and more (From 1st to top without neutral)
YT12A-BS
12 V 36.0 kC (10 Ah)/10 HR
15 A
10 A
10 A
10 A
15 A
10 A
10 A
30 A
E
L
E-02, 13, 19, 24, 28, 33
E-19
Unit: mm (in)
NOTE
SPECIFICATION
1.2.4.3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
142 – 194 Ω
0.5 V and more
Type
18 – 22 Ω at 20 – 30 °C (68 – 86 °F)
Gap
SPECIFICATION
42 mm
30G1 (For E-33), 30G0 (For the others)
1 200 ± 100 r/min
1 500 – 2 000 r/min (When cold engine)
2.0 – 4.0 mm
(0.08 – 0.16 in)
NOTE
0.6 V and more
Battery voltage
85 V and more
4.5 – 5.5 V
Approx. 0.6 kΩ
Approx. 4.5 kΩ
Approx. 0.6 V
Approx. 4.5 V
Approx. 7 Ω
5/9
THROTTLE BODY
WATTAGE
ITEM
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
6/9
E-03, 24, 28, 33
E-02, 19
E-02, 13, 19, 24, 28, 33
E-19
Unit: W
STANDARD
LIMIT
STANDARD/SPECIFICATION
2.0
Axial E-03, 24, 28, 33
—
Others (0.08)
55 W
←
2.0
Radial
—
(0.08)
60/55 W
←
Front
17 M/C × MT 3.50
—
5W
Rear
—
LED 17 M/C × MT 5.50
←
0.25
18 W × 4
←
Front
—
(0.010)
5W
←
0.25
Rear
—
LED
←
(0.010)
LED
←
LED
←
LIMIT
LEDSTANDARD
←
250 kPa
Front
—
LED (2.50 kgf/cm², 36 psi)
←
290 kPa
Rear
—
LED (2.90 kgf/cm², 42 psi)
←
250 kPa
LED
←
Front
—
(2.50 kgf/cm², 36 psi)
290 kPa
Rear
— mm (in)
Unit:
(2.90 kgf/cm², 42 psi)
STANDARD
LIMIT
Front
120/70
ZR17 M/C (58 W)
—
60 – ZR17
70 M/C (73 W)
Rear
180/55
—
(2.4 – 2.8)
DUNLOP: D218F
E-03, 28, 33
5.3
–
5.7
5.0
Front
Front
BRIDGESTONE:
BT014F SE
Others
(0.209 – 0.224)
(0.20)
DUNLOP:
D218
E-03,4.5
28, 33
4.8 – 5.2
Rear
(0.189
–
0.205)
(0.18)
BRIDGESTONE: BT014R E
Others
0.30
1.6
—
Front
—
(0.012)
(0.06)
19.050 – 19.093
2.0
Front
—
Rear
(0.7500 —
– 0.7517)
(0.08)
14.000
–
14.043
Rear
—
(0.5512 – 0.5529)
19.018 – 19.034
Front
—
(0.7487 – 0.7494)
13.957 – 13.984
Rear
—
(0.5495 – 0.5506)
30.230 – 30.306
Leading
—
(1.1902 – 1.1931)
Front
33.960 – 34.036
Trailing
—
(1.3370 – 1.3400)
38.180 – 38.230
Rear
—
(1.5031 – 1.5051)
30.150 – 30.200
Leading
—
(1.1870 – 1.1890)
Front
33.884 – 33.934
Trailing
—
(1.3340 – 1.3360)
38.060
– 38.093
Rear
—
(1.4984 – 1.4997)
DOT 4
—
7/9
8/9
E-02, 13, 19, 24, 28, 33
E-19
62
WATTAGE ITEM
SUSPENSION
Unit: mm
Unit:(in)
W
STANDARD
LIMIT
STANDARD/SPECIFICATION
STANDARD
LIMIT
2.0
Axial E-03, 24, 28, 33
—
Others (0.08)
120
—
55 W (4.72) —
←
2.0
Radial
239
(0.08)
60/55 W 244.6
←
(9.63)
(9.41)
Front
17
M/C × MT 3.50
—
5W
100
Rear
M/C × MT 5.50
—
LED 17
←
(3.94)
0.25
18 W
×4
SUZUKI
OIL
SS-05 or an
—
Front FORK
— equivalent fork oil ←
(0.010)
5 W 481 ml
←
—
0.25
(16.3/16.9
US/Imp
Rear
— oz)
LED
←
(0.010)
43
LED (1.69)
←
—
TIRE
High
indicator
light
LED
←
Frontbeam
fork spring
adjuster
4 th groove from top
—
ITEM
STANDARD
LIMIT
Neutral
indicator
light
LED1/2 turns out from stiffest position ←
Front fork
damping
force adjuster
Rebound 1 and
—
Cold
inflation
tire pressure
250 kPa
FI
indicator
light/Oil
pressure indiFront
—
Compres(Solo light/Engine
riding)
psi) position ←
cator
coolant temp.
LED1/2(2.50
1 and
turnskgf/cm²,
out from36
stiffest
—
sion
indicator light
290 kPa
Rear
—
Rear
shock
absorber
spring
pre-set
195.3
(2.90
kgf/cm²,
42
psi)
Fuel
level indicator light
LED
←
—
length
(7.69)
Cold inflation
tire pressure
kPa
Engine
RPM indicator
light
LED3/4 turns 250
←
Front
Rear
Rebound
1 and
out from36
stiffest
—
(Dual shock
riding)absorber damping
(2.50 kgf/cm²,
psi) position
force adjuster
Compres290 stiffest
kPa position
1 turn out from
—
Rear
— mm (in)
BRAKE + WHEEL
Unit:
sion
(2.90 kgf/cm², 42 psi)
ITEM
STANDARD
LIMIT
Rear
wheel travel
130ZR17 M/C (58 W)
Tire size
Front
120/70
—
(5.1)
Rear brake pedal height
60 – ZR17
70 M/C (73 W)
Rear
180/55
—
(2.4—
– 2.8)
Swingarm pivot shaft runout
0.3
Tire type
DUNLOP: D218F
E-03,
28, 33
(0.01)
Brake disc thickness
5.3 – 5.7
5.0
Front
Front
BRIDGESTONE:
BT014F SE
Others
(0.209 – 0.224)
(0.20)
DUNLOP:
D218
E-03,
28, 33
FUEL + OIL
4.8 – 5.2
4.5
Rear
(0.189 – 0.205)
(0.18)
BRIDGESTONE:
BT014R E
Others
ITEM
SPECIFICATION
NOTE
Brake
discdepth
runout
0.30
Tire tread
1.6
—
Fuel
type
Use
only unleaded gasoline
of at least 90 pump
Front
—
(0.012)
(Recommended depth)
(0.06)
octane (R/2 + M/2).
Master cylinder bore
19.050 – 19.093
2.0
Front
—
Gasoline
containing
MTBE
(Methyl
Tertiary
Butyl
Rear
(0.7500 —
– 0.7517)
E-03,
28, 33
(0.08)
Ether), less than 10% ethanol, or less than 5%
14.000 – 14.043
Rear
—
methanol with appropriate
cosolvents
(0.5512
– 0.5529)and corrosion inhibitor is permissible.
Master cylinder piston diam
19.018 – 19.034
Front used should(0.7487
—
Gasoline
be graded
95 octane or
– 0.7494)
Others
higher. An unleaded gasoline
13.957is–recommended.
13.984
Rear
—
(0.5495 –16.5
0.5506)
Fuel tank capacity
L
E-33
US/lmp
gal)
Brake caliper cylinder bore
30.230
– 30.306
Including Leading (4.4/3.6
—
(1.1902
reserve
17 L – 1.1931)
Front
Others
(4.5/3.7
US/lmp
gal)
33.960
– 34.036
Trailing
—
(1.3370 – 1.3400)
Fuel level
Approx. 1.7 L
indicator light
38.180
– 38.230
(1.8/1.5
US/lmp
qt)
Rear
—
lighting
(1.5031 – 1.5051)
Enginecaliper
oil typepiston diam
SAE 10 W-40, API,30.150
SF or SG
Brake
– 30.200
Leading
—
(1.1870
Engine oil capacity
2.8 L– 1.1890)
Front
change
(3.0/2.5
US/lmp
qt)
33.884
– 33.934
Trailing
—
(1.3340
3.1 L– 1.3360)
Filter change
(3.3/2.7
US/lmp qt)
38.060
– 38.093
Rear
—
(1.4984 –3.6
1.4997)
L
Overhaul
(3.8/3.2
US/lmp qt)
Brake fluid type
DOT 4
—
ITEM
Wheel rim runout
ITEM
Front fork stroke
Headlight
HI
Front fork spring free length LO
Wheel rim
size
Position
light
Front fork oil level (without spring,
Brake
light/Taillight
outer tube
fully compressed)
Wheelsignal
axleoilrunout
Turn
light
Front
fork
type
License
plate
light
Front fork
oil capacity
(each leg)
Combination meter light
Frontsignal
fork inner
tube outside
diam.
Turn
indicator
light
7/9
8/9
9/9
GSX-R1000
A
S
VALVE + VALVE GUIDE
ITEM
Valve diam.
STANDARD
29
(1.14)
24
(0.94)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
4.000 – 4.012
(0.1575 – 0.1580)
3.975 – 3.990
(0.1565 – 0.1571)
3.955 – 3.970
(0.1557 – 0.1563)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve seat width
Valve head radial runout
Valve spring free length
----
IN. & EX.
----
IN. & EX.
----
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
----
IN. & EX.
----
IN. & EX.
127 – 147 N
(13.0 – 15.0 kgf, 28.7 – 33.1 lbs)
at length 32.85 mm (1.29 in)
ITEM
EX.
Camshaft journal oil clearance
IN. & EX.
ITEM
Camshaft journal holder I.D.
STANDARD
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
IN. & EX.
----
Camshaft journal O.D.
IN. & EX.
---Camshaft runout
------0.10
(0.004)
---0.20
(0.008)
----
----
----
----
Cam chain pin (at arrow “3”)
Cylinder head distortion
14th pin
----
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
1 000 kPa
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
-------
Unit: mm (in)
LIMIT
STANDARD
Compression pressure
difference
(10142kgf/cm²,
psi )
200 kPa
----
( 2 kgf/cm²,
28 psi )
0.030 – 0.040
(0.0012 – 0.0016)
73.000 – 73.015
(2.8740 – 2.8746)
72.965 – 72.980
(2.8726 – 2.8732)
Measure at 15 mm (0.6 in) from the skirt end.
0.120
(0.0047)
Nicks or
Scratches
----
----
Unit: mm (in)
LIMIT
36.71
(1.445)
35.68
(1.405)
0.150
(0.0059)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
---1st
R
Approx 8.0 (0.31)
2nd
RN
Approx 10.2 (0.40)
1st
R
2nd
RN
1st
Piston ring groove width
E-02, 03, 19, 24, 28, 33
E-19
0.06 – 0.18
(0.002 – 0.007)
0.06 – 0.18
(0.002 – 0.007)
----
2nd
---1.01 – 1.03
(0.0398 – 0.0406)
0.81 – 0.83
(0.0319 – 0.0327)
1.51 – 1.53
(0.0594 – 0.0602)
1st
2nd
Oil
1/11
LIMIT
----
----
STANDARD
37.01 – 37.06
(1.457 – 1.459)
35.98 – 36.03
(1.417 – 1.418)
0.032 – 0.066
(0.0013 – 0.0026)
IN.
Unit: mm (in)
LIMIT
0.03
(0.001)
37.0
(1.46)
CAMSHAFT + CYLINDER HEAD
Cam height
P
M
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
Valve spring tension
E
L
E-02, 13, 19, 24, 28, 33
E-19
2/11
72.880
(2.8693)
0.02
(0.008)
6.4
(0.25)
8.2
(0.32)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
----------
E-02, 03, 19, 24, 28, 33
E-19
63
ITEM
Piston ring thickness
STANDARD
0.97 – 0.99
(0.0382 – 0.0390)
0.77 – 0.79
(0.0303 – 0.0311)
16.002 – 16.008
(0.6300 – 0.6302)
15.995 – 16.000
(0.6297 – 0.6299)
1st
2nd
Piston pin bore I.D.
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing
thickness
Right side
Left side
Crankshaft thrust clearance
Crankshaft runout
---0.080
(0.0031)
Radiator cap valve opening
pressure
Cooling fan thermo-switch
operating temperature
Engine coolant type
Engine coolant
STANDARD
100 – 400 kPa
(1.0 – 4.0 kgf/cm², 14 – 57 psi)
at 3 000 r/min
ITEM
Clutch lever play
Clutch release screw
Drive plate thickness
No. 1, 2 and 3
Drive plate claw width
No. 1, 2 and 3
Driven plate distortion
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.45 – 2.95
(0.096 – 0.116)
13.85 – 13.96
(0.5453 – 0.5496)
77.77
(3.062)
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
----
Shift fork to groove clearance
----
Shift fork groove width
0.05
(0.002)
Unit: mm (in)
LIMIT
0.080
(0.00315)
STANDARD
1.553 (73/47)
2.470 (42/17)
2.687 (43/16)
2.052 (39/19)
1.681 (37/22)
1.450 (29/20)
1.304 (30/23)
1.208 (29/24)
0.10 – 0.30
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
DID530
110 links
Low
2nd
3rd
4th
5th
Top
Shift fork thickness
Drive chain
Type
Links
E
L
20-pitch length
Drive chain slack (on side-stand)
----
Gearshift lever height
P
M
E-02, 03, 19, 24, 28, 33
E-19
A
S
STANDARD/SPECIFICATION
NOTE
Approx. 82 °C (180 °F)
----
8 mm (0.31 in) and over at 95 °C (203 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
50 °C
Approx. 0.811 kΩ
(122 °F)
80 °C
Approx. 0.318 kΩ
(176 °F)
110 °C
Approx. 0.142 kΩ
(230 °F)
93 – 123 kPa
(0.93 – 1.23 kgf/cm², 13.2 – 17.5 psi)
OFF ON
Approx. 105 °C (221 °F)
ON OFF
Approx. 100 °C (212 °F)
Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of
50:50.
Reserve
Approx. 250 ml
tank side
(0.3/0.2 US/lmp qt)
Engine
Approx. 2 150 ml
side
(2.3 – 1.9 US/lmp qt)
----
Unit: mm (in)
LIMIT
------2.15
(0.085)
13.05
(0.5138)
0.10
(0.004)
73.9
(2.909)
-------
CKP sensor resistance
CKP sensor peak voltage
70 – 220 Ω
TP sensor output voltage
-------
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
----
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
Approx. 1.2 L (1.3/1.1 US/lmp qt)/30 sec.
STP sensor output voltage
3.7 – 4.4 V
0.6 V and more
When
cranking
When
leaning 65°
From 1st to
Top
Battery voltage
80 V
When
cranking
4.5 – 5.5 V
Approx. 0.5 kΩ
Approx. 3.9 kΩ
Approx. 0.5 V
Approx. 3.7 V
Approx. 6.5 Ω
Closed
Opened
Closed
Opened
STV actuator resistance
EXCVA position sensor
input voltage
EXCVA position sensor
resistance
EXCVA position sensor
output voltage
When
cranking
4.5 – 5.5 V
Approx. 2.6 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.1 kΩ
Opened
Approx. 4.3 kΩ
Closed
Approx. 1.1 V
Opened
Approx. 4.3 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.6 V at 760 mmHg (100 kPa)
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
NOTE
0.5 V and more
NOTE
E-02, 03, 19, 24, 28, 33
E-19
----
0.5 V and more
GP switch voltage
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
----
E-02, 03, 19, 24, 28, 33
E-19
SPECIFICATION
0.9 – 1.7 kΩ
----
----
---------319.4
(12.57)
----
ITEM
CMP sensor resistance
CMP sensor peak voltage
----
----
----
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
----
Unit: mm (in) Except ratio
LIMIT
------------------------0.50
(0.020)
20 – 30
(0.79 – 1.18)
60 – 70
(2.36 – 2.76)
4/11
Leaning
5/11
----
----
Clutch spring free height
----
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
LIMIT
CLUTCH
----
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening
temperature
Thermostat valve lift
ECT sensor resistance
ITEM
Oil pressure (at 60 °C, 140 °F)
----
STANDARD
0.020 – 0.044
(0.00079 – 0.00173)
22.984 – 23.000
(0.9049 – 0.9055)
3/11
16.030
(0.6311)
15.980
(0.6291)
0.080
(0.0031)
BALANCER
Balancer shaft journal O.D.
OIL PUMP
----
----
----
ITEM
Balancer shaft journal oil clearance
----
Unit: mm (in)
LIMIT
16.040
(0.6315)
0.30
(0.012)
STANDARD
16.010 – 16.018
(0.6303 – 0.6306)
0.10 – 0.20
(0.004 – 0.008)
19.95 – 20.00
(0.7854 – 0.7874)
20.10 – 20.15
(0.7913 – 0.7933)
0.032 – 0.056
(0.0013 – 0.0022)
34.976 – 35.000
(1.3770 – 1.3780)
0.016 – 0.040
(0.0006 – 0.0016)
34.976 – 35.000
(1.3770 – 1.3780)
2.420 – 2.440
(0.0953 – 0.0961)
2.360 – 2.500
(0.0929 – 0.0984)
0.070 – 0.110
(0.0028 – 0.0043)
Conrod big end side clearance
LIMIT
4.5 – 5.5 V
Approx. 3.1 kΩ
Closed
Opened
At
adjustment
position
0.5 – 1.3 V
3.7 – 4.5 V
6/11
E-02, 03, 19, 24, 28, 33
E-19
64
THROTTLE BODY
WATTAGE
ITEM
SPECIFICATION
42 mm
40F5 (For E-33), 40F4 (For the others)
1 150 ± 100 r/min
2 200 r/min (After warming up)
2.0 – 4.0 mm
(0.08 – 0.16 in)
Bore size
I.D. No.
Idle r/min
Fast idle r/min
Throttle cable play
ELECTRICAL
ITEM
Firing order
Spark plug
SPECIFICATION
1.2.4.3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
70 – 220 Ω
0.5 V and more
Type
Gap
Spark performance
CKP sensor resistance
CKP sensor peak voltage
Ignition coil resistance
Secondary
Ignition coil primary peak voltage
Generator coil resistance
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
Headlight
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Terminal
0.8 – 2.5 Ω
Primary
8 – 18 kΩ
Unit: W
ITEM
80 V
0.2 – 0.9 Ω
HI
LO
Position/Parking light
Brake light/Taillight
Turn signal light
License plate light
Combination meter light
Turn signal indicator light
High beam indicator light
Neutral indicator light
FI indicator light/Oil pressure
indicator light/Engine coolant
temp. indicator light
Fuel level indicator light
Engine RPM indicator light
STANDARD/SPECIFICATION
E-03, 24, 28, 33
Others
60/55 W
←
55/55 W
55 W
5W
LED
←
18 W × 4
←
5W
←
LED
←
LED
←
LED
←
LED
←
LED
←
LED
LED
←
←
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
65 V (AC) and more at 5 000 r/min
Front
Rear
14.0 – 15.5 V at 5 000 r/min
3–5Ω
0.6 V and more (From 1st to top without neutral)
FTX12-BS
12 V 36 kC (10 Ah)/10 HR
10 A (E-02, 19)/15 A (E-03, 24, 28, 33)
10 A
10 A
15 A
10 A
10 A
30 A
Brake disc runout
Master cylinder piston diam
Front &
Rear
Front
Rear
Brake caliper cylinder bore
Front
E
L
ITEM
Brake caliper piston diam
Front
Rear
Brake fluid type
Wheel rim runout
Wheel rim size
Wheel axle runout
A
S
STANDARD
26.920 – 26.970
Leading
(1.0598 – 1.0618)
31.950 – 32.000
Trailing
(1.2579 – 1.2598)
38.110 – 38.130
(1.5004 – 1.5012)
DOT 4
Axial
----
Radial
----
Front
Rear
17 M/C × MT 3.50
17 M/C × MT 6.00
Front
----
Rear
P
M
E-02, 03, 19, 24, 28, 33
E-19
----
LIMIT
----------
---2.0
(0.08)
2.0
(0.08)
------0.25
(0.010)
0.25
(0.010)
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring,
outer tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Front fork damping force
adjuster
Rear shock absorber spring
pre-set length
Rear shock absorber damping
force adjuster
Rear wheel travel
Front
Rear
Front
Rear
STANDARD
250 kPa
(2.50 kgf/cm², 36 psi)
290 kPa
(2.90 kgf/cm², 42 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
290 kPa
(2.90 kgf/cm², 42 psi)
120/70 ZR17 M/C (58 W)
190/50 ZR17 M/C (73 W)
BRIDGESTONE: BT011F F
BRIDGESTONE: BT012R F
Front
----
Rear
----
Front
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
Tire type
Tire tread depth
(Recommended depth)
9/11
LIMIT
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
13.957 – 13.984
(0.5495 – 0.5506)
27.000 – 27.076
Leading
(1.0630 – 1.0660)
32.030 – 32.106
Trailing
(1.2610 – 1.2640)
38.180 – 38.230
(1.5031 – 1.5051)
8/11
STANDARD
120
(4.92)
230.0
(9.06)
101
(3.98)
SUZUKI FORK OIL L01 or an equivalent fork oil
509 ml
(17.2/17.9 US/Imp oz)
4.5 th groove from top
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
130
(5.1)
Swingarm pivot shaft runout
-------------------
E-02, 03, 19, 24, 28, 33
E-19
SUSPENSION
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
---5.0
(0.177)
4.5
(0.177)
0.30
(0.012)
----
Master cylinder bore
Rear
7/11
Unit: mm (in)
LIMIT
STANDARD
60 – 70
(2.4 – 2.8)
5.3 – 5.7
(0.209 – 0.224)
4.8 – 5.2
(0.189 – 0.205)
----
Unit: mm (in)
LIMIT
---225
(8.86)
------------------------------0.3
(0.01)
------------------------1.6
(0.06)
2.0
(0.08)
E-02, 03, 19, 24, 28, 33
E-19
10/11
E-02, 03, 19, 24, 28, 33
E-19
65
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
SPECIFICATION
NOTE
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2).
Gasoline containing MTBE (Methyl Tertiary Butyl
E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Gasoline used should be graded 95 octane or
Others
higher. An unleaded gasoline is recommended.
Including
18 L
reserve
(4.8/4.0 US/lmp gal)
Fuel level
Approx. 4.2 L
indicator light
(1.1/0.9 US/lmp gal)
lighting
SAE 10 W-40, API, SF or SG
3.0 L
change
(3.2/2.6 US/lmp qt)
3.3 L
Filter change
(3.5/2.9 US/lmp qt)
3.6 L
Overhaul
(3.8/3.2 US/lmp qt)
11/11
GZ125/U
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length (IN. & EX.)
STANDARD
25.5
22.5
0.03 – 0.08
0.13 – 0.18
0.010 – 0.037
0.030 – 0.057
—
5.000 – 5.012
4.975 – 4.990
4.955 – 4.970
—
—
—
0.9 – 1.1
—
—
—
38.1 – 43.9 N
(3.9 – 4.4 kgf)
at length 26.78 mm
89.6 – 103.0 N
(9.1 – 10.5 kgf)
at length 29.78 mm
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
Valve spring tension (IN. & EX.)
INNER
OUTER
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
STANDARD
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
P
M
E-02, 03, 19, 24, 28, 33
E-19
A
S
VALVE + GUIDE
E
L
33.620 – 33.660
33.300 – 33.340
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
Unit: mm
LIMIT
—
—
—
—
—
—
0.35
—
—
—
0.05
0.5
1.7
—
0.03
31.3
33.6
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
—
Piston pin bore
Piston pin O.D.
—
CONROD + CRANKSHAFT
Unit: mm
LIMIT
33.320
33.000
0.150
—
—
0.10
—
—
0.05
0.05
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crankshaft web to web width
Crankshaft runout
STANDARD
1 100 – 1 500 kPa
(11.0 – 15.0 kgf/cm2)
0.040 – 0.050
57.000 – 57.015
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
1st
R
Approx. 7.2
2nd R
Approx. 5.0
1st
0.20 – 0.32
2nd
0.20 – 0.32
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
14.002 – 14.008
13.992 – 14.000
STANDARD
14.006 – 14.014
—
0.10 – 0.45
15.95 – 16.00
53.0 ± 0.1
—
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
STANDARD
2.000 (30/15)
Above 10 kPa (0.1 kgf/cm2)
Below 30 kPa (0.3 kgf/cm2)
at 3 000 r/min
0.05
5.7
4.0
0.70
0.70
0.180
0.150
—
—
—
—
—
14.030
13.980
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
LIMIT
—
—
Unit: mm
ITEM
Clutch cable play
P-02, 19
P-19
56.880
OIL PUMP
CLUTCH
1/5
Unit: mm
LIMIT
800 kPa
(8 kgf/cm2)
0.120
57.090
STANDARD
10 – 15
LIMIT
—
1/8 – 1/4 turn back
2.9 – 3.1
11.8 – 12.0
—
—
—
2.6
11.0
0.10
29.5
2/5
P-02, 19
P-19
66
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Countershaft length
(Low to 2nd)
Drive chain
Unit: mm Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
—
—
—
—
STANDARD
3.470 (59/17)
3.000 (45/15)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.142 (24/21)
0.956 (22/23)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
No. 1, No. 2
No. 3
No. 1, No. 2
No. 3
—
88.0 +0.1
- 0.2
Type
Links
20-pitch length
Drive chain slack
RK428FDZ
132
—
5 – 15
—
—
259.0
—
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
Starter plunger cable play
ITEM
Spark plug
Gap
Spark performance
Ignition coil resistance
Wheel axle runout
Wheel rim size
Tire size
Front
Rear
Tire tread depth
Front
Rear
HI
LO
A
S
—
—
1.6
1.6
Unit: mm
LIMIT
—
301
—
—
—
—
—
0.3
TIRE PRESSURE
NORMAL RIDING
FRONT
REAR
kPa
175
200
psi
25
29
kPa
175
225
DUAL RIDING
kgf/cm2
1.75
2.25
psi
25
33
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type and grade
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
13.0 L
2.9 L
SAE 10W-40, API SF or SG
Change
850 ml
Filter
950 ml
change
Overhaul
1 300 ml
5/5
NOTE
P-02, 19
P-19
Bl – G
Y–Y
Unit: mm
STANDARD/SPECIFICATION
Front
Front
E
L
P
M
LIMIT
2.0
2.0
0.25
0.25
—
—
terminal –
terminal
terminal –
Plug cap
Unit: W
ITEM
P-02, 19
P-19
NOTE
SPECIFICATION
60
55
4
21/5
10
1.7
3.4
3.4
1.7
BRAKE + WHEEL
STANDARD/SPECIFICATION
—
—
—
—
16M/C × MT 2.50
15M/C × MT 3.00
110/90-16 59P, 110/90-16M/C 59P or
110/90-16M/C 59S
130/90-15M/C 66P or
130/90-15M/C 66S
—
—
SOLO RIDING
kgf/cm2
1.75
2.00
17 – 28 kΩ
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
Turn signal indicator light
High beam indicator light
STANDARD/SPECIFICATION
120
308
37
SUZUKI fork oil SS-08 (#10)
336 ml
120
90
—
COLD INFLATION
TIRE PRESSURE
Secondary
More than 200 V
Pick-up
150 – 300 Ω
Charging
0.3 – 1.5 Ω
Pick-up coil peak voltage
More than 4.0 V
Generator Max. output
175 W at 5 000 r/min
Generator no-load voltage
More than 45 V (AC) at 5 000 r/min
Regulated voltage
13.5 – 15.0 V at 5 000 r/min
Starter relay resistance
3–6Ω
Battery
Type designation
FTX7L-BS
Capacity
12V 21.6 kC (6 Ah)/10HR
Fuse size
20A
Headlight
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork inner tube O.D.
Front fork oil type
Front fork oil capacity (each leg)
Front fork oil level
Rear wheel travel
Swingarm pivot shaft runout
3 – 5Ω
ITEM
3/5
Axial
Radial
Front
Rear
Front
Rear
Primary
Ignition coil primary peak voltage
Generator coil resistance
Rear brake pedal free travel
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Brake drum I.D.
Brake lining thickness
ITEM
Wheel rim runout
SPECIFICATION
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8 mm
Over 8 mm at 1 atm.
Type
WATTAGE
SPECIFICATION
MIKUNI BS26SS
26 mm
12FH
1 500 ± 100 r/min
17.1 ± 0.5 mm
# 112.5
5D109-3rd
P-0
# 12.5
2 turns out
2 – 4 mm
0.5 – 1.0 mm
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
ELECTRICAL
Rear
Rear
20 – 30
50
5.0 ± 0.2
—
12.700 – 12.743
12.657 – 12.684
42.850 – 42.900
42.772 – 42.822
DOT 4
—
—
4/5
LIMIT
—
—
4.5
0.30
—
—
—
—
—
130.7
1.5
P-02, 19
P-19
67
GZ250
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
26
(1.0)
22
(0.9)
0.03 – 0.08
(0.001 – 0.003)
0.08 – 0.13
(0.003 – 0.005)
0.025 – 0.052
(0.0010 – 0.0020)
0.040 – 0.067
(0.0016 – 0.0026)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
—
5.500
(0.2165
5.460
(0.2150
5.445
(0.2144
IN.
EX.
– 5.512
– 0.2170)
– 5.475
– 0.2156)
– 5.460
– 0.2150)
Unit: mm (in)
LIMIT
—
Camshaft journal oil clearance
Camshaft journal holder I.D.
R. side
L. side
—
Camshaft journal O.D.
—
R. side
0.35
(0.014)
L. side
—
Camshaft runout
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
Rocker arm shaft O.D.
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
3.6
(0.14)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
40.1
(1.58)
18.4 – 21.6 kgf
(40.56 – 47.62 lbs)
at length 35.0 mm (1.38 in)
IN.
—
12.000
(0.4724
11.966
(0.4711
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
—
Piston diam.
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
18.006 – 18.014
(0.7089 – 0.7092)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.65
(0.004 – 0.026)
20.95 – 21.00
(0.825 – 0.827)
60.0 ± 0.1
(2.362 ± 0.004)
Conrod big end width
Crankshaft web to web width
Crankshaft runout
—
Balancer spring free length
—
—
—
CLUTCH
ITEM
Clutch cable play
Clutch release screw
Drive plate thickness
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
3.45 – 3.55
(0.136 – 0.140)
15.9 – 16.0
(0.626 – 0.630)
No.1
No.2
Drive plate claw width
3/8
Approx. 11.0 (0.43)
2nd
0.10 – 0.22
(0.004 – 0.009)
0.22 – 0.34
(0.009 – 0.013)
1st
—
2nd
—
2/8
ITEM
Driven plate distortion
Clutch spring free length
LIMIT
—
—
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
3.15
(0.124)
15.0
(0.590)
P-03, 09, 19, 28, 33
0.05
(0.002)
8.0
(0.31)
8.8
(0.35)
0.50
(0.020)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
P-03, 09, 19, 28, 33
LIMIT
0.10
(0.004)
40.9
(1.61)
STANDARD
3.238 (68/21)
2.733 (41/15)
2.636 (29/11)
1.687 (27/16)
1.263 (24/19)
1.000 (20/20)
0.818 (18/22)
0.20 – 0.40
(0.008 – 0.016)
4.25 – 4.35
(0.167 – 0.171)
3.95 – 4.05
(0.156 – 0.159)
D.I.D.520VC5
110
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Type
Links
20-pitch
length
—
0.05
(0.002)
10.0
(0.39)
71.880
(2.8299)
—
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
0.120
(0.0047)
72.085
(2.8380)
—
TRANSMISSION + DRIVE CHAIN
Unit: mm (in)
LIMIT
18.040
(0.7102)
3.0
(0.12)
1.0
(0.04)
—
STANDARD
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.60
(0.024)
—
—
—
—
319.4
(12.57)
—
Drive chain slack
5 – 15
(0.2 – 0.6)
—
CARBURETOR
SPECIFICATION
ITEM
STANDARD
2.812 (68/21 × 33/38)
Above 30 kPa (0.3 kgf/cm2, 4.3 psi)
Below 70 kPa (0.7 kgf/cm2, 10.0 psi)
at 3 000 r/min
Approx. 10.0 (0.39)
N
—
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60°C, 140°F)
N
—
—
—
0.05
(0.002)
0.05
(0.002)
1st
P
M
18.030
(0.7098)
17.980
(0.7079)
– 12.018
– 0.4731)
– 11.984
– 0.4718)
2nd
E
L
P-03, 09, 19, 28, 33
LIMIT
—
0.10
(0.004)
STANDARD
1 000 – 1 400 kPa
(10.0 – 14.0 kgf/cm2, 142 – 199 psi)
0.045 – 0.055
(0.0018 – 0.0022)
72.000 – 72.015
(2.8346 – 2.8352)
71.950 – 71.965
(2.8327 – 2.8333)
Measure at 15 mm (0.6 in) from the skirt end.
1st
Piston ring to groove clearance
STANDARD
1.01 – 1.03
(0.040 – 0.041)
1.21 – 1.23
(0.047 – 0.048)
2.51 – 2.53
(0.099 – 0.100)
0.975 – 0.990
(0.0384 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
18.002 – 18.008
(0.7087 – 0.7090)
17.992 – 18.000
(0.7083 – 0.7087)
—
—
Piston ring end gap
1st
—
CYLINDER + PISTON + PISTON RING
Piston ring free end gap
ITEM
Piston ring groove width
—
—
Cylinder distortion
1/8
Unit: mm (in)
LIMIT
34.690
(1.3657)
34.730
(1.3673)
0.150
(0.0059)
STANDARD
34.990 – 35.040
(1.3776 – 1.3795)
35.030 – 35.080
(1.3791 – 1.3811)
0.032 – 0.066
(0.0013 – 0.0026)
25.012 – 25.025
(0.9847 – 0.9852)
20.012 – 20.025
(0.7879 – 0.7884)
24.959 – 24.980
(0.9826 – 0.9835)
19.959 – 19.980
(0.7858 – 0.7866)
EX.
—
IN. & EX.
IN. & EX.
ITEM
Cam height
—
Valve stem runout
Valve spring tension
CAMSHAFT + CYLINDER HEAD
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot air jet No.1
Pilot air jet No.2
Pilot screw
Throttle cable play
Starter plunger cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.A.J.1)
(P.A.J.2)
(P.S.)
P-03, 09, 28
MIKUNI BSR32
32 mm
13F3
1 300 ± 100 r/min
13.0 ± 0.5 mm
# 120
5C65
P-0M
# 17.5
# 87.5
# 120
PRE-SET
2 – 4 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
4/8
P-33
←
←
13F4
←
←
←
←
←
←
←
←
←
←
←
P-03, 09, 19, 28, 33
68
CARBURETOR
ITEM
SPECIFICATION
P-19
MIKUNI BSR32
32 mm
13F9
1 300 ± 100 r/min
13.0 ± 0.5 mm
# 115
5C60-3rd
P-0
# 17.5
# 87.5
# 140
2 and 1/2 turns out
2 – 4 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot air jet No. 1
Pilot air jet No. 2
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.A.J.1)
(P.A.J.2)
(P.S.)
Starter plunger cable play
Fuse size
HI
Headlight
LO
Turn signal
Ignition
Taillight
Spark plug
Gap
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
Generator Max. output
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Primary
3 – 5Ω
Secondary
17 – 28 kΩ
Headlight
Unit: mm (in)
NOTE
Terminal –
Terminal
Terminal –
Plug cap
HI
LO
Position light
Brake light/Taillight
Turn signal light
Front turn signal light/Running light
Speedometer light
Neutral indicator light
Turn signal indicator light
High beam indicator light
Bl – G
Y–Y
21/5
21 (rear)
21/5
1.7
3.4
3.4
1.7
ITEM
Rear brake pedal free travel
Brake disc thickness
Brake disc runout
Brake caliper cylinder bore
E
L
Brake lining thickness
A
S
Radial
Wheel axle runout
Front
Wheel rim size
Front
Rear
—
—
Rear
Tire size
Tire tread depth
—
Rear
16 × MT2.50 or 16M/C × MT2.50
15M/C × MT3.00
110/90-16 59P, 110/90-16M/C 59P or
110/90-16M/C 59S
130/90-15M/C 66P or
130/90-15M/C 66S
Front
—
Front
Rear
—
STANDARD/SPECIFICATION
120
(4.7)
308
(12.1)
SUZUKI fork oil SS-08 (#10)
336 ml
(11.4/11.8 US/lmp oz)
120
(4.7)
90
(3.5)
Front fork spring free length
Front fork oil type
Front fork oil capacity (each leg)
Front fork oil level
Rear wheel travel
Swingarm pivot shaft runout
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
4.5
(0.18)
0.30
(0.012)
Rear
—
Rear
—
—
—
—
—
—
130.7
(5.15)
1.5
(0.06)
P-03, 09, 19, 28, 33
FUEL + OIL
ITEM
SPECIFICATION
Fuel type
NOTE
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank including reserve
—
Unit: mm (in)
LIMIT
Unit: mm (in)
LIMIT
12.700 – 12.743
(0.4999 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
42.850 – 42.900
(1.6870 – 1.6890)
42.772 – 42.822
(1.6839 – 1.6859)
DOT 4
6/8
—
1.6
(0.06)
2.0
(0.08)
SUSPENSION
ITEM
Front fork stroke
P
M
P-03, 09, 19, 28, 33
—
←
←
←
←
—
Master cylinder piston diam.
STANDARD/SPECIFICATION
←
←
←
←
←
←
Front
Brake fluid type
Brake drum I.D.
Axial
P-09
←
←
STANDARD/SPECIFICATION
20 – 30
(0.8 – 1.2)
50
(2.0)
5.0 ± 0.2
Front
(0.20 ± 0.01)
Master cylinder bore
5/8
SPECIFICATION
P-19
←
←
4
←
10
BRAKE + WHEEL
Rear brake pedal height
More than 200 V
Pick-up
400 – 650 Ω
Charging
0.1 – 1.5 Ω
More than 5.0 V
210 W at 5 000 r/min
More than 60 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–6Ω
FTX7L-BS
12V 21.6 kC (6 Ah)/10HR
P-03, 28, 33
60
55
Brake caliper piston diam.
ITEM
Wheel rim runout
P-19
The others
P-19
The others
P-19
The others
Unit: W
ITEM
SPECIFICATION
NGK: DR8EA
DENSO: X24ESR-U
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
NOTE
WATTAGE
ELECTRICAL
ITEM
SPECIFICATION
20 A
10 A
15 A
10 A
15 A
10 A
15 A
10 A
10 A
Main
reserve
Engine oil type and grade
Engine oil capacity
13 L
(3.4/2.9 US/lmp gal)
14 L
(3.7/3.1 US/lmp gal)
2.9 L
(0.8/0.6 US/lmp gal)
SAE 10W-40, API SF or SG
1 300 ml
Change
(1.4/1.1 US/lmp qt)
Filter
1 400 ml
change
(1.5/1.2 US/lmp qt)
1 700 ml
Overhaul
(1.8/1.5 US/lmp qt)
P-03, 28, 33
The others
P-19, 33
The others
301
(11.9)
—
—
—
—
0.3
(0.01)
—
TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
175
200
SOLO RIDING
kgf/cm2
1.75
2.00
7/8
psi
25
29
kPa
175
225
DUAL RIDING
kgf/cm2
1.75
2.25
psi
25
33
P-03, 09, 19, 28, 33
8/8
P-03, 09, 19, 28, 33
69
LS650
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
33
(1.3)
28
(1.1)
8.5
(0.33)
8.5
(0.33)
0.08 – 0.13
(0.003 – 0.005)
0.025 – 0.055
(0.0010 – 0.0022)
0.040 – 0.070
(0.0016 – 0.0028)
IN.
EX.
Valve lift
IN.
EX.
Valve clearance (when cold)
Valve guide to valve stem
clearance
IN. & EX.
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
—
7.000
(0.2756
6.960
(0.2740
6.945
(0.2734
EX.
– 7.015
– 0.2762)
– 6.975
– 0.2746)
– 6.960
– 0.2740)
Unit: mm (in)
LIMIT
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
Left
Right &
Center
—
Camshaft journal O.D.
—
Left
Right &
Center
—
0.35
(0.014)
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
—
Rocker arm shaft O.D.
IN. & EX.
—
Cylinder head distortion
—
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.9
(0.11)
Valve seat width
IN. & EX.
1.0 – 1.2
(0.039 – 0.047)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
35.6
(1.40)
40.4
(1.59)
OUTER
IN.
—
IN. & EX.
6.9 – 8.5 kgf
(15.2 – 18.7 lbs)
at length 31.0 mm (1.2 in)
16.4 – 18.8 kgf
(36.2 – 41.4 lbs)
at length 33.0 mm (1.3 in)
STANDARD
36.174 – 36.228
(1.4242 – 1.4263)
36.419 – 36.473
(1.4338 – 1.4359)
0.032 – 0.066
(0.0013 – 0.0026)
20.012 – 22.025
(0.7879 – 0.7884)
25.012 – 25.025
(0.9847 – 0.9852)
19.959 – 19.976
(0.7858 – 0.7865)
24.959 – 24.976
(0.9826 – 0.9833)
EX.
—
Valve head thickness
INNER
ITEM
Cam height
—
Valve stem runout
Valve spring tension (IN. & EX.)
CAMSHAFT + CYLINDER HEAD
12.000
(0.4724
11.966
(0.4711
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
ITEM
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
STANDARD
1.23 – 1.25
(0.0484 – 0.0492)
1.21 – 1.23
(0.0476 – 0.0484)
2.81 – 2.83
(0.1106 – 0.1114)
1.175 – 1.190
(0.0463 – 0.0469)
1.175 – 1.190
(0.0463 – 0.0469)
23.000 – 23.006
(0.9055 – 0.9057)
22.996 – 23.000
(0.9054 – 0.9055)
CONROD + CRANKSHAFT + BALANCER
ITEM
Corod small end I.D.
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
70.0 ± 0.1
(2.756 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
Balancer spring free length
—
LIMIT
—
—
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
3.45 – 3.55
(0.136 – 0.140)
No. 1
No. 2
3/8
Unit: mm (in)
—
0.05
(0.002)
9.2
(0.36)
11.2
(0.44)
1.00
(0.039)
1.00
(0.039)
0.18
(0.007)
0.15
(0.006)
Approx. 11.5 (0.45)
2nd
T
Approx. 14.0 (0.55)
1st
0.30 –
(0.012 –
0.25 –
(0.010 –
1st
—
—
2/8
STANDARD
15.8 – 16.0
(0.622 – 0.630)
15.9 – 16.0
(0.626 – 0.630)
No. 1
No. 2
—
—
Clutch spring free length
—
—
DRIVE TRAIN
Unit: mm (in)
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.039)
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
—
—
0.05
(0.002)
10.0
(0.39)
Shift fork thickness
Drive belt
LIMIT
15.0
(0.591)
15.1
(0.594)
0.1
(0.004)
33.0
(1.30)
Unit: mm (in) Except ratio
STANDARD
LIMIT
1.810 (67/37)
—
2.956 (68/23)
—
2.333 (35/15)
—
1.578 (30/19)
—
1.142 (24/21)
—
0.956 (22/23)
—
0.884 (23/26)
—
0.10 – 0.30
0.50
(0.004 – 0.012)
(0.020)
5.50 – 5.60
—
(0.217 – 0.220)
5.50 – 5.60
—
(0.217 – 0.220)
5.50 – 5.60
—
(0.217 – 0.220)
5.30 – 5.40
—
(0.209 – 0.213)
BANDO: 133U-14M 40.0
—
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Shift fork groove width
93.880
(3.6961)
E-03, 28, 33
Driven plate distortion
23.030
(0.9067)
22.980
(0.9047)
0.45
0.018)
0.40
0.016)
2nd
3rd drive
gear
4th driven
gear
Top driven
gear
No. 1, No. 2
& No. 3
Type
Number of
teeth
133
Gearshift lever height
STANDARD
2.203 (68/36 × 35/30)
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
—
—
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
ITEM
Drive plate claw width
—
—
T
E
L
P
M
—
3–5
(0.12 – 0.20)
1st
2nd
E-03, 28, 33
—
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
0.120
(0.0047)
94.080
(3.7039)
Cylinder distortion
Piston ring to groove clearance
—
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 200 psi)
0.050 – 0.060
(0.0020 – 0.0024)
94.000 – 94.015
(3.7008 – 3.7014)
93.945 – 93.960
(3.6986 – 3.6992)
Measure at 20 mm (0.8 in) from the skirt end.
—
Piston ring free end gap
—
0.05
(0.002)
0.05
(0.002)
CYLINDER + PISTON + PISTON RING
Piston ring end gap
1/8
– 12.018
– 0.4731)
– 11.984
– 0.4718)
—
De-comp. cable play
—
0.10
(0.004)
—
Cylinder head cover distortion
Unit: mm (in)
LIMIT
35.880
(1.4126)
36.120
(1.4220)
0.150
(0.0060)
60
(2.4)
LIMIT
—
—
—
—
Unit: mm (in)
LIMIT
—
2.62
(0.103)
3.15
(0.124)
E-03, 28, 33
4/8
E-03, 28, 33
70
CARBURETOR
WATTAGE
SPECIFICATION
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
E-03, 28
MIKUNI BS40SS
40 mm
24C9
1 100 ± 100 r/min
27.95 ± 1.0 mm
(1.1 ± 0.04 in)
#
5C39
E-33
←
←
24CA
←
Type
Gap
Primary
10 – 25 kΩ
P
M
A
S
Unit: mm (in)
Brake drum I.D.
Rear
Brake lining thickness
Rear
Brake disc thickness
Front
Brake disc runout
Front
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Wheel rim runout
Axial
E
L
E-03, 28, 33
STANDARD
20 – 30
(0.8 – 1.2)
60
(2.4)
Rear brake pedal height
Tire tread depth
O/G
O/W – Ground
Plug cap –
Ground
20 A
ITEM
Rear brake pedal free travel
Tire size
NOTE
1.28 at 20 °C (68 °F)
BRAKE + WHEEL
Wheel rim size
5
3
3
1.7
3
8
More than 100 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
2–6Ω
YB14L-B2
12 V
50.4 kC (14 Ah)/10 HR
5/8
Wheel axle runout
21/5
21
←
SPECIFICATION
NGK: DPR8EA-9
N.D.: X24EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
0.1 – 1.0 Ω
170 – 270 Ω
1–7Ω
Secondary
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery
Type designation
Voltage
Capacity
Standard
electrolyte S.G.
Fuse size
HI
LO
Unit: mm (in)
ITEM
Spark performance
Solenoid resistance
Pick-up coil resistance
Ignition coil resistance
SPECIFICATION
60
55
Parking or City light
Brake light/Taillight
Turn signal light
Running light
(within front turn signal light)
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
License light
←
ELECTRICAL
Spark plug
Headlight
←
←
←
←
←
←
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
#120
(P.J.)
#
(P.S.) PRE-SET (1 and 1/2 turns back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
Unit: W
ITEM
LIMIT
—
—
—
—
4.5 ± 0.2
(0.18 ± 0.01)
—
12.700
(0.4999
12.657
(0.4983
42.850
(1.6870
42.770
(1.6839
–
–
–
–
–
–
–
–
12.743
0.5017)
12.684
0.4994)
42.926
1.6900)
42.820
1.6858)
—
Radial
—
Front
—
Rear
—
Front
Rear
Front
Rear
19 × 2.15
15M/C × 2.75
100/90-19M/C 57H
140/80-15 M/C 67H
Front
—
Rear
—
160.7
(6.33)
1.5
(0.06)
4.0
(0.16)
0.30
(0.012)
—
—
—
ITEM
Front fork stroke
Unit: mm (in)
STANDARD
140
(5.5)
LIMIT
Front fork spring free length
Front fork oil level
Rear wheel travel
Swingarm pivot shaft runout
—
392.5
(15.45)
75.0
(2.95)
80
(3.1)
—
—
0.3
(0.001)
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
200
225
—
SOLO RIDING
kgf/cm2
2.00
2.25
psi
29
33
kPa
200
250
DUAL RIDING
kgf/cm2
2.00
2.50
psi
29
36
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the reserch method.
Gasoline containing MTBE (MethyI Tertiary ButyI
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
Including
10.5 L
reserve
(2.8/2.3 US/Imp gal)
Only
2.5 L
reserve
(0.66/0.55 US/lmp gal)
SAE 10W-40, API SF or SG
Oil
1 800 ml
change
(1.9/1.6 US/lmp qt)
Oil and
2 000 ml
filter change
(2.1/1.8 US/lmp qt)
Engine
2 400 ml
overhaul
2.5/2.1 US/lmp qt)
Fork oil #15
447 ml
(15.11/15.74 US/lmp oz)
Brake fluid type
E-03, 28, 33
NOTE
—
TIRE PRESSURE
Front fork oil type
Front fork oil capacity (each leg)
7/8
E-03, 28, 33
SUSPENSION
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
6/8
NOTE
E-03, 28, 33
Spacer
L: 135 mm
DOT 4
8/8
E-03, 28, 33
71
LT-160/F160
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
28
(1.1)
25
(1.0)
0.03 – 0.08
(0.001 – 0.003)
0.05 – 0.10
(0.002 – 0.004)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Unit: mm (in)
LIMIT
—
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
P-03
EX.
—
IN.
—
P-33
EX.
—
—
Camshaft journal oil clearance
IN. & EX.
—
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Camshaft runout
IN. & EX
—
Rocker arm I.D.
IN. & EX
EX.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2155 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2153)
—
Rocker arm shaft O.D.
IN. & EX
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
0.03
(0.001)
39.5
(1.56)
Valve stem O.D.
IN.
Valve spring free length (IN. & EX.)
—
Valve spring tension (IN. & EX.)
18.4 – 21.6 kgf
(40.6 – 47.6 lbs)
at length 36.8 mm (1.45 in)
12.000
(0.4724
11.977
(0.4715
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
—
Piston diam.
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
—
0.10 – 0.45
(0.0039 – 0.0177)
15.95 – 16.00
(0.628 – 0.630)
53.0 ± 0.1
(2.087 ± 0.004)
Crankshaft runout
P
M
P-03, 19, 24, 28, 33, 51
—
14.030
(0.5524)
13.980
(0.5504)
Unit: mm (in)
LIMIT
14.040
(0.5528)
3.0
(0.12)
1.00
(0.039)
—
0.05
(0.002)
STANDARD
Above 30 kPa (0.30 kgf/cm2, 4.3 psi)
Below 70 kPa (0.70 kgf/cm2, 10.0 psi)
at 3 000 r/min
LIMIT
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
Drive plate claw width
STANDARD
0 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
Driven plate distortion
—
Clutch spring free length
—
Clutch shoe
—
Clutch engagement
Clutch lock-up
2 200 ± 200 r/min
3 500 ± 250 r/min
—
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.43)
0.10
(0.004)
27.6
(1.09)
No groove at
any parts
—
—
P-03, 19, 24, 28, 33, 51
1st & 2nd
0.010 – 0.025
(0.004 – 0.010)
1st
—
2nd
—
1st & 2nd
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Shift fork groove width
No. 1, No. 2
& No. 3
Shift fork thickness
No. 1, No. 2
& No. 3
Reverse
Reverse
Drive chain
Type
Links
20-pitch
length
Drive chain slack
Gearshift lever height
—
2/7
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
0.120
(0.0047)
58.100
(2.2874)
57.880
(2.2787)
0.05
(0.002)
4.7
(0.19)
6.0
(0.24)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
P-03, 19, 24, 28, 33, 51
Unit: mm (in) Except ratio
STANDARD
LIMIT
3.736 (71/19)
—
3.545 (39/11)
—
3.166 (38/12)
—
2.142 (30/14)
—
1.588 (27/17)
—
1.200 (24/20)
—
0.950 (19/20)
—
2.833 (29/12 × 34/29)
—
0.10 – 0.30
0.50
(0.004 – 0.012)
(0.020)
4.50 – 4.60
—
(0.177 – 0.181)
4.00 – 4.10
—
(0.157 – 0.161)
4.30 – 4.40
—
(0.169 – 0.173)
3.80 – 3.90
—
(0.150 – 0.154)
TAKASAGO: RK520SM
—
84
—
319.4
—
(12.57)
20 – 30
—
(0.8 – 1.2)
10
—
(0.4)
CARBRETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Starter jet
Pilot screw
Throttle cable play
Starter cable play
3/7
Approx. 5.8 (0.23)
Approx. 7.4 (0.29)
DRIVE TRAIN
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
R
R
Oil
—
—
1st
2nd
E
L
Piston ring groove width
LIMIT
—
0.05
(0.002)
0.05
(0.002)
—
Piston ring to groove clearance
STANDARD
1.17 – 1.19
(0.046 – 0.047)
14.002 – 14.008
(0.5513 – 0.5515)
13.996 – 14.000
(0.5510 – 0.5512)
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
0.030 – 0.040
(0.0012 – 0.0016)
58.000 – 58.015
(2.2835 – 2.2841)
57.965 – 57.980
(2.2821 – 2.2827)
Measure at 20 mm (0.8 in) from the skirt end.
Piston ring end gap
1st & 2nd
—
0.10
(0.004)
CYLINDER + PISTON + PISTON RING
Piston ring free end gap
ITEM
Piston ring thickness
—
—
Cylinder distortion
1/7
Unit: mm (in)
LIMIT
33.470
(1.3177)
33.090
(1.3028)
33.190
(1.3067)
33.060
(1.3016)
0.150
(0.0059)
STANDARD
33.768 – 33.808
(1.3295 – 1.3310)
33.390 – 33.430
(1.3146 – 1.3161)
33.490 – 33.530
(1.3185 – 1.3201)
33.353 – 33.393
(1.3131 – 1.3147)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(G.S.)
(P.S.)
SPECIFICATION
P-03
P-33
MIKUNI VM20SS
MIKUNI BS26SS
20 mm
26 mm
02C02
02C1
1 500 ± 100 r/min
←
25.8 ± 1.0 mm
21.4 ± 1.0 mm
(1.02 ± 0.04 in)
(0.84 ± 0.04 in)
#87.5
#
5FU96-3rd
4DN13-1st
O-1
#22.5
#
#22.5
#20
1 and 5/8 turns back
PRE-SET
3 – 5 mm
←
(0.12 – 0.20 in)
0.5 – 1.0 mm
←
(0.02 – 0.04 in)
4/7
P-03, 19, 24, 28, 33, 51
72
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Magneto coil resistance
Generator no-load voltage
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard
electrolyte S.G.
Fuse size
Unit: mm (in)
NOTE
SPECIFICATION
NGK: DPR7EA-9
ND: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
Primary
0.1 – 1.0 Ω
Secondary
10 – 25 kΩ
BRAKE + WHEEL
ITEM
Front brake lever free travel
Rear brake pedal free travel
Brake drum I.D.
Terminal –
Ground
Plug cap –
Ground
BI – G
Y–Y
Pulser
380 – 600 Ω
Charging
0.5 – 1.2 Ω
More than 55 V (AC) at 5 000 r/min
Approx. 150 W at 5 000 r/min
13.5 – 15.5 V at 5 000 r/min
3–7Ω
YB9A-A
12 V 32.4 kC (9 Ah)/10 HR
Front
Rear
Steering angle
1.28 at 20 °C (68 °F)
Wheel rim size
Tire size
Unit: W
Tire tread depth
SPECIFICATION
45
45
5
3.4
3.4
HI
LO
Taillight
Reverse indicator light
Neutral indicator light
41°
30°
2.4 m (7.9 ft)
3 – 11 (0.1 – 0.4)
8°
31 (1.2)
Rear
—
Front
Rear
Front
Rear
15 A
ITEM
—
—
Inside
Outside
8 × 5.5 AT
8 × 8.0 AT
AT 20 × 7-8
AT 22 × 10-8
4.0
(0.16)
4.0
(0.16)
Front
Rear
Unit: mm (in)
LIMIT
—
—
120.7
(4.75)
150.7
(5.93)
1.5
(0.06)
—
—
—
—
—
—
8.0
(0.31)
—
—
—
—
—
Brake lining thickness
Turning radius
Toe-in (with 75 kg, 165 lbs)
Caster
Trail
Wheel axle runout
WATTAGE
Headlight
STANDARD/SPECIFICATION
30
(1.2)
20 – 30
(0.8 – 1.2)
—
—
SUSPENSION
ITEM
Rear shock absorber spring
setting
Front wheel travel
Rear wheel travel
Swingarm pivot shaft runout
STANDARD
LIMIT
3rd position
—
80
(3.1)
90
(3.5)
—
—
0.6
(0.02)
NOTE
—
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
E
L
FRONT
REAR
5/7
A
S
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
8.5 L
(2.2/1.9 US/lmp gal)
1.1 L
(0.3/0.2 US/lmp gal)
SAE 10W-40, API, SF or SG
1 500 ml
Change
(1.6/1.3 US/lmp qt)
1 700 ml
Filter change
(1.8/1.5 US/lmp qt)
1
900 ml
Overhaul
(2.0/1.8 US/lmp qt)
7/7
P
M
P-03, 19, 24, 28, 33, 51
NOTE
P-03, 19, 24, 28, 33, 51
kPa
25
20
6/7
LOAD CAPACITY
130 kg (285 lbs)
kgf/cm2
0.25
0.20
psi
3.6
2.9
P-03, 19, 24, 28, 33, 51
73
LT-A400/F
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
30.6
(1.20)
27.0
(1.06)
0.05 – 0.10
(0.002 – 0.004)
0.22 – 0.27
(0.009 – 0.011)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
LIMIT
¬ 17.5
—
Camshaft journal O.D.
¬ 17.5
—
Camshaft runout
—
—
—
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
38.8
(1.53)
IN. & EX.
182 – 210 N
(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)
at length 31.5 mm (1.24 in)
—
CAMSHAFT + CYLINDER HEAD
Cam height
STANDARD
33.130 – 33.190
(1.3043 – 1.3067)
33.130 – 33.190
(1.3043 – 1.3067)
0.032 – 0.066
(0.0013 – 0.0026)
0.028 – 0.059
(0.0011 – 0.0023)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.6894 – 0.6900)
IN.
EX.
Camshaft journal oil clearance
¬ 22
¬ 17.5
Camshaft journal holder I.D.
¬ 22
¬ 17.5
1/7
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
ITEM
Conrod small end I.D.
STANDARD
20.006 – 20.014
(0.7876 – 0.7879)
—
Conrod big end side clearance
0.10 – 0.55
(0.004 – 0.022)
21.95 – 22.00
(0.864 – 0.866)
60.0 ± 0.1
(2.362 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
32.830
(1.2925)
32.830
(1.2925)
0.150
(0.0059)
0.150
(0.0059)
—
ITEM
Compression pressure
(Automatic-decomp. actuated)
Piston to cylinder clearance
Cylinder bore
LIMIT
—
—
20.030
(0.7886)
19.980
(0.7866)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
Piston ring end gap
—
DRIVE TRAIN
3/7
—
0.05
(0.002)
0.05
(0.002)
—
0.060 – 0.075
(0.0023 – 0.0030)
82.000 – 82.015
(3.2283 – 3.2289)
81.930 – 81.945
(3.2256 – 3.2262)
Measure at 15 mm (0.6 in) from the skirt end.
0.120
(0.0047)
82.070
(3.2311)
—
0.05
(0.002)
8.9
(0.35)
8.3
(0.33)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
1st
R
Approx. 11.2 (0.44)
2nd
R
Approx. 10.4 (0.41)
2nd
0.15 –
(0.006 –
0.15 –
(0.006 –
1st
—
2nd
—
—
—
2/7
ITEM
Drive belt width
Movable driven face spring
free length
Shift fork to groove clearance
High/Low
Reverse
Shift fork thickness
0.27
0.011)
0.27
0.011)
1.01 – 1.03
(0.0398 – 0.0406)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
1st
2nd
Shift fork groove
width
81.880
(3.2236)
—
E
L
Piston ring groove width
LIMIT
Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi)
High/Low
Reverse
Front/rear output shaft bevel gear
backlash
Front drive (differential) gear
backlash
Rear drive (final) gear backlash
P-17, 24, 28, 33
STANDARD
30.3
(1.19)
215.0
(8.46)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
5.50 – 5.60
(0.217 – 0.220)
5.30 – 5.40
(0.209 – 0.213)
5.30 – 5.40
(0.209 – 0.213)
0.03 – 0.15
(0.001 – 0.006)
0.05 – 0.10
(0.002 – 0.004)
0.08 – 0.013
(0.0031 – 0.0051)
LIMIT
29.3
(1.15)
204.3
(80.4)
0.50
(0.020)
—
—
—
—
—
—
—
ENGINE OIL TEMP. SWITCH + COOLING FAN THERMO-SWITCH
ITEM
Engine oil temp. indicator
light switch operating temperature
Cooling fan thermo-switch
operating temperature
STANDARD/SPECIFICATION
OFF→ON
Approx. 160 °C (320 °F)
ON→OFF
Approx. 140 °C (284 °F)
OFF→ON
Approx. 120 °C (248 °F)
ON→OFF
Approx. 110 °C (230 °F)
LIMIT
—
—
—
—
—
CARBURETOR
LIMIT
140.5
(5.53)
No groove at
any part
—
—
Unit: mm (in) Except ratio
STANDARD
Variable change (2.938 – 0.813)
2.730 (42/19 × 21/17)
3.600 (36/10)
3.600 (36/10)
2.500 (40/16)
1.375 (33/24)
2.000 (32/16)
—
Unit: mm (in)
1st
Piston ring to groove clearance
Unit: mm (in)
1 900 – 2 300 r/min
3 400 – 4 000 r/min
12.018
0.4731)
11.984
0.4718)
—
LIMIT
Clutch shoe
—
STANDARD
Cylinder distortion
P
M
STANDARD
Above 110 kPa (1.1 kgf/cm2, 16 psi)
Below 150 kPa (1.5 kgf/cm2, 21 psi)
at 3 000 r/min
STANDARD
140.0 – 140.2
(5.512 – 5.520)
—
CYLINDER + PISTON + PISTON RING
—
0.080
(0.0031)
ITEM
Clutch wheel I.D.
ITEM
Automatic transmission ratio
Secondary reduction ratio
Final reduction ratio
Front
Rear
Transfer gear ratio
Low
High
Reverse
Cylinder head cover distortion
Oil
—
CLUTCH
Clutch engagement r/min
Clutch lock-up r/min
—
—
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
—
0.10
(0.004)
12.000 –
(0.4724 –
11.973 –
(0.4714 –
Cylinder head distortion
—
Unit: mm (in)
Conrod deflection
IN. & EX.
IN. & EX.
Piston ring free end gap
A
S
CONROD + CRANKSHAFT
Rocker arm I.D.
Rocker arm shaft O.D.
P-17, 24, 28, 33
STANDARD
0.970 – 0.990
(0.0382 – 0.0390)
0.970 – 0.990
(0.0382 – 0.0390)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7870 – 0.7874)
—
—
Piston diam.
Unit: mm (in)
ITEM
LIMIT
22.025
0.8671)
17.525
0.6900)
21.980
0.8654)
17.484
0.6883)
—
Valve seat width
Valve spring tension
¬ 22
—
Valve stem end length
IN. & EX.
STANDARD
22.012 –
(0.8666 –
17.512 –
(0.6894 –
21.959 –
(0.8645 –
17.466 –
(0.6876 –
¬ 22
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
2.3
(0.09)
Valve head thickness
ITEM
Camshaft journal holder I.D.
LIMIT
—
—
—
—
—
—
—
P-17, 24, 28, 33
ITEM
Caburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Slow jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(S.J.)
(P.S.)
SPECIFICATION
P-17, 24, 28
KEIHIN CVK32
32 mm
38F2
1 500 ± 100 r/min
17.0 ± 1.0 mm
(0.67 ± 0.04 in)
#122
NBZA
#6
#38
2 and 1/4 turns back
3 – 5 mm
(0.12 – 0.20 in)
4/7
P-33
←
←
38F1
←
←
#
←
#
#
PRE-SET
←
P-17, 24, 28, 33
74
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Ignition coil primary peak voltage
Unit: mm (in)
ITEM
Rear brake cable play
Rear brake pedal free travel
Secondary
12 – 22 kΩ
Pick-up
Power
source
Charging
130 – 250 Ω
Terminal –
Terminal
Plug cap –
Terminal
Bl – G
0.05 – 1.2 Ω
Y–W
0.1 – 1.5 Ω
B–B
More than 60 V (AC) at 5 000 r/min
Approx. 225 W at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
: Ground
: W/BI
: G, : BI
: Y, : W
More than 180 V
Pick-up coil peak voltage
Power source coil peak voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
Main
Power source
Headlight (HI)
Headlight (LO)
Taillight
Ignition
Fan
BRAKE + WHEEL
Rear brake pedal height
0.1 – 1.0 Ω
Primary
Generator coil resistance
Unit: mm (in)
NOTE
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
More than 4.0 V
More than 0.3 V
3–5Ω
YTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
30 A
10 A
10 A
10 A
10 A
10 A
10 A
Brake disc thickness
Front
STANDARD/SPECIFICATION
3–5
(0.12 – 0.20)
5 – 15
(0.2 – 0.6)
20 – 30
(0.8 – 1.2)
3.3 – 3.7
(0.130 – 0.146)
Brake disc runout
—
Brake drum I.D.
Rear
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Brake fluid type
Steering angle
—
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
32.030 – 32.080
(1.2610 – 1.2630)
31.948 – 31.998
(1.2578 – 1.2598)
DOT 4
47°
47°
3.1 m (10.2 ft)
4±4
(0.16 ± 0.16)
0.3°
3°
12 × 6.0 AT
12 × 7.5 AT
AT25 8-12 ✩ ✩
AT25 10-12 ✩ ✩
Right
Left
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Front
Rear
Front
Rear
Tire size
Tire tread depth
WATTAGE
Front
—
Rear
—
Unit: W
SPECIFICATION
ITEM
P-17
30 × 2 pcs.
30 × 2 pcs.
21/5
1.7
3.4
3.4
3.4
3.4
21
Headlight
HI
LO
Brake light/Taillight
Speedometer light
Reverse indicator light
Neutral indicator light
Engine oil temp. indicator light
High beam indicator light
Reverse light
Others
←
←
←
←
←
←
←
—
—
5/7
P
M
P-17, 24, 28, 33
TIRE PRESSURE
A
S
LT-A400
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
32.5
27.5
0.325
0.275
kPa
kgf/cm2
32.5
30
0.325
0.30
psi
NOTE
4.7
4.0
LOAD CAPACITY
UP TO 172 kg (380 lbs)
psi
NOTE
4.7
4.4
LOAD CAPACITY
UP TO 172 kg (380 lbs)
LT-A400F
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
Front /Rear drive gear oil type
Front drive (differential) gear oil
capacity
Rear drive gear oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
15.0 L
(4.0/3.3 US/lmp gal)
3.3 L
(0.9/0.7 US/lmp gal)
SAE 10W-40, API SF or SG
2 900 ml
Change
(3.1/2.6 US/lmp qt)
3 100 ml
Filter change
(3.3/2.7 US/lmp qt)
3 400 ml
Overhaul
(3.6/3.0 US/lmp qt)
Hypoid gear oil SAE #90,
API grade GL-5
300 ml
(10.1/10.6 US/lmp oz)
350 ml
(11.8/12.3 US/lmp oz)
7/7
E
L
NOTE
P-03, 28, 33
Others
P-17, 24, 28, 33
6/7
LIMIT
—
—
—
3.0
(0.12)
0.30
(0.012)
160.7
(6.33)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
P-17, 24, 28, 33
75
LT-A500F
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
30.6
(1.20)
27.0
(1.06)
0.05 – 0.10
(0.002 – 0.004)
0.17 – 0.22
(0.007 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Unit: mm (in)
LIMIT
ITEM
Cam height
—
IN.
Camshaft journal oil clearance
—
«22
«17.5
—
Camshaft journal holder I.D.
—
«22
«17.5
—
Camshaft journal O.D.
—
«22
«17.5
—
—
Camshaft runout
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
2.3
(0.09)
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
Valve seat width
IN. & EX.
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
38.3
(1.53)
IN. & EX.
18.6 – 21.4 kgf
(41.0 – 47.2 lbs)
at length 31.5 mm (1.24 in)
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
(Automatic-decomp. actuated)
Piston to cylinder clearance
—
Cylinder bore
—
0.030 – 0.040
(0.0012 – 0.0016)
87.500 – 87.515
(3.4449 – 3.4455)
87.465 – 87.480
(3.4435 – 3.4441)
Measure at 15 mm (0.6 in) from the skirt end.
Nicks or
Scratches
1st
R
Approx. 11.2 (0.44)
2nd
R
Approx. 11.9 (0.47)
1st
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
P
M
—
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
0.097 – 0.99
(0.0382 – 0.0390)
1.17 – 1.19
(0.0461 – 0.0469)
23.002 – 23.008
(0.9056 – 0.9058)
22.995 – 23.000
(0.9053 – 0.9055)
LIMIT
0.180
(0.0071)
0.150
(0.0059)
—
—
—
23.030
(0.9067)
22.980
(0.9047)
ITEM
Conrod small end I.D.
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
71.0 ± 0.1
(2.795 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
Unit: mm (in)
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
STANDARD
Above 130 kPa (1.3 kgf/cm2, 18 psi)
Below 170 kPa (1.7 kgf/cm2, 24 psi)
at 3 000 r/min
CLUTCH
ITEM
Clutch wheel I.D.
STANDARD
140.0 – 140.2
(5.512 – 5.520)
Clurch shoe
Clutch engagement r/min
Clutch lock-up r/min
—
1 600 – 2 000 r/min
3 600 – 4 200 r/min
3/8
LIMIT
—
Unit: mm (in)
LIMIT
140.5
(5.53)
No groove at
any part
—
—
P-24, 28, 33
0.25
0.009)
0.25
0.009)
DRIVE TRAIN
ITEM
Automatic transmission ratio
Secondary reduction ratio
Final reduction ratio
Front
Rear
Transfer gear ratio
Low
High
Reverse
Drive belt width
Movable driven face spring free
length
Shift fork to groove clearance
Shift fork groove
width
High/Low
Reverse
CONROD + CRANKSHAFT
0.10 –
(0.004 –
0.10 –
(0.004 –
Shift fork thickness
High/Low
Reverse
Front/rear output shaft bevel gear
backlash
Front drive (defferential) gear backlash
Rear drive (final) gear backlash
STANDARD
Variable change (2.876 – 0.703)
2.562 (41/16)
3.600 (36/10)
3.600 (36/10)
2.500 (40/16)
1.200 (30/25)
2.000 (28/16 × 32/28)
36.7
(1.44)
153.0
(6.02)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
5.50 – 5.60
(0.217 – 0.220)
5.30 – 5.40
(0.209 – 0.213)
5.30 – 5.40
(0.209 – 0.213)
0.03 – 0.15
(0.001 – 0.006)
0.05 – 0.10
(0.002 – 0.004)
0.08 – 0.013
(0.0031 – 0.0051)
—
87.380
(3.4402)
0.05
(0.002)
8.9
(0.35)
9.5
(0.37)
0.50
(0.020)
0.50
(0.020)
2/8
—
—
Unit: mm (in)
LIMIT
Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi)
E
L
P-24, 28, 33
A
S
2nd
Piston ring groove width
—
0.05
(0.002)
0.05
(0.002)
STANDARD
2nd
—
—
—
Piston ring end gap
STANDARD
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
Piston ring free end gap
1st
—
—
0.10
(0.004)
12.000
(0.4724
11.973
(0.4714
Cylinder distortion
ITEM
Piston ring to groove clearance
—
—
—
Piston diam.
1/8
Unit: mm (in)
LIMIT
33.130
(1.3043)
33.200
(1.3071)
0.150
(0.0059)
0.150
(0.0059)
STANDARD
33.430 – 33.498
(1.3161 – 1.3188)
33.500 – 33.568
(1.3189 – 1.3216)
0.032 – 0.066
(0.0013 – 0.0026)
0.028 – 0.059
(0.0011 – 0.0023)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.6894 – 0.6900)
21.959 – 21.980
(0.8645 – 0.8654)
17.466 – 17.484
(0.6876 – 0.6883)
EX.
—
Valve stem deflection
Valve spring tension
CAMSHAFT + CYLINDER HEAD
P-24, 28, 33
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
35.7
(1.41)
145.4
(5.72)
0.50
(0.020)
—
—
—
—
—
—
—
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Engine coolant temp. indicator light
switch operating temperature
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
STANDARD/SPECIFICATION
73.5 – 76.5 °C
(164 – 170 °F)
Over 3 mm (0.12 in) at 90 °C (194 °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)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
2 000 ml
(2.1/1.8 US/lmp qt)
4/8
LIMIT
—
—
—
—
—
—
—
—
—
P-24, 28, 33
76
CARBURETOR
ITEM
SPECIFICATION
ITEM
Fuse size
P-24, 28
KEIHIN CVK36
36 mm
03G0
1 300 ± 100 r/min
17.0 ± 1.0 mm
(0.67 ± 0.04 in)
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
(M.J.)
#128
Jet needle
(J.N.)
NBAY
Needle jet
(N.J.)
#6
Slow jet
(S.J.)
#35
(P.S.)
1 and 7/8 turns back
Choke cable play
ITEM
Headlight
#
PRE-SET
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
←
←
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
NGK: CR6E
DENSO: U20ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Generator coil resistance
Primary
0.1 – 1.5 Ω
Secondary
12 – 22 kΩ
150 – 300 Ω
0.05 – 1.0 Ω
0.1 – 1.5 Ω
Pick-up
Power source
Charging
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Ignition coil primary peak voltage
More than 4.0 V
More than 0.3 V
3–5Ω
YTX20CH-BS
12 V 64.8 kC (18 Ah)/10 HR
5/8
Front
Rear
Brake fluid type
Steering angle
Right
Left
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Tire size
Tire type
Auxiliary light
Brake light/Taillight
Speedometer light
Reverse indicator light
Neutral indicator light
Parking indicator light
Hight beam indicator light
Engine coolant temp. indicator light
BRAKE + WHEEL
ITEM
Rear brake cable play
Terminal –
Ground
Plug cap –
Terminal
Bl – G
Y–W
B–B
Rear brake pedal height
Brake disc thickness
Front
Rear
STANDARD/SPECIFICATION
3–5
(0.12 – 0.20)
15 – 25
(0.59 – 0.98)
3.3 – 3.7
(0.130 – 0.146)
3.8 – 4.2
(0.209 – 0.224)
Brake disc runout
—
Master cylinder bore
Approx. 325 W at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
Pick-up coil peak voltage
Power source coil peak voltage
Starter relay resistance
Battery
Type designation
Capacity
ITEM
Brake caliper piston diam.
NOTE
SPECIFICATION
30 × 2 pcs.
30 × 2 pcs.
40
21/5
LED
LED
LED
LED
LED
LED
HI
LO
More than 60 V (AC) at 5 000 r/min
More than 150 V
Front
Rear
Front
Rear
Front
Rear
: Ground
: W/Bl
: G, : Bl
: Y, : W
Master cylinder piston diam.
—
—
Front
Rear
E
L
Brake caliper cylinder bore
Front
Rear
—
P
M
—
—
—
—
Fuel tank including
A
S
Tire tread depth
Front
Rear
P-24, 28, 33
STANDARD/SPECIFICATION
31.948 – 31.998
(1.2578 – 1.2598)
33.884 – 33.934
(1.3340 – 1.3360)
DOT 4
45°
45°
3.0 m (9.8 ft)
7±4
(0.30 ± 0.16)
0.45°
3.3°
12 × 6.0 AT
12 × 7.5 AT
AT25 8-12 ✩ ✩
AT25 10-12 ✩ ✩
DUNLOP: KT121D
DUNLOP: KT405D
NOTE
WATTAGE
←
#
Pilot screw
Throttle cable play
←
#
SPECIFICATION
30 A
10 A
10 A
10 A
10 A
15 A
10 A
Main
Power source
Headlight (HI)
Headlight (LO)
Tail
Ignition
Fan
P-33
←
←
03G1
←
LIMIT
—
– 14.043
– 0.5529)
– 12.743
– 0.5017)
– 13.984
– 0.5506)
– 12.684
– 0.4994)
– 32.280
– 1.2630)
– 34.036
– 1.3400)
6/8
—
—
3.0
(0.12)
3.5
(0.197)
0.30
(0.012)
—
—
—
—
—
—
P-24, 28, 33
FUEL + OIL
ITEM
Fuel type
—
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
14.000
(0.5512
12.700
(0.5000
13.957
(0.5495
12.657
(0.4983
32.030
(1.2610
33.960
(1.3370
Unit: mm (in)
LIMIT
reserve
reserve
Engine oil type
Engine oil capacity
Front/Rear drive gear oil type
Front drive (differential) gear oil
capacity
Rear drive gear oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
19.0 L
(5.0/4.2 US/lmp gal)
4.2 L
(1.1/0.9 US/lmp gal)
SAE 10W-40, API SF or SG
2 500 ml
Change
(2.6/2.2 US/lmp qt)
Filter
2 700 ml
change
(2.9/2.4 US/lmp qt)
3 200 ml
Overhaul
(3.4/2.8 US/lmp qt)
Hypoid gear oil SAE #90
API grade GL-5
300 ml
(10.1/10.6 US/lpm oz)
350 ml
(11.8/12. US/lpm oz)
NOTE
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
NOTE
35
30
0.35
0.30
5.1
4.4
LOAD CAPACITY
UP TO 172 kg (380 lbs)
VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs)
7/8
P-24, 28, 33
8/8
P-24, 28, 33
77
LT-F250
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
32
(1.3)
28
(1.1)
0.03 – 0.08
(0.001 – 0.003)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
Valve seat width
0.88 – 1.08
(0.035 – 0.043)
IN. & EX.
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
IN. & EX.
256 – 294 N
(25.6 – 29.4 kgf, 56.4 – 64.8 lbs)
at length 36.6 mm (1.44 in)
Valve spring tension
Unit: mm (in)
LIMIT
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
—
IN.
EX.
—
—
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
—
12.000
(0.4724
11.977
(0.4715
Cylinder bore
Piston diam.
Piston ring end gap
1st
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 18 mm (0.71 in) from the skirt end.
1st
R
Approx. 8.7 (0.34)
2nd
R
Approx. 9.0 (0.35)
0.10
(0.004
0.10
(0.004
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.087 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
P
M
LIMIT
—
—
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
—
—
—
0.08
(0.003)
STANDARD
Above 50 kPa (0.50 kgf/cm2, 7.1 psi)
Below 80 kPa (0.80 kgf/cm2, 11.3 psi)
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
ITEM
Clutch release screw
Drive plate thickness
—
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)
Clutch wheel I.D.
—
2/7
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Transmission gear
Low
ratio
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Secondary bevel gear backlash
Rear drive (final) bevel gear backlash
STANDARD
1/16 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
—
27.0
(1.06)
116.00 – 116.15
(4.567 – 4.573)
—
1 700 – 2 100 r/min
3 100 – 3 600 r/min
STANDARD
3.250 (65/20)
1.235 (21/17)
3.200 (32/10)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (29/12 × 34/29)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.177 – 0.181)
4.30 – 4.40
(0.169 – 0.173)
17
(0.7)
0.03 – 0.15
(0.001 – 0.006)
0.05 – 0.30
(0.002 – 0.012)
4/7
Unit: mm (in)
LIMIT
1 200 kPa
(12 kgf/cm2, 171 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
7.0
(0.28)
7.2
(0.28)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
E-17, 24, 28, 33
DRIVE TRAIN
—
E-17, 24, 28, 33
—
Clutch shoe
Clutch engagement r/min
Clutch lock-up r/min
Gearshift lever height
3/7
1st
CLUTCH
—
16.030
(0.6311)
15.980
(0.6291)
– 0.25
– 0.010)
– 0.25
– 0.010)
2nd
E
L
E-17, 24, 28, 33
STANDARD
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.01 – 2.03
(0.0791 – 0.0799)
0.97 – 0.99
(0.038 – 0.039)
1.17 – 1.19
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.992 – 16.000
(0.6296 – 0.6299)
—
Approx. 1 400 kPa (14 kgf/cm2, 199 psi)
2nd
Piston ring to groove clearance
ITEM
Piston ring groove width
—
0.05
(0.002)
0.05
(0.002)
—
Piston ring free end gap
1/7
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
Cylinder distortion
—
—
0.10
(0.004)
CYLINDER + PISTON + PISTON RING
Piston to cylinder clearance
0.03
(0.001)
43.0
(1.69)
—
—
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
Unit: mm (in)
LIMIT
33.480
(1.3181)
32.690
(1.2870)
0.150
(0.0059)
STANDARD
33.780 – 33.820
(1.3299 – 1.3315)
32.990 – 33.030
(1.2988 – 1.3004)
0.036 – 0.066
(0.0014 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.976
(0.8645 – 0.8652)
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.43)
0.10
(0.004)
*25.7
(1.01)
116.5
(4.59)
No groove at
any part
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
—
E-17, 24, 28, 33
78
CARBRETOR
WATTAGE
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Starter (enricher) cable play
E-24, 28
MIKUNI BS29
29 mm
05G0
1 500 ± 100 r/min
17.1 ± 1.0 mm
(0.67 ± 0.04 in)
#137.5
4DJ24-1st
P-0M
#100
#17.5
2 and 7/8 turns back
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
SPECIFICATION
E-17
←
←
05G2
←
Spark plug
Gap
Spark performance
Ignition coil resistance
Secondary
Generator coil resistance
Rear brake pedal free travel
←
←
Brake disc thickness
More than 120 V
80 – 155 Ω
0.5 – 1.5 Ω
Pick-up
Charging
Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
More than 4.0 V
kPa
25
20
VEHICLE LOAD CAPACITY LIMIT: 132 kg (291 lbs)
FUEL + OIL
TEM
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Rear drive (final) gear oil type
Rear drive (final) gear oil capacity
←
ITEM
Rear brake cable play
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Ground
: B/W,
: W/Bl
B/Y – G/W
Y–Y
: G/W,
: B/Y
Rear
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
A
S
psi
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.6 L
(2.8/2.3 US/lmp gal)
2.6 L
(0.7/0.6 US/lmp gal)
SAE 10W-40, API SF or SG
2 200 ml
Change
(2.3/1.9 US/lmp qt)
Filter
2 300 ml
change
(2.4/2.0 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)
7/7
NOTE
E-28, 33
E-17, 24
E-17, 24, 28, 33
—
—
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
32.030 – 32.080
(1.2610 –1.2630)
31.948 – 31.998
(1.2578 – 1.2598)
DOT 4
2.6 m (8.5 ft)
2±4
(0.08 ± 0.16)
0°
9°30’
11 × 5.5 AT
9 × 8.0 AT
AT22 × 7-11✩
AT22 × 10-9✩
Brake fluid type
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Front
Rear
Front
Rear
E
L
P
M
E-17, 24, 28, 33
STANDARD/SPECIFICATION
3–5
(0.12 – 0.20)
20 – 30
(0.79 – 1.18)
3.3 – 3.7
Front
(0.130 – 0.146)
Front
Wheel axle runout
3.6
2.9
←
←
Brake drum I.D.
Tire tread depth
0.25
0.20
3
3
Brake disc runout
Tire size
kgf/cm2
E-28, 33
30 × 2 pcs.
30 × 2 pcs.
21/5
SPECIFICATION
E-24
←
←
←
BRAKE + WHEEL
Approx. 150 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX12-BS
12V 36.0 kC (10 Ah)/10HR
20A
TIRE PRESSURE
Fuel type
#
More than 60 V (AC)
5/7
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
←
←
10 – 20 kΩ
Ignition coil primary peak voltage
Brake light/Taillight
Backup light
Reverse indicator light
Neutral indicator light
High beam indicator light
←
0.05 – 1.0 Ω
Primary
HI
LO
←
#
PRE-SET
SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Headlight
←
←
←
←
←
←
ELECTRICAL
ITEM
E-33
←
←
05G1
←
←
Unit: W
ITEM
Front
—
Rear
—
Rear
—
6/7
E-17
←
←
←
21
←
←
3.4
Unit: mm (in)
LIMIT
—
—
3.0
(0.12)
0.30
(0.012)
140.7
(5.54)
—
—
—
—
—
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
3.0
(0.12)
E-17, 24, 28, 33
79
LT-F300F
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
33
(1.3)
28
(1.1)
0.03 – 0.08
(0.001 – 0.003)
0.17 – 0.22
(0.007 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
—
5.500
(0.2165
5.475
(0.2156
5.455
(0.2148
EX.
– 5.512
– 0.2170)
– 5.490
– 0.2161)
– 5.470
– 0.2154)
Unit: mm (in)
LIMIT
—
Camshaft journal oil clearance
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
Camshaft runout
0.35
(0.014)
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
Cylinder head distortion
—
—
Cylinder head cover distortion
—
IN. & EX.
—
Valve stem end length
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
0.03
(0.001)
35.1
(1.38)
39.9
(1.57)
—
Valve spring tension (IN. & EX.)
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
at length 32.5 mm (1.28 in)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
at length 36.0 mm (1.42 in)
INNER
OUTER
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring end gap
1st
R
Approx. 8.2 (0.32)
2nd
R
Approx. 8.5 (0.33)
2nd
0.15 – 0.30
(0.006 – 0.012)
0.50 – 0.65
(0.020 – 0.026)
1st
—
1st
E
L
Piston ring groove width
2nd
—
1st
1.01 – 1.04
(0.040 – 0.041)
1.22 – 1.24
(0.048 – 0.049)
2.01 – 2.03
(0.079 – 0.080)
2nd
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
STANDARD
0.97 – 0.99
(0.038 – 0.039)
1.17 – 1.19
(0.046 – 0.047)
17.002 – 17.008
(0.6694 – 0.6696)
16.996 – 17.000
(0.6691 – 0.6693)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
17.006 – 17.014
(0.6695 – 0.6698)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
55.0 ± 0.1
(2.165 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
P
M
E-24, 28
—
LIMIT
—
—
17.030
(0.6705)
16.980
(0.6685)
Unit: mm (in)
LIMIT
17.040
(0.6709)
3.0
(0.12)
1.00
(0.039)
—
—
0.08
(0.003)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
STANDARD
1.566 (47/30)
Above 30 kPa (0.30 kgf/cm2, 4.3 psi)
Below 70 kPa (0.70 kgf/cm2, 10.0 psi)
at 3 000 r/min
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
STANDARD
1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
Clutch wheel I.D.
—
116.00 – 116.15
(4.567 – 4.573)
Clutch shoe
Clutch engagement r/min
Clutch lock-up r/min
—
1 700 – 2 100 r/min
3 100 – 3 700 r/min
3/7
LIMIT
—
—
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.43)
0.10
(0.004)
27.5
(1.08)
Scuffing or
scratch on contacting surface
No groove at
any part
—
—
E-24, 28
Oil
No. 1, No. 2
& No. 3
Subtransmission
No. 1, No. 2
Reverse
Shift fork thickness
—
—
—
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2, 114 psi)
0.120
(0.0047)
68.580
(2.7000)
68.380
(2.6921)
0.05
(0.002)
6.6
(0.26)
6.8
(0.27)
0.50
(0.020)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
2/7
ITEM
Sub-transmission fork to groove
clearance
Reverse fork to groove clearance
Shift fork groove
width
—
0.05
(0.002)
0.05
(0.002)
—
Piston ring to groove clearance
1/7
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
0.050 – 0.060
(0.0020 – 0.0024)
68.500 – 68.515
(2.6968 – 2.6974)
68.445 – 68.460
(2.6947 – 2.6953)
Measure at 18 mm (0.71 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
—
12.000
(0.4724
11.977
(0.4715
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Unit: mm (in)
LIMIT
33.820
(1.3315)
33.490
(1.3185)
0.150
(0.0059)
0.10
(0.004)
—
—
Valve head thickness
—
IN.
—
—
INNER
STANDARD
34.112 – 34.152
(1.3430 – 1.3446)
33.790 – 33.830
(1.3303 – 1.3319)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
IN. & EX.
OUTER
ITEM
—
Valve stem runout
Valve spring free length
(IN. & EX.)
CAMSHAFT + CYLINDER HEAD
Cam height
—
No. 1, No. 2
& No. 3
Subtransmission
No. 1, No. 2
Reverse
Gearshift lever height
E-24, 28
STANDARD
0.05 – 0.25
(0.002 – 0.010)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.177 – 0.181)
LIMIT
0.50
(0.020)
0.50
(0.020)
5.45 – 5.55
(0.215 – 0.219)
—
4.00 –
(0.157 –
4.30 –
(0.169 –
4.10
0.161)
4.40
0.173)
—
5.30 – 5.40
(0.209 – 0.213)
—
3.80 – 3.90
(0.150 – 0.154)
17
(0.7)
—
—
—
—
SHAFT DRIVE
ITEM
Secondary drive bevel gear backlash (Engine side)
Final drive bevel gear pre-load
(Dif. side)
Differential side gear backlash
(Right side)
Final drive bevel gear backlash
(Dif. side)
STANDARD
0.07 – 0.15
(0.003 – 0.006)
30 – 70 N·cm
(3 – 7 kgf·cm, 2.6 – 6.1 lb-in)
0.05 – 0.10
(0.002 – 0.004)
0.01 – 0.05
(0.004 – 0.002)
OIL TEMP. THERMO-SWITCH
ITEM
Oil temp. indicator light thermoswitch operating temperature
Cooling fan thermo-switch operating temperature
STANDARD
Approx. 160
Approx. 140
Approx. 120
Approx. 110
OFF → ON
ON → OFF
OFF → ON
ON → OFF
4/7
Unit: mm (in)
LIMIT
—
—
—
—
Unit: mm (in)
LIMIT
°C (320 °F)
°C (284 °F)
°C (248 °F)
°C (230 °F)
E-28
E-24
E-24, 28
80
CARBURETOR
WATTAGE
SPECIFICATION
E-24, 28
MIKUNI BSR29SS
29 mm
39D2
1 500 ± 100 r/min
13 ± 0.5 mm
(0.51 ± 0.02 in)
#117.5
5D112-2nd
P-0M
#105
#15
#70
2 and 1/4 turns back
#160
3 – 5 mm
(0.12 – 0.20 in)
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Starter jet
Pilot screw
Pilot air jet
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(G.S.)
(P.S.)
(P.A.J.)
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 – 0.7
(0.024 – 0.028)
Over 8 mm (0.3 in) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
0.1 – 0.5 Ω
Primary
Secondary
Ignition coil primary peak voltage
Generator coil resistance
12 – 20 kΩ
More than 100 V
90 – 140 Ω
0.1 – 1.0 Ω
More than 2.5 V
Pick-up
Charging
Pick-up coil peak voltage
Generator no-load voltage
(When the engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Standard electrolyte
S.G.
Fuse size
Main
Power source
Fan
Headlight
Front
Rear
Unit: mm (in)
NOTE
Rear brake pedal height
Brake disc thickness
Front
Brake disc runout
Front
Brake caliper cylinder bore
Front
Terminal –
Ground
Plug cap –
Ground
Brake caliper piston diam.
Front
Brake hluid type
Brake drum I.D.
Rear
B/Y – G/W
Y–Y
Brake lining thickness
Rear
Master cylinder bore
Front
Master cylinder piston diam.
Steering angle
Tire tread depth
Front
E-24, 28
—
TIRE PRESSURE
FOR E-24
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
LIMIT
—
—
4.0
(0.16)
4.0
(0.16)
kgf/cm2
psi
30
27.5
0.30
0.275
4.4
4.0
kPa
kgf/cm2
psi
30
27.5
0.30
0.275
4.4
4.0
kPa
VEHICLE LOAD CAPACITY LIMIT: 177 kg
FOR E-28
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs)
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Differential gear oil type
Differential gear oil capacity
Brake fluid type
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Use only unleaded gasoline of at least 87 pump
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.
12 L
(3.2/2.6 US/lmp gal)
2.0 L
(0.5/0.4 US/lmp gal)
SAE 10W-40, API SF or SG
3 500 ml
Change
(3.7/3.1 US/lmp qt)
Filter
3 600 ml
change
(3.8/3.2 US/lmp qt)
4 300 ml
Overhaul
(4.5/3.8 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
150 ml
(5.1/5.3 US/lmp oz)
DOT 4
7/7
—
Front
E
L
Camber (with 75 kg, 165 lbs)
Kingpin inclination
Caster
Wheel rim size
NOTE
E-24
E-28
E-24, 28
– 25.450
– 1.0020)
– 25.368
– 0.9987)
—
Inside
Outside
P
M
E-24, 28
—
Rear
—
25.400
(1.0000
25.318
(0.9967
DOT 4
Turning radius
Toe-in (with 75 kg, 165 lbs)
E-24
STANDARD
AT24 × 8-11 ✩✩
AT25 × 10-12 ✩✩
STANDARD
3–5
(0.1 – 0.2)
20 – 30
(0.8 – 1.2)
0
3.3 – 3.7
(0.130 – 0.146)
Rear brake pedal free travel
A
S
ITEM
3.4
ITEM
Rear brake lever cable play
5/7
Tire size
E-28
←
←
←
←
←
←
←
BRAKE + WHEEL
1.28 at 20 °C (68 °F)
20 A
5A
10 A
E-24
30 × 2 pcs.
30 × 2 pcs.
18
5 × 2 pcs.
3 × 2 pcs.
3.4
3.4
1.7
3.4
HI
LO
Brake light
Taillight
Speedometer light
Reverse indicator light
Neutral indicator light
High beam indicator light
Cooling fan indicator light
Engine oil temp. indicator light
More than 60 V (AC)
Approx. 200 W at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–6Ω
Y50-N18A-A
12 V 72 kC (20 Ah)/10HR
Unit: W
SPECIFICATION
ITEM
Front
Rear
6/7
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
36° ± 3°
26° ± 3°
3.2 m (10.5 ft)
16 – 24
(0.63 – 0.94)
1° (Negative)
8° 54’
5° 30’
11 × 6.0 AT
12 × 8.0 AT
Unit: mm (in)
LIMIT
—
—
—
3.0
(0.12)
0.30
(0.012)
—
—
—
180.7
(7.11)
1.5
(0.06)
—
—
—
—
—
—
—
—
—
E-24, 28
81
LT-F400F
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
30.6
(1.20)
27.0
(1.06)
0.05 – 0.10
(0.002 – 0.004)
0.22 – 0.27
(0.009 – 0.011)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
5.000 – 5.012
(0.1969 – 0.1973)
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
—
Camshaft journal O.D.
—
« 17.5
Camshaft runout
—
IN. & EX.
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
38.8
(1.53)
IN. & EX.
182 – 210 N
(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)
at length 31.5 mm (1.24 in)
IN. & EX.
—
Valve stem end length
Valve spring tension
« 22
—
—
Valve head thickness
« 22
« 17.5
—
0.9 – 1.1
(0.035 – 0.043)
—
« 22
« 17.5
—
IN. & EX.
IN. & EX.
STANDARD
33.130 – 33.190
(1.3043 – 1.3067)
33.130 – 33.190
(1.3043 – 1.3067)
0.032 – 0.066
(0.0013 – 0.0026)
0.028 – 0.059
(0.0011 – 0.0023)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.6894 – 0.6900)
21.959 – 21.980
(0.8645 – 0.8654)
17.466 – 17.484
(0.6876 – 0.6883)
IN.
—
—
Valve seat width
—
Unit: mm (in)
ITEM
Cam height
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
2.3
(0.09)
IN. & EX.
Valve stem runout
CAMSHAFT + CYLINDER HEAD
LIMIT
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
12.000 –
(0.4724 –
11.973 –
(0.4714 –
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
(Automatic-decomp. actuated)
Piston to cylinder clearance
—
Cylinder bore
Piston ring free end gap
A
S
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
—
1.01 – 1.03
(0.0398 – 0.0406)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
0.970 – 0.990
(0.0382 – 0.0390)
0.970 – 0.990
(0.0382 – 0.0390)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7870 – 0.7874)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.55
(0.004 – 0.022)
21.95 – 22.00
(0.864 – 0.866)
60.0 ± 0.1
(2.362 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
—
0.05
(0.002)
8.9
(0.35)
8.3
(0.33)
0.50
(0.020)
0.50
(0.020)
R
Approx. 11.2 (0.44)
R
Approx. 10.4 (0.41)
0.15 –
(0.006 –
0.15 –
(0.006 –
Clutch wheel I.D.
—
Clutch shoe
—
Clutch engagement r/min
Clutch lock-up r/min
ITEM
Clutch release screw
Drive plate thickness
Drive plate claw width
—
Driven plate distortion
—
3/8
1 500 – 1 900 r/min
3 400 – 4 000 r/min
LIMIT
33.7
(1.33)
140.5
(5.53)
No groove at
any part
—
—
—
—
—
20.030
(0.7886)
19.980
(0.7866)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
—
0.080
(0.0031)
DRIVE TRAIN
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Front
Rear
Transfer reduction ratio
Low
High
Transmission gear ratio
Low
2nd
3rd
4th
Top
Reverse
Transmission shift fork to groove
clearance
Transfer shift fork to groove
clearance
Reverse shift fork to groove
clearance
Shift fork groove
Transmission
width
LIMIT
—
Reverse
Shift fork thickness
Transmission
Unit: mm (in)
STANDARD
1/16 – 1/8 turn back
2.92 – 3.08
(0.115 – 0.121)
13.85 – 13.95
(0.545 – 0.549)
81.880
(3.2236)
P-17, 24, 28, 33
STANDARD
35.4
(1.39)
140.0 – 140.2
(5.512 – 5.520)
Transfer
CLUTCH
0.27
0.011)
0.27
0.011)
2/8
Transfer
STANDARD
Above 60 kPa (0.6 kgf/cm2, 9 psi)
Below 100 kPa (1.0 kgf/cm2, 14 psi)
at 3 000 r/min
LIMIT
—
ITEM
Clutch spring free length
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
—
0.05
(0.002)
0.05
(0.002)
0.120
(0.0047)
82.070
(3.2311)
1st
P
M
Unit: mm (in)
STANDARD
20.006 – 20.014
(0.7876 – 0.7879)
—
0.060 – 0.075
(0.0023 – 0.0030)
82.000 – 82.015
(3.2283 – 3.2289)
81.930 – 81.945
(3.2256 – 3.2262)
Measure at 15 mm (0.6 in) from the skirt end.
E
L
P-17, 24, 28, 33
LIMIT
0.180
(0.0071)
0.150
(0.0059)
12.018
0.4731)
11.984
0.4718)
Unit: mm (in)
2nd
—
—
0.10
(0.004)
Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi)
1st
Piston ring end gap
STANDARD
—
STANDARD
2nd
1st
—
CYLINDER + PISTON + PISTON RING
Cylinder distortion
ITEM
Piston ring to groove clearance
—
—
Piston diam.
1/8
LIMIT
32.830
(1.2925)
32.830
(1.2925)
0.150
(0.0059)
0.150
(0.0059)
LIMIT
—
2.62
(0.103)
13.05
(0.514)
0.10
(0.004)
P-17, 24, 28, 33
Reverse
Front/rear output shaft bevel gear
backlash
Front drive (differential) gear
backlash
Rear drive (final) gear backlash
STANDARD
2.392 (67/28)
1.133 (17/15)
3.600 (36/10)
3.600 (36/10)
2.453 (35/13 × 19/21)
1.296 (35/27)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.178 – 0.181)
5.50 – 5.60
(0.217 – 0.220)
4.00 – 4.10
(0.157 – 0.161)
4.30 – 4.40
(0.169 – 0.173)
5.30 – 5.40
(0.209 – 0.213)
3.80 – 3.90
(0.150 – 0.154)
0.03 – 0.15
(0.001 – 0.006)
0.05 – 0.10
(0.002 – 0.004)
0.08 – 0.013
(0.0031 – 0.0051)
4/8
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
0.50
(0.020)
—
—
—
—
—
—
—
—
—
P-17, 24, 28, 33
82
ENGINE OIL TEMP. SWITCH + COOLING FAN THERMO-SWITCH
ITEM
Engine oil temp. indicator
light switch operating temperature
Cooling fan thermo-switch
operating temperature
STANDARD/SPECIFICATION
OFF→ON
Approx. 160 °C (320 °F)
ON→OFF
Approx. 140 °C (284 °F)
OFF→ON
Approx. 120 °C (248 °F)
ON→OFF
Approx. 110 °C (230 °F)
LIMIT
—
—
—
—
Battery
Fuse size
CARBURETOR
ITEM
Caburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Slow jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(S.J.)
(P.S.)
SPECIFICATION
P-17, 24, 28
KEIHIN CVK32
32 mm
38FB
1 500 ± 100 r/min
17.0 ± 1.0 mm
(0.67 ± 0.04 in)
#122
NBZA
#6
#38
1 and 7/8 turns back
3 – 5 mm
(0.12 – 0.20 in)
P-33
←
←
38FC
←
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Generator coil resistance
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Ignition coil primary peak voltage
←
Unit: mm (in)
NOTE
12 – 22 kΩ
130 – 250 Ω
0.05 – 1.2 Ω
Y–W
0.1 – 1.5 Ω
B–B
Approx. 225 W at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
: Ground
: W/BI
: G, : BI
: Y, : W
More than 180 V
More than 4.0 V
More than 0.3 V
3–5Ω
5/8
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Front
Rear
Front
Rear
Tire size
Tire tread depth
Rear brake pedal free travel
Front
Brake disc runout
Front
Brake drum I.D.
Rear
—
Master cylinder bore
Front
14.000 –
(0.5512 –
13.957 –
(0.5495 –
32.030 –
(1.2610 –
31.948 –
(1.2578 –
DOT 4
A
S
STANDARD/SPECIFICATION
47°
47°
3.1 m (10.2 ft)
4±4
(0.16 ± 0.16)
0.3°
3°
12 × 6.0 AT
12 × 7.5 AT
AT25 8-12 ✩ ✩
AT25 10-12 ✩ ✩
Front
—
Rear
—
LIMIT
—
—
—
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
P
M
TIRE PRESSURE
14.043
0.5529)
13.984
0.5506)
32.080
1.2630)
31.998
1.2598)
6/8
LIMIT
—
—
—
3.0
(0.12)
0.30
(0.012)
160.7
(6.33)
—
—
—
—
—
P-17, 24, 28, 33
]
ITEM
Engine oil capacity
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
—
E
L
Master cylinder piston diam.
Brake fluid type
P-17, 24, 28, 33
STANDARD/SPECIFICATION
3–5
(0.12 – 0.20)
5 – 15
(0.2 – 0.6)
20 – 30
(0.8 – 1.2)
3.3 – 3.7
(0.130 – 0.146)
Brake disc thickness
More than 60 V (AC) at 5 000 r/min
Right
Left
Unit: mm (in)
Rear brake pedal height
Pick-up
Power
source
Charging
Others
←
←
←
←
←
←
←
—
—
BRAKE + WHEEL
ITEM
Rear brake cable play
Secondary
ITEM
P-17
30 × 2 pcs.
30 × 2 pcs.
21/5
1.7
3.4
3.4
3.4
3.4
21
HI
LO
Brake light/Taillight
Speedometer light
Reverse indicator light
Neutral indicator light
Engine oil temp. indicator light
High beam indicator light
Reverse light
Terminal –
Terminal
Plug cap –
Terminal
Bl – G
Pick-up coil peak voltage
Power source coil peak voltage
Starter relay resistance
Steering angle
Unit: W
Headlight
←
#
#
PRE-SET
0.1 – 1.0 Ω
Primary
NOTE
SPECIFICATION
ITEM
#
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
SPECIFICATION
YTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
30 A
10 A
10 A
10 A
10 A
10 A
10 A
WATTAGE
←
ELECTRICAL
ITEM
Type designation
Capacity
Main
Power source
Headlight (HI)
Headlight (LO)
Taillight
Ignition
Fan
Front /Rear drive gear oil type
Front drive (differential) gear oil
capacity
Rear drive gear oil capacity
SPECIFICATION
3 000 ml
(3.2/2.6 US/lmp qt)
3 200 ml
Filter change
(3.4/2.8 US/lmp qt)
3 500 ml
Overhaul
(3.7/3.1 US/lmp qt)
Hypoid gear oil SAE #90,
API grade GL-5
300 ml
(10.1/10.6 US/lmp oz)
350 ml
(11.8/12.3 US/lmp oz)
NOTE
Change
LT-F400
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
NOTE
32.5
27.5
0.325
0.275
4.7
4.0
LOAD CAPACITY
UP TO 172 kg (380 lbs)
kPa
kgf/cm2
psi
NOTE
32.5
30
0.325
0.30
4.7
4.4
LOAD CAPACITY
UP TO 172 kg (380 lbs)
LT-F400F
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
15.0 L
(4.0/3.3 US/lmp gal)
3.3 L
(0.9/0.7 US/lmp gal)
SAE 10W-40, API SF or SG
7/8
NOTE
P-03, 28, 33
Others
P-17, 24, 28, 33
8/8
P-17, 24, 28, 33
83
LT-F500F
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
30.6
(1.20)
27.0
(1.06)
0.05 – 0.10
(0.002 – 0.004)
0.17 – 0.22
(0.007 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0024)
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
—
5.000
(0.1969
4.975
(0.1959
4.955
(0.1951
EX.
– 5.012
– 0.1973)
– 4.990
– 0.1965)
– 4.970
– 0.1957)
Unit: mm (in)
LIMIT
—
Camshaft journal oil clearance
Right &
Center
Camshaft journal holder I.D.
Right &
Center
Left
—
Left
—
0.35
(0.014)
Camshaft journal O.D.
Right &
Center
Left
—
—
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
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)
38.3
(1.53)
—
IN.
—
12.000
(0.4724
11.973
(0.4714
Cylinder head distortion
—
Cylinder head cover distortion
—
ITEM
Compression pressure
(Automatic-decomp. actuated)
Piston to cylinder clearance
—
R
1st
E
L
R
Approx. 12.0 (0.47)
0.08 –
(0.003 –
0.08 –
(0.003 –
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
70.9 – 71.1
(2.791 – 2.799)
Conrod big end width
Crank web to web width
Crankshaft runout
P
M
P-24, 28, 33
1.30 – 1.32
(0.051 – 0.052)
1.01 – 1.03
(0.040 – 0.041)
2.51 – 2.53
(0.0988 – 0.0996)
1.08 – 1.10
(0.042 – 0.043)
0.97 – 0.99
(0.038 – 0.039)
23.002 – 23.008
(0.9056 – 0.9058)
22.992 – 23.000
(0.9052 – 0.9055)
LIMIT
0.180
(0.0071)
0.150
(0.0059)
CLUTCH
ITEM
Clutch release screw
Drive plate tickness
STANDARD
1/4 – 2/4 turn back
2.92 – 3.08
(0.115 – 0.121)
Drive plate claw width
—
Driven plate distortion
—
—
Clutch spring free length
—
Clutch wheel I.D.
—
Clurch shoe
Unit: mm (in)
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.039)
—
—
—
140.0 – 140.2
(5.512 – 5.520)
—
Clutch engagement r/min
Clutch lock-up r/min
Front
Rear
Low
High
Transmission gear
Low
ratio
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Transfer gear ratio
—
0.08
(0.003)
STANDARD
Above 120 kPa (1.2 kgf/cm2, 17.0 psi)
Below 160 kPa (1.6 kgf/cm2, 23.0 psi)
at 3 000 r/min
LIMIT
Transfer fork to groove clearance
—
Reverse fork to groove clearance
Shift fork groove
width
No. 1 & No. 2
Transfer
Reverse
Shift fork thickness
No. 1 & No. 2
Transfer
Reverse
3/8
P-24, 28, 33
1 500 – 1 900 r/min
3 400 – 4 000 r/min
DRIVE TRAIN
ITEM
Primary reduction ratio
Final reduction ratio
STANDARD
2.032 (63/31)
4.080 (17/15 × 36/10)
4.080 (17/15 × 36/10)
2.419 (22/23 × 27/17 × 43/27)
1.592 (43/27)
3.090 (34/11)
1.750 (28/16)
1.200 (24/20)
0.875 (21/24)
1.724 (21/29)
2.636 (24/11 × 29/24)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
5.5 – 5.6
(0.217 – 0.220)
5.5 – 5.6
(0.217 – 0.220)
5.0 – 5.1
(0.197 – 0.201)
5.3 – 5.4
(0.209 – 0.213)
5.3 – 5.4
(0.209 – 0.213)
4.8 – 4.9
(0.189 – 0.193)
4/8
Unit: mm (in)
LIMIT
800 kPa
(8.0 kgf/cm2,
114 psi)
—
Nicks or
Scratches
87.380
(3.4402)
0.05
(0.002)
5.0
(0.20)
9.6
(0.38)
0.50
(0.020)
0.50
(0.020)
P-24, 28, 33
—
23.030
(0.9067)
22.980
(0.9047)
0.20
0.008)
0.20
0.008)
2/8
—
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
—
0.05
(0.002)
0.05
(0.002)
Approx. 6.2 (0.24)
2nd
2nd
—
0.030 – 0.040
(0.0012 – 0.0016)
87.500 – 87.515
(3.4449 – 3.4455)
87.465 – 87.480
(3.4435 – 3.4441)
Measure at 15 mm (0.6 in) from the skirt end.
2nd
Piston ring groove width
– 12.018
– 0.4731)
– 11.984
– 0.4718)
Approx. 1 000 kPa (10.0 kgf/cm2, 142 psi)
1st
Piston ring end gap
—
—
0.10
(0.004)
—
Piston ring free end gap
STANDARD
—
STANDARD
Cylinder distortion
1st
—
CYLINDER + PISTON + PISTON RING
Piston diam.
ITEM
Piston ring to groove clearance
—
—
Cylinder bore
1/8
Unit: mm (in)
LIMIT
33.130
(1.3043)
33.200
(1.3071)
0.150
(0.0059)
0.150
(0.0059)
STANDARD
33.430 – 33.498
(1.3161 – 1.3188)
33.500 – 33.568
(1.3189 – 1.3216)
0.032 – 0.066
(0.0013 – 0.0026)
0.028 – 0.059
(0.0011 – 0.0023)
22.012 – 22.025
(0.8666 – 0.8671)
17.512 – 17.525
(0.6894 – 0.6900)
21.959 – 21.980
(0.8645 – 0.8654)
17.466 – 17.484
(0.6876 – 0.6883)
EX.
—
IN. & EX.
18.2 – 21.0 kgf
(41.0 – 46.3 lbs)
at length 31.5 mm (1.24 in)
ITEM
Cam height
—
Valve stem runout
Valve spring free length
(IN. & EX.)
Valve spring tension (IN. & EX.)
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
LIMIT
—
2.62
(0.103)
12.9
(0.51)
0.10
(0.004)
33.8
(1.33)
Scuffing or
scratch on contacting surface
No groove at
any part
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
0.50
(0.020)
—
—
—
—
—
—
P-24, 28, 33
84
SHAFT DRIVE
ITEM
Secondary drive bevel gear backlash
Final drive bevel gear backlash
Unit: mm (in)
LIMIT
STANDARD
0.05 – 0.15
(0.002 – 0.006)
0.08 – 0.13
(0.0031 – 0.0051)
0.05 – 0.10
(0.0020 – 0.0040)
Front differential drive bevel gear
backlash
ELECTRICAL
ITEM
Spark plug
—
—
Gap
Spark performance
Ignition coil resistance
—
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Engine coolant temp. indicator light
switch operating temperature
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
STANDARD
73.5 – 76.5 °C
(164 – 170 °F)
Over 3 mm (0.12 in) at 90 °C (194 °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)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
2 000 ml
(2.1/1.8 US/lmp qt)
Generator coil resistance
—
—
E-03, 28
KEIHIN CVK36
36 mm
03GF
1 300 ± 100 r/min
17.0 ± 1.0 mm
(0.67 ± 0.04 in)
(M.J.)
#
(J.N.)
NBAY
Needle jet
(N.J.)
Slow jet
(S.J.)
Pilot screw
(P.S.)
E-33
←
←
03GG
←
←
PRE-SET
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
←
Choke cable play
←
5/8
ITEM
Rear brake pedal height
Brake caliper cylinder bore
Front
Rear
A
S
Brake caliper piston diam.
Front
Rear
Brake disc thickness
Front
Rear
STANDARD/SPECIFICATION
15 – 25
(0.2 – 0.6)
32.030 – 32.080
(1.2610 – 1.2630)
33.960 – 34.036
(1.3346 – 1.3400)
31.948 – 31.998
(1.2578 – 1.2598)
33.884 – 33.934
(1.3340 – 1.3360)
3.3 – 3.7
(0.130 – 0.146)
3.8 – 4.2
(0.150 – 0.165)
Brake disc runout (Front & Rear)
Master cylinder bore
—
14.000 – 14.043
(0.5512 – 0.5529)
12.700 – 12.743
(0.5000 – 0.5017)
13.957 – 13.984
(0.5495 – 0.5506)
12.657 – 12.684
(0.4983 – 0.4994)
DOT 4
45°
45°
3.0 m (9.8 ft)
7±4
(0.30 ± 0.16)
0.45°
3.3°
12 × 6.0 AT
12 × 7.5 AT
AT25 8-12 ✩ ✩
AT25 10-12 ✩ ✩
DUNLOP: KT121D
DUNLOP: KT405D
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake fluid type
Steering angle
Right
Left
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Tire size
Tire type
Front
Rear
Front
Rear
Front
Rear
Tire tread depth
—
—
7/8
14.0 – 15.5 V at 5 000 r/min
More than 150 V
3–5Ω
YTX20CH-BS
12 V 64.8 kC (8 Ah)/10 HR
30 A
10 A
10 A
10 A
10 A
15 A
10 A
: Bl/W, : W/B
SPECIFICATION
30 × 2 pcs.
30 × 2 pcs.
40
21/5
LED
LED
LED
LED
LED
LED
HI
LO
E
L
P
M
P-24, 28, 33
BRAKE + WHEEL
The rotation of
the generator
Approx. 325 W at 5 000 r/min
Auxiliary light
Brake light/Taillight
Speedometer light
Reverse indicator light
Neutral indicator light
Parking indicator light
Hight beam indicator light
Engine coolant temp. indicator light
←
1 and 3/8 turns back
Throttle cable play
Terminal –
Ground
Plug cap –
Terminal
Bl – G
Y–W
B–B
More than 60 V (AC) at 5 000 r/min
ITEM
Headlight
←
#
150 – 300 Ω
0.05 – 1.0 Ω
0.1 – 1.5 Ω
NOTE
WATTAGE
←
#
Pick-up
Power source
Charging
Regulated voltage
Ignition coil primary peak voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
Main
Power source
Headlight (HI)
Headlight (LO)
Tail
Ignition
Aux
←
Main jet
Jet needle
0.1 – 1.5 Ω
12 – 22 kΩ
Generator no-load voltage
(When engine is cold)
Generator Max. output
—
SPECIFICATION
ITEM
Primary
Secondary
LIMIT
CARBURETOR
Carburetor type
Bore size
I.D. No
Idle r/min
Float height
SPECIFICATION
NGK: CR6E
DENSO: U20ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
Type
Unit: mm (in)
LIMIT
—
—
—
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
—
Fuel type
ITEM
Fuel tank including
—
reserve
reserve
Engine oil type
Engine oil capacity
—
—
—
—
—
—
—
kPa
kgf/cm2
psi
NOTE
35
30
0.35
0.30
5.1
4.4
LOAD CAPACITY
UP TO 172 kg (380 lbs)
VEHICLE LOAD CAPACITY LIMIT: 172 kg (380 lbs)
FUEL + OIL
—
P-24, 28, 33
TIRE PRESSURE
—
3.0
(0.118)
3.5
(0.138)
0.30
(0.012)
6/8
Front/Rear drive gear oil type
Front drive (differential) gear oil
capacity
Rear drive gear oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
19.0 L (5.0/4.2 US/lmp gal)
4.2 L (1.1/0.9 US/lmp gal)
SAE 10W-40, API SF or SG
3 400 ml
Change
(3.6/3.0 US/lmp qt)
Filter
3 600 ml
change
(3.8/3.2 US/lmp qt)
4 000 ml
Overhaul
(4.2/3.5 US/lmp qt)
Hypoid gear oil SAE #90,
API grade GL-5
270 – 370 ml
(9.1 – 12.5/9.5 – 13.0 US/lpm oz)
250 – 350 ml
(8.5 – 10.1/8.8 – 10.6 US/lpm oz)
NOTE
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
P-24, 28, 33
8/8
P-24, 28, 33
85
LT-V700F
ENGINE TOP END
Unit: mm (in)
ITEM
Rocker arm inside diameter
Rocker shaft diameter
Cam height
IN.
EX.
Camshaft bearing clearance
φ 18
φ 22
Camshaft journal diameter
φ 18
φ 22
Camshaft bearing inside diameter
φ 18
φ 22
Camshaft runout
STANDARD
12.000 – 12.018
(0.4724 – 0.4731)
11.973 – 11.984
(0.4714 – 0.4718)
35.622 – 35.736
(1.4024 – 1.4069)
35.363 – 35.477
(1.3922 – 1.3967)
0.016 – 0.052
(0.0006 – 0.0020)
0.020 – 0.062
(0.0008 – 0.0024)
17.966 – 17.984
(0.7073 – 0.7080)
21.959 – 21.980
(0.8645 – 0.8653)
18.000 – 18.018
(0.7087 – 0.7094)
22.000 – 22.021
(0.8661 – 0.8670)
TIR 0.02 (0.0008) or less
KACR operating engine speed
Cylinder compression
(Electric starter)
Cylinder head warp
Valve clearance
IN.
EX.
Valve head thickness
IN.
EX.
760 ± 30 r/min
Usable range
294 – 520 kPa
(3.0 – 5.3 kgf/cm2, 43 – 75 psi)
@ 280 r/min
—
0.10 – 0.15
(0.0039 – 0.0059)
0.20 – 0.25
(0.0079 – 0.0098)
0.5 (0.020)
0.8 (0.031)
Valve stem bend
—
Valve stem diameter
4.975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
IN.
EX.
LIMIT
12.05
(0.474)
11.95
(0.470)
35.52
(1.398)
35.26
(1.388)
0.14
(0.0055)
0.15
(0.0059)
17.94
(0.706)
21.93
(0.863)
18.08
(0.712)
22.08
(0.870)
TIR 0.1
(0.0039)
—
ITEM
Valve guide inside diameter
Valve guide to valve stem
clearance (Wobble method)
Valve seat cutting angle
Valve seat surface outside
diameter
ITEM
Throttle leverrod
free
play
Connecting
bend
Choke lever free play
Connecting
rod twist
Carburetor type
Main jet
Connecting rod big end side
clearance
Main air jet
Connecting
Needle jet rod big end bearing
insert
to crankpin clearance
Jet needle
Crankpin
Piot jet diameter
Pilot air jet
Pilot screw
Carburetor synchronization
marking
vacuum
Starter jet
Connecting rod big end inside
Idle speed
diameter
Service fuel level
marking
Float height
Connecting rod big end bearing
Air cleaner element oil
insert thickness
COOLING SYSTEM
ITEM
Coolant type
Crankshaft runout
Coolant
color
Crankshaft
main jourCoolant
mixing ratio
nal diameter
Coolant freezing
Crankshaft
main point
bearCoolant
amount
ing
bore total
diameter
Shift fork ear thickness
Radiator cap relief pressure
Shift drum groove
Thermostat valve opening temperwidth
ature
Thermostat valve full opening lift
Coolant valve closing temperature
Valve seat surface width
Valve spring free length
IN. & EX.
IN. & EX.
Cylinder inside diameter
Piston diameter
Piston to cylinder clearance
Oversize piston and rings
Piston ring to groove clearance
Top
Second
Piston ring groove width
0.05 (0.002)
—
Top
Second
Piston ring thickness
—
0.3 (0.012)
0.5 (0.020)
TIR 0.05
(0.002)
4.96
(0.1953)
4.94
(0.1945)
Piston ring end gap
Top &
Second
Top
Second
Oil
Unit: mm (in)
STANDARD
STANDARD
LIMIT
2 – 3 (0.08 – 0.12)
TIR 0.2/100
—
(0.008/3.94)
About 3 (0.12)
TIR 0.2/100
KEIHIN, CVKR-D32
—
(0.008/3.94)
Front
#138
0.16 – 0.46
0.7
Rear
#142
(0.0063 – 0.0181)
(0.028)
#80
0.028 – 0.052 #6
0.09
(0.0011 – 0.0020)
(0.0035)
NBZL
39.984 – 40.000#40
39.97
(1.5742 – 1.5748)
(1.5736)
#130
39.984
–
39.992
1 and 1/2 turns out
—
None
(1.5742 – 1.57449)
Less than 2.7 kPa (2 cmHg)
39.993
–
40.000
difference between carburetors
—
(1.57452 – 1.5748)
#95
43.000 – 43.016
1 100 ± 50 r/min
—
(1.6929 – 1.6939)
15 ± 1
43.000 – 43.008
(0.59 ± 0.04)
—
None
(1.6929 – 1.69323)
below the punch mark
43.009 – 43.016
4.0 ± 1
—
(1.69326 – 1.6935)
(0.16 ± 0.04)
1.482 – 1.486
High-quality foam air filter oil
—
Brown
(0.05835 – 0.05850)
1.486 – 1.490
—
Yellow
(0.05850 – 0.05866)
STANDARD
1.490
– 1.494
—
Green
Permanent
of antifreeze
(0.05866 –type
0.05882)
(Soft water TIR
and 0.04
ethylene glycol plus corrosion and
TIR 0.10
rust inhibitor chemicals
for
aluminum
engines
and
radiators)
(0.0016) or less
(0.0039)
41.984 –Green
42.000
41.96
φ 42 Side
Soft
water 50%,
Coolant 50%
(1.6529
– 1.6535)
(1.652)
–35 –°C42.041
(–31 °F)
42.025
42.08
φ 42 Side
2.4 L –(2.54
US qt)
(1.6545
1.6552)
(1.6567)
(Reserve tank5.9
full– level
including
radiator
and
engine)
6.0
5.8
93 – 123 kPa
(0.2322 – 0.2362)
(0.228)
2
(0.95
6.05––1.25
6.15kgf/cm , 14 – 18 psi)
6.25
STANDARD
5.000 – 5.012
(0.1969 – 0.1973)
0.03 – 0.11
(0.0012 – 0.0043)
0.09 – 0.17
(0.0035 – 0.0067)
45°, 32°, 60°
29.4 – 29.6
(1.157 – 1.165)
25.2 – 25.4
(0.992 – 1.000)
0.5 – 1.0
(0.02 – 0.04)
41.3
(1.626)
81.994 – 82.006
(3.2281 – 3.2286)
81.949 – 81.964
(3.2263 – 3.2269)
at 5 (0.20) from the skirt end
0.030 – 0.057
(0.0012 – 0.0022)
+0.5 (0.020)
0.040 – 0.080
(0.0016 – 0.0032)
0.030 – 0.070
(0.0012 – 0.0028)
1.030 – 1.050
(0.0405 – 0.0413)
1.020 – 1.040
(0.0402 – 0.0409)
0.97 – 0.99
(0.0382 – 0.0390)
0.20 – 0.30
(0.0079 – 0.0118)
0.30 – 0.45
(0.0118 – 0.0177)
0.20 – 0.70
(0.0079 – 0.0276)
E
L
P
M
E-28, 33
(0.2382
69.5 –
– 0.2421)
72.5 °C (157 – 162 °F)
IN.
EX.
—
A
S
FUEL SYSTEM
CRANKSHAFT/TRANSMISSION
IN.
EX.
TIR: Total Indicator Readings
1/9
IN. & EX.
2/9
Front final gear case oil
(same engine oil)
Type
Viscosity
Oil level
Capacity
LSD clutch torque
(when variable differential control
lever is released.)
LSD clutch torque
(when variable differential control
lever is pulled in.)
Bevel gear backlash
Rear axle shaft runout
Rear final gear case oil
Type
Oil level
Capacity
Rear final bevel gear backlash
—
—
—
39.5
(1.555)
82.10
(3.232)
81.80
(3.220)
—
—
0.18
(0.0071)
0.17
(0.0067)
1.13
(0.0445)
1.12
(0.0441)
0.90
(0.035)
0.60
(0.0236)
0.75
(0.0295)
1.00
(0.0394)
E-28, 33
FINAL DRIVE
ITEM
Output bevel gear backlash
LIMIT
5.08
(0.20)
0.31
(0.0122)
0.37
(0.0146)
—
STANDARD
0.05 – 0.11
(0.0020 – 0.0043)
at output drive shaft spline
API SF or SG
API SH or SJ with JASO MA class
SAE 10W-40
Filler opening bottom
0.43 L (0.45 US qt)
Unit: mm (in)
LIMIT
—
—
—
—
—
15 – 20 N·m
(1.5 – 2.0 kgf-m, 11 – 14 ft-lb)
—
157 N·m
(16 kgf-m, 116 ft-lb) or more
—
0.10 – 0.20
(0.004 – 0.008)
at pinion gear spline
—
TIR 1 (0.04) or less
TIR 2
(0.08)
MOBIL Fluid 424 or CITGO TRANSGARD TRACTOR HYDRAULIC FLUID
Filler opening bottom
0.9 L (0.95 US qt)
0.07 – 0.14
(0.003 – 0.006)
at pinion gear spline
—
—
—
—
TIR: Total Indicator Readings
(0.246)
TIR:°CTotal
Readings
8 mm (0.31 in) or more @ 85
(185Indicator
°F)
70 °C (158 °F) or more at 25 kPa (0.25 kgf/cm2, 3.6 psi)
5/9
3/9
E-28, 33
4/9
E-28, 33
86
FUEL SYSTEM
ITEM
Throttle lever free play
Choke lever free play
Carburetor type
Main jet
Unit: mm (in)
STANDARD
2 – 3 (0.08 – 0.12)
About 3 (0.12)
KEIHIN, CVKR-D32
#138
#142
#80
#6
NBZL
#40
#130
1 and 1/2 turns out
Less than 2.7 kPa (2 cmHg)
difference between carburetors
#95
1 100 ± 50 r/min
15 ± 1
(0.59 ± 0.04)
below the punch mark
4.0 ± 1
(0.16 ± 0.04)
High-quality foam air filter oil
Front
Rear
Main air jet
Needle jet
Jet needle
Piot jet
Pilot air jet
Pilot screw
Carburetor synchronization
vacuum
Starter jet
Idle speed
Service fuel level
Float height
Air cleaner element oil
ITEM
Coolant color
Coolant mixing ratio
Coolant freezing point
Coolant total amount
Radiator cap relief pressure
Thermostat valve opening temperature
Thermostat valve full opening lift
Coolant valve closing temperature
Unit: mm (in)
ITEM
Torque converter actuator lever
guide shoe wear
Drive belt deflection
STANDARD
22 – 27
(0.87 – 1.06)
1.16 – 3.48
(0.0457 – 0.1370)
Up to 0.20 (0.008)
27.985 – 28.085
(1.1018 – 1.1057)
37.985 – 38.085
(1.4955 – 1.4994)
60.4 (2.38)
40.000 – 40.039
(1.5748 – 1.5763)
99.5 (3.92)
Drive pulley shoe side clearance
Drive pulley cover bushing inside
diameter
Drive pulley sheave bushing inside
diameter
Drive pulley spring free length
Driven pulley sheave bushing
inside diameter
Driven pulley spring free length
ITEM
Battery type
Battery capacity
Alternator type
Regulator/rectifier output voltage
Alternator output voltage
Stator coil resistance
Spark plug
Ignition coil
69.5 – 72.5 °C (157 – 162 °F)
8 mm (0.31 in) or more @ 85 °C (185 °F)
70 °C (158 °F) or more at 25 kPa (0.25 kgf/cm2, 3.6 psi)
STANDARD
Sealed Battery
12 V 12 Ah
Three-phase AC
14 – 15 V
39 – 59 V@3 000 r/min
0.33 – 0.49 Ω
Gap
0.7 – 0.8 mm (0.028 – 0.031 in)
Cap resistance
3.75 – 6.25 kΩ
3 needle arcing
7 mm (0.28 in) or more
distance
Primary winding
resistance
0.09 – 0.13 Ω
Secondary winding resistance
3.8 – 5.8 kΩ
E
L
Primary peak
voltage
Crankshaft sensor resistance
Crankshaft sensor peak voltage
ITEM
Vehicle-down Sensor
Detection time
Output voltage
Electric Starter motor
Commutator
diameter
Brush length
Fuel pump pressure
Fuel level sensor resistance
2WD/4WD actuator resistance
Engine brake actuator resistance
Forward/reverse detecting sensor
resistance
Rear brake light switch timing
Radiator fan switch resistance
Radiator fan switch operating
temperature
Coolant temperature warning light
switch resistance
Coolant temperature warning light
switch operating temperature
A
S
Magnetic flux detection method
Detection angle
P
M
E-28, 33
STANDARD
Detection
method
More than 65 ± 5 °
for each bank
Within 0.5 – 1.0 sec.
0.4 – 1.4 V (with sensor arrow
mark pointed up)
3.7 – 4.4 V (with sensor tilted
60 – 70 ° or more, right or left)
28 mm (1.10 in)
12 mm (0.47 in)
17.7 – 22.6 kPa
(0.18 – 0.23 kgf/cm2, 2.6 – 3.3 psi)
Fuel level
120 Ω
position
Empty level
3Ω
position
4 (Red) –
3 – 15 Ω
6 (Black)
1 (Orange) –
3.5 – 6.5 kΩ
3 (Blue)
2 (Yellow) –
630 – 3 720 Ω
3 (Blue)
4 (Red) –
3 – 15 Ω
6 (Black)
1 (Orange) –
3.5 – 6.5 kΩ
3 (Blue)
2 (Yellow) –
630 – 5 330 Ω
3 (Blue)
NOTE
—
—
—
Y/G, BK/Y
LIMIT
27 mm (1.06 in)
LIMIT
4 mm (0.16 in)
100 V or more
110 – 140 Ω
2 V or more
6/9
—
STANDARD
DOT 3 or DOT 4
4.0 (0.16)
3.3 – 3.7
( 0.130 – 0.146)
TIR 0.4
(0.016) or less
60 – 65 (2.2 – 2.4)
above footboad
1–2
(0.04 – 0.08)
15 – 25
(0.6 – 1.0)
Front disc runout
Rear brake pedal position
Rear brake lever free play
Rear brake pedal free play
ITEM
Toe-in of front wheels
Front tire
—
Tire air pressure (when cold)
—
Maximun tire air pressure
(to seat beads, when cold)
Tire tread depth
—
—
—
—
—
Size
Type
Size
Type
Front
Front
—
Rear
—
—
—
SUSPENSIONS
ITEM
Shock absorbers spring preload
setting position
LIMIT
—
—
—
—
—
—
—
—
3
(0.12)
4
(0.16)
Unit: mm (in)
STANDARD
Spring free length minus
29.9 (1.18)
Rear
STEERING
LIMIT
Spring free
length minus
22.9 (0.90) to
36.9 (1.45)
Unit: mm (in)
ITEM
Tie-Rod Length
E-28, 33
—
STANDARD
0 – 20 (0 – 0.79) at 1G
AT 25 × 8-12
DUNLOP, KT121A, Tubeless
AT 25 × 10-12
DUNLOP, KT127A, Tubeless
28 kPa
(0.28 kgf/cm2, 4.0 psi)
35 kPa
(0.35 kgf/cm2, 5.0 psi)
250 kPa
(2.5 kgf/cm2, 36 psi)
—
—
—
TIR 0.5
(0.020)
Unit: mm (in)
Rear
—
—
3 (0.12)
WHEELS/TIRES
Rear tire
1.2 – 1.6 kΩ
LIMIT
—
1 (0.04)
TIR: Total Indicator Readings
—
—
—
Front:
GW – BK/Y
Rear:
BL/W – BK/Y
Front:
BK/Y – Plug cap
Rear:
BK/Y – Plug cap
Front:
Ground
G/W
Rear:
Ground
BL/W
BK/W – BL
Y, G/W
Unit: mm (in)
ITEM
Brake fluid type
Front brake pad lining thickness
Front disc thickness
—
—
NOTE
—
—
—
—
B–B
B–B
—
—
E-28, 33
BRAKES
—
ON after 10 mm (0.4 in) of pedal travel
ON: Less than 0.5 Ω
OFF: More than 1 MΩ
OFF → ON
96 – 100 °C (205 – 212 °F)
ON → OFF
91 – 95 °C (196 – 203 °F)
ON: less than 0.5 Ω
OFF: More than 1 MΩ
OFF → ON
112 – 118 °C (234 – 244 °F)
ON → OFF
108 – 111 °C (226 – 232 °F)
7/9
—
0.64
(0.0252)
—
28.12
(1.107)
38.12
(1.501)
—
40.07
(1.578)
—
ELECTRICAL SYSTEM
STANDARD
Permanent type of antifreeze
(Soft water and ethylene glycol plus corrosion and
rust inhibitor chemicals for aluminum engines and radiators)
Green
Soft water 50%, Coolant 50%
–35 °C (–31 °F)
2.4 L (2.54 US qt)
(Reserve tank full level including radiator and engine)
93 – 123 kPa
(0.95 – 1.25 kgf/cm2, 14 – 18 psi)
5/9
LIMIT
6
(0.24)
—
Drive belt height (parallel portion)
COOLING SYSTEM
Coolant type
CONVERTER SYSTEM
STANDARD
315 (12.4)
8/9
LIMIT
—
E-28, 33
87
ENGINE OIL
ITEM
Engine oil type
Engine oil viscosity
Engine oil capacity
STANDARD
API SF or SG
API SH or SJ with JASO MA class
SAE 10W-40
When filter
1.54 L (1.63 US qt)
is not removed
When filter is
1.75 L (1.85 US qt)
removed
When engine is
2.05 L (2.17 US qt)
completely dry
Oil pressure
@ 4500 r/min,
oil temp. 110 °C (230 °F)
480 kPa
(4.9 kgf/cm2, 69.7 psi)
9/9
VALVE + GUIDE
ITEM
Tappet clearance (when cold)
Piston ring thickness
Valve guide to valve stem
clearance
Piston pin bore
Piston pin O.D.
Valve stem deflection
1st
IN.
2nd
EX.
Oil
IN.
1st
EX.
2nd
IN.
EX.
IN. & EX.
Valve guide I.D.
CONROD
+ CRANKSHAFT IN. & EX.
ITEM
Valve stem O.D.
Conrod small end I.D.
IN.
Conrod deflection
EX.
Valve stem runout
Conrod big end side clearance
IN. & EX.
Valve head thickness
Conrod big end width
IN. & EX.
Valve stem end length
Crank web to web width
IN. & EX.
Valve
seat width
Crankshaft
runout
IN. & EX.
Valve head radial runout
IN. & EX.
A
S
Unit:
mm (in)
LIMIT
LIMIT
—
—
—
—
—
—
—
—
—
—
16.030
(0.6311)
—
15.980
(0.6291)
0.35
(0.014)
CAMSHAFT + CYLINDER HEAD
Rocker arm I.D.
IN. & EX.
5.500 – 5.512
(0.2165 – 0.2170)
STANDARD
5.475 – 5.490
16.006
– 16.014
(0.2156
– 0.2161)
(0.6302 – 0.6305)
5.455 – 5.470
(0.2148
– 0.2154)
—
Unit:
— mm (in)
LIMIT
—
16.040
(0.6315)
—
3.0
(0.12)
0.05
1.0
(0.002)
(0.04)
0.5
(0.02)
—
2.5
—
(0.10)
Rocker arm shaft O.D.
IN. & EX.
0.10 – 0.45—
(0.004 – 0.018)
—
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1—
(2.087 ± 0.004)
0.88 – 1.08
—
(0.035
– 0.043)
—
IN. & EX.
—
STANDARD
2
, 4.3
Above 30 kPa (0.3256
kgf/cm
– 294
N psi)
2
, 9.9
psi) lbs)
Below
70
kPa
(0.7
kgf/cm
IN. & EX.
(26.1 – 30.0 kgf, 57.5
– 66.1
at length
3 000 36.6
r/minmm (1.44 in)
at
Drive plate claw width
0.08
—
(0.003)
0.03
(0.001)
43.0
LIMIT
(1.69)
—
—
ITEM
Cam height
STANDARD
1/16 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.9 – 12.0
(0.469 – 0.472)
Driven plate distortion
—
Clutch spring free length
28.9
(1.14)
116.00 – 116.15
(4.567 – 4.573)
Clutch wheel I.D.
Clutch shoe
—
3/7
1/7
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.433)
0.10
(0.004)
27.5
(1.08)
116.5
(4.59)
No groove at
any part
E-19, 28, 33
STANDARD
33.780 – 33.820
(1.3299 – 1.3315)
32.990 – 33.030
(1.2988 – 1.3004)
0.036 – 0.066
(0.0014 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.976
(0.8645 – 0.8652)
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
—
Cylinder head cover distortion
—
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
1 400 kPa
(14.0 kgf/cm2, 199 psi)
Piston to cylinder clearance
Cylinder bore
Piston diam.
0.040 – 0.050
(0.0016 – 0.0020)
66.000 – 66.015
(2.5984 – 2.5990)
65.955 – 65.970
(2.5966 – 2.5972)
Measure at 18 mm (0.71 in) from the skirt end.
Cylinder distortion
Piston ring end gap
Piston ring to groove clearance
—
1st
R
Approx. 8.7 (0.34)
2nd
R
Approx. 9.0 (0.35)
2nd
0.10 – 0.25
(0.004 – 0.010)
0.10 – 0.25
(0.004 – 0.010)
1st
—
2nd
—
1st
2/7
—
—
—
—
0.05
(0.002)
0.05
(0.002)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Unit: mm (in)
LIMIT
33.480
(1.3181)
32.690
(1.2870)
0.150
(0.0059)
0.10
(0.004)
—
12.000
(0.4724
11.977
(0.4715
Cylinder head distortion
Piston ring free end gap
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
P
M
STANDARD
STANDARD
1.01 – 1.03
(0.039832
– 0.0406)
(1.3)
1.21
– 1.23
(0.047628
– 0.0484)
(1.1)
2.01
– 2.03
(0.0791
0.0799)
0.03 –– 0.08
(0.001
– 0.003)
0.97 –
0.99
(0.038
– 0.13
0.039)
0.08 –
(0.003
– 0.005)
1.17 –
1.19
(0.046
0.047)
0.010 –
– 0.037
(0.0004
– 0.0015)
16.002
– 16.008
(0.6300 0.030
– 0.6302)
– 0.057
(0.0012
–
15.992 – 16.0000.0024)
(0.6296 – 0.6299)
—
OIL PUMP
Valve spring free length
ITEM
Oil pressure
60 °C, 140 °F)
Valve
spring (at
tension
E
L
E-28, 33
LT-Z250
ITEM
Piston ring groove
width
Valve diam.
Unit: mm (in)
NOTE
Unit: mm (in)
LIMIT
1 200 kPa
(12.0 kgf/cm2,
171 psi)
0.120
(0.0047)
66.090
(2.6020)
65.880
(2.5937)
0.05
(0.002)
7.0
(0.28)
7.2
(0.28)
0.50
(0.020)
0.5
(0.020)
0.180
(0.007)
0.150
(0.006)
E-19, 28, 33
88
ITEM
Piston ring groove width
STANDARD
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.01 – 2.03
(0.0791 – 0.0799)
0.97 – 0.99
(0.038 – 0.039)
1.17 – 1.19
(0.046 – 0.047)
16.002 – 16.008
(0.6300 – 0.6302)
15.992 – 16.000
(0.6296 – 0.6299)
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
Conrod big end side clearance
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.087 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
LIMIT
—
ITEM
Clutch engagement r/min.
Clutch lock-up r/min.
STANDARD
1 700 – 2 100 r/min
3 100 – 3 700 r/min
LIMIT
—
—
—
DRIVE TRAIN
—
—
—
16.030
(0.6311)
15.980
(0.6291)
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
1st
2nd
3rd
4th
5th
Reverse
Shift fork to groove clearance
STANDARD
3.047 (64/21)
1.133 (17/15)
3.200 (32/10)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (34/12)
0.10 – 0.30
(0.004 – 0.012)
4.50 – 4.60
(0.169 – 0.173)
4.30 – 4.40
(0.169 – 0.173)
0 – 10
(0 – 0.393)
Shift fork groove width
Shift fork thickness
Gearshift lever height
—
—
—
0.08
(0.003)
STANDARD
Above 30 kPa (0.3 kgf/cm2, 4.3 psi)
Below 70 kPa (0.7 kgf/cm2, 9.9 psi)
at 3 000 r/min
LIMIT
Secondary bevel gear
backlash
Rear drive (final) bevel gear
backlash
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
—
0.5
(0.020)
—
—
—
0.03 – 0.15
(0.001 – 0.006)
—
0.05 – 0.30
(0.002 – 0.012)
—
CARBRETOR
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
—
SPECIFICATION
ITEM
(M.J.)
(J.N.)
(N.J.)
(P.J.)
E-19, 28
MIKUNI BSR29
29 mm
(1.14 in)
21G0
1 500 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#125
5DH54-2nd
P-0M
#20
(P.S.)
Carburetor type
Bore size
CLUTCH
ITEM
Clutch release screw
Drive plate thickness
STANDARD
1/16 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.9 – 12.0
(0.469 – 0.472)
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
28.9
(1.14)
116.00 – 116.15
(4.567 – 4.573)
Clutch wheel I.D.
Clutch shoe
—
3/7
Spark plug
SPECIFICATION
NGK: DR7EA
DENSO: X22ESR-U
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
0.05 – 1.0 Ω
Primary
10.5 – 19.0 kΩ
Ω
Secondary
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
120 V and more
80 – 155 Ω
0.5 – 1.2 Ω
4.0 V and more
Pick-up
Charging
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Terminal
: B/W : W/Bl
Bl/Y – G/W
Y–Y
: G/W : Bl/Y
Approx. 150 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX9-BS
12V 28.8 kC (8 Ah)/10HR
20 A
WATTAGE
SPECIFICATION
40
40
21/5
3
3
HI
LO
Brake light/Taillight
Reverse indicator light
Neutral indicator light
←
21G1
←
←
#
←
E
L
Pilot screw
#
#
1 and 1/2 turns back
PRE-SET
Throttle cable play
3 – 5 mm
(0.12 – 0.20 in)
←
Starter (enricher) plunger cable
play
0.5 – 1.0 mm
(0.02 – 0.04 in)
←
4/7
E-19, 28, 33
BRAKE + WHEEL
ITEM
Rear brake lever play
Rear brake pedal free travel
Brake disc thickness
Front
Brake disc runout
Front
Brake drum I.D.
Rear
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
STANDARD/SPECIFICATION
3–5
(0.12 – 0.20)
20 – 30
(0.79 – 1.18)
2.8 – 3.2
(0.110 – 0.126)
—
—
12.700 – 12.743
(0.5000 – 0.5017)
12.657 – 12.684
(0.4983 – 0.4994)
32.030 – 32.080
(1.2610 –1.2630)
31.948 – 31.998
(1.2578 – 1.2598)
DOT 4
2.7 m (8.9 ft)
5±4
(0.20 ± 0.16)
0°
7° 40’
10 × 5.5 AT
9 × 8.0 AT
AT22 × 7-10 ✩✩
AT20 × 10-9 ✩
Brake fluid type
Turning radius
Toe-in (with 75 kg, 165 lbs)
Unit: W
Headlight
Float height
Main jet
Jet needle
Needle jet
Pilot jet
P
M
65 V (AC) and more at 5 000 r/min
ITEM
I.D. No.
Idle r/min
E-19, 28, 33
A
S
ELECTRICAL
ITEM
Unit: mm (in)
LIMIT
—
2.4
(0.094)
11.0
(0.433)
0.10
(0.004)
27.5
(1.08)
116.5
(4.59)
No groove at
any part
E-33
←
Camber
Caster
Wheel rim size
Tire size
Tire tread depth
Wheel axle runout
Front
Rear
Front
Rear
Front
—
Rear
—
Rear
—
Unit: mm (in)
LIMIT
—
—
2.5
(0.098)
0.30
(0.012)
140.7
(5.54)
—
—
—
—
—
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
3.0
(0.12)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
30
25
0.30
0.25
4.4
3.6
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
5/7
E-19, 28, 33
6/7
E-19, 28, 33
89
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
Reserve
Engine oil type
Engine oil capacity
Final gear oil type
Final gear oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated
by the Research Method.
Gasoline containing MTBE (MethyI Tertiary
ButyI Ether), less than 10% ethanol, or less than
5% methanol with appropriate cosolvents and
corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.6 L
(2.8/2.3 US/lmp gal)
2.6 L
(0.7/0.6 US/lmp gal)
SAE 10W-40, API SF or SG
2 200 ml
Change
(2.3/1.9 US/lmp qt)
2 300 ml
Filter change
(2.4/2.0 US/lmp qt)
2
500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Hypoid gear oil SAE #90, API grade GL-5
190 ml
(6.4/6.7 US/lmp oz)
7/7
LT-Z400
ITEM
IN.
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
The others
P
M
Unit: mm (in)
LIMIT
—
IN. & EX.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
—
EX.
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
38.8
(1.53)
IN. & EX.
182 – 210 N
(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)
at length 31.5 mm (1.24 in)
IN.
—
0.35
(0.014)
STANDARD
36.320 – 36.370
(1.4299 – 1.4319)
35.200 – 35.250
(1.3858 – 1.3878)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
EX.
Camshaft journal oil clearance
—
Valve spring tension
Cam height
Camshaft journal holder I.D.
Valve stem runout
Valve spring free length
ITEM
—
IN. & EX.
IN.
CAMSHAFT + CYLINDER HEAD
—
5.000 – 5.012
(0.1969 – 0.1973)
4-975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
Valve stem O.D.
E
L
E-19, 28, 33
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
EX.
Tappet clearance (when cold)
E-28, 33
A
S
VALVE + GUIDE
Valve diam.
NOTE
15th pin
—
Cylinder head cover distortion
—
—
—
0.05
(0.002)
0.5
(0.02)
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
STANDARD
1 000 kPa
(10.0 kgf/cm2, 142 psi)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
—
—
Piston ring free end gap
Piston ring end gap
1st
R
Approx. 6.9 (0.27)
2nd
R
Approx. 11.5 (0.45)
0.08
(0.003
0.08
(0.003
1st
2nd
Piston ring to groove clearance
1st
—
Piston ring groove width
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
1st
2nd
Oil
1/7
E-19, 28, 33
– 0.20
– 0.008)
– 0.20
– 0.008)
—
2nd
2/7
—
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
Unit: mm (in)
LIMIT
36.020
(1.4181)
34.900
(1.3740)
0.150
(0.0059)
Unit: mm (in)
LIMIT
—
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.5
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
—
E-19, 28, 33
90
ITEM
Piston ring thickness
STANDARD
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
Conrod big end side clearance
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Conrod big end width
Crank web to web width
Crankshaft runout
—
Balancer spring free length
—
DRIVE TRAIN + DRIVE CHAIN
LIMIT
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
—
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
CLUTCH
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
—
Clutch spring free length
—
3/7
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
—
Unit: mm (in)
LIMIT
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
A
S
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 mm (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
Generator coil resistance
Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
Primary
0.1 – 1.0 Ω
Secondary
12 – 20 kΩ
Pick-up
Signal
Charging
Drive chain
More than 130 V
350 – 670 Ω
0.09 – 0.50 Ω
0.1 – 1.5 Ω
More than 2.0 V
LIMIT
—
—
ITEM
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
Starter (enricher) cable play
SPECIFICATION
E-03, 28
MIKUNI BSR36
36 mm
07G0
1 500 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#130
5E26-1
P-0M
#22.5
2 and 1/4 turns back
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
4/7
Headlight
HI
LO
Brake light/Taillight
Reverse indicator light
Neutral indicator light
Engine coolant temp. indicator light
—
—
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Brake disc thickness
←
#
PRE-SET
←
←
E-19, 28, 33
Front
Rear
STANDARD/SPECIFICATION
0 – 10
(0 – 0.4)
32.03 – 32.08
(1.2610 – 1.2630)
33.96 – 34.01
(1.3370 – 1.3390)
31.948 – 31.998
(1.2578 – 1.2598)
33.878 – 33.928
(1.3338 – 1.3357)
DOT 4
2.8 – 3.2
(0.110 – 0.126)
3.8 – 4.2
(0.150 – 0.165)
Brake disc runout (Front & Rear)
Master cylinder bore
—
12.700 – 12.743
(0.5000 – 0.5017)
14.000 – 14.043
(0.5512 – 0.5529)
12.657 – 12.684
(0.4983 – 0.4994)
13.957 – 13.984
(0.5495 – 0.5506)
3.1 m (10.2 ft)
5±4
(0.20 ± 0.16)
–0.9°
8.5°
Front
Rear
Master cylinder piston diam.
Front
Rear
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
E-19, 28, 33
←
#
SPECIFICATION
30 × 2 pcs.
30 × 2 pcs.
21/5
3
3
3
More than 65 V (AC)
5/7
E-33
←
←
07G1
←
Unit: W
ITEM
ITEM
Rear brake pedal height
Approx. 150 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
* 20 A/10 A
—
WATTAGE
BRAKE + WHEEL
Terminal –
Ground
Plug cap –
Terminal
: B/W, : B
G – BI
W–B
Br – Br
: G, :Bl
—
—
—
319.4
(12.57)
—
E
L
—
—
—
—
Unit: mm (in)
NOTE
—
30 – 40
(1.2 – 1.6)
P
M
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.5
(0.020)
CARBRETOR
E-19, 28, 33
STANDARD/SPECIFICATION
73.5 – 76.5 °C
(164 – 170 °F)
Over 6 mm (0.24 in) at 90°C (194 °F)
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)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 200 ml (1.3/1.1 US/lmp qt)
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Type
Links
20-pitch
length
Shift fork thickness
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
LIMIT
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Engine coolant temp. indicator light
switch operating temperature
Shift fork groove width
—
0.08
(0.003)
10.3
(0.41)
STANDARD
Above 20 kPa (0.2 kgf/cm2, 2.8 psi)
Below 60 kPa (0.6 kgf/cm2, 8.5 psi)
at 3 000 r/min
Low
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Drive chain slack
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
STANDARD
2.960 (74/25)
2.857 (40/14)
2.538 (33/13)
1.666 (30/18)
1.238 (26/21)
1.000 (23/23)
0.846 (22/26)
2.153 (28/13)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK520KZO
96
6/7
Unit: mm (in)
LIMIT
—
—
—
—
—
—
2.5
(0.098)
3.5
(0.138)
0.30
(0.012)
—
—
—
—
E-19, 28, 33
91
ITEM
Wheel rim size
Tire size
Tire type
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
10 × 5.5 AT
9 × 8.0 AT
AT22 × 7R10 ✩✩
AT20 × 10R9 ✩✩
DUNLOP: KT331
DUNLOP: KT335
Front
—
Rear
—
Rear
—
Wheel axle runout
LIMIT
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
6.0
(0.24)
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
30
27.5
0.30
0.275
4.4
4.0
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
10.0 L (2.6/2.2 US/lmp qt)
2.7 L (0.7/0.6 US/lmp qt)
SAE 10W-40, API SF or SG
Change
2 000 ml (2.1/1.8 US/lmp qt)
Filter change
2 100 ml (2.2/1.8 US/lmp qt)
Overhaul
2 200 ml (2.3/1.9 US/lmp qt)
7/7
RM-Z250
IN.
EX.
Camshaft journal clearance
Camshaft journal diameter
Camshaft journal inside diameter
Camshaft journal runout
Cylinder compression
Cylinder head warp
Valve clearance
Valve/valve guide clearance
(Wobble method)
TIR 0.01 (0.0004) or less
IN.
IN. & EX.
IN.
EX.
Valve seat cutting angle
Valve seat surface outside
diameter
IN.
EX.
Valve seat surface width
Valve spring free length
LIMIT
34.54
(1.3598)
33.84
(1.3322)
0.15
(0.0059)
21.93
(0.8634)
22.08
(0.8693)
TIR 0.1
(0.0039)
Usable range
431 – 706 kPa
(4.4 – 7.2 kgf/cm2, 62.5 – 102 psi)
@ 5 kicks
—
0.10 – 0.15
IN.
(0.0039 – 0.0059)
0.17 – 0.22
EX.
(0.0067 – 0.0087)
EX.
Valve guide inside diameter
STANDARD
34.642 – 34.758
(1.3639 – 1.3684)
33.941 – 34.057
(1.3363 – 1.3408)
0.020 – 0.062
(0.0008 – 0.0024)
21.959 – 21.980
(0.8645 – 0.8654)
22.000 – 22.021
(0.8661 – 0.8670)
TIR 0.02 (0.0008) or less
Valve stem bend
Valve stem diameter
P
M
Unit: mm (in)
ITEM
IN. & EX.
E
L
E-19, 28, 33
A
S
ENGINE TOP END
Cam height
NOTE
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
4.500 – 4.512
(0.1772 – 0.1776)
0.03 – 0.10
(0.0012 – 0.0039)
0.08 – 0.16
(0.0031 – 0.0063)
45°, 32°, 60°, 67.5°
30.62 – 30.82
(1.2055 – 1.2134)
24.62 – 24.82
(0.9693 – 0.9772)
0.50 – 1.0
(0.0197 – 0.0394)
37.88 (1.4913)
ITEM
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/ring groove clearance
Piston ring groove width
Piston ring thickness
Piston ring end gap
—
Top
Top
Top
Top
Oil
Piston pin diameter
0.05 (0.0020)
—
Piston pin hole diameter
—
Connecting rod small end inside
diameter
TIR 0.05
(0.0020)
4.46
(0.1756)
4.44
(0.1748)
4.57
(0.1779)
0.26
(0.0102)
0.32
(0.0126)
—
STANDARD
77.000 – 77.012
(3.0315 – 3.0320)
76.955 – 96.970
(3.0297 – 3.0303)
0.030 – 0.057
(0.0012 – 0.0022)
0.04 – 0.08
(0.0016 – 0.0031)
0.83 – 0.85
(0.0327 – 0.0335)
0.77 – 0.79
(0.0303 – 0.0311)
0.15 – 0.25
(0.0059 – 0.0098)
0.20 – 0.70
(0.0079 – 0.0276)
15.992 – 15.997
(0.6296 – 0.6298)
16.004 – 16.010
(0.6301 – 0.6303)
16.010 – 16.018
(0.6303 – 0.6306)
CRANKSHAFT/TRANSMISSION
ITEM
Connecting rod big end radial
clearance
Connecting rod big end side
clearance
Crankshaft runout
Shift fork ear thickness
Gear shift fork groove width
—
Shift fork guide pin diameter
—
Shift drum groove width
STANDARD
0.002 – 0.014
(0.00008 – 0.0006)
0.25 – 0.35
(0.0098 – 0.0138)
TIR 0.03 (0.012) or less
4.9 – 5.0
(0.1929 – 0.1969)
5.05 – 5.15
(0.1988 – 0.2028)
5.9 – 6.0
(0.2323 – 0.2362)
6.05 – 6.20
(0.2382 – 0.2441)
LIMIT
77.06
(3.0339)
76.82
(3.0244)
—
0.18
(0.0071)
0.93
(0.0366)
0.70
(0.0276)
0.55
(0.0217)
1.0
(0.0394)
15.96
(0.628)
16.07
(0.633)
16.05
(0.632)
Unit: mm (in)
LIMIT
0.06
(0.0024)
0.55
(0.0217)
TIR 0.08
(0.0031)
4.8
(0.1890)
5.25
(0.2070)
5.8
(0.2283)
6.3
(0.2480)
—
37.0 (1.4567)
TIR: Total Indicator Readings
1/6
P-03, 19, 28, 24
2/6
P-03, 19, 28, 24
92
CLUTCH
Unit: mm (in)
ITEM
Clutch lever free play
STANDARD
2.0 – 3.0
(0.08 – 0.12)
2.72 – 2.88
(0.107 – 0.113)
1.5 – 1.7
(0.059 – 0.067)
0.15 (0.0059) or less
0.2 (0.0079) or less
46.8 (1.843)
0.04 – 0.55
(0.0016 – 0.0217)
Friction plate thickness
Steel plate thickness
Friction plate warp
Steel plate warp
Clutch spring free length
Friction plate/clutch housing
clearance
FINAL DRIVE
ITEM
Drive chain
Drive chain slack
Engline sprocket diameter
Rear sprocket diameter
Rear sprocket warp
STANDARD
DAIDO: D.I.D 520DMA2
114 links
317.5 – 318.2
20-link length
(12.50 – 12.53)
52 – 62
(2.05 – 2.44)
55.48 – 55.68 (2.184 – 2.192) /13T
232.62 – 233.12 (9.158 – 9.178) /48T
Under 0.4 (0.016)
Type
Links
Front
Rear
Front
Rear
Front
Front &
Rear
Not more than 0.25 (0.098)
WHEELS/TIRES
Axle runout (/100 mm)
Tire air pressure
Front tire
Magneto coil resistance
Ignition timing (Disconnect the
throttle sensor lead)
Ignition coil
Axial &
Radial
Front &
Rear
Front &
Rear
Size
Throttle sensor ignition coil primary
peak voltage
Throttle sensor input voltage
Output voltage
Size
Type
(Tester range)
250 V AC
(Tester range)
50 V AC
(Tester range)
×1Ω
(Tester range)
×1Ω
LIMIT
—
—
—
1 (0.04)
1 (0.04)
2.5
(0.10)
3.5
(0.14)
0.3 (0.01)
LIMIT
2 (0.08)
0.1 (0.004)
0.2 (0.008)
ITEM
Front fork oil level
(Fully compressed, spring
removed)
Front fork spring free length
Rear shock absorber rebound
damping adjustment
(From the seated position; adjuster
turned fully clockwise)
Rear shock absorber spring
preload adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear shock absorber spring free
length
Gas reservoir compression
damping adjustment
(From the seated position; adjuster
turned fully clockwise)
Gas reservoir pressure
—
—
Sleeve outside diameter
—
—
—
Rocker arm mounting bolt runout
59 V or more
16 V or more
27.2 – 40.8 Ω
1.76 – 2.64 Ω
NOTE
: B/R –
: R/W
: Y –
: Y
: B/R –
: R/W
: Y/W –
: Y
8° BTDC @ 2 000 r/min
3 needle arcing
distance
Secondary
winding
resistance
Primary
winding
resistance
type
7 mm (0.26 in) or more
0.28 – 0.34 Ω (@ 20 °C)
7.65 – 10.35 kΩ (@ 20 °C)
NGK CR8EB
0.7 – 0.8 mm
(0.026 – 0.031 in)
176 V or above
Around 5 V
When the
throttle valve
completely
closed
When the
throttle fully
opened
0.58 – 0.78 V
E
L
P
M
1.0 (0.039) or less
100 kPa
(1.0 kgf/cm2, 14 psi)
80/100-21 51M
BRIDGESTONE M601, Tube
M201, Tube (EU)
100/90-19 57M
BRIDGESTONE M602, Tube
M202, Tube (EU)
STANDARD
80 – 120 Ω
gap
Unit: mm (in)
STANDARD
Type
Rear tire
ITEM
Crankshaft sensor resistance
Magneto output voltage
(Reading @ 4 000 r/min)
P-03, 19, 28, 24
STANDARD
Adjustable (to suit rider)
DOT 3 or DOT 4
DOT 4
3.8 (0.150)
6.4 (0.252)
2.85 – 3.15
(0.112 – 0.124)
3.85 – 4.15
(0.152 – 0.163)
STANDARD
Permanent type anti-freeze for aluminum engines and radiators
Green
Soft water 50%, anti-freeze 50%
1.2 L (1.27 US qt)
93 – 123 kPa
(0.95 – 1.25 kgf/cm2, 13 – 18 psi)
ELECTRICAL SYSTEM)
Spark plug
Unit: mm (in)
Rear
ITEM
Wheel rim runout
—
54.8 (2.157)
232.1 (9.138)
0.5 (0.020)
A
S
BRAKES
Brake disc runout
LIMIT
—
—
323
(12.72)
STANDARD
KEIHIN FCR37
#68
#60
#178
#1.5
0BEKS
3rd groove from the top
#40
#100
2 and 1/4 turns out
6.5 ± 1
(0.256 ± 0.039)
8±1
(0.315 ± 0.039)
3/6
Brake disc thickness
2.62
(0.1031)
1.4
(0.055)
0.3 (0.0118)
0.3 (0.0118)
44.9 (1.768)
0.9
(0.035)
ITEM
Coolant type
Coolant color
Coolant mixing ratio
Coolant total amount
Radiator cap relief pressure
Unit: mm (in)
ITEM
Carburetor type
Starter jet
Leak jet
Main jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Slow jet
Slow air jet
Pilot air screw
Servise fuel level (above the bottom edge of the carburetor body)
Float height
Brake pad lining thickness
—
COOLING SYSTEM
Unit: mm (in)
FUEL SYSTEM
ITEM
Brake lever free play
Brake fluid type
LIMIT
3.5 – 3.7 V
4/6
P-03, 19, 28, 24
STANDARD
95 (3.7) from top of outer tube
460 (18.11)
LIMIT
(Adjustable
range)
70 –120
(2.8 – 4.7)
450 (17.72)
12 clicks counterclockwise
(Adjustable
range)
16 clicks
113 (4.41)
(Adjustable
range)
109 –129.5
(4.29 – 5.098)
260 (10.24)
255 (10.04)
11 clicks counterclockwise
(Adjustable
range)
16 clicks
980 kPa
(10 kgf/cm2, 142 psi)
19.987 – 20.000
Tie-rod
(0.7869 – 0.7874)
Rocker arm
19.987 – 20.000
Large
(0.7869 – 0.7874)
Rocker arm
15.995 – 16.000
Small
(0.6297 – 0.6299)
Under 0.1 (0.004)
—
19.85
(0.781)
19.85
(0.781)
15.85
(0.624)
0.2 (0.008)
EU: European Model
ENGINE OIL
SUSPENSIONS
ITEM
Front fork air pressure
Front fork rebound damping
adjustment
(From the seated position; adjuster
turned fully clockwise)
Front fork compression damping
adjustment
(From the seated position; adjuster
turned fully clockwise)
Front fork oil viscosity
Front fork oil capacity
Unit: mm (in)
STANDARD
Atmospheric pressure
LIMIT
—
11 clicks counterclockwise
12 clicks counterclockwise (EU)
(Adjustable
range)
16 clicks
8 clicks counterclockwise
11 clicks counterclockwise (EU)
(Adjustable
range)
16 clicks
KAYABA 01 or SAE 0W CORRESPOND
564 ± 4 ml
(19.07 ± 0.14 US oz)
5/6
—
—
P-03, 19, 28, 24
ITEM
Engine oil type
Engine oil viscosity
Engine oil capacity
Engine oil level
(After warm-up or driving)
Engine oil pressure
(Oil temperature 90 °C,
engine speed 4 000 r/min)
STANDARD
Castrol “R4 Superbike” 5W-40
API SH or SJ with JASO MA
SAE 10W-30, 10W-40 or 10W-50
When filter is not
1.3 L (1.4 US qt)
removed
When filter is
1.35 L (1.43 US qt)
removed
When engine is
1.5 L (1.6 US qt)
completely dry
Unit: mm (in)
NOTE
Upper level
19.6 kPa
(0.2 kgf/cm2, 2.8 psi)
6/6
P-03, 19, 28, 24
93
RV125
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
Unit: mm
LIMIT
—
—
—
—
—
—
—
—
—
0.35
0.05
0.5
2.5
—
0.03
36.8
40.1
STANDARD
30
26
0.08 – 0.13
0.13 – 0.18
0.010 – 0.037
0.030 – 0.057
5.500 – 5.512
5.475 – 5.490
5.455 – 5.470
—
—
—
—
0.9 – 1.1
—
—
—
76 – 90 N
(7.8 – 9.2 kgf)
at length 32.5 mm
186 – 219 N
(18.9 – 22.3 kgf)
at length 36.0 mm
INNER
OUTER
—
ITEM
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
0.040 – 0.055
57.000 – 57.015
56.955 – 56.970
Measure at 8 mm from the skirt end.
—
1st
R
Approx. 7.2
2nd
R
Approx. 5.0
1st
0.20 – 0.32
2nd
0.20 – 0.32
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.970 – 0.990
2nd
0.970 – 0.990
14.002 – 14.008
13.992 – 14.000
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
1/6
ITEM
Oil pressure (at 60 °C, 140 °F)
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
A
S
Shift fork thickness
Countershaft length
(Low to 2nd)
Drive chain
No. 1
No. 2
No. 1
No. 2
—
—
—
—
259.0
15 – 25
20
(between footrest top and gearshift lever top)
—
STANDARD
–37.3 – –60.0 kPa (–280 – –450 mmHg)
LIMIT
—
—
PAIR SYSTEM
—
Unit: mm
LIMIT
—
2.65
11.5
0.10
31.0
2/6
E-02, 19
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8 mm
Over 8 mm at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Primary
1.6 – 2.7 Ω
Secondary
18 – 26 kΩ
0.4 – 0.8 Ω
∞Ω
Generator coil resistance
Pick-up coil peak voltage
More than 2.0 V
Ignition coil primary peak voltage
More than 200 V
172 – 288 Ω
∞Ω
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
NOTE
tap –
tap
Plug cap –
tap
B–B
Ground – B
: Bl, : B/W
: Bl, : G
: B, :
Ground
G – Bl
G – Ground
More than 60 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10 HR
20 A
WATTAGE
ITEM
Negative pressure range
Unit: W
ITEM
Headlight
CARBURETOR
SPECIFICATION
E-02, 19
MIKUNI BS26
26 mm
13GA
1 500 ± 100 r/min
17.1 ± 1.0 mm
# 115
4EJ44-2nd
P-0M
# 105
# 15
PRE-SET (2 turns out)
2.0 – 4.0 mm
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
LIMIT
STANDARD
10 – 15
2.95 – 3.15
11.8 – 12.0
—
32.6
Pick-up coil resistance
88.0 +0.1
-0
DID 428
132
Type
Links
20-pitch
length
Drive chain slack
Gearshift lever height
Unit: mm (Except ratio)
LIMIT
—
—
—
—
—
—
—
—
0.50
—
—
—
—
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
STANDARD
Above 15 kPa (0.15 kgf/cm2)
Below 35 kPa (0.35 kgf/cm2)
at 3 000 r/min
E
L
P
M
E-02, 19
STANDARD
3.470 (59/17)
3.400 (51/15)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.833 (20/24)
0.10 – 0.30
5.0 – 5.1
5.5 – 5.6
4.8 – 4.9
5.3 – 5.4
0.05
5.8
4.0
0.7
0.7
0.18
0.15
—
—
—
—
—
14.030
13.980
STANDARD
14.006 – 14.014
—
0.10 – 0.45
15.95 – 16.00
53.0 ± 0.1
—
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
56.880
OIL PUMP
CLUTCH
DRIVE TRAIN + DRIVE CHAIN
Unit: mm
LIMIT
980 kPa
(9.8 kgf/cm2,
140 psi)
0.120
57.090
CONROD + CRANKSHAFT
Unit: mm
LIMIT
33.87
33.50
0.150
—
—
0.10
—
—
0.05
0.05
STANDARD
34.17 – 34.22
33.80 – 33.85
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.977 – 11.995
—
—
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
ITEM
Compression pressure
—
CAMSHAFT + CYLINDER HEAD
Cam height
CYLINDER + PISTON + PISTON RING
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
3/6
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
E-02, 19
HI
LO
STANDARD/SPECIFICATION
E-02
E-19
60
←
55
←
5
4
21/5
←
21
←
1.7
←
3.4
←
1.7
←
3.4
←
4/6
E-02, 19
94
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
STANDARD/SPECIFICATION
20 – 30
5 – 15
—
4.0 ± 0.2
—
12.700 – 12.743
12.657 – 12.684
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
—
18 M/C × MT 2.50
14 M/C × MT 4.50
130/80-18 M/C 66P
180/80-14 M/C 78P
—
—
Unit: mm
LIMIT
—
—
110.7
3.5
0.30
—
—
—
—
—
2.0
2.0
0.25
0.25
—
—
—
—
4.0
4.0
STANDARD/SPECIFICATION
110
382.9
171
SUZUKI FORK OIL #10 or an equivalent fork oil
230 ml
136
—
Unit: mm
LIMIT
—
375
—
—
—
—
0.6
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
Front
Rear
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline type is recommended.
7.5 L
1.8 L
SAE 10W-40, API SF or SG
Change
850 ml
Filter change
950 ml
Overhaul
1 200 ml
NOTE
TIRE PRESSURE
COLD INFLATION TIRE PRESSURE
(SOLO AND DUAL RIDING)
FRONT
REAR
kPa
kgf/cm2
125
125
1.25
1.25
5/6
SD110/S
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length
spring tension
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
25.0
22.0
0.04 – 0.07
0.04 – 0.07
0.010 – 0.037
0.030 – 0.057
—
5.000 – 5.012
4.975 – 4.990
4.955 – 4.970
—
—
—
0.9 – 1.1
—
—
147 N (14.9 kgf) at length 25.8 mm
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
STANDARD
27.61 – 27.71
27.42 – 27.52
10.003 – 10.018
9.981 – 9.990
—
IN.
EX.
IN. & EX.
IN. & EX.
P
M
E-02, 19
A
S
VALVE + GUIDE
E
L
Unit: mm
LIMIT
—
—
—
—
—
—
0.35
—
—
—
0.05
0.5
2.3
—
0.03
30.9
—
Unit: mm
LIMIT
27.31
27.12
—
—
0.05
6/6
E-02, 19
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
STANDARD
1 400 kPa
(14.0 kgf/cm2)
0.035 – 0.045
53.500 – 53.515
53.460 – 53.475
Measure at 11 mm from the skirt end.
—
1st
R
Approx. 6.5
2nd
R
Approx. 4.6
1st
0.10 – 0.25
2nd
0.10 – 0.25
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.970 – 0.990
2nd
0.970 – 0.990
14.002 – 14.008
13.996 – 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft thrust clearance
Crankshaft runout
STANDARD
14.006 – 14.024
—
0.10 – 0.45
16.95 – 17.00
42.0 ± 0.1
0.02 – 0.07
—
Unit: mm
LIMIT
950 kPa
(9.5 kgf/cm2,)
0.120
53.595
53.380
0.05
5.2
3.6
0.50
0.50
0.180
0.150
—
—
—
—
—
14.030
13.980
Unit: mm
LIMIT
14.040
3.0
1.00
—
—
—
0.08
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
Above 10 kPa (0.1 kgf/cm2)
Below 30 kPa (0.3 kgf/cm2)
at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
1/6
P-42
STANDARD
10 – 15
2.65 – 2.95
11.8 – 12.0
—
—
2/6
LIMIT
—
Unit: mm
LIMIT
—
2.35
11.0
0.10
29.2
P-42
95
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
STANDARD
3.666 (77/21)
2.643 (37/14)
3.000 (33/11)
1.875 (30/16)
1.368 (26/19)
1.052 (20/19)
0.10 – 0.30
4.5 – 4.6
4.3 – 4.4
D. I. D. 428
100
No. 1 & No. 2
No. 1 & No. 2
Type
Links
20-pitch
length
—
Unit: mm Except ratio
LIMIT
—
—
—
—
—
—
0.50
—
—
—
—
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Secondary
ITEM
Front brake cable play (SD110)
Rear brake pedal free travel
Brake drum I.D.
4.0 V and more
Generator coil resistance
Brake disc thickness (SD110S)
Brake disc runout (SD110S)
Master cylinder bore (SD110S)
Master cylinder piston diam.
(SD110S)
Brake caliper cylinder bore
(SD110S)
Brake caliper piston diam.
(SD110S)
Brake fluid type (SD110S)
Wheel rim runout
Wheel rim size
Wheel axle runout
Front
12.657 – 12.684
Front
27.00 – 27.05
Front
Solo riding
Dual riding
Tire size
Tire type
Tire tread depth
Unit: W
E
L
P
M
Unit: mm
LIMIT
—
—
110.7
110.7
3.0
0.3
4/6
P-42
SUSPENSION
ITEM
Front fork stroke
Front fork inner tube O.D.
Front fork spring free length
Front fork oil level (without spring,
inner tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Rear shock absorber spring
adjuster
Swingarm pivot shaft runout
STD/SPEC.
90
27
297
Unit: mm
LIMIT
—
—
291
137
—
Suzuki fork oil G-10 (#10) or equivalent fork oil
101 ml
—
—
1st set
—
—
0.6
STD/SPEC.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.5 L
2.0 L
SAE 10W-40, API SF or SG
Change
700 ml
Filter change
800 ml
Overhaul
900 ml
NOTE
FUEL + OIL
26.93 – 26.95
ITEM
Axial
Radial
Front
Rear
Front
Rear
—
—
1.40 × 18
1.60 × 18
—
—
2.0
2.0
—
—
0.25
0.25
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
STD/SPEC.
175 kPa (1.75 kgf/cm2)
200 kPa (2.00 kgf/cm2)
175 kPa (1.75 kgf/cm2)
280 kPa (2.80 kgf/cm2)
2.50-18 6PR
2.75-18 6PR
PANTHER
PANTHER
—
—
LIMIT
—
—
—
—
—
—
—
—
1.6 mm
1.6 mm
5/6
Terminal –
Ground
Plug cap –
Ground
: Ground –
: White/Blue
: Green/White
: Blue/Yellow
Black –
Light green
White/Red –
Ground
Gray – Ground
STD/SPEC.
25
25
18/5
10
3.4
3.4
3.4
1.7
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Neutral indicator light
Turn signal indicator light
High beam indicator light
DOT 4
ITEM
0.5 – 2.0 Ω
ITEM
Headlight
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
TIRE
Cold inflation
pressure
180 – 280 Ω
Charging
NOTE
WATTAGE
A
S
Front
Rear
Front
Front
Front
Pickup
Lighting
0.3 – 1.5 Ω
Approx. 100 W at 5 000 r/min
13.0 – 16.0 V at 5 000 r/min
Type designation
OEM2.5E
Capacity
12 V 9 kC (2.5 Ah)/10 HR
Standard
1.280
electrolyte S.G
10 A
Fuse size
P-42
STANDARD
15 – 25
20 – 30
—
—
3.8 – 4.2
—
12.700 – 12.743
130 V and more
Pickup coil peak voltage
Generator Max. output
Regulated voltage
Battery
3/6
BRAKE + WHEEL
10 – 20 kΩ
Ignition coil primary peak voltage
256
SPECIFICATION
MIKUNI BS22SS
ø 22 mm
23F5
1500 ± 100 r/min
10.5 ± 0.5 mm
# 92.5
4J61-2nd
E-1
# 80
# 15
2-3/8 turns out
2 – 4 mm
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
0.2 – 1.5 Ω
Primary
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
STD/SPEC.
NGK: C6HSA
DENSO: U20FS-U
0.6 – 0.7 mm
Over 8 mm at 1 atm.
P-42
6/6
P-42
96
SV650/S/SU/U
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Valve clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
Unit: mm (in)
LIMIT
STANDARD
31
(1.2)
25.5
(1.0)
0.1 – 0.2
(0.004 – 0.008)
0.2 – 0.3
(0.008 – 0.012)
0.020 – 0.047
(0.0008 – 0.0019)
0.030 – 0.057
(0.0012 – 0.0022)
4.500 – 4.512
(0.1772 – 0.1776)
4.465 – 4.480
(0.1758 – 0.1764)
4.455 – 4.470
(0.1754 – 0.1760)
EX.
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
—
Camshaft journal O.D.
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
IN. & EX.
—
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
36.8
(1.45)
39.8
(1.57)
41 – 47 N
(4.2 – 4.8 kgf, 9.03 – 10.36 lbs)
at length 29.9 mm (1.18 in)
166 – 192 N
(17.0 – 19.6 kgf, 36.60 – 42.33 lbs)
at length 33.4 mm (1.31 in)
16th pin
—
ITEM
Compression pressure
STANDARD
1 500 kPa
(15 kgf/cm2, 213 psi)
Compression pressure difference
—
Piston to cylinder clearance
—
0.055 – 0.065
(0.0022 – 0.0026)
81.000 – 81.015
(3.1890 – 3.1896)
80.940 – 80.955
(3.1866 – 3.1872)
Measure at 20 mm (0.79 in) from the skirt end.
Cylinder bore
Piston diam.
Cylinder distortion
—
Piston ring free end gap
—
Piston ring end gap
Piston ring to groove clearance
1st
Approx. 9.5 (0.37)
2nd
Approx. 11 (0.43)
1st
2nd
0.20 – 0.35
(0.008 – 0.014)
0.20 – 0.35
(0.008 – 0.0014)
1st
—
E
L
Piston ring groove width
2nd
—
1st
1.21 – 1.23
(0.0476 – 0.0484)
1.01 – 1.03
(0.0398 – 0.0406)
2.01 – 2.03
(0.0791 – 0.0799)
2nd
Oil
1/10
ITEM
Piston ring thickness
A
S
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
P
M
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
STANDARD
1.17 – 1.19
(0.0461 – 0.0469)
0.97 – 0.99
(0.0382 – 0.0390)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7871 – 0.7874)
1st
LIMIT
—
—
20.030
(0.7886)
19.980
(0.7866)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.170 – 0.320
(0.0067 – 0.0126)
20.95 – 21.00
(0.825 – 0.827)
42.17 – 42.22
(1.660 – 1.662)
0.032 – 0.056
(0.0013 – 0.0022)
37.976 – 38.000
(1.4951 – 1.4960)
0.002 – 0.029
(0.0001 – 0.0011)
41.985 – 42.000
(1.6529 – 1.6535)
LIMIT
20.040
(0.7890)
0.5
(0.02)
—
0.05
(0.002)
STANDARD
Above 200 kPa (2.0 kgf/cm², 28 psi)
Below 600 kPa (6.0 kgf/cm², 85 psi)
at 3 000 r/min
LIMIT
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
2/10
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Unit: mm (in)
ITEM
Conrod small end I.D.
—
0.10
(0.004)
—
0.05
(0.002)
—
CYLINDER + PISTON + PISTON RING
—
IN. & EX.
SV650
SV650S
SV650SU
SV650U
—
—
Valve head thickness
OUTER
IN.
—
Unit: mm (in)
LIMIT
35.76
(1.408)
34.38
(1.354)
0.150
(0.0059)
STANDARD
36.060 – 36.105
(1.4196 – 1.4214)
34.680 – 34.725
(1.3654 – 1.3671)
0.032 – 0.066
(0.0013 – 0.0026)
22.012 – 22.025
(0.8666 – 0.8671)
21.959 – 21.980
(0.8645 – 0.8654)
EX.
—
Valve seat width
INNER
ITEM
Cam height
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
Valve spring tension
(IN. & EX.)
CAMSHAFT + CYLINDER HEAD
SV650S
SV650
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
—
Shift fork thickness
—
Drive chain
20-pitch
length
—
0.080
(0.0031)
—
Type
Links
0.080
(0.0031)
Drive chain slack (on side-stand)
Gearshift lever height
SV650
SV650S
SV650
SV650S
SV650SU
SV650U
Unit: mm (in)
LIMIT
1 100 kPa
(11 kgf/cm2,
156 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.120
(0.0047)
81.075
(3.1919)
80.88
(3.184)
0.05
(0.002)
7.6
(0.30)
8.8
(0.34)
0.70
(0.028)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
—
—
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
Unit: mm (in) Except ratio
STANDARD
LIMIT
2.088 (71/34)
—
2.933 (44/15)
—
3.000 (45/15)
—
2.461 (32/13)
—
1.777 (32/18)
—
1.380 (29/21)
—
1.125 (27/24)
—
0.961 (25/26)
—
0.851 (23/27)
—
0.1 – 0.3
0.50
(0.004 – 0.012)
(0.020)
5.5 – 5.6
—
(0.217 – 0.220)
5.3 – 5.4
—
(0.209 – 0.213)
DID525V8
—
SV650
110 links
—
SV650S
108 links
—
319.4
—
(12.57)
20 – 30
—
(0.79 – 1.18)
60 – 70
—
(2.4 – 2.8)
55 – 60
—
(2.2 – 2.4)
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
CLUTCH
—
Unit: mm (in)
ITEM
Clutch cable play
Clutch release screw
Drive plate thickness
No. 1 & No. 2
Drive plate claw width
No. 1 & No. 2
Driven plate distortion
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turns back
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
—
Clutch spring free length
53.1
(2.09)
3/10
SV650
SV650S
SV650SU
SV650U
LIMIT
—
—
2.62
(0.103)
12.9
(0.507)
0.10
(0.004)
50.5
(1.99)
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
4/10
SV650
SV650S
SV650SU
SV650U
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
97
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature sensor
resistance
Radiator cap valve opening pressure
Cooling fan thermo-switch operating
temperature
Engine coolant type
Engine coolant including reserve
FI SENSORS+ SECONDARY THROTTLE VALVE ACTUATOR
STANDARD
NOTE
Approx. 88 °C (190 °F)
—
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
20 °C
Approx. 2.45 kΩ
(68 °F)
40 °C
Approx.
1.148 kΩ
(104 °F)
60 °C
Approx.
0.587 kΩ
(140 °F)
80 °C
Approx.
0.322 kΩ
(176 °F)
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
OFF→ON
Approx. 98 °C (208 °F)
ON→OFF
Approx. 92 °C (198 °F)
Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio
of 50:50.
Reserve
Approx. 250 ml
tank side
(0.26/0.22 US/lmp qt)
Engine
Approx. 1 480 ml
side
(1.43/1.19 US/lmp qt)
—
—
—
—
TP sensor output voltage
—
—
—
—
—
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating
set pressure
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
Min. 168 ml (5.7/5.9 US/lmp oz)
for 10 sec. at 300 kPa (3.0 kgf/cm², 43 psi)
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
NOTE
STV actuator resistance
PAIR solenoid valve resistance
Approx. 300 kPa (3.0 kgf/cm², 43 psi)
SPECIFICATION
130 – 240 Ω
3.7 V (When cranking) and more
4.5 – 5.5 V
Approx. 2.7 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
19.1 – 19.7 kΩ
Approx. 0.4 – 1.4 V
1.0 V and more (From 1st to Top)
Battery voltage
4.5 – 5.5 V
Closed
Approx. 0.58 kΩ
Opened
Approx. 4.38 kΩ
Closed
Approx. 0.58 V
Opened
Approx. 4.38 V
7 – 14 Ω
20 – 24 kΩ at 20 °C (68 °F)
THROTTLE BODY
ITEM
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
5/10
Firing order
Spark plug
Type
Gap
Spark performance
Crankshaft position sensor resistance
Ignition coil resistance
SPECIFICATION
1.2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8 mm
(0.028 – 0.031 in)
Over 8 mm (0.3 in) at 1 atm.
130 – 240 Ω
2–5Ω
Primary
Secondary
Crankshaft position sensor peak voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When cold)
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Fuel
Ignition
Fan motor
Signal
Main
24 – 37 kΩ
3.7 V and more
P
M
Unit: mm (in)
NOTE
BI – G
tap –
tap
tap –
Plug cap
When
cranking
150 V and more
0.2 – 0.7 Ω
Approx. 375 W at 5 000 r/min
Unit: W
ITEM
Headlight
ITEM
Rear brake pedal height
60 W × 2
55 W × 2
5W
LED
21 W
5W
LED
LED
LED
LED
LED
LED
SV650
Front
Rear
Brake disc runout
Master cylinder bore
—
15.870 –
(0.6248 –
14.000 –
(0.5512 –
15.827 –
(0.6231 –
13.957 –
(0.5495 –
30.230 –
(1.1902 –
38.180 –
(1.5031 –
30.150 –
(1.1870 –
38.098 –
(1.4999 –
DOT 4
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Wheel rim runout
Axial
15.913
0.6265)
14.043
0.5529)
15.854
0.6242)
13.984
0.5506)
30.306
1.1931)
38.230
1.5051)
30.200
1.1890)
38.148
1.5019)
—
Radial
7/10
←
←
←
←
←
←
←
←
←
STANDARD
50 – 60
(1.97 – 2.36)
60 – 70
(2.36 – 2.76)
4.5
(0.18)
5.0
(0.20)
SV650S
Brake disc thickness
SPECIFICATION
SV650
E-03, 24, 28, 33
60 W
55 W
SV650S
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure/Coolant temp./FI indicator light
Fuel indicator light
BRAKE + WHEEL
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
WATTAGE
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX12A-BS
12 V 36.0 kC (10 Ah)/10 HR
15 A
10 A
15 A
10 A
10 A
10 A
15 A
10 A
30 A
SV650
SV650S
SV650SU
SV650U
SV650
SV650S
SV650SU
SV650U
6/10
60 V (AC) and more at 5 000 r/min
SV650S
SV650
SV650S
SV650
SPECIFICATION
17G0 (Others), 17G1 (For E-33)
39 mm
1 800 – 2 400 r/min at 25 °C (77 °F)
1 300 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
E
L
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
A
S
ELECTRICAL
ITEM
SV650
SV650S
SV650SU
SV650U
NOTE
—
8/10
SV650
SV650S
SV650SU
SV650U
Others
←
←
5W
←
←
←
←
←
←
←
←
←
Unit: mm (in)
LIMIT
—
—
4.0
(0.16)
4.5
(0.18)
0.3
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
98
ITEM
STANDARD
17 M/C × MT3.50
17 M/C × MT4.50
Wheel rim size
Front
Rear
Wheel axle runout
Front
—
Rear
—
LIMIT
—
—
0.25
(0.010)
0.25
(0.010)
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
SV650
SV650S
Front fork oil level (without spring,
outer tube fully compressed)
TIRE
ITEM
Cold inflation tire pressure
(Solo riding)
Front
Cold inflation tire pressure
(Dual riding)
Front
STD/SPEC.
225 kPa
(2.25 kgf/cm², 33 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
225 kPa
(2.25 kgf/cm², 33 psi)
250 kPa
(2.50 kgf/cm², 36 psi)
120/60 ZR17 M/C (55 W)
160/60 ZR17 M/C (69 W)
DUNLOP: D220FST L
DUNLOP: D220ST L
Rear
Rear
Tire size
Front
Rear
Front
Rear
Tire type
Tire tread depth
Front
—
Rear
—
—
SV650S
—
Front fork spring adjuster
Front fork oil type
—
Front fork oil capacity (each leg)
SV650S
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Rear shock absorber spring
pre-set length
Rear wheel travel
Engine oil type
Engine oil capacity
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
STANDARD
36
(1.42)
33
(1.30)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.046
(0.0004 – 0.0018)
0.030 – 0.066
(0.0012 – 0.0026)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
Valve stem deflection
IN. & EX.
—
Valve stem runout
IN. & EX.
—
Valve head thickness
—
—
—
—
—
—
—
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
0.03
(0.001)
41.2
(1.62)
Valve spring free length
IN. & EX.
—
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
at length 35.6 mm (1.40 in)
Valve spring tension
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
ITEM
Camshaft runout
Cam drive idle gear/sprocket
thrust clearance
STANDARD
37.78 – 37.82
(1.487 – 1.489)
36.38 – 36.42
(1.432 – 1.434)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8650 – 0.8659)
STANDARD
IN. & EX.
—
0.15 – 0.29
(0.006 – 0.011)
1/9
—
—
—
—
—
—
—
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
0.015 – 0.025
(0.0006 – 0.0010)
98.000 – 98.015
(3.8583 – 3.8589)
97.980 – 97.995
(3.8575 – 3.8581)
Measure at 10 mm (0.4 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
—
1st
Approx. 8.8 (0.35)
2nd
Approx. 10.1 (0.40)
0.15
(0.006
0.30
(0.012
1st
2nd
Piston ring to groove clearance
1st
—
– 0.35
– 0.014)
– 0.45
– 0.018)
—
2nd
—
0.93 – 0.95
(0.0366 – 0.0374)
1.55 – 1.57
(0.0610 – 0.0618)
1.01 – 1.03
(0.0398 – 0.0406)
2.51 – 2.53
(0.0988 – 0.0996)
0.86 – 0.91
(0.034 – 0.036)
1.38 – 1.40
(0.054 – 0.055)
0.97 – 0.99
(0.038 – 0.039)
1st
2nd
Oil
Piston ring thickness
1st
2nd
—
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
0.05
(0.002)
—
Piston ring groove width
Unit: mm (in)
LIMIT
37.48
(1.476)
36.08
(1.420)
0.150
(0.0059)
SV650
SV650S
SV650SU
SV650U
10/10
Cylinder head distortion
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
—
STD/SPEC.
NOTE
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Gasoline used should be graded 91 octane or
Others
higher. An unleaded gasoline is recommended.
16 L (4.2/3.5 US/lmp gal)
E-33
17 L (4.5/3.7 US/lmp gal)
Others
SAE 10W-40, API SF or SG
2 300 ml
Change
(2.4/2.0 US/lmp qt)
2 700 ml
Filter change
(2.9/2.4 US/lmp qt)
3 100 ml
Overhaul
(3.3/2.7 US/lmp qt)
P
M
Unit: mm (in)
LIMIT
—
420
(16.5)
428
(16.8)
0.3
(0.01)
—
E
L
E-02, 03, 19, 24, 28, 33
E-02, 03, 19, 24, 28, 33
E-02, 19
E-02, 19
A
S
VALVE + GUIDE
Unit: mm (in)
LIMIT
FUEL + OIL
Fuel tank capacity
SV1000/UD/UF
SV650
SV650S
Swingarm pivot shaft runout
ITEM
9/10
SV650
—
Fuel type
SV650
SV650S
SV650SU
SV650U
SV650
LIMIT
STD/SPEC.
130
(5.1)
429
(16.89)
437.4
(17.22)
92
(3.62)
96
(3.78)
3rd groove from Top
SUZUKI FORK OIL SS8 or
equivalent fork oil
490 ml
(20.2/17.3 US/Imp oz)
485 ml
(16.4/17.1 US/Imp oz)
4/7
3/7
137
(5.4)
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2,
114 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.12
(0.0047)
Nicks or
Scratches
97.880
(3.8535)
0.05
(0.002)
7.0
(0.28)
8.1
(0.32)
0.7
(0.03)
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
—
—
—
—
—
—
—
—
LIMIT
0.10
(0.004)
—
E-02, 03, 19, 24, 28, 33
E-19
2/9
E-02, 03, 19, 24, 28, 33
E-19
99
ITEM
Piston pin bore I.D.
STANDARD
22.002 – 22.008
(0.8662 – 0.8665)
21.993 – 22.000
(0.8658 – 0.8661)
Piston pin O.D.
LIMIT
22.030
(0.8673)
21.980
(0.8654)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Unit: mm (in)
LIMIT
22.040
(0.8677)
0.50
(0.020)
STANDARD
22.010 – 22.018
(0.8665 – 0.8668)
0.17 – 0.32
(0.007 – 0.013)
21.95 – 22.00
(0.864 – 0.866)
44.17 – 44.22
(1.739 – 1.741)
0.040 – 0.064
(0.0016 – 0.0025)
44.976 – 45.000
(1.7707 – 1.7717)
0.002 – 0.029
(0.0008 – 0.0011)
47.985 – 48.000
(1.8892 – 1.8898)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
0.05
(0.002)
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
LIMIT
No. 1
No. 2 and 3
Drive plate claw width
No. 1
No. 2 and 3
STANDARD
2.92 –
(0.115 –
3.72 –
(0.146 –
13.85 –
(0.545 –
13.90 –
(0.547 –
Driven plate distortion
—
Clutch spring free length
28.1
(1.11)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
Clutch master cylinder bore
Clutch master cylinder piston
diam.
3/9
ITEM
Drive chain
Type
Links
20-link
length
A
S
Gearshift lever height
20 – 30
(0.8 – 1.2)
—
55 – 65
(2.2 – 2.6)
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
Fuel pump discharge amount
Fuel pressure regulator operating set pressure
E
L
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
168 ml and more (5.7/5.9 US/lmp oz)
for 10 seconds at 300 kPa (3.0 kgf/cm2, 43 psi)
ITEM
STP sensor output voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
SPECIFICATION
3.7 V and more
130 – 240 Ω
5.0 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 4.0 V at 100 kPa (760 mmHg)
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
—
—
—
—
—
—
—
—
E-02, 03, 19, 24, 28, 33
E-19
4 – 5 Ω at 23 °C (73.4 °F)
NOTE
E-02, 19
E-02, 19
E-02, 19
20 – 24 Ω at 20 °C (68 °F)
THROTTLE BODY
ITEM
I.D. No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
NOTE
ELECTRICAL
SPECIFICATION
16G1 (For E-33), 16G2 (Others)
52 mm
1 900 – 2 500 r/min at 25 °C (77 °F)
1 200 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
Unit: mm (in)
ITEM
Firing order
Spark plug
SPECIFICATION
1·2
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Crankshaft position sensor
resistance
Ignition coil resistance
Crankshaft position sensor peak
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
200 V and more (When cranking)
—
—
—
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
STANDARD
Approx. 0.58 V at input voltage is 5.0 V
Approx. 4.38 V at input voltage is 5.0 V
7 – 14 Ω
0.4 V and less at idle speed
0.6 V and more at 3 000 r/min
Closed
Opened
FI-SENSORS
ITEM
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
—
—
—
STANDARD
1.838 (57/31)
2.352 (40/17)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
4/9
STV actuator resistance
Heated oxygen sensor output
voltage
NOTE
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
LIMIT
Unit: mm (in) Expect ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
P
M
LIMIT
—
—
319.4
(12.6)
—
Drive chain slack
DRIVE TRAIN
E-02, 03, 19, 24, 28, 33
E-19
STANDARD
RK50SMOZ1
110 links, ENDLESS
—
—
Approx. 1 950 ml
(2.1/1.7 US/lmp qt)
Shift fork thickness
—
—
ITEM
STANDARD
Thermostat valve opening tem86.5 – 89.5 °C
perature
(188 – 193 °F)
Thermostat valve lift
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
Radiator cap valve opening
110 kPa
pressure
(1.1 kgf/cm2, 15.6 psi)
Approx. 105 °C (221 °F)
Cooling fan thermo-switch oper- OFF → ON
ating temperature
Approx. 100 °C (212 °F)
ON →OFF
Engine coolant temperature
20 °C
Approx. 2.45 kΩ
sensor resistance
(68 °F)
40 °C
Approx. 1.15 kΩ
(104 °F)
60 °C
Approx. 0.58 kΩ
(140 °F)
80 °C
Approx. 0.32 kΩ
(176 °F)
Engine coolant type
Use an anti-freeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of
50:50.
Engine coolant
Reservoir
Approx. 250 ml
(0.3/0.2 US/lmp qt)
tank side
Shift fork groove width
—
LIMIT
THERMOSTAT + RADIATOR + FAN + COOLANT
Engine
side
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
0.10
(0.004)
26.7
(1.05)
3.08
0.121)
3.88
0.153)
13.96
0.550)
14.00
0.551)
STANDARD
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
DOT 4
Clutch release cylinder piston
diam.
Clutch fluid type
—
CLUTCH
ITEM
Drive plate thickness
ITEM
Clutch release cylinder bore
130 – 240 Ω
2.8 – 4.2 Ω
24 – 36 kΩ
Primary
Secondary
NOTE
Bl – G
tap – tap
tap – Plug cap
5.0 V and more
When cranking
200 V and more
When cranking
0.2 – 0.7 Ω
Approx. 400 W at 5 000 r/min
Y–Y
75 V and more (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
4.5 – 5.5 V
Approx. 0.58 kΩ
Approx. 4.38 kΩ
Closed
Opened
5/9
E-02, 03, 19, 24, 28, 33
E-19
6/9
E-02, 03, 19, 24, 28, 33
E-19
100
ITEM
Fuse size
Headlight
STANDARD
10 A
10 A
10 A
15 A
10 A
15 A
30 A
HI
LO
Fuel
Ignition
Turn signal
Fan motor
Main
NOTE
Rear
Brake fluid type
Wheel rim runout
(Front & Rear)
SPECIFICATION
60
55
5
LED
21 × 4
LED
LED
LED
LED
LED
HI
LO
Position light (For E-02, 19)
Brake light/Taillight
Turn signal light
Speedometer/Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Fuel indicator light
Coolant temperature/oil pressure/FI indicator light
License light
Brake disc thickness
Rear
15.870 –
(0.6248 –
14.000 –
(0.5512 –
15.827 –
(0.6231 –
13.957 –
(0.5495 –
30.230 –
(1.1902 –
33.960 –
(1.3370 –
38.180 –
(1.5031 –
Rear
Front
Rear
Leading
Front
Trailing
Rear
Unit: mm (in)
LIMIT
ITEM
Rear wheel travel
4.5
(0.18)
4.5
(0.18)
0.30
(0.012)
—
—
Front
Rear
Front
Rear
Front
Rear
17M/C × MT 3.50
17M/C × MT 5.50
120/70 ZR17M/C (58W), tubeless
180/55 ZR17M/C (73W), tubeless
MICHELIN: PILOT ROAD B
MICHELIN: PILOT ROAD B
Front
—
Rear
—
—
—
—
A
S
0.3
(0.01)
psi
36
36
kPa
250
290
DUAL RIDING
kgf/cm2
2.50
2.90
psi
36
42
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or higher.
An unleaded gasoline is recommended.
16 L (4.2/3.5 US/lmp gal)
17 L (4.5/3.7 US/lmp gal)
SAE 10W-40, API SF or SG
2 700 ml
Change
(2.9/2.4 US/lmp qt)
2 900 ml
Filter change
(3.1/2.6 US/lmp qt)
3 300 ml
Overhaul
(3.5/2.9 US/lmp qt)
9/9
NOTE
E-03, 28, 33
The others
E-33
The others
E-02, 03, 19, 24, 28, 33
E-19
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
ITEM
Front fork stroke
STANDARD
120
(4.7)
305
(12.0)
Front fork spring free length
Front fork oil level
(without spring, inner tube fully
compressed)
Front fork oil type
Front fork oil capacity (each leg)
LIMIT
—
298
(11.7)
147
(5.8)
—
SUZUKI FORK OIL L01 or an equivalent fork oil
508 ml
(17.2/17.9 US/lmp oz)
7th groove from top
Rebound 1 and 1/4 turns out from stiffest position
Compres1 turn out from stiffest position
sion
—
E
L
P
M
E-02, 03, 19, 24, 28, 33
E-19
—
SOLO RIDING
kgf/cm2
2.50
2.50
SUSPENSION
Rear shock absorber spring preset length
Rear shock absorber damping
Rebound
force adjuster
Compression
—
FUEL + OIL
Engine oil type
Engine oil capacity
Rear
Wheel rim size
Front fork spring adjuster
Front fork damping force
adjuster
—
NOTE
—
TIRE PRESSURE
kPa
250
250
—
STANDARD
130
(5.1)
Swingarm pivot shaft runout
Fuel tank
—
—
15.913
0.6265)
14.043
0.5529)
15.854
0.6242)
13.984
0.5506)
30.280
1.1921)
34.010
1.3389)
38.230
1.5051)
7/9
ITEM
—
Front
Tire tread depth
STANDARD
55 – 65
(2.17 – 2.56)
5.0 ± 0.2
(0.197 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
COLD INFLATION
TIRE PRESSURE
Radial
Tire type
—
Master cylinder piston diam.
—
5
Front
Brake disc runout
(Front & Rear)
Master cylinder bore
LIMIT
Wheel axle runout
LED
ITEM
Rear brake pedal height
Fuel type
Axial
Tire size
BRAKE + WHEEL
FRONT
REAR
Front
Unit: W
ITEM
Headlight
STANDARD
30.167 – 30.200
(1.1876 – 1.1890)
33.901 – 33.934
(1.3346 – 1.3360)
38.115 – 38.148
(1.5005 – 1.5019)
DOT 4
Leading
Trailing
WATTAGE
Brake caliper cylinder bore
ITEM
Brake caliper piston diam.
202
(8.0)
—
—
—
—
—
3/4 turn out from stiffest position
—
1 and 3/4 turns out from stiffest position
—
8/9
E-02, 03, 19, 24, 28, 33
E-19
101
SV1000SD/SF
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem deflection
Valve stem runout
Valve head thickness
Unit: mm (in)
LIMIT
STANDARD
36
(1.42)
33
(1.30)
0.10 – 0.20
(0.004 – 0.008)
0.20 – 0.30
(0.008 – 0.012)
0.010 – 0.046
(0.0004 – 0.0018)
0.030 – 0.066
(0.0012 – 0.0026)
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
—
—
CYLINDER + PISTON + PISTON RING
—
ITEM
Compression pressure
(Automatic de-comp. actuated)
—
Compression pressure difference
—
Piston to cylinder clearance
—
Cylinder bore
—
Piston diam.
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
41.2
(1.62)
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
at length 35.6 mm (1.40 in)
Cam height
STANDARD
37.78 – 37.82
(1.487 – 1.489)
36.38 – 36.42
(1.432 – 1.434)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8650 – 0.8659)
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Camshaft runout
IN. & EX.
—
Piston ring end gap
Unit: mm (in)
LIMIT
37.48
(1.476)
36.08
(1.420)
0.150
(0.0059)
—
1st
Approx. 8.8 (0.35)
2nd
Approx. 10.1 (0.40)
STANDARD
22.010 – 22.018
(0.8665 – 0.8668)
0.17 – 0.32
(0.007 – 0.013)
21.95 – 22.00
(0.864 – 0.866)
44.17 – 44.22
(1.739 – 1.741)
0.040 – 0.064
(0.0016 – 0.0025)
44.976 – 45.000
(1.7707 – 1.7717)
0.002 – 0.029
(0.0008 – 0.0011)
47.985 – 48.000
(1.8892 – 1.8898)
1st
1st
2nd
Oil
Piston ring thickness
1st
Conrod big end side clearance
Conrod big end width
Crank pin width
2nd
Piston pin bore I.D.
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft runout
P
M
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
0.05
(0.002)
STANDARD
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
ITEM
Drive plate thickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
3.72 – 3.88
(0.146 – 0.153)
13.85 – 13.96
(0.545 – 0.550)
13.90 – 14.00
(0.547 – 0.551)
—
0.93 – 0.95
(0.0366 – 0.0374)
1.55 – 1.57
(0.0610 – 0.0618)
1.01 – 1.03
(0.0398 – 0.0406)
2.51 – 2.53
(0.0988 – 0.0996)
0.86 – 0.91
(0.034 – 0.036)
1.38 – 1.40
(0.054 – 0.055)
0.97 – 0.99
(0.038 – 0.039)
22.002 – 22.008
(0.8662 – 0.8665)
21.993 – 22.000
(0.8658 – 0.8661)
2/9
No. 1
No. 2 and 3
Drive plate claw width
No. 1
No. 2 and 3
Driven plate distortion
Clutch spring free length
Clutch master cylinder bore
Clutch master cylinder piston
diam.
Clutch release cylinder bore
Clutch release cylinder piston
diam.
Clutch fluid type
—
28.1
(1.11)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
DOT 4
Engine
side
—
—
—
22.030
(0.8673)
21.980
(0.8654)
Shift fork groove width
—
Drive chain
—
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
Unit: mm (in) Expect ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratio
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork thickness
Type
Links
20-link
length
STANDARD
1.838 (57/31)
2.352 (40/17)
2.666 (32/12)
1.933 (29/15)
1.500 (27/18)
1.227 (27/22)
1.086 (25/23)
1.000 (24/24)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK50SMOZ1
108 links, ENDLESS
—
20 – 30
(0.8 – 1.2)
55 – 65
(2.2 – 2.6)
Drive chain slack
—
E-02, 03, 19, 24, 28, 33
E-19
—
—
E-02, 03, 19, 24, 28, 33
E-19
Approx. 1 950 ml
(2.1/1.7 US/lmp qt)
Gearshift lever height
3/9
—
ITEM
STANDARD
Thermostat valve opening tem86.5 – 89.5 °C
perature
(188 – 193 °F)
Thermostat valve lift
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
Radiator cap valve opening
110 kPa (1.1 kgf/cm2, 15.6 psi)
pressure
Approx. 105 °C (221 °F)
Cooling fan thermo-switch oper- OFF → ON
ating temperature
Approx. 100 °C (212 °F)
ON →OFF
Engine coolant temperature
20 °C
Approx. 2.45 kΩ
sensor resistance
(68 °F)
40 °C
Approx. 1.15 kΩ
(104 °F)
60 °C
Approx. 0.58 kΩ
(140 °F)
80 °C
Approx. 0.32 kΩ
(176 °F)
Engine coolant type
Use an anti-freeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of
50:50.
Engine coolant
Reservoir
Approx. 250 ml
(0.3/0.2 US/lmp qt)
tank side
—
—
—
THERMOSTAT + RADIATOR + FAN + COOLANT
—
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
0.10
(0.004)
26.7
(1.05)
0.05
(0.002)
7.0
(0.28)
8.1
(0.32)
0.7
(0.03)
0.7
(0.03)
0.18
(0.0071)
0.15
(0.0059)
—
DRIVE TRAIN
CLUTCH
97.880
(3.8535)
– 0.35
– 0.014)
– 0.45
– 0.018)
E
L
—
Unit: mm (in)
LIMIT
22.040
(0.8677)
0.50
(0.020)
0.15
(0.006
0.30
(0.012
1st
2nd
—
0.10
(0.004)
Unit: mm (in)
LIMIT
800 kPa
(8 kgf/cm2,
114 psi)
200 kPa
(2 kgf/cm2,
28 psi)
0.12
(0.0047)
Nicks or
Scratches
0.015 – 0.025
(0.0006 – 0.0010)
98.000 – 98.015
(3.8583 – 3.8589)
97.980 – 97.995
(3.8575 – 3.8581)
Measure at 10 mm (0.4 in) from the skirt end.
2nd
Piston ring to groove clearance
—
A
S
ITEM
Conrod small end I.D.
—
—
Piston ring free end gap
E-02, 03, 19, 24, 28, 33
E-19
CONROD + CRANKSHAFT
0.05
(0.002)
Cylinder distortion
Piston pin O.D.
1/9
—
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
Piston ring groove width
ITEM
LIMIT
STANDARD
—
Valve seat width
CAMSHAFT + CYLINDER HEAD
STANDARD
0.15 – 0.29
(0.006 – 0.011)
—
Valve head radial runout
Valve spring tension
ITEM
Cam drive idle gear/sprocket
thrust clearance
Cylinder head distortion
4/9
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
—
E-02, 03, 19, 24, 28, 33
E-19
102
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
Fuel pump discharge amount
SPECIFICATION
11 – 13 Ω at 20 °C (68 °F)
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 operating set pressure
THROTTLE BODY
NOTE
ITEM
ID No.
Bore size
Fast idle r/min
Idle r/min
Throttle cable play
NOTE
ELECTRICAL
Approx. 300 kPa (3.0 kgf/cm2, 43 psi)
SPECIFICATION
16G0 (For E-02, 19), 16G1 (For E-33), 16G2 (For E-03, 24, 28)
52 mm
1 900 – 2 500 r/min at 25 °C (77 °F)
1 200 ± 100 r/min/Warmed engine
2.0 – 4.0 mm
(0.08 – 0.16 in)
FI-SENSORS
ITEM
CMP sensor peak voltage
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor resistance
TP sensor output voltage
ECT sensor input voltage
ECT sensor resistance
IAT sensor input voltage
IAT sensor resistance
AP sensor input voltage
AP sensor output voltage
TO sensor resistance
TO sensor voltage
GP switch voltage
Injector voltage
Ignition coil primary peak voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
SPECIFICATION
3.7 V and more
130 – 240 Ω
5.0 V and more (When cranking)
4.5 – 5.5 V
Approx. 2.5 V at idle speed
4.5 – 5.5 V
Closed
Approx. 1.12 kΩ
Opened
Approx. 4.26 kΩ
Closed
Approx. 1.12 V
Opened
Approx. 4.26 V
4.5 – 5.5 V
Approx. 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx 2.45 kΩ at 20 °C (68 °F)
4.5 – 5.5 V
Approx. 4.0 V at 100 kPa (760 mmHg)
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
STV actuator resistance
Heated oxygen sensor output
voltage
Heated oxygen sensor resistance
PAIR solenoid valve resistance
4 – 5 Ω at 23 °C (73.4 °F)
E-02, 19
E-02, 19
P
M
E-02, 03, 19, 24, 28, 33
E-19
Headlight
A
S
SPECIFICATION
60 × 2
55 × 2
5×2
LED
21 × 4
LED
LED
LED
LED
LED
HI
LO
Position light
Brake light/Taillight
Turn signal light
Speedometer/Tachometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Fuel indicator light
Coolant temperature/oil pressure/FI indicator light
License light
5
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
STANDARD
55 – 65
(2.17 – 2.56)
5.0 ± 0.2
(0.197 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
Brake disc runout
(Front & Rear)
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
15.870
(0.6248
14.000
(0.5512
15.827
(0.6231
13.957
(0.5495
30.230
(1.1902
33.960
(1.3370
38.180
(1.5031
30.167
(1.1876
33.901
(1.3346
38.115
(1.5005
DOT 4
Rear
Rear
Leading
Front
Trailing
Rear
Leading
Front
Trailing
Rear
Brake fluid type
7/9
– 15.913
– 0.6265)
– 14.043
– 0.5529)
– 15.854
– 0.6242)
– 13.984
– 0.5506)
– 30.280
– 1.1921)
– 34.010
– 1.3389)
– 38.230
– 1.5051)
– 30.200
– 1.1890)
– 33.934
– 1.3360)
– 38.148
– 1.5019)
STANDARD
Axial
—
17 × MT 3.50, 17M/C × MT 3.50
17 × MT 5.50, 17M/C × MT 5.50
120/70 ZR17M/C (58W), tubeless
180/55 ZR17M/C (73W), tubeless
MICHELIN: PILOT SPORT E
MICHELIN: PILOT SPORT L
Front
—
Rear
—
Tire size
Unit: mm (in)
Front fork spring free length
Front fork oil level
(without spring, inner tube fully
compressed)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Front fork damping force
adjuster
LIMIT
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
—
Rear
—
—
E-02, 03, 19, 24, 28, 33
E-19
Front
Rear
Front
Rear
Front
Rear
ITEM
Front fork stroke
—
6/9
Wheel rim size
SUSPENSION
—
FTX14-BS
12 V 43.2 kC (12 Ah)/10 HR
15 A
15 A
10 A
15 A
10 A
15 A
30 A
—
—
—
14.0 – 15.5 V at 5 000 r/min
3–6Ω
—
4.5
(0.18)
4.5
(0.18)
0.30
(0.012)
—
Y–Y
Front
Tire tread depth
—
When cranking
0.2 – 0.7 Ω
Approx. 400 W at 5 000 r/min
Radial
Unit: mm (in)
LIMIT
—
When cranking
Wheel axle runout
Tire type
LED
5.0 V and more
200 V and more
75 V and more (AC) at 5 000 r/min
ITEM
Wheel rim runout
(Front & Rear)
Bl – G
tap – tap
tap – Plug cap
2.8 – 4.2 Ω
24 – 36 kΩ
E
L
E-02, 19
NOTE
130 – 240 Ω
Primary
Secondary
Crankshaft position sensor peak
voltage
Ignition coil primary peak voltage
Generator coil resistance
Generator Max. output
Generator no-load voltage
(When engine is cold)
Regulated voltage
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
HI
Headlight
LO
Fuel
Ignition
Turn signal
Fan motor
Main
Unit: W
ITEM
Brake caliper piston
diam.
Gap
20 – 24 Ω at 20 °C (68 °F)
WATTAGE
SPECIFICATION
1·2
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Type
Spark performance
Crankshaft position sensor
resistance
Ignition coil resistance
4.5 – 5.5 V
Approx. 0.58 kΩ
Approx. 4.38 kΩ
Approx. 0.58 V at input voltage is 5.0 V
Approx. 4.38 V at input voltage is 5.0 V
7 – 14 Ω
0.4 V and less at idle speed
0.6 V and more at 3 000 r/min
5/9
Brake caliper cylinder bore
Firing order
Spark plug
200 V and more (When cranking)
Closed
Opened
Closed
Opened
Unit: mm (in)
ITEM
STANDARD
115
(4.5)
295.2
(11.6)
LIMIT
289
(11.4)
164
(6.5)
—
—
SUZUKI FORK OIL L01 or an equivalent fork oil
503 ml
(17.0/17.7 US/lmp oz)
6th groove from top
Rebound
1 turn out from stiffest position
Compres1 turn out from stiffest position
sion
Rear shock absorber spring preset length
Rear shock absorber damping
Rebound
force adjuster
Compression
Rear wheel travel
199.3
(7.85)
—
—
—
—
—
—
3/4 turn out from stiffest position
—
2 and 1/4 turns out from stiffest position
—
—
Swingarm pivot shaft runout
—
130
(5.1)
—
—
0.3
(0.01)
—
E-02, 03, 19, 24, 28, 33
E-19
8/9
E-02, 03, 19, 24, 28, 33
E-19
103
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
kPa
250
250
FRONT
REAR
SOLO RIDING
kgf/cm2
2.50
2.50
psi
36
36
kPa
250
290
DUAL RIDING
kgf/cm2
2.50
2.90
psi
36
42
FUEL + OIL
ITEM
Fuel type
Fuel tank
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or higher.
An unleaded gasoline is recommended.
16 L (4.2/3.5 US/lmp gal)
17 L (4.5/3.7 US/lmp gal)
SAE 10W-40, API SF or SG
2 700 ml
Change
(2.9/2.4 US/lmp qt)
2
900 ml
Filter change
(3.1/2.6 US/lmp qt)
3
300
ml
Overhaul
(3.5/2.9 US/lmp qt)
9/9
UH125
ITEM
Valve clearance (When cold)
Valve guide to valve stem clearance
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem deflection
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length (IN. & EX.)
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
CAMSHAFT + CYLINDER HEAD
ITEM
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
The others
E-33
The others
STANDARD
32.46 – 32.53
31.92 – 31.99
0.032 – 0.066
0.028 – 0.059
22.012 – 22.025
17.512 – 17.525
21.959 – 21.980
17.466 – 17.484
---12.000 – 12.018
11.973 – 11.984
----
IN.
EX.
φ 22
φ 17.5
φ 22
φ 17.5
φ 22
φ 17.5
IN. & EX.
IN. & EX.
E
L
P
M
E-02, 03, 19, 24, 28, 33
E-19
STANDARD
22.0
19.0
0.05 – 0.10
0.10 – 0.15
0.010 – 0.037
0.030 – 0.057
5.000 – 5.012
4.975 – 4.990
4.955 – 4.970
------------0.9 – 1.1
---------53 – 65 N
(5.3 – 6.5 kgf)
at length 28 mm
131 – 151 N
(13.1 – 15.1 kgf)
at length 31.5 mm
Valve spring tension (IN. & EX.)
Cam height
E-03, 28, 33
A
S
VALVE + GUIDE
Valve diam.
NOTE
Unit: mm
LIMIT
---------------------------0.35
0.05
0.5
1.8
---0.03
35.0
37.8
-------
Unit: mm
LIMIT
32.16
31.62
0.150
0.150
------------0.10
------0.05
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
E-02, 19
STANDARD
16.006 – 16.014
---0.10 – 0.45
16.95 – 17.00
53.0 ± 0.1
----
LIMIT
1550 kPa
(15.5 kgf/cm2)
0.120
57.090
56.880
0.05
5.8
4.6
0.70
0.70
0.18
0.15
---------------16.030
15.980
Unit: mm
LIMIT
16.040
3.0
1.00
------0.10
OIL PUMP
ITEM
Oil pressure (at 60 °C)
STANDARD
Above 120 kPa (1.2 kgf/cm2)
Below 180 kPa (1.8 kgf/cm2)
at 3000 r/min
CLUTCH
Clutch
Clutch
Clutch
Clutch
1/6
Unit: mm
STANDARD
1 700 kPa
(17.0 kgf/cm2)
0.040 – 0.050
57.000 – 57.015
56.955 – 56.970
Measure at 15 mm from the skirt end.
---1st
R
Approx. 7.2
2nd RN
Approx. 5.8
1st
0.20 – 0.32
2nd
0.20 – 0.32
1st
---2nd
---1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
16.002 – 16.008
15.995 – 16.000
ITEM
wheel I.D.
shoe thickness
engagement
lock-up
STANDARD
125.0 – 125.2
---Approx. 3 800 ± 300
Approx. 6 000 ± 500
2/6
LIMIT
----
Unit: mm
LIMIT
125.5
2.0
-------
E-02, 19
104
REDUCTION GEAR + DRIVE BELT
ITEM
Reduction ratio
Final reduction ratio
Drive belt width
Movable driven face spring free
length
STD/SPEC.
Variable change (2.930 – 0.770)
9.965 (45/17 × 64/17)
22.1
Unit: mm Except ratio
LIMIT
------21.1
ITEM
Ignition timing
Spark plug
STD/SPEC.
10° B.T.D.C. at 1 600 r/min
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8 mm
Over 8 mm at 1 atm.
148 – 222 Ω
Type
Gap
150
142.5
Spark performance
Signal generator resistance
Signal generator peak voltage
CARBURETOR
SPECIFICATION
E-02, 19
KEIHIN CVK24
24 mm
49F0
1 600 ± 100 r/min
7.0 ± 1.0 mm
16.0 ± 1.0 mm
#115
Press-fitted
NCHA
φ 2.1
θ = 12°
#35
PRE-SET
2.0 – 4.0 mm
ITEM
Carburator type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Main air jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
ELECTRICAL
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Ignition coil resistance
More than 1.3 V
Primary
0.09 – 0.13 Ω
Secondary
15.4 – 18.1 kΩ
Ignition coil primary peak voltage
More than 150 V
More than 40 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
1–7Ω
Type designation
Capacity
Main
Fuse size
FTX9-BS
12 V 28.8 kC (8 Ah)/10HR
20 A
WATTAGE
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temperature switch
resistance
Radiator cap valve opening pressure
Electric fan thermo-switch operating temperature
Engine coolant type
Engine coolant capacity
STD/SPEC.
LIMIT
----
Over 3 mm at 95 °C
Approx. 80 °C
47.5 – 56.8 Ω
Approx. 100 °C
26.2 – 29.3 Ω
110 kPa (1.1 kgf/cm2)
----------
ITEM
Brake disc thickness
Brake drum I.D.
Brake disc runout
Brake fluid type
Wheel rim runout
Wheel rim size
Wheel axle runout
P
M
Unit: mm
LIMIT
3.8 – 4.2
3.5
----
130.7
----
0.3
DOT 4
----
------12 × MT 2.50
12 × MT 3.00
----
2.0
2.0
------0.25
TIRE
ITEM
COLD INFLATION PRESSURE
(SOLO/DUAL RIDING)
STD/SPEC.
200/200 kPa
(2.00/2.00 kgf/cm2)
225/280 kPa
(2.25/2.80 kgf/cm2)
110/90-12 64L
130/70-12 62L
HOOP B03G
HOOP B02G
Front
Rear
Tire size
Tire type
Tire tread depth
(Recommend depth)
Front
Rear
Front
Rear
Front
----
Rear
----
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring,
inner tube fully compressed)
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
STD/SPEC.
100
301
STD/SPEC.
35
35
5×2
21/5 × 2
21 × 4
5
1.2
1.2
1.2
1.2
1.2
5
4/6
E-02, 19
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Fuel level gauge resistance
Engine oil type
Engine oil capacity
Reduction gearbox oil type
Reduction gearbox oil capacity
STD/SPEC.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.0 Liter
Full
4 – 10 Ω
Empty
90 – 100 Ω
SAE 10W-40, API SF or SG
Change
1 200 ml
Filter
1 300 ml
change
Overhaul
1 500 ml
SAE 10W-40, API SF or SG
Change
120 ml
Overhaul
130 ml
NOTE
LIMIT
------------------0.8 mm
(1.6 mm)
0.8 mm
(1.6 mm)
Unit: mm
LIMIT
---294
87.7
----
Suzuki fork oil G-10 (#10) or equivalent fork oil
106 ml
83
----------
5/6
E
L
-------
E-02, 19
STANDARD
Front &
Rear
Parking
Front &
Rear
Front &
Rear
Axial
Radial
Front
Rear
Front
HI
LO
Parking or position light
Brake light/Taillight
Turn signal light
License light
Speedometer light
Fuel meter light
Water temp. meter light
Turn signal indicator light
High beam indicator light
Trunk light
----
A
S
BRAKE + WHEEL
Headlight
----------
OFF → ON
Approx. 105 °C
ON → OFF
Approx. 100 °C
Use an anti-freeze/engine coolant compatible with
an aluminum radiator, mixed with distilled water
only, at the ratio of 50:50.
Reserve tank
Approx. 250 ml
only
Including
Approx. 1 250 ml
reserve
3/6
Unit: W
ITEM
Approx. 82 °C
Green – White
White –
Green
White/Blue –
Black/White
Plug cap –
White/Blue
Black/White –
Black/Yellow
0.50 – 0.62 Ω
Approx. 225 W at 5 000 r/min
Generator coil resistance
Generator Max.output
Generator no-load voltage
(When cold)
Regulated voltage
Starter relay resistance
Battery
THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT
NOTE
E-02, 19
6/6
E-02, 19
105
UH150
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (When cold)
Lash-adjuster plunger stroke
Valve guide to valve stem clearance
Valve guide to valve stem
clearance
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem deflection
stem deflection
stem
guiderunout
I.D.
head thickness
stem end length
seat width
stem O.D.
head radial runout
spring free length (IN. & EX.)
STANDARD
22.0
33
(1.3)
19.0
0.05 40
– 0.10
(1.6)
0.10 – 0.15
0 – 0.5
(0 –0.010
0.02) – 0.037
0.030
0.010 – 0.057
0.037
(0.0004
0.0015)
5.000 –– 5.012
0.040 –
– 4.990
0.070
4.975
(0.0016 – 0.0028)
4.955 – 4.970
—
----
IN.
IN.
EX.
IN.
EX.
EX.
IN.
EX.
IN.
IN. & EX.
IN.
EX.
EX.
IN. &
& EX.
EX.
IN.
IN. & EX.
IN.
IN. & EX.
IN.EX.
& EX.
IN. & EX.
IN. IN.
& EX.
INNER
EX.
OUTER
Valve spring
stem runout
Valve
tension (IN. & EX.)
IN. & EX.
INNER
Valve head thickness
IN. & EX.
Valve stem end length
OUTER
IN.
5.500 ---– 5.512
(0.2165---– 0.2170)
7.000 ---– 7.015
(0.2756 – 0.2762)
0.9 – 1.1
5.475 – 5.490
(0.2156---– 0.2161)
6.945 ---– 6.960
(0.2734---– 0.2740)
53 –—65 N
(5.3 – 6.5 kgf)
at length 28 mm
—
131 – 151 N
(13.1 – 15.1 kgf)
at length—31.5 mm
EX.
—
CAMSHAFT + CYLINDER HEAD
Valve seat width
ITEM
Cam height
Camshaft
clearance
Valve headjournal
radial oil
runout
Valve spring
free length
Camshaft
journal
holder I.D.
(INTAKE)
Camshaft journal O.D.
Valve spring free length
(EXHAUST)
Camshaft
runout
Valve spring
tension (INTAKE)
Rocker
arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Valve spring tension (EXHAUST)
0.9 – 1.1
STANDARD
(0.035 – 0.043)
33.00 – 33.07
1.0 – 1.2
32.66 – 32.73
(0.039
0.047)
φ 22
0.032 – 0.066
IN. & EX.
—
φ 17.5
0.028 – 0.059
φ 22
22.012 —
– 22.025
INNER
φ 17.5
17.512 – 17.525
OUTER
φ 22
21.959 —
– 21.980
φ 17.5
17.466 – 17.484
—
---5.3 – –6.5
kgf
IN. & EX.
12.000
12.018
INNER
(11.68 – 14.33 Ibs)
IN. & EX.
11.973
11.984
at length
28.0– mm
(1.10 in)
---- – 14.2 kgf
14.0
OUTER
(30.86 – 31.31 Ibs)
at length 31.5 mm (1.24 in)
20.3 – 23.3 kgf
(44.75 – 51.37 Ibs)
at length 35.0 mm (1.38 in)
IN.
IN.
EX.
EX.
1/6
1/8
Camshaft
journal holder I.D.
Cylinder distortion
Piston ring free end gap
35.0
—
37.8
0.05
(0.002)
---0.5
(0.02)
---2.5
(0.10)
2.2
(0.09)
Unit: mm
LIMIT
—
32.70
—
32.36
Piston ring thickness
0.150
0.03
(0.001)
0.150
35.0
---(1.38)
---37.8
---(1.49)
---40.6
(1.60)
0.10
---—
---0.05
—
—
—
1st
ITEM
Compression
Cam
height pressure
—
—
—
—
—
23.030
(0.9067)
22.980
(0.9047)
Unit: mm (in)
LIMIT
23.040
(0.9071)
0.3
(0.012)
LIMIT
—
---—
------0.080
(0.0031)
---—
---0.080
---(0.0031)
---—
---—
---—
---—
0.05
(0.002)
STANDARD
1 600 kPa35.680 – 35.730
2
IN.
(16.0 kgf/cm(1.4047
)
– 1.4067)
0.040 – 0.050
36.880 – 36.930
EX.
(1.4521
– 1.4537)
62.000 – 62.015
0.032 – 0.066
IN. & EX. 61.955 – 61.970
(0.0013
0.0026)
Measure at 15 mm from the skirt– end.
Front head right side, ---20.012 – 20.025
rear head left side
(0.7879 – 0.7884)
1st
R
Approx. 8.6
Front head left side,
25.012 – 25.025
2nd
Approx.
7.2 – 0.9852)
rear RN
head right side
(0.9847
1st head right side, 0.15 19.959
– 0.27 – 19.980
Front
rear
head
left
side
(0.7858
2nd
0.20 – 0.32 – 0.7866)
Front
24.959 – 24.980
1st head left side,
---rear head right side
(0.9826 – 0.9835)
2nd
---1stFront & Rear
1.01 – 1.03 —
Piston to cylinder clearance
Cylinder bore
Camshaft
journal oil clearance
Piston
diam.
Piston ringjournal
end gap
Camshaft
O.D.
Piston ring to groove clearance
Camshaft runout
Piston ring groove width
2nd
Oil
1st
2nd
Rocker arm I.D.
Rocker arm shaft O.D.
Piston pin bore
Piston pin O.D.
1.01 14.000
– 1.03
2.01(0.5511
– 2.03
0.97 16.000
– 0.99
(0.6299
0.97 – 0.99
13.966
16.002 – 16.008
(0.5498
15.996 – 16.000
15.966
(0.6286
IN.
EX.
IN.
EX.
ITEM
Piston to cylinder clearance
Oil pressure (at 60 °C, 140 °F)
Cylinder bore
Piston diam.
CLUTCH
ITEM
Cylinder
distortion
Clutch wheel
I.D.
Clutch shoe thickness
Piston ring free end gap
Clutch engagement
Clutch lock-up
STANDARD
0.02 – 0.03
Above(0.0008
120 kPa
(1.2 kgf/cm2)
– 0.0012)
Below 180 kPa (1.8 kgf/cm2)
96.000
– 96.015
at 3 000
r/min
(3.7795 – 3.7801)
95.975 – 95.990
(3.7785 – 3.7791)
Measure at 16 mm
(0.6 in) from the skirt end.
STANDARD
125.0 —
– 125.2
---1st
T
Approx.Approx.
3 600 ±13.5
300(0.53)
E
L
2nd
T
Approx. 6 500 ± 500
Approx. 14.0 (0.55)
2/6
2/8
E-19
E-02, 03, 19, 24, 28,
33
Unit:Unit:
mmmm
(in)
LIMIT
1 450
kPa
35.38
(14.5
kgf/cm2)
(1.393)
0.120
36.58
(1.440)
62.090
0.150
61.880
(0.0060)
0.05
—
6.9
—
5.8
0.50
—
0.70
0.18
—
0.15
0.10
---(0.004)
---—
------—
---—
16.030
15.980
—
0.05
Unit: mm
(0.002)
LIMIT
0.05
16.040
(0.002)
3.0
1.00mm (in)
Unit:
---LIMIT
---0.10
—
—
ITEM
STANDARD
Cylinder head cover distortion
Conrod small end I.D.
16.006 —
– 16.014
Conrod deflection
---Conrod big end +
side
clearance+ PISTON RING
0.10 – 0.45
CYLINDER
PISTON
Conrod big end width
16.95 – 17.00
ITEM
STANDARD
Crank web to web width
53.0 ± 0.1
Campression pressure
1 000 – ---1 400 kPa
Crankshaft
runout
(Automatic de-compression
(10 – 14 kgf/cm2, 142 – 199 psi)
actuated)
Campression
OIL
PUMPpressure difference
—
200 kPa
(2 kgf/cm2)
LIMIT
0.120
(0.0047)
---Nicks or
Scratches
95.88
Unit: mm
(37.7748)
LIMIT
0.05
125.5
(0.002)
2.0
10.8
---(0.43)
---11.2
(0.44)
E-19
E-02, 03, 19, 24, 28,
33
OIL PUMP
ELECTRICAL
ITEM
Ignition
timing
Oil
pump
reduction ratio
Spark
plug (at 60 °C, 140 °F)
Oil
pressure
Spark performance
CLUTCH
Signal generator resistance
Signal generator
peak voltage
ITEM
Drive plate thickness
Ignition coil resistance
Drive plate claw width
Driven plate distortion
Ignition coil primary peak voltage
Clutch spring free length
Generator coil resistance
Generator
Max.
output bore
Clutch master
cylinder
Generator no-load voltage
(Whenmaster
cold) cylinder piston
Clutch
diam.
Regulated
voltage
Clutch release
cylinder bore
Starter
relay resistance
Battery
Clutch release cylinder piston
diam.
Fuse size
DRIVE
TRAIN
WATTAGE ITEM
Primary reduction ratio
ITEM
Secondary reduction ratio
Headlight
HI
Final reduction ratio
LO
Gear ratios
Low
Parking or position light
2nd
Brake light/Taillight
3rd
Turn signal light
4th
License light
Top
Speedometer light
Shift fork to groove clearance
Fuel meter light
Water
temp.
meter
light
Shift fork
groove
width
Turn signal indicator light
Shift fork
thickness
High
beam
indicator light
Trunk light
Damper spring free length
STD/SPEC.
LIMIT
STANDARD
10°1.154
B.T.D.C.
at ×
1 31/40)
600 r/min
(76/51
—
2
NGK:
CR8E
(3.5
kgf/cm
, 50 psi)
TypeAbove 350 kPa
2
DENSO:
U24ESR-N
, 92 psi)
—
Below 650 kPa
(6.5 kgf/cm
at 3 000
Gap
0.7r/min
– 0.8 mm
Over 8 mm at 1 atm.
Unit:
mm (in)
148 – 222 Ω
Green
– White
LIMIT
White –
STANDARD
More
than 1.3 V
Green
2.90 – 3.10
2.60
White/Blue
(0.114 0.09
– 0.122)
(0.102) –
Primary
– 0.13 Ω
Black/White
15.6 – 15.8
14.8
Plug
cap –
(0.61415.4
– 0.622)
(0.583)
Secondary
– 18.1 kΩ
White/Blue
0.10
—
Black/White
–
(0.004)
More than 150 V
Black/Yellow
34.47
32.7
0.50(1.357)
– 0.62 Ω
(1.29)
Approx.14.000
225 W–at
5 000 r/min
14.043
—
(0.5512 – 0.5529)
More than 40 V (AC) at 5 000 r/min
13.957 – 13.984
—
(0.5495
–
0.5506)
13.5 – 15.0 V at 5 000 r/min
33.600
1 – –733.662
Ω
—
(1.3228 – 1.3253)
Type desFTX9-BS
33.550 – 33.575
ignation
—
(1.3209 – 1.3218)
Capacity
12 V 28.8 kC (8 Ah)/10 HR
Main
20 A
Unit: mm (in) Except ratio
STANDARD
1.490 (76/51)
STD/SPEC.
0.852 (29/34)
35
2.666 (19/19 × 32/12)
35
3.000 (36/12)
5×2
1.823 (31/17)
21/5 × 2
1.333 (28/21)
21 × 4
1.041 (25/24)
5
0.884 (23/26)
1.2
0.1 – 0.3
(0.004 – 0.012)1.2
5.50 – 5.60 1.2
(0.217 – 0.220)1.2
5.30 – 5.40 1.2
(0.209 – 0.213)
5
—
Gearshift lever height
82
(3.23)
0.03 – 0.15
(0.001 – 0.006)
0.03 – 0.64
(0.001 – 0.025)
Secondary bevel gear backlash
Final bevel gear backlash
3/6
3/8
– 14.018
– 0.5519)
– 16.018
– 0.6303)
– 13.984
– 0.5506)
– 15.984
– 0.6293)
Cylinder head+distortion
CONROD
CRANKSHAFT
P
M
Unit: mm Except ratio
LIMIT
LIMIT
0.70
(0.028)
---1.00
---(0.039)
21.1
0.180
(0.007)
142.5
0.150
(0.006)
1.210 – 1.230
SPECIFICATION
(0.0476
– 0.0484)
KEIHIN
CVK24
1.510
– 1.530
2nd
(0.0594 –
240.0602)
mm
2.810 –49FA
2.830
Oil
(0.1106 – 0.1114)
1 600–±1.175
100 r/min
1.160
1st
7.0–±0.0463)
1.0 mm
(0.0457
1.470
16.0–±1.490
1.0 mm
2nd
(0.0579 –#112
0.0587)
(M.J.)
23.002 – 23.008
(M.A.J.)
Press-fitted
(0.9056 – 0.9058)
Jet
needle
(J.N.)
NBUB
Piston
pin O.D.
22.992 – 23.000
φ 2.1
(0.9052 – 0.9055)
Needle jet
(N.J.)
Throttle valve
(Th.V.)
θ = 12°
Pilot jet
(P.J.)
#20
CONROD
+ CRANKSHAFT
Pilot screw
(P.S.)
PRE-SET
ITEM
STANDARD
Throttle
cable
play
2.0
–
Conrod small end I.D.
23.015 – 23.0234.0 mm
(0.9061 – 0.9064)
Conrod big end side clearance
0.10 – 0.20
THERMOSTAT
+ RADIATOR + FAN + ENGINE
COOLANT
(0.004 – 0.008)
ITEM
STD/SPEC.
Conrod big end width
21.95 – 22.00
Thermostat valve opening temper(0.864
0.866)
Approx.– 82
°C
ature
Crank pin width
22.10 – 22.15
Thermostat valve lift
Over
3 mm
at 95 °C
(0.870
– 0.872)
Engine
47.5 – 56.8 Ω
Conrod coolant
big endtemperature
oil clearancesensor Approx. 80 °C 0.024 – 0.042
resistance
Approx. 100 °C (0.0009 – 0.0017)
26.2 – 29.3 Ω
Crank pincap
O.D.
49.982 – 50.000 2
Radiator
valve opening pres110
kPa (1.1
kgf/cm )
(1.9678
– 1.9685)
sure
Crankshaft
oil clearance
0.020 – 0.050
Electric
fan journal
thermo-switch
operatOFF → ON
Approx. 105 °C
(0.0008 – 0.0020)
ing temperature
ON → OFF
Approx. 100 °C
Crankshaft journal O.D.
51.965 – 51.980
Engine coolant type
Use an anti-freeze/engine
coolant compatible with
(2.0459 – 2.0465)
an aluminum radiator, mixed with distilled water
Crankshaft journal I.D.
52.000 – 52.015
only, at the ratio of
50:50.– 2.0478)
(2.0472
Engine coolant
capacity
Reserve tank
Crankshaft
thrust
bearing
1.925 – 2.175
Approx. 250 ml
only
thickness
(0.0758 – 0.0856)
Including
Crankshaft thrust clearance
0.05 –Approx.
0.10 1 250 ml
reserve
(0.002 – 0.004)
Crankshaft runout
—
ITEM
Carburator type
Bore size
I.D. No.
Idle
r/min
Piston
ring thickness
Fuel level
Float height
Main jet
Pistonairpin
Main
jetbore
---—
------—
---0.35
0.35
(0.014)
0.05
—
0.5
1.8
—
---—
0.03
E-19
E-02, 03, 19, 24, 28,
33
STANDARD
STD/SPEC.
0.30 – 0.45
(0.012
– 0.018)
Variable change
(2.930
– 0.770)
0.45
– 0.60
9.264 (45/17
× 63/18)
2nd
(0.018
–
0.024)
22.1
1st
150 —
1st
2nd
CARBURETOR
Piston ring groove width
CAMSHAFT++PISTON
CYLINDER
CYLINDER
+ PISTON
HEAD RING
A
S
REDUCTION
GEAR + DRIVE BELT
ITEM
Piston ring endITEM
gap
Reduction ratio
Final reduction ratio
Drive belt width
Piston ring
to groove
clearance
Movable
driven
face spring
free
length
Unit:Unit:
mmmm
(in)
LIMIT
---—
------—
---—
----
4/6
4/8
LIMIT
Unit: W
—
—
—
—
—
—
—
—
0.5
(0.020)
—
—
73.6
(2.90)
—
—
—
E-19
E-02, 03, 19, 24, 28,
33
106
CARBURETOR
BRAKE
+ WHEEL
ITEM
ITEM
Brake disc thickness
Carburetor type
Brake
drum I.D.
Bore size
Brake
disc runout
I.D. No.
Idle r/min
Brake
fluid type
Float height
Wheel rim runout
Main jet
(M.J.)
Wheel rim size
Jet needle
(J.N.)
Wheel
Needleaxle
jet runout
(N.J.)
Throttle valve
(Th.V.)
TIRE
Pilot jet
(P.J.)
ITEM
Pilot screw
(P.S.)
COLD INFLATION PRESSURE
(SOLO/DUAL RIDING)
Throttle cable play
Tire size
CARBURETOR
Tire type
ITEM
Carburetor
type
Tire
tread depth
(Recommend
depth)
Bore size
I.D. No.
Idle r/min
Float height
←
#
#32.5
STD/SPEC.
PRE-SET
PRE-SET
F: 2 1/4 turns back
F: 2 turns
200/200
kPaback
R:Front
2 1/8 turns back (2.00/2.00
R: 2 turns
back
2
)
kgf/cm
2.0 – 4.0 mm
225/280 ←
kPa
Rear
(0.08 – 0.16 in)
(2.25/2.80 kgf/cm2)
Front
110/90-12 64L
Rear
130/70-12 62L
SPECIFICATION
Front
HOOP
B03G
E-03
Rear
HOOP B02G
BDSR36
Front
---36.5 mm
Rear
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
Valve
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length
spring tension
IN. & EX.
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder head distortion
Cylinder head cover distortion
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
Engine oil type
Engine oil capacity
Reduction gearbox oil type
Reduction gearbox oil capacity
STD/SPEC.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
10.0 Liter
Full
4 – 10 Ω
Empty
90 – 100 Ω
SAE 10W-40, API SF or SG
Change
1 200 ml
Filter
1 300 ml
change
Overhaul
1 500 ml
SAE 10W-40, API SF or SG
Change
120 ml
Overhaul
130 ml
NOTE
---------E-33
---←
0.8 mm
← (1.6 mm)
10F7 0.8 mm
(1.6 mm)
←
←
←
←
←
←
←
←
Unit: mm
LIMIT
---294
-------------
←
E
L
P
M
LIMIT
—
—
—
—
—
—
0.35
—
—
—
0.05
0.5
2.2
—
0.03
37.2
—
Unit: mm
STANDARD
32.866 – 32.906
Front
32.893 – 32.933
Rear
32.628 – 32.668
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.973 – 11.984
—
—
1/6
Fuel tank capacity
Fuel level gauge resistance
E-19
E-02, 03, 19, 24, 28,
33
STANDARD
17.5
19
0.10 – 0.15
0.18 – 0.23
0.010 – 0.037
0.030 – 0.057
—
4.500 – 4.512
4.475 – 4.490
4.455 – 4.470
—
—
—
0.9 – 1.1
—
—
118 – 136 N
(12.0 – 13.9 kgf)
at length 33.7 mm
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
ITEM
Fuel type
← ----
Unit: mm
ITEM
FUEL + OIL
F: 1 3/4 turns back
---- back
R: 1 3/8 turns
A
S
VALVE + GUIDE
Valve guide to valve stem
clearance
←
←
LIMIT
PRE-SET
#90
Suzuki fork oil
G-10 (#10) or equivalent fork oil
#
106 ml
PRE-SET 83
2.0 – 4.0 mm
(0.08 – 0.16 in)
VL125/U
Valve clearance (when cold)
←
2.0
←2.0
---F: 5D124-3
---R: 5E19-3
0.25
P-0M
10F1
---1 000 ± 100 r/min
7.0 ± 0.5 mm
(0.28 ± 0.02 in)
F: # STD/SPEC.
R: #
100
F: 5D95-56 301
R: 5E9-56
87.7
5/6
5/8
Valve diam.
0.3
10F9
←
#90
SUSPENSION
ITEM
Main jet
(M.J.)
Front fork stroke
Jet
needle
Front
fork spring free length (J.N.)
Front fork oil level (without spring,
Needle
jet fully compressed) (N.J.)
inner
tube
Throttle
valve
(Th.V.)
Front
fork
oil type
Pilot jet
(P.J.)
Front
fork oil capacity (each leg)
Pilot
screw
(P.S.)
Rear wheel travel
Throttle cable play
Unit: mm
LIMIT
E-02,3.5
19
←
130.7
←
STANDARD
SPECIFICATION
Front &E-28
3.8 – E-24
4.2
RearBDSR36
←
Parking
---- ←
36.5 mm
Front &10F1
---10F2
Rear
1 000&± 100 r/min
←
Front
DOT 4
Rear
7.0 ± 0.5 mm
←
(0.28
±
0.02
in)
Axial
---F: #
F:
Radial
----#112.5
R: #110
R: #
Front
12 × MT 2.50
F: 5D95-56
F: 5D94-56-3
Rear
12 ×R:MT
3.00
R: 5E9-56
5E8-56-3
Front
----P-0
LIMIT
32.57
32.60
32.33
0.150
—
—
0.10
—
—
0.05
0.05
E-02, 19
E-19
6/6
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin bore
Pisron pin O.D.
Unit: mm
STANDARD
1 100 – 1 500 kPa
(11 – 15 kgf/cm2)
0.03 – 0.04
44.000 – 44.015
43.965 – 43.980
Measure at 10 mm from the skirt end.
—
1st
R
Approx. 4.3
2nd
RN
Approx. 5.4
1st
0.10 – 0.25
2nd
0.10 – 0.25
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
12.002 – 12.008
11.996 – 12.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
E-19
STANDARD
12.006 – 12.014
—
0.10 – 0.56
15.95 – 16.00
66.9 – 67.1
—
LIMIT
—
0.12
44.100
43.880
0.05
3.4
4.3
0.50
0.50
0.18
0.15
—
—
—
—
—
12.030
11.980
Unit: mm
LIMIT
12.040
3.0
1.0
—
—
0.08
OIL PUMP
ITEM
Oil pressure (at 60 °C)
STANDARD
35 – 60 kPa
(0.35 – 0.60 kgf/cm2)
at 3 000 r/min
2/6
LIMIT
—
E-02, 19
E-19
107
CLUTCH
Unit: mm
ITEM
Clutch cable play
STANDARD
10 – 15
Drive plate thickness
No. 1
No. 2
No. 1 & 2
Drive plate claw width
Driven plate distortion
Clutch spring free length
2.92 – 3.08
3.42 – 3.58
15.9 – 16.0
2.6
3.1
15.1
0.10
38.5
—
40.5
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Secondary reduction ratio
Gear ratios
LIMIT
—
STANDARD
3.173 (73/23)
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Type
Links
20-pitch length
Drive chain slack
4.000 (56/14)
2.636 (29/11)
1.647 (28/17)
1.217 (28/23)
0.952 (20/21)
0.818 (18/22)
0.20 – 0.40
4.25 – 4.35
3.95 – 4.05
RK428HO
142 links
254
20 – 30
Unit: mm Except ratio
LIMIT
—
—
—
—
—
—
—
0.60
—
—
—
—
269.2
—
ELECTRICAL
Unit: mm
ITEM
Ignition timing
Spark plug
SPECIFICATION
10° B.T.D.C. at 1 400 r/min
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8
Over 8 at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
NOTE
1.8 – 3.0 Ω
Primary
Secondary
18 – 28 kΩ
Ignition coil primary peak voltage
More than 250 V
Generator coil resistance
Signal generator coil resistance
Signal generator peak voltage
Generator Max. output
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
0.3 – 1.1 Ω
180 – 280 Ω
More than 4.5 V
200 W at 5 000 r/min
More than 60 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–6Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10HR
20 A
terminai –
terminal
terminal –
Plug cap
W or B/Y –
Ground Y–Y
Bl – G
B
– G
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
SPECIFICATION
MIKUNI BDS26
26 mm
26F5
1 400 ± 100 r/min
11.0 ± 1.0 mm
9.9 ± 1.0 mm
# 102.5
4DP24-3rd
O-1
# 17.5
3 turns back
2 – 4 mm
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
3/6
WATTAGE
P
M
E-02, 19
E-19
A
S
Unit: W
SPECIFICATION
ITEM
Headlight
E-02
60
55
5
21/5
21
1.7
1.7
1.7
1.7
HI
LO
Position/parking light
Brake light/Taillight
Turn signal light
Speedmeter light
Neutral indicator light
Turn signal indicator light
High beam indicator light
E-19
←
←
4
←
←
←
←
←
←
BRAKE + WHEEL
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Brake drum I.D.
Wheel rim runout
Wheel axle runout
Wheel rim size
Front
Front
Front
Front
Front
Front
STANDARD
20 – 30
LIMIT
—
50 – 60
—
4.5
0.30
—
—
—
—
—
130.7
2.0
2.0
0.25
0.25
—
—
5.0
—
12.700 – 12.743
12.657 – 12.684
42.85 – 42.90
42.772 – 42.822
DOT 4
—
—
—
—
—
18M/C × MT2.50
15M/C × MT3.00
Rear
Axial
Radial
Front
Rear
Front
Rear
SUSPENSION
E-02, 19
E-19
ITEM
Cold inflation tire pressure
(Solo riding)
STD/SPEC.
175 kPa
(1.75 kgf/cm2)
Front
200 kPa
(2.00 kgf/cm2)
175 kPa
(1.75 kgf/cm2)
225 kPa
(2.25 kgf/cm2)
90/90-18M/C 51P
130/90-15M/C 66P
IRC: GS-21F
IRC: NR31
—
—
Rear
Cold inflation tire pressure
(Dual riding)
Front
Rear
Tire size
Tire tread depth
(Recommended depth)
Front
Rear
Front
Rear
Front
Rear
LIMIT
—
—
—
—
—
—
—
—
1.6 mm
1.6 mm
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil capacity
STD/SPEC.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Including reserve
12.0 L
reserve
3.0 L
SAE 10W-40, API SF or SG
Change
1 800 ml
Filter change
1 900 ml
Overhaul
2 100 ml
NOTE
Unit: mm
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
4/6
TIRE
Tire type
Unit: mm
ITEM
Rear brake pedal free travel
E
L
STD/SPEC.
120
LIMIT
—
290.3
88
SUZUKI FORK OIL #10 or equivalent fork oil
406 ml
90
—
284
—
—
—
—
0.3
5/6
E-02, 19
E-19
6/6
E-02, 19
E-19
108
VL250
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve
Valve
Valve
Valve
Valve
Valve
STANDARD
19.5
stem runout
head thickness
stem end length
seat width
head radial runout
spring free length
22.5
0.10 – 0.15
0.18 – 0.23
0.010 – 0.037
0.030 – 0.057
—
4.500 – 4.512
4.475 – 4.490
4.455 – 4.470
—
—
—
0.9 – 1.1
—
—
—
118 – 136 N
(12.0 – 13.9 kgf)
at length 33.7 mm
Valve spring tension
IN. & EX.
CAMSHAFT + CYLINDER HEAD
ITEM
Cam height
STANDARD
32.90 – 32.94
IN.
EX.
Camshaft journal oil clearance
Camshaft journal holder I.D.
Camshaft journal O.D.
Camshaft runout
Rocker arm I.D.
Rocker arm shaft O.D.
Cylinder distortion
Cylinder head distortion
Cylinder head cover distortion
Front
Rear
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
33.10 – 33.14
32.96 – 33.00
0.032 – 0.066
22.012 – 22.025
21.959 – 21.980
—
12.000 – 12.018
11.973 – 11.984
—
—
—
No. 1
No. 2
No. 1 & 2
Drive plate claw width
Driven plate distortion
Clutch spring free length
2.92 – 3.08
3.42 – 3.58
15.9 – 16.0
—
43.0
DRIVE TRAIN + DRIVE CHAIN
ITEM
Primary reduction ratio
Secondary reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Type
Links
20-pitch length
Drive chain slack
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Throttle valve
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(Th.V.)
(P.S.)
STANDARD
3.173 (73/23)
2.866 (43/15)
2.636 (29/11)
1.647 (28/17)
1.217 (28/23)
0.952 (20/21)
0.818 (18/22)
0.20 – 0.40
4.25 – 4.35
3.95 – 4.05
D.I.D.520V
114 links
—
20 – 30
SPECIFICATION
E-19
MIKUNI BDS28SS
28 mm
27F5
1300 ± 100 r/min
11.0 ± 1.0 mm
9.9 ± 1.0 mm
#97.5
4DM11-3rd
O-2M
#15
#140
2 and 1/4 turns back
2 – 4 mm
3/6
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Unit: mm (in)
LIMIT
—
2.6
3.1
15.1
0.10
40.9
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.60
—
—
—
—
319.4
—
—
200 kPa
(2 kgf/cm2)
0.12
52.090
—
0.04 – 0.05
52.000 – 52.015
51.955 – 51.970
Measure at 10 mm from the skirt end.
1st
R
Approx. 6.0
2nd R
Approx. 4.9
1st
0.15 – 0.30
2nd
0.15 – 0.30
1st
—
2nd
—
1st
1.01 – 1.03
2nd
1.01 – 1.03
Oil
2.01 – 2.03
1st
0.97 – 0.99
2nd
0.97 – 0.99
15.002 – 15.008
14.992 – 15.000
51.880
4.8
3.9
0.50
0.50
0.18
0.15
—
—
—
—
—
15.030
14.980
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Unit: mm (in)
LIMIT
15.040
3.0
1.0
—
—
0.080
STANDARD
15.006 – 15.014
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
—
0.10 – 0.56
15.95 – 16.00
66.9 – 67.1
—
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
20 – 70 kPa
(0.2 – 0.7 kgf/cm2)
at 3 000 r/min
LIMIT
—
E
L
P
M
CARBRETOR
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam.
E-19, 24
STANDARD
10 – 15
Drive plate thickness
Compression pressure difference
Unit: mm (in)
LIMIT
32.60
32.80
32.66
0.150
—
—
0.10
—
—
0.05
0.05
0.05
Unit: mm (in)
LIMIT
STANDARD
800 – 1 200 kPa
(8 – 12 kgf/cm2)
Piston pin bore
Pisron pin O.D.
A
S
ITEM
Clutch cable play
ITEM
Compression pressure
—
1/6
CLUTCH
CYLINDER + PISTON + PISTON RING
Unit: mm (in)
LIMIT
—
—
—
—
—
—
0.35
—
—
—
0.05
0.5
2.2
—
0.03
37.2
37.2
2/6
E-19, 24
v
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Unit: mm (in)
NOTE
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
Over 8 at 1 atm.
Primary
1.8 – 3.0 Ω
Secondary
18 – 28 kΩ
Ignition coil primary peak voltage
More than 250 V
Generator coil resistance
Signal generator coil resistance
Signal generator peak voltage
Generator Max. output
Generator no-load voltage
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
Main
Headlight (HI)
Headlight (LO)
Ignition
Signal
Meter
0.3 – 1.1 Ω
180 – 280 Ω
More than 4.5 V
200 W at 5 000 r/min
More than 60 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–6Ω
YTX7L-BS
12 V 21.6 kC (6 Ah)/10HR
20 A
15 A
15 A
10 A
15 A
10 A
terminai –
terminal
terminal –
Plug cap
W or B/Y –
Ground Y–Y
Bl – G
B–G
WATTAGE
Unit: W
SPECIFICATION
ITEM
E-24
←
←
27F2
←
←
←
#107.5
←
O-0
#17.5
←
3 turns back
←
Headlight
Position light
Brake light/Taillight
Turn signal light
Speedmeter light
Neutral indicator light
Turn signal indicator light
High beam indicator light
E-19, 24
HI
LO
E-19
60
55
4
21/5
21
1.7
1.7
1.7
1.7
4/6
E-24
←
←
←
←
←
←
←
←
E-19, 24
109
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Brake drum I.D.
Wheel rim runout
Wheel axle runout
Wheel rim size
STANDARD
20 – 30
50 – 60
Front
Front
Front
Front
Front
Front
Front
Rear
Axial
Radial
Front
Rear
Front
Rear
5.0
—
12.700 – 12.743
12.657 – 12.684
42.85 – 42.90
42.772 – 42.822
DOT 4
—
—
—
—
—
18 × MT2.15 or 18M/C × MT2.15
15M/C × MT3.00
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
STD/SPEC.
120
300.5
111
SUZUKI FORK OIL #10 or equivalent fork oil
388 ml
90
—
Unit: mm (in)
LIMIT
—
—
4.5
0.30
—
—
—
—
—
130.7
2.0
2.0
0.25
0.25
—
—
Unit: mm (in)
LIMIT
—
294
—
—
—
—
0.3
5/6
VL800/Z
ITEM
Valve diam.
EX.
Valve clearance
(when cold)
IN.
EX.
Valve guide to valve stem clearance
IN.
EX.
Valve stem deflection
IN. & EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
—
5.500
(0.2165
5.475
(0.2156
5.455
(0.2148
including reserve
reserve
Engine oil type
Engine oil capacity
—
Camshaft journal O.D.
IN. & EX.
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
—
Cam height
IN. & EX.
—
120 – 139 N
(6.51 – 7.49 kgf, 14.35 – 16.51 lbs)
at length 32.5 mm (1.28 in)
65 – 74 N
(12.09 – 13.91 kgf, 26.65 – 30.67 lbs)
at length 36.0 mm (1.42 in)
12.000 –
(0.4724 –
11.966 –
(0.4711 –
—
Cylinder head cover distortion
—
ITEM
Compression pressure
—
—
0.10
(0.004)
12.018
0.4731)
11.984
0.4718)
—
—
0.05
(0.002)
0.05
(0.002)
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
Compression pressure difference
—
Cylinder bore
Piston diam.
—
0.045 – 0.055
(0.0018 – 0.0022)
83.000 – 83.015
(3.2677 – 3.2683)
82.950 – 82.965
(3.2657 – 3.2663)
Measure at 15 mm (0.6 in) from the skirt end.
1st
2nd
Piston ring end gap
Approx. 9.6 (0.38)
R
Approx. 11.8 (0.46)
0.20 – 0.35
(0.008 – 0.014)
0.20 – 0.35
(0.008 – 0.014)
1st
2nd
E-02, 03, 19, 24, 28, 33
—
CYLINDER + PISTON + PISTON RING
Piston ring free end gap
1/8
—
—
Cylinder head distortion
Piston to cylinder clearance
—
NOTE
Unit: mm (in)
LIMIT
35.65
(1.404)
36.62
(1.442)
35.20
(1.386)
36.28
(1.428)
0.150
(0.0059)
STANDARD
35.95 – 35.99
IN.
(1.415 – 1.417)
Front
36.92 – 36.96
EX.
(1.454 – 1.455)
35.50 – 35.54
IN.
(1.398 – 1.399)
Rear
36.58 – 36.62
EX.
(1.440 – 1.442)
0.032 – 0.066
(0.0013 – 0.0026)
No.1 Left side
20.012 – 20.025
No.2 Right side
(0.7879 – 0.7884)
No.1 Right side
25.012 – 25.025
No.2 Left side
(0.9847 – 0.9852)
No.1 Left side
19.959 – 19.980
No.2 Right side
(0.7858 – 0.7866)
No.1 Right side
24.959 – 24.980
No.2 Left side
(0.9826 – 0.9835)
Rocker arm shaft O.D.
IN. & EX.
INNER
ITEM
Rocker arm I.D.
Valve head radial runout
—
—
—
—
—
1.6 mm
2.0 mm
E-19, 24
CAMSHAFT + CYLINDER HEAD
—
—
—
6/6
Camshaft runout
—
OUTER
STD/SPEC.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
12.0 L
3.0 L
SAE 10W-40, API SF or SG
Change
1 800 ml
Filter change
1 900 ml
Overhaul
2 100 ml
—
0.9 – 1.1
(0.035 – 0.043)
—
E
L
—
IN. & EX.
—
OUTER
Fuel tank
Camshaft journal oil clearance
IN. & EX.
IN. & EX.
INNER
ITEM
Fuel type
Camshaft journal holder I.D.
Valve seat width
—
Front
FUEL + OIL
—
– 5.512
– 0.2170)
– 5.490
– 0.2161)
– 5.470
– 0.2154)
IN. & EX.
Valve spring tension
Tire tread depth
—
Valve stem end length
Valve spring free length
Tire type
—
200 kPa
(2.00 kgf/cm2)
175 kPa
(1.75 kgf/cm2)
225 kPa
(2.25 kgf/cm2)
90/90-18 51P or 90/90-18M/C 51P
150/80-15M/C 70P
IRC: GS-21F
IRC: GS-21R
—
—
Front
Rear
Front
Rear
Front
Rear
—
0.05
(0.002)
0.5
(0.02)
3.1
(0.12)
Valve head thickness
Tire size
—
0.35
(0.014)
Front
Rear
—
—
EX.
Valve stem runout
Cold inflation tire pressure
(Dual riding)
Unit: mm (in)
LIMIT
STD/SPEC.
175 kPa
(1.75 kgf/cm2)
Rear
P
M
Unit: mm (in)
LIMIT
STANDARD
30
(1.18)
26
(1.02)
0.08 – 0.13
(0.003 – 0.005)
0.17 – 0.22
(0.007 – 0.009)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
ITEM
Cold inflation tire pressure
(Solo riding)
E-19, 24
A
S
4 STROKE
VALVE + GUIDE
TIRE
2/8
Unit: mm (in)
LIMIT
1 100 kPa
(11 kgf/cm2, 156 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
83.085
(3.2711)
82.880
(3.2630)
7.7
(0.30)
9.4
(0.37)
0.70
(0.028)
0.70
(0.028)
E-02, 03, 19, 24, 28, 33
110
ITEM
Piston ring groove clearance
Piston ring groove width
STANDARD
1st
—
2nd
—
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
LIMIT
0.180
(0.007)
0.150
(0.006)
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
0.970 – 0.990
(0.0382 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
20.002 – 20.008
(0.7875 – 0.7877)
19.992 – 20.000
(0.7871 – 0.7874)
—
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
Clutch release screw
Drive plate thickness
—
Drive plate claw width
—
Driven plate distortion
—
Clutch spring free length
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
—
—
No.1
TRANSMISSION
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
No.1
No.1
No.2
—
—
ITEM
Secondary bevel gear backlash
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot air jet
Pilot screw
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.A.J.)
(P.S.)
Throttle cable play
E-02, 19, 24
MIKUNI BDSR34
34 mm
41F1
1 100 ± 100 r/min
9 ± 1.0 mm
(0.35 ± 0.04 in)
7.0 ± 0.5 mm
(2.76 ± 0.02 in)
#132.5
5E22-3rd
P-0M
#95
#27.5
#55
PRE-SET
(3 turns back)
2 – 4 mm
(0.08 ± 0.16 in)
LIMIT
—
P
M
E-02, 03, 19, 24, 28, 33
A
S
SPECIFICATION
E-03, 28
←
←
41F2
←
E-33
←
←
41F3
←
←
←
←
←
#
←
←
←
←
←
←
←
PRE-SET
←
←
←
5E23
←
#
ELECTRICAL
Firing order
Spark plug
SPECIFICATION
1·2
NGK: DPR7EA-9
DENSO: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Generator coil resistance
Primary
2–6Ω
Secondary
15 – 30 kΩ
LIMIT
—
—
Pickup coil peak voltage
Generator no-load voltage
(When engine cold)
Regulated voltage
Generator maximum output
Starter relay resistance
Battery
Fuse size
160 – 300 Ω
0.2 – 1.5 Ω
More than 1.5 V
Pickup coil
Charging coil
More than 70 V (AC) at 5 000 r/min
Type
designation
Capacity
—
—
—
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Terminal
#1: W,
: Ground
#1: B/Y,
: Ground
G – Bl
Y–Y
: Bl, : G
Y–Y
FTX12-BS
12 V 36 kC (10Ah)/10HR
10 A
10 A
15 A
15 A
10 A
30 A
10 A
HI
LO
Signal
Ignition
Meter
Main
Power source
—
Unit: mm (in)
LIMIT
14.0 – 15.5 V at 5 000 r/min
375 W at 5 000 r/min
3–7Ω
Headlight
—
—
—
E-02, 03, 19, 24, 28, 33
More than 200 V
Approximately 75 °C (167 °F)
Over 6 mm (0.24 in) at 90 °C (194 °F)
OFF →
Approximately 120°C (248°F)
ON
ON →
Approximately 113°C (235.4°F)
OFF
Radiator cap valve opening pres95 – 125 kPa
sure
(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)
Cooling fan thermoswitch operating
OFF →
Approximately 105°C (221°F)
temperature
ON
ON →
Approximately 100°C (212°F)
OFF
Engine coolant type
Use an antifreeze/coolant compatible with aluminum radiators, mixed with distilled water only, at the
ratio of 50:50
Engine coolant capacity
1 500 ml
(1.6 US qt, 1.3 lmp qt)
4/8
ITEM
—
—
58.5
(2.30)
—
Ignition coil primary peak voltage
STANDARD/SPECIFICATION
5/8
Drive side
Damper spring free length
THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Engine coolant temp. switch operating temperature
STANDARD
0.05 – 0.32
(0.002 – 0.013)
0.03 – 0.064
(0.001 – 0.025)
E
L
Final bevel gear backlash
3/8
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
SHAFT DRIVE
0.05
(0.002)
STANDARD
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
No.1
No.2
Shift fork thickness
OIL PUMP
ITEM
Oil pressure (at 60°C, 140°F)
STANDARD
1.690 (71/42)
1.133 (17/15)
3.090 (34/11)
2.461 (32/13)
1.631 (31/19)
1.227 (27/22)
1.000 (25/25)
0.814 (22/27)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
4.50 – 4.60
(0.177 – 0.181)
5.30 – 5.40
(0.209 – 0.213)
4.30 – 4.40
(0.169 – 0.173)
No.2
0.080
(0.0031)
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
46.8
(1.84)
—
Shift fork groove width
—
—
49.2
(1.94)
0.080
(0.0031)
—
Unit: mm (in)
LIMIT
STANDARD
10 – 15
(0.4 – 0.6)
1/4 turn back
2.92 – 3.08
(0.115 – 0.121)
3.42 – 3.58
(0.135 – 0.141)
15.9 – 16.0
(0.626 – 0.630)
No.2
20.030
(0.7886)
19.980
(0.7866)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866)
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
40.982 – 41.000
(1.6135 – 1.6142)
0.020 – 0.050
(0.0008 – 0.0020)
47.965 – 47.980
(1.8884 – 1.8890)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
Crankshaft runout
ITEM
Clutch cable play
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
CLUTCH
—
—
WATTAGE
Unit: W
ITEM
E-03, 28, 33
60
55
—
Headlight
—
Position/Parking light
Brake light/Taillight
21/5
Turn signal light
21/5 (Front), 21 (Rear)
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
E-02, 03, 19, 24, 28, 33
HI
LO
6/8
SPECIFICATION
E-24
←
←
←
21
←
←
←
←
←
←
The others
←
←
4
←
←
←
←
←
←
←
←
E-02, 03, 19, 24, 28, 33
111
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level (without spring)
Front fork oil type
Front fork oil capacity (each leg)
Front fork spring adjuster
Rear shock absorber spring
adjuster
Rear wheel travel
STANDARD/SPECIFICATION
140
(5.51)
551.7
(21.73)
177
(6.96)
SUZUKI FORK OIL SS-08 or an equivalent fork oil
412 ml
(24.0 US oz, 25.0 lmp oz)
—
Brake drum I.D.
Rear
Brake disc thickness
Front
5.0 ± 0.2
(0.20 ± 0.01)
12.700
(0.5000
12.657
(0.4983
30.230
(1.1901
30.150
(1.1870
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Wheel rim runout
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
J16 M/C × MT3.00
J15 M/C × MT4.00
– 12.743
– 0.5017)
– 12.684
– 0.4993)
– 30.306
– 1.1931)
– 30.200
– 1.1889)
7/8
VL1500
IN.
EX.
IN.
EX.
Valve stem deflection
—
Fuel tank including reserve
reserve
(flicker)
—
Engine oil type
Engine oil capacity
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
Camshaft journal holder I.D.
—
EX.
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
IN.
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
2.2
(0.09)
Rocker arm I.D.
IN.
EX.
Valve head radial runout
IN. & EX.
—
Valve spring free length
(INTAKE)
INNER
—
OUTER
—
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
40.6
(1.60)
—
OUTER
Valve spring tension (EXHAUST)
5.3 – 6.5 kgf
(11.68 – 14.33 Ibs)
at length 28.0 mm (1.10 in)
14.0 – 14.2 kgf
(30.86 – 31.31 Ibs)
at length 31.5 mm (1.24 in)
20.3 – 23.3 kgf
(44.75 – 51.37 Ibs)
at length 35.0 mm (1.38 in)
1/8
—
Rocker arm shaft O.D.
IN.
EX.
—
Cylinder head cover distortion
—
ITEM
Campression pressure
(Automatic de-compression
actuated)
Campression pressure difference
Piston to cylinder clearance
Cylinder bore
—
Cylinder distortion
Piston ring free end gap
E-03, 28, 33
Other models
LIMIT
35.38
(1.393)
36.58
(1.440)
0.150
(0.0060)
—
—
—
—
0.10
(0.004)
– 14.018
– 0.5519)
– 16.018
– 0.6303)
– 13.984
– 0.5506)
– 15.984
– 0.6293)
—
—
—
—
0.05
(0.002)
0.05
(0.002)
CYLINDER + PISTON + PISTON RING
Piston diam.
E-02, 03, 19, 24, 28, 33
14.000
(0.5511
16.000
(0.6299
13.966
(0.5498
15.966
(0.6286
Cylinder head distortion
—
—
– 35.730
– 1.4067)
– 36.930
– 1.4537)
– 0.066
– 0.0026)
– 20.025
– 0.7884)
– 25.025
– 0.9852)
– 19.980
– 0.7866)
– 24.980
– 0.9835)
—
EX.
—
—
INNER
Camshaft journal O.D.
NOTE
Unit: mm (in)
—
IN.
—
—
—
—
—
1.6
(0.06)
2.0
(0.08)
E-02, 03, 19, 24, 28, 33
STANDARD
35.680
IN.
(1.4047
36.880
EX.
(1.4521
0.032
IN. & EX.
(0.0013
Front head right side,
20.012
rear head left side
(0.7879
Front head left side,
25.012
rear head right side
(0.9847
Front head right side,
19.959
rear head left side
(0.7858
Front head left side,
24.959
rear head right side
(0.9826
Front & Rear
—
Valve spring free length
(EXHAUST)
Valve spring tension (INTAKE)
8/8
Camshaft runout
0.9 – 1.1
(0.035 – 0.043)
1.0 – 1.2
(0.039 – 0.047)
—
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane or 91 octane (R/2 + M/2) 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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
17.0 L
(4.5/3.7 US/lmp gal)
1.5 L
(0.4/0.3 US/lmp gal)
SAE 10W-40, API SF or SG
3 000 ml
Change
(3.2/2.6 US/lmp qt)
Filter
3 400 ml
change
(3.6/3.0 US/lmp qt)
3 700 ml
Overhaul
(3.9/3.3 US/lmp qt)
SAE 90 hypoid gear oil with
GL-5 under API classification
200 – 220 ml
(6.8/7.0 – 7.4/7.7 US/lmp oz)
DOT 4
1 500 ml
(1.6/1.3 US/lmp qt)
—
EX.
Valve seat width
Cam height
—
—
IN.
ITEM
Camshaft journal oil clearance
5.500 – 5.512
(0.2165 – 0.2170)
7.000 – 7.015
(0.2756 – 0.2762)
5.475 – 5.490
(0.2156 – 0.2161)
6.945 – 6.960
(0.2734 – 0.2740)
—
—
CAMSHAFT + CYLINDER HEAD
—
IN.
Valve stem O.D.
Brake fluid type
Coolant capacity
—
0.35
(0.014)
—
E
L
Final bevel gear oil capacity
LIMIT
—
EX.
Final bevel gear oil type
P
M
IN. & EX.
Valve guide I.D.
ITEM
180.7
(7.11)
4.5
(0.18)
0.30
(0.012)
—
Front
Rear
—
FUEL + OIL + COOLANT
Fuel type
—
E-02, 03, 19, 24, 28, 33
STANDARD
33
(1.3)
40
(1.6)
0 – 0.5
(0 – 0.02)
0.010 – 0.037
(0.0004 – 0.0015)
0.040 – 0.070
(0.0016 – 0.0028)
Lash-adjuster plunger stroke
Valve guide to valve stem
clearance
Unit: mm (in)
LIMIT
Unit: mm (in)
ITEM
Front
Front
Rear
Front
Rear
—
A
S
VALVE + GUIDE
Valve diam.
Tire size
Tire tread depth
—
Front
Rear
—
Front
Wheel rim size
—
0.3
(0.01)
Master cylinder bore
Wheel axle runout
Cold inflation tire pressure
(Dual riding)
—
Unit: mm (in)
LIMIT
STANDARD/SPECIFICATION
200 kPa
(2.00 kgf/cm2, 29 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
200 kPa
(2.00 kgf/cm2, 29 psi)
250 kPa
(2.50 kgf/cm2, 36 psi)
130/90-16M/C 67H
170/80-15 M/C 77H
IRC GS-23F
IRC GS-23R
Rear
—
—
Brake disc runout
540.6
(21.29)
Tire type
STANDARD
20 – 30
(0.8 – 1.2)
75 – 85
(3.0 – 3.3)
Rear brake pedal height
ITEM
Cold inflation tire pressure
(Solo riding)
—
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
—
TIRE
105
(4.13)
(4)
Swingarm pivot shaft runout
Unit: mm (in)
LIMIT
Unit: mm (in)
STANDARD
LIMIT
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
—
—
200 kPa
(2 kgf/cm2)
0.120
(0.0047)
Nicks or
Scratches
0.02 – 0.03
(0.0008 – 0.0012)
96.000 – 96.015
(3.7795 – 3.7801)
95.975 – 95.990
(3.7785 – 3.7791)
Measure at 16 mm (0.6 in) from the skirt end.
—
1st
T
Approx. 13.5 (0.53)
2nd
T
Approx. 14.0 (0.55)
2/8
95.88
(37.7748)
0.05
(0.002)
10.8
(0.43)
11.2
(0.44)
E-02, 03, 19, 24, 28, 33
112
ITEM
Piston ring end gap
2nd
STANDARD
0.30 –
(0.012 –
0.45 –
(0.018 –
1st
—
1st
Piston ring to groove clearance
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
LIMIT
0.70
(0.028)
1.00
(0.039)
0.180
(0.007)
0.150
(0.006)
0.45
0.018)
0.60
0.024)
—
1.210 – 1.230
(0.0476 – 0.0484)
1.510 – 1.530
(0.0594 – 0.0602)
2.810 – 2.830
(0.1106 – 0.1114)
1.160 – 1.175
(0.0457 – 0.0463)
1.470 – 1.490
(0.0579 – 0.0587)
23.002 – 23.008
(0.9056 – 0.9058)
22.992 – 23.000
(0.9052 – 0.9055)
ITEM
Conrod small end I.D.
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft journal I.D.
Crankshaft thrust bearing
thickness
Crankshaft thrust clearance
—
STANDARD
1.154 (76/51 × 31/40)
Above 350 kPa (3.5 kgf/cm2, 50 psi)
Below 650 kPa (6.5 kgf/cm2, 92 psi)
at 3 000 r/min
CLUTCH
Driven plate distortion
—
—
Clutch spring free length
—
34.47
(1.357)
14.000 – 14.043
(0.5512 – 0.5529)
13.957 – 13.984
(0.5495 – 0.5506)
33.600 – 33.662
(1.3228 – 1.3253)
33.550 – 33.575
(1.3209 – 1.3218)
Clutch master cylinder bore
23.030
(0.9067)
22.980
(0.9047)
Clutch master cylinder piston
diam.
Clutch release cylinder bore
Unit: mm (in)
Clutch release cylinder piston
diam.
LIMIT
23.040
(0.9071)
0.3
(0.012)
—
0.05
(0.002)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
DRIVE TRAIN
—
Shift fork groove width
Shift fork thickness
—
Damper spring free length
STANDARD
1.490 (76/51)
0.852 (29/34)
2.666 (19/19 × 32/12)
3.000 (36/12)
1.823 (31/17)
1.333 (28/21)
1.041 (25/24)
0.884 (23/26)
0.1 – 0.3
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
5.30 – 5.40
(0.209 – 0.213)
E
L
Gearshift lever height
Secondary bevel gear backlash
Final bevel gear backlash
3/8
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
Throttle valve
Pilot jet
Pilot screw
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Throttle cable play
E-28
BDSR36
36.5 mm
10F1
1 000 ± 100 r/min
7.0 ± 0.5 mm
(0.28 ± 0.02 in)
F: #
R: #
F: 5D95-56
R: 5E9-56
#90
#
PRE-SET
F: 2 1/4 turns back
R: 2 1/8 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
P
M
E-02, 03, 19, 24, 28, 33
A
S
SPECIFICATION
E-24
←
←
10F2
←
E-02, 19
←
←
10F9
←
←
←
F: #112.5
R: #110
F: 5D94-56-3
R: 5E8-56-3
P-0
←
#32.5
PRE-SET
F: 2 turns back
R: 2 turns back
←
PRE-SET
F: 1 3/4 turns back
R: 1 3/8 turns back
←
←
F: 5D124-3
R: 5E19-3
P-0M
←
←
CARBURETOR
SPECIFICATION
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
E-03
BDSR36
36.5 mm
10F1
1 000 ± 100 r/min
7.0 ± 0.5 mm
(0.28 ± 0.02 in)
F: #
R: #
F: 5D95-56
R: 5E9-56
#90
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
E-33
←
←
10F7
←
←
←
←
←
←
←
←
←
—
—
—
—
LIMIT
—
—
—
—
—
—
—
—
0.5
(0.020)
—
—
73.6
(2.90)
82
(3.23)
0.03 – 0.15
(0.001 – 0.006)
0.03 – 0.64
(0.001 – 0.025)
—
—
—
4/8
E-02, 03, 19, 24, 28, 33
Unit: mm (in)
ITEM
Firing order
Spark plug
SPECIFICATION
R·F
NGK: DPR7EA-9
DENSO: X22EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
178 – 242 Ω
More than 2.4 V
1–7Ω
Type
Gap
Spark performance
Signal coil resistance
Signal coil peak voltage
Ignition coil resistance
Primary
Secondary
Ignition coil primary peak voltage
Generator Max. output
Generator no-load voltage
(when engine is cold)
Regulated voltage
Starter relay resistance
De-comp. solenoid resistance
Fuel pump resistance
Fuel pump discharge amount
Battery
Type designation
Voltage
Capacity
Standard
electrolyte S.G.
Fuse size
HI
Headlight
LO
Signal
Ignition
Main
Power source
Speedometer
Front
Rear
18 – 28 kΩ
More than 190 V
More than 200 V
Approx. 340 W at 5 000 r/min
NOTE
Bl – G
tap – tap
Plug cap –
tap
B/Y – Ground
W – Ground
More than 80 V (AC) at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
3–6Ω
0.1 – 1.0 Ω
1 – 2.5 Ω
More than 600 ml (1.27 US qt)/min
FTH16-BS-1
12 V
50.4 kC (14 Ah)/10HR
1.320 at 20 °C (68 °F)
10
10
15
15
30
10
10
A
A
A
A
A
A
A
WATTAGE
Unit: W
ITEM
Headlight
Speedometer light
Turn signal indicator light
E-02, 03, 19, 24, 28, 33
LIMIT
2.60
(0.102)
14.8
(0.583)
0.10
(0.004)
32.7
(1.29)
—
ELECTRICAL
Position/Parking light
Brake light/Taillight
Turn signal light
5/8
—
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
—
—
LIMIT
—
Unit: mm (in)
STANDARD
2.90 – 3.10
(0.114 – 0.122)
15.6 – 15.8
(0.614 – 0.622)
Drive plate claw width
—
STANDARD
23.015 – 23.023
(0.9061 – 0.9064)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866)
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
49.982 – 50.000
(1.9678 – 1.9685)
0.020 – 0.050
(0.0008 – 0.0020)
51.965 – 51.980
(2.0459 – 2.0465)
52.000 – 52.015
(2.0472 – 2.0478)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
Crankshaft runout
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
ITEM
Drive plate thickness
—
CONROD + CRANKSHAFT
OIL PUMP
HI
LO
Front
Rear
E-03, 28, 33
60
55
SPECIFICATION
E-24
←
←
21/5
21/5
21
0.84
1.7
←
21
←
←
←
6/8
Others
←
←
4
←
←
←
←
←
E-02, 03, 19, 24, 28, 33
113
ITEM
High beam indicator light
Neutral indicator light
Fuel level warning light
Oil pressure indicator light
E-03, 28, 33
1.7
1.7
1.7
LED
SUSPENSION
SPECIFICATION
E-24
←
←
←
←
BRAKE + WHEEL
STANDARD
98
(3.86)
4.8 – 5.2
(0.189 – 0.205)
6.6 – 7.0
(0.260 – 0.276)
Front
Rear
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Rear
15.870 –
(0.6248 –
12.700 –
(0.5000 –
15.827 –
(0.6231 –
12.657 –
(0.4983 –
30.230 –
(1.1902 –
30.230 –
(1.1902 –
30.150 –
(1.1870 –
30.150 –
(1.1870 –
Wheel rim runout
Axial
—
Rear
Rear
Rear
4.5
(0.18)
6.3
(0.25)
0.30
(0.012)
15.913
0.6265)
12.743
0.5017)
15.854
0.6242)
12.684
0.4994)
30.306
1.1931)
30.306
1.1931)
30.200
1.1890)
30.200
1.1890)
—
Rear
—
Front
Rear
Front
Rear
16 × MT3.50, 16M/C × MT3.50
15M/C × MT5.00
150/80-16 71H, 150/80-16M/C 71H
180/70-15M/C 76H
Front
—
Rear
—
ITEM
Valve diam.
—
Fuel tank
—
Engine oil type
Engine oil capacity
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Fuel fork oil type
Fuel fork oil capacity (each leg)
Bevel gear oil type
Bevel gear oil capacity
STANDARD
—
—
—
kPa
200
250
SOLO RIDING
kgf/cm2
2.00
2.50
P
M
Unit: mm (in)
LIMIT
8/8
CAMSHAFT + CYLINDER HEAD
STANDARD
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
Rocker arm shaft O.D.
IN. & EX.
EX.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
—
Cylinder head distortion
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
—
Valve stem and length
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
4.0
(0.16)
Cylinder head cover distortion
Valve head thickness
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
INNER
—
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
EX.
Valve clearance
(when cold)
Valve guide to valve stem
clearance
Valve stem O.D.
IN. & EX.
IN.
IN.
OUTER
—
Valve spring tension
6.51 – 7.49 kgf
(14.35 – 16.51 lbs)
at length 32.5 mm (1.28 in)
12.09 – 13.91 kgf
(26.65 – 30.67 lbs)
at length 36.0 mm (1.42 in)
INNER
OUTER
Cam height
—
—
Camshaft journal oil clearance
—
Camshaft journal holder I.D.
—
—
Camshaft journal O.D.
35.954 – 35.994
(1.4155 – 1.4171)
36.919 – 36.959
EX.
(1.4535 – 1.4551)
0.032 – 0.066
(0.0013 – 0.0026)
No. 1 Left side
20.012 – 20.025
No. 2 Right side
(0.7879 – 0.7884)
No. 1 Right side
25.012 – 25.025
No. 2 Left side
(0.9847 – 0.9852)
No. 1 Left side
19.959 – 19.980
No. 2 Right side
(0.7858 – 0.7866)
No. 1 Right side
24.959 – 24.980
No. 2 Left side
(0.9826 – 0.9835)
IN.
Camshaft runout
ITEM
Compression pressure
12.000 –
(0.4724 –
11.966 –
(0.4711 –
Cylinder bore
Piston diam.
—
—
0.045 – 0.055
(0.0018 – 0.0022)
83.000 – 83.015
(3.2677 – 3.2683)
82.950 – 82.965
(3.2657 – 3.2663)
Measure at 15 mm (0.6 in) from the skirt end.
—
—
Piston ring free end gap
1st
R
Approx. 10.5 (0.413)
2nd
R
Approx. 11.8 (0.465)
0.20
(0.008
0.20
(0.008
1st
2nd
Piston ring to groove clearance
E-03, 28, 33
The others
– 0.35
– 0.014)
– 0.35
– 0.014)
1st
—
2nd
—
2/9
LIMIT
35.660
(1.4039)
36.620
(1.4417)
0.150
(0.0060)
—
—
—
—
—
—
0.05
(0.002)
0.05
(0.002)
1 300 – 1 600 kPa
(13 – 16 kgf/cm2, 185 – 228 psi)
Cylinder distortion
E-03, 28, 33
12.018
0.4731)
11.984
0.4718)
STANDARD
Compression pressure difference
Piston to cylinder clearance
LIMIT
0.10
(0.004)
—
CYLINDER + PISTON + PISTON RING
Piston ring end gap
1/9
psi
29
36
Unit: mm (in)
ITEM
—
IN.
DUAL RIDING
kgf/cm2
2.00
2.50
E-02, 03, 19, 24, 28, 33
EX.
EX.
Valve lift
—
kPa
200
250
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
15.0 L
(4.0/3.3 US/Imp gal)
SAE 10W-40, API SF or SG
3 700 ml
Change
(3.9/3.3 US/lmp qt)
Filter
4 300 ml
change
(4.5/3.8 US/lmp qt)
5 000 ml
Overhaul
(5.3/4.4 US/lmp qt)
SUZUKI FORK OIL SS-08 (#10) or
equivalent fork oil
439 ml
(14.8/15.5 US/lmp oz)
Hypoid Gear oil #90 API GL-5
200 – 220 ml
Final
(6.8/7.0 – 7.4/7.7 US/lmp oz)
DOT 4
30
(1.18)
26
(1.02)
8.5
(0.33)
8.5
(0.33)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.036 – 0.057
(0.0012 – 0.0022)
IN.
psi
29
36
E
L
Brake fluid type
E-02, 03, 19, 24, 28, 33
A
S
VALVE + GUIDE
ITEM
Fuel type
—
Wheel rim size
VS800GL
FRONT
REAR
—
—
7/8
COLD INFLATION
TIRE PRESSURE
—
—
—
573
(22.56)
FUEL + OIL
—
Front
Unit: mm (in)
NOTE
LIMIT
TIRE PRESSURE
—
Radial
Tire tread depth
Rear shock absorber spring
set length
Rear wheel travel
—
Wheel axle runout
Tire size
Front fork oil level
LIMIT
—
Front
STANDARD
140
(5.5)
585
(23.03)
169.0
(6.65)
222.0
(8.74)
118
(4.6)
Front fork spring free length
Unit: mm (in)
ITEM
Rear brake pedal height
Brake disc thickness
ITEM
Front fork stroke
Others
←
←
←
←
Unit: mm (in)
LIMIT
1 100 kPa
(11 kgf/cm2,
156 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
83.085
(3.2711)
82.880
(3.2630)
0.05
(0.002)
8.4
(0.331)
9.4
(0.370)
0.70
(0.028)
0.70
(0.028)
0.180
(0.007)
0.150
(0.006)
E-03, 28, 33
114
ITEM
Piston ring groove width
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0996)
0.970 – 0.990
(0.0382 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
20.002 – 20.008
(0.7875 – 0.7877)
19.996 – 20.000
(0.7827 – 0.7874)
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
Crankshaft runout
—
Drive plate claw width
—
Driven plate distortion
—
Clutch spring free length
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
40.982 – 41.000
(1.6135 – 1.6142)
0.020 – 0.050
(0.0008 – 0.0020)
47.965 – 47.980
(1.8884 – 1.8890)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
Conrod big end width
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
Clutch master cylinder bore
Clutch release cylinder piston
diam.
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Final bevel gear backlash
0.05 – 0.32
(0.002 – 0.013)
0.03 – 0.64
(0.001 – 0.025)
Drive side
CARBURETOR
—
—
SPECIFICATION
E-03
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
P
M
Unit: mm (in)
LIMIT
STANDARD
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
MIKUNI BS36SS (No. 1)
36 mm
38E1
1 200 ± 50 r/min
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D35-1st
MIKUNI BDS36SS (No. 2)
←
←
←
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#
5D47-1st
#125
#
(PRE-SET)
2.0 – 4.0 mm
(0.08 – 0.16 in)
#110
#
(PRE-SET)
←
CARBURETOR
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
MIKUNI BS36SS (No. 1)
36 mm
38E4
1 200 ± 50 r/min
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#132.5
5D61-3rd
P-7
#125
#45
(PRE-SET) 1 and 1/8 turns back
2.0 – 4.0 mm
(0.08 – 0.16 in)
5/9
MIKUNI BDS36SS (No. 2)
←
←
←
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#127.5
5D48-3rd
P-2
#110
#40
(PRE-SET) 1 and 1/4 turns back
←
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
—
—
—
—
E-03, 28, 33
CARBURETOR
SPECIFICATION
E-33
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
MIKUNI BS36SS (No. 1)
36 mm
38E5
1 200 ± 50 r/min
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D35-1st
MIKUNI BDS36SS (No. 2)
←
←
←
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#
5D47-1st
#125
#
(PRE-SET)
2.0 – 4.0 mm
(0.08 – 0.16 in)
#110
#
(PRE-SET)
←
ELECTRICAL
Unit: mm (in)
ITEM
SPECIFICATION
Firing order
Spark plug
1·2
N.G.K.: DPR8EA-9
Type
N.D.: X24EPR-U9
0.8 – 0.9
Gap
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
Approx. 50 – 200 Ω (G – Bl)
Primary
2–6Ω
Secondary
Generator no-load voltage
(When engine cold)
Generator Max. output
Regulated voltage
Starter motor brush length
Commutator under-cut
Starter relay resistance
Battery
Fuse size
E-03, 28, 33
—
4/9
Spark performance
Signal coil resistance
Ignition coil resistance
SPECIFICATION
E-28
ITEM
—
E
L
—
A
S
ITEM
Secondary bevel gear backlash
No. 2
E-03, 28, 33
SHAFT DRIVE
No. 1
No. 1
LIMIT
—
3/9
—
1.690 (71/42)
1.133 (30/30 × 17/15)
3.090 (34/11)
2.285 (32/14)
1.631 (31/19)
1.227 (27/22)
1.000 (25/25)
0.851 (23/27)
0.10 – 0.30
(0.004 – 0.012)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
4.50 – 4.60
(0.177 – 0.181)
5.30 – 5.40
(0.209 – 0.213)
4.30 – 4.40
(0.169 – 0.173)
No. 2
Shift fork thickness
1.859 (71/42 × 32/29)
Above 350 kPa (3.5 kg/cm2, 50 psi)
Below 650 kPa (6.5 kg/cm2, 92 psi)
at 3 000 r/min
—
STANDARD
No. 1
0.05
(0.002)
OIL PUMP
14.043
0.5529)
13.984
0.5506)
38.162
1.5024)
38.075
1.4990)
TRANSMISSION
No. 2
—
STANDARD
14.000 –
(0.5512 –
13.957 –
(0.5495 –
38.100 –
(1.5000 –
38.042 –
(1.4977 –
Clutch master cylinder piston
diam.
Clutch release cylinder bore
—
—
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
2.92 – 3.08
(0.115 – 0.121)
3.45 – 3.55
(0.136 – 0.140)
15.8 – 16.0
(0.622 – 0.630)
No. 1
No. 2
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
2.62
(0.103)
3.15
(0.124)
15.0
(0.591)
0.10
(0.004)
34.0
(1.34)
STANDARD
—
STANDARD
Conrod big end side clearance
ITEM
Drive plate thickness
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
CLUTCH
LIMIT
STANDARD
1st
Headlight
Signal
Ignition
Main
Power source
15 – 40 kΩ
NOTE
tap – tap
Plug cap –
tap
More than 75 V (AC) at 5 000 r/min
250 W at 5 000 r/min
13.5 – 15.5 V at 5 000 r/min
Limit: 9.0 (0.35)
Limit: 0.2 (0.008)
2–6Ω
Type designation
YB16B-A1
Capacity
12 V 57.6 kC (16 Ah)/10 HR
Standard
1.28 at 20 °C (68 °F)
electrolyte S.G.
10 A
10 A
10 A
25 A
10 A
6/9
—
N.D.
E-03, 28, 33
115
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
HI
LO
60
55
3.4
21/5
21/5 (Front), 21 (Rear)
3.4
1.7
3
1.7
1.7
1.7
8
Parking light
Brake light/Taillight
Turn signal light
Speedometer light
Water temp. meter light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure indicator light
License light
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
STANDARD
20 – 30
(0.8 – 1.2)
40
(1.6)
Rear brake pedal height
Brake lining thickness
Brake drum I.D.
Rear
—
Brake disc thickness
Front
5.0 ± 0.2
(0.20 ± 0.01)
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Wheel rim runout
Axial
—
Radial
—
Front
—
Wheel axle runout
Wheel rim size
– 12.743
– 0.5017)
– 12.684
– 0.4993)
– 42.926
– 1.6900)
– 42.820
– 1.6858)
Rear
—
Front
Rear
J19 × 2.15
J15M/C × MT3.00
7/9
ITEM
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity
(each leg)
Final bevel gear oil type
Final bevel gear oil capacity
Brake fluid type
Coolant capacity
Unit: mm (in)
LIMIT
—
STANDARD
LIMIT
—
—
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
STANDARD
LIMIT
130
(5.12)
—
Rear wheel travel
Swingarm pivot shaft runout
—
348.3
(13.71)
124.3
(4.89)
90
(3.5)
—
—
0.30
(0.012)
NOTE
—
TIRE PRESSURE
1.5
(0.056)
180.7
(7.11)
4.5
(0.18)
0.30
(0.012)
NORMAL RIDING
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
200
225
SOLO RIDING
kg/cm2
2.00
2.25
psi
29
33
kPa
225
250
DUAL RIDING
kg/cm2
2.25
2.50
psi
33
36
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
E-03, 28, 33
E-33
Others
LIMIT
—
—
ON
Over 6 mm (0.24 in) at 90 °C (194 °F)
1.1 ± 0.15 kg/cm2
(15.6 ± 2.1 psi, 110 ± 15 kPa)
Approx. 105 °C (221 °F)
OFF
Approx. 100 °C (212 °F)
—
E
L
P
M
NOTE
75.0 ± 1.5 °C (167 ± 2.7 °F)
9/9
—
Rear
Front fork oil level
THERMOSTAT + RADIATOR + FAN
ITEM
Thermostat valve opening
temperature
Thermostat valve lift
Radiator cap valve release
pressure
Electric fan thermoswitch operating
temperature
Front
Front fork spring free length
E-03, 28, 33
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane or 91 octane (R/2 + M/2) 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.
11.0 L
(2.9/2.4 US/lmp gal)
12.0 L
(3.2/2.6 US/lmp gal)
3.0 L
(0.8/0.7 US/lmp gal)
SAE 10W-40, API SF or SG
2 400 ml
Change
(2.5/2.1 US/lmp qt)
2 800 ml
Filter change
(3.0/2.5 US/lmp qt)
3 300 ml
Overhaul
(3.5/2.9 US/lmp qt)
Fork oil #10
413 ml
(14.0/14.5 US/lmp oz)
SAE 90 hypoid gear oil
with GL-5 under API classification
200 – 220 ml
(6.8/7.0 – 7.4/7.7 US/lmp oz)
DOT 4
1 700 ml
(1.8/1.5 US/lmp qt)
Fuel type
Tire tread depth
ITEM
Front fork stroke
A
S
FUEL + OIL + COOLANT
STANDARD
100/90-19 57H, 100/90-19M/C 57H
140/90-15 70H, 140/90-15M/C 70H
—
—
12.700
(0.5000
12.657
(0.4983
42.850
(1.6870
42.770
(1.6839
Front
Rear
SUSPENSION
—
Rear
Brake disc runout
ITEM
Tire size
—
—
E-03, 28, 33
8/9
E-03, 28, 33
116
VS1400GLP
VALVE + GUIDE
ITEM
Valve diam.
STANDARD
33
(1.3)
40
(1.6)
8
(0.31)
9
(0.35)
0 – 0.5
(0 – 0.02)
0.010 – 0.037
(0.0004 – 0.0015)
0.040 – 0.070
(0.0016 – 0.0028)
IN.
EX.
Valve lift
IN.
EX.
Lash-adjuster plunger stroke
Valve guide to valve stem clearance
IN.
EX.
Valve stem deflection
Valve guide I.D.
Valve stem runout
OUTER
—
Valve spring tension (EXHAUST)
—
ITEM
—
EX.
IN. & EX.
—
—
IN. & EX.
—
IN. & EX.
—
INNER
—
OUTER
—
Valve spring free length
(EXHAUST)
—
Camshaft journal O.D.
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.10)
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
40.5
(1.59)
IN. & EX.
—
Camshaft journal oil clearance
—
—
Valve spring free length
(INTAKE)
IN.
EX.
Camshaft journal holder I.D.
0.9 – 1.3
(0.04 – 0.05)
Valve head radial runout
35.683 –
(1.4048 –
36.883 –
(1.4521 –
0.032 –
(0.0013 –
22.012 –
(0.7879 –
25.012 –
(0.9847 –
19.959 –
(0.7858 –
24.959 –
(0.9826 –
—
0.35
(0.014)
IN. & EX.
STANDARD
Cam height
—
Valve stem and length
5.3 – 6.5 kgf
(11.68 – 14.33 lbs)
at length 28.0 mm (1.10 in)
14.0 – 14.2 kgf
(30.86 – 31.31 lbs)
at length 31.5 mm (1.24 in)
20.3 – 23.3 kgf
(44.75 – 51.37 lbs)
at length 35.0 mm (1.38 in)
CAMSHAFT + CYLINDER HEAD
—
—
5.500 – 5.512
(0.2165 – 0.2170)
7.000 – 7.012
(0.2756 – 0.2761)
5.475 – 5.490
(0.2156 – 0.2161)
6.945 – 6.960
(0.2734 – 0.2740)
Valve head thickness
Valve seat width
—
IN. & EX.
Front head right side,
rear head left side
Front head left side,
rear head right side
Front head right side,
rear head left side
Front head left side,
rear head right side
Camshaft runout
Front & Rear
Rocker arm I.D.
IN.
14.000 –
(0.5511 –
16.000 –
(0.6299 –
13.966 –
(0.5498 –
15.966 –
(0.6286 –
EX.
Rocker arm shaft O.D.
IN.
EX.
Cylinder head distortion
ITEM
Compression pressure
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
Compression pressure difference
Piston to cylinder clearance
Cylinder bore
Piston diam.
—
0.05 – 0.06
(0.0020 – 0.0024)
94.000 – 94.015
(3.7008 – 3.7014)
93.945 – 93.960
(3.6986 – 3.6992)
Measure at 16 mm (0.6 in) from the skirt end.
Cylinder distortion
Piston ring free end gap
Piston ring end gap
—
1st
T
Approx. 14.5 (0.57)
2nd
T
Approx. 11.5 (0.45)
1st
2nd
Piston ring to groove clearance
1st
2nd
Piston ring groove width
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
STANDARD
0.30 – 0.45
(0.012 – 0.018)
0.25 – 0.40
(0.010 – 0.016)
0.040 – 0.075
(0.0016 – 0.0030)
0.025 – 0.060
(0.0010 – 0.0024)
1.230 – 1.250
(0.0484 – 0.0492)
1.510 – 1.530
(0.0594 – 0.0602)
2.810 – 2.830
(0.1106 – 0.1114)
1.175 – 1.190
(0.0463 – 0.0469)
1.470 – 1.485
(0.0579 – 0.0585)
23.000 – 23.006
(0.9055 – 0.9057)
22.996 – 23.000
(0.9054 – 0.9055)
93.880
(3.6960)
E
L
2/9
—
—
Unit: mm (in)
LIMIT
35.41
(1.394)
35.61
(1.378)
0.150
(0.0060)
—
—
—
—
—
—
—
—
—
—
E-03, 28, 33
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
49.982 – 50.000
(1.9678 – 1.9685)
0.020 – 0.050
(0.0008 – 0.0020)
51.965 – 51.980
(2.0459 – 2.0465)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
Crankshaft runout
Unit: mm (in)
LIMIT
23.040
(0.9071)
0.3
(0.012)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
0.05
(0.002)
STANDARD
1.274 (79/48 × 31/40)
Above 350 kPa (3.5 kg/cm2, 50 psi)
Below 650 kPa (6.5 kg/cm2, 92 psi)
at 3 000 r/min
LIMIT
—
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
—
—
—
CLUTCH
—
ITEM
Drive plate thickness
No. 1
23.030
(0.9067)
22.980
(0.9047)
Drive plate claw width
No. 1
STANDARD
2.72 – 2.88
(0.107 – 0.113)
3.45 – 3.55
(0.136 – 0.140)
15.8 – 16.0
(0.622 – 0.630)
15.9 – 16.0
(0.626 – 0.630)
No. 2
No. 2
Driven plate distortion
Clutch spring free length
—
No. 1
—
No. 2
Clutch master cylinder bore
Clutch master cylinder piston
diam.
3/9
—
v
Crank pin O.D.
0.05
(0.002)
11.6
(0.46)
9.2
(0.36)
0.70
(0.028)
0.70
(0.028)
0.180
(0.0071)
0.150
(0.0059)
—
0.05
(0.002)
0.05
(0.002)
1.5 – 2.5
(0.06 – 0.10)
1.0 – 2.0
(0.04 – 0.08)
Front
P
M
Unit: mm (in)
LIMIT
880 kPa
(8 kgf/cm2, 114 psi)
200 kPa
(2 kgf/cm2, 28 psi)
0.120
(0.0047)
94.080
(3.7039)
14.018
0.5519)
16.018
0.6303)
13.984
0.5506)
15.984
0.6293)
—
De-comp. lever clearance
—
0.10
(0.004)
—
Cylinder head cover distortion
E-03, 28, 33
CYLINDER + PISTON + PISTON RING
35.723
1.4064)
36.923
1.4537)
0.066
0.0026)
22.025
0.7884)
25.025
0.9852)
19.980
0.7866)
24.980
0.9835)
—
Rear
1/9
LIMIT
STANDARD
INNER
IN.
IN.
ITEM
Valve spring tension (INTAKE)
—
IN. & EX.
EX.
Valve stem O.D.
Unit: mm (in)
LIMIT
E-03, 28, 33
—
14.000 –
(0.5512 –
13.957 –
(0.5495 –
4/9
14.043
0.5529)
13.984
0.5506)
Unit: mm (in)
LIMIT
2.42
(0.095)
3.15
(0.124)
15.2
(0.600)
15.2
(0.600)
0.10
(0.004)
27.6
(1.09)
20.0
(0.79)
—
—
E-03, 28, 33
117
ITEM
Clutch release cylinder bore
STANDARD
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
Clutch release cylinder piston
diam.
TRANSMISSION
ITEM
Primary reduction ratio
Secondary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
STANDARD
No. 1
No. 2
No. 3
Shift fork thickness
No. 1
No. 2
No. 3
1.645 (79/48)
0.852 (29/34 × 19/19)
2.666 (32/12)
3.000 (36/12)
1.823 (31/17)
1.333 (28/21)
1.086 (25/23)
0.960 (24/25)
0.1 – 0.3
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
5.50 – 5.60
(0.217 – 0.220)
5.50 – 5.60
(0.217 – 0.220)
5.30 – 5.40
(0.209 – 0.213)
5.30 – 5.40
(0.209 – 0.213)
5.30 – 5.40
(0.209 – 0.213)
Damper spring free length
Gearshift lever height
Final bevel gear backlash
Drive side
ITEM
Carburetor type
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
—
Carburetor type
—
—
Unit: mm (in)
LIMIT
ITEM
Fuel level
Float height
—
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
—
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
Firing order
Spark plug
Type
Gap
Spark performance
Signal coil resistance
Ignition coil resistance
A
S
Primary
Secondary
Generator Max. output
Generator no-load voltage
Regulated voltage
Starter motor brush length
Commutator under-cut
Starter relay resistance
De-comp. solenoid resistance
Side stand and neutral relay
Fuel pump resistance
Fuel pump discharge amount
Battery
Type designation
Voltage
Capacity
Standard
electrolyte S.G.
Fuse size
HEADLIGHT
SIGNAL
IGNITION
MAIN
POWER SOURCE
10 – 25 kΩ
Bl – G, B – Y
tap – tap
Plug cap –
tap
Approx. 340 W at 5 000 r/min
More than 80 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
N.D.
Limit: 9.0 (0.35)
Limit: 0.2 (0.008)
2–6Ω
0.1 – 1.0 Ω
120 ± 20 % Ω
1–2Ω
More than 600 ml (1.27 US qt)/min
FTH 16 – BS-1
12 V
50.4 kC (14 Ah)/10 HR
ITEM
Rear brake pedal height
HI
LO
Parking or city light
Brake light/Taillight
Turn signal light
Running light
Speedometer light
Master cylinder bore
—
12.700
(0.5000
12.700
(0.5000
12.657
(0.4983
12.657
(0.4983
42.850
(1.6870
42.850
(1.6870
42.770
(1.6839
42.770
(1.6839
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Brake caliper piston diam.
Front
Front
Rear
Wheel rim runout
Wheel axle runout
Wheel rim size
27/8
21
5
3
7/9
65
(2.6)
5.0 ± 0.2
(0.197 ± 0.008)
6.0 ± 0.2
(0.236 – 0.008)
Front
Rear
Unit: W
Headlight
STANDARD
Brake disc runout
SPECIFICATION
E-03, 28, 33
60
55
ITEM
Tire size
Tire tread depth
E-03, 28, 33
E-03, 28, 33
BRAKE + WHEEL
Rear
WATTAGE
←
SPECIFICATION
E-03, 28, 33
1.7
1.7
1.7
1.7
7.5
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure indicator light
License light
Brake disc thickness
A
A
A
A
A
#110
#
PRE-SET
(1 and 3/4 turns back)
6/9
ITEM
1.32 at 20 °C (68 °F)
10
10
10
25
10
←
17.0 ± 0.5 mm
(0.67 ± 0.02 in)
9.1 ± 0.5 mm
(0.36 ± 0.02 in)
#
5D51-1st
#120
#
PRE-SET
(1 and 1/16 turns back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
P
M
Unit: mm (in)
NOTE
MIKUNI
BDS36SS
(No. 2)
←
←
E
L
E-03, 28, 33
SPECIFICATION
1.2
N.G.K.: DPR8EA-9
DENSO: X24EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
240 ± 20 % Ω
1–7Ω
MIKUNI
BS36SS
(No. 1)
36 mm
38BE
1 000 ± 100
r/min
9.5 ± 0.5 mm
(0.37 ± 0.02 in)
27.7 ± 0.5 mm
(1.09 ± 0.02 in)
#
5D35-1st
Bore size
I.D. No.
Idle r/min
Throttle cable play
ELECTRICAL
SPECIFICATION
E-28
ITEM
—
—
5/9
SPECIFICATION
E-03
E-33
MIKUNI
MIKUNI
MIKUNI
MIKUNI
BS36SS
BDS36SS
BS36SS
BDS36SS
(No. 1)
(No. 2)
(No. 1)
(No. 2)
36 mm
←
36 mm
←
38BE
←
38BF
←
1 000 ± 100
1
000
±
100
←
←
r/min
r/min
9.5 ± 0.5 mm
17.0 ± 0.5 mm
9.5 ± 0.5 mm
17.0 ± 0.5 mm
(0.37 ± 0.02 in) (0.67 ± 0.02 in) (0.37 ± 0.02 in) (0.67 ± 0.02 in)
27.7 ± 0.5 mm
9.1 ± 0.5 mm
27.7 ± 0.5 mm
9.1 ± 0.5 mm
(1.09 ± 0.02 in) (0.36 ± 0.02 in) (1.09 ± 0.02 in) (0.36 ± 0.02 in)
(M.J.)
#
#
#
#
(J.N.)
5D35-1st
5D51-1st
5D35-1st
5D51-1st
(N.J.)
(Th.V.)
#120
#110
#120
#110
(P.J.)
#
#
#
#
(P.S.)
PRE-SET
PRE-SET
PRE-SET
←
(1 and 1/16
(1 and 3/4
turns back)
turns back)
2.0 – 4.0 mm
2.0 – 4.0 mm
←
←
(0.08 – 0.16 in)
(0.08 – 0.16 in)
CARBURETOR
—
65
(2.6)
STANDARD
0.03 – 0.15
(0.001 – 0.006)
0.03 – 0.64
(0.001 – 0.025)
CARBURETOR
—
88.5
(3.48)
SHAFT DRIVE
ITEM
Secondary bevel gear backlash
LIMIT
– 12.743
– 0.5017)
– 12.743
– 0.5017)
– 12.684
– 0.4994)
– 12.684
– 0.4994)
– 42.926
– 1.6900)
– 42.926
– 1.6900)
– 42.820
– 1.6858)
– 42.820
– 1.6858)
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
Front
Rear
J19 × 2.15
J15M/C × MT4.00
110/90-19 62H, 110/90-19M/C 62H
170/80-15 77H, 170/80-15 M/C 77H
Front
—
Rear
—
8/9
Unit: mm (in)
LIMIT
—
4.5
(0.18)
5.5
(0.22)
0.30
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
E-03, 28, 33
118
SUSPENSION
ITEM
Front fork stroke
160
(6.3)
—
—
549
(21.6)
203
(7.99)
—
Front fork spring free length
Front fork oil level
Rear shock absorber spring
adjuster
Rear wheel travel
Unit: mm (in)
NOTE
LIMIT
STANDARD
2/5
105
(4.1)
—
—
0.30
(0.012)
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
200
200
SOLO RIDING
kg/cm2
2.00
2.00
psi
29
29
kPa
200
225
DUAL RIDING
kg/cm2
2.00
2.25
psi
29
33
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity
(each leg)
Bevel gear oil type
Bevel gear oil capacity
Brake fluid type
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane or 91 octane (R/2 + M/2) 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.
13.0 L
(3.4/2.9 US/lmp gal)
3.0 L
(0.8/0.7 US/lmp gal)
SAE 10W-40, API SF or SG
3 700 ml
Change
(3.9/3.3 US/lmp qt)
4 300 ml
Filter change
(4.5/3.8 US/lmp qt)
5 000 ml
Overhaul
(5.3/4.4 US/lmp qt)
Fork oil #10
353 ml
(11.9/12.4 US/lmp oz)
Hypoid Gear oil #90 API GL-5
200 – 220 ml
Final
(6.8 – 7.4/7.0 – 7.7 US/lmp oz)
DOT 4
9/9
VZ800
E-03, 28, 33
ITEM
STANDARD
P
M
Unit: mm (in)
LIMIT
EX.
30
(1.18)
26
(1.02)
0.08 – 0.13
(0.003 – 0.005)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
—
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Valve stem O.D.
IN.
5.500 – 5.512
(0.2165 – 0.2170)
5.475 – 5.490
(0.2156 – 0.2161)
5.455 – 5.470
(0.2148 – 0.2154)
IN.
EX.
Valve clearance
(when cold)
Valve guide to valve stem
clearance
IN. & EX.
IN.
EX.
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
Valve stem end length
—
Camshaft journal holder I.D.
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
Rocker arm shaft O.D.
IN. & EX.
IN. & EX.
—
Valve head radial runout
IN. & EX.
—
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
Valve spring tension
6.51 – 7.49 kgf
(14.35 – 16.51 lbs)
at length 32.5 mm (1.28 in)
12.09 – 13.91 kgf
(26.65 – 30.67 lbs)
at length 36.0 mm (1.42 in)
INNER
OUTER
Camshaft journal O.D.
No.1 Left side
No.2 Right side
No.1 Left side
No.2 Right side
No.1 Left side
No.2 Right side
No.1 Left side
No.2 Right side
—
—
—
IN.
EX.
—
0.9 – 1.1
(0.35 – 0.043)
—
STANDARD
Cam height
Camshaft journal oil clearance
IN. & EX.
INNER
ITEM
—
Valve seat width
OUTER
CAMSHAFT + CYLINDER HEAD
—
0.05
(0.002)
0.5
(0.02)
3.1
(0.12)
Valve spring free length
E
L
E-03, 28, 33
A
S
VALVE + GUIDE
Valve diam.
NOTE
12.000
(0.4724
11.966
(0.4711
—
Cylinder head cover distortion
—
1 500 kPa
(15 kg/cm2, 213 psi)
Campression pressure difference
—
Cylinder bore
Piston diam.
Piston ring free end gap
—
0.045 – 0.055
(0.0018 – 0.0022)
83.000 – 83.015
(3.2677 – 3.2683)
82.950 – 82.965
(3.2657 – 3.2663)
Measure at 15 mm (0.6 in) from the skirt end.
—
1st
2nd
Piston ring end gap
Approx. 10.5 (0.413)
R
Approx. 11.8 (0.465)
0.20
(0.008
0.20
(0.008
1st
2nd
Piston ring to groove clearance
E-03, 28, 33
P-37
– 0.35
– 0.014)
– 0.35
– 0.014)
1st
—
2nd
—
2/9
—
—
—
—
—
0.05
(0.002)
0.05
(0.002)
STANDARD
Cylinder distortion
1/9
– 12.018
– 0.4731)
– 11.984
– 0.4718)
CYLINDER + PISTON + PISTON RING
ITEM
Campression pressure
—
0.10
(0.004)
—
Cylinder head distortion
Piston to cylinder clearance
—
35.954 – 36.002
(1.4155 – 1.4174)
36.919 – 36.967
(1.4535 – 1.4554)
0.032 – 0.066
(0.0013 – 0.0026)
20.012 – 20.025
(0.7879 – 0.7884)
25.012 – 25.025
(0.9847 – 0.9852)
19.959 – 19.980
(0.7858 – 0.7866)
24.959 – 24.980
(0.9826 – 0.9835)
Unit: mm (in)
LIMIT
35.660
(1.4039)
36.620
(1.4417)
0.150
(0.0059)
Unit: mm (in)
LIMIT
1 100 kPa
(11 kg/cm2, 156 psi)
200 kPa
(2 kg/cm2, 28 psi)
0.120
(0.0047)
83.085
(3.2711)
82.880
(3.2630)
0.05
(0.002)
8.40
(0.331)
9.44
(0.372)
0.50
(0.020)
0.50
(0.020)
0.180
(0.0071)
0.150
(0.0059)
E-03, 28, 33
P-37
119
ITEM
Piston ring groove width
LIMIT
STANDARD
1st
2nd
Oil
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
1.01 – 1.03
(0.0398 – 0.0406)
1.21 – 1.23
(0.0476 – 0.0484)
2.51 – 2.53
(0.0988 – 0.0966)
0.970 – 0.990
(0.0382 – 0.0390)
1.170 – 1.190
(0.0461 – 0.0469)
20.002 – 20.008
(0.7875 – 0.7877)
19.996 – 20.000
(0.7827 – 0.7874)
Conrod big end side clearance
Conrod big end width
Crank pin width
Conrod big end oil clearance
Crank pin O.D.
Crankshaft journal oil clearance
Crankshaft journal O.D.
Crankshaft journal bearing I. D.
Crankshaft thrust bearing thickness
Crankshaft thrust clearance
—
Drive plate thickness
—
Drive plate claw width
—
Driven plate distortion
23.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
—
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
3.42 – 3.58
(0.135 – 0.141)
15.9 – 16.0
(0.626 – 0.630)
No. 1
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
0.05
(0.002)
—
No. 1
—
No. 2
—
RADIATOR + FAN
ITEM
Radiator cap valve release
pressure
Cooling fan thermo-switch
operating temperature
TRANSMISSION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Shift fork groove width
Shift fork thickness
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pressure (at 60 °C, 140 °F)
LIMIT
—
STANDARD
1.364 (83/44 × 34/47)
Above 450 kPa (4.5 kg/cm2, 64 psi)
Below 750 kPa (7.5 kg/cm2, 107 psi)
at 3 000 r/min
—
Drive chain
Type
Links
20-pitch
length
E
L
Drive chain slack
Gearshift lever height
3/9
A
S
CARBURETOR
SPECIFICATION
E-03
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
P
M
E-03, 28, 33
P-37
MIKUNI BS36SS (No. 1)
36 mm
48EF
1 200 ± 100 r/min
7.3 ± 0.5 mm
(0.29 ± 0.02 in)
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D83
MIKUNI BS36SS (No. 2)
←
←
←
15.0 ± 0.5 mm
(0.59 ± 0.02 in)
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#
5C43
←
#115
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
#
←
←
CARBURETOR
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
STANDARD
1.886 (83/44)
3.200 (48/15)
2.461 (32/13)
1.578 (30/19)
1.200 (24/20)
0.956 (22/23)
0.800 (20/25)
0.10 – 0.30
(0.004 – 0.012)
5.50 – 5.60
(0.217 – 0.220)
5.30 – 5.40
(0.209 – 0.213)
D.I.D. 50VM
116 links, ENDLESS
—
—
—
—
—
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
15 – 25
(0.6 – 1.0)
50
(2.0)
—
—
4/9
E-03, 28, 33
P-37
CARBURETOR
SPECIFICATION
E-33
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
MIKUNI BS36SS (No. 1)
36 mm
48EG
1 200 ± 100 r/min
7.3 ± 0.5 mm
(0.29 ± 0.02 in)
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D83
MIKUNI BDS36SS (No. 2)
←
←
←
15.0 ± 0.5 mm
(0.59 ± 0.02 in)
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#
5C43
←
#115
#
PRE-SET
2.0 – 4.0 mm
(0.08 – 0.16 in)
#
←
←
CARBURETOR
SPECIFICATION
E-28
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
LIMIT
STANDARD
110 ± 15 kPa
(1.1 ± 0.15 kg/cm2, 15.6 ± 2.1 psi)
ON
Approx. 105 °C (221 °F)
OFF
Approx. 100 °C (212 °F)
ON
Approx. 120 °C (248 °F)
OFF
Approx. 113 °C (235 °F)
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
24.6
(0.97)
23.3
(0.92)
—
Clutch spring free length
Engine coolant temperature switch
operating temperature
—
Unit: mm (in)
LIMIT
STANDARD
No. 2
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
0.10 – 0.20
(0.004 – 0.008)
21.95 – 22.00
(0.864 – 0.866)
22.10 – 22.15
(0.870 – 0.872)
0.024 – 0.042
(0.0009 – 0.0017)
40.982 – 41.000
(1.6135 – 1.6142)
0.020 – 0.050
(0.0008 – 0.0020)
47.965 – 47.980
(1.8884 – 1.8890)
48.000 – 48.015
(1.8898 – 1.8904)
1.925 – 2.175
(0.0758 – 0.0856)
0.05 – 0.10
(0.002 – 0.004)
Crankshaft runout
ITEM
Clutch cable play
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
CLUTCH
—
MIKUNI BS36SS (No. 1)
36 mm
48FF
1 200 ± 100 r/min
7.3 ± 0.5 mm
(0.29 ± 0.02 in)
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D83
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
#115
(P.J.)
#
(P.S.) PRE-SET (1 and 1/2 turns back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
5/9
SPECIFICATION
P-37
ITEM
MIKUNI BDS36SS (No. 2)
←
←
←
15.0 ± 0.5 mm
(0.59 ± 0.02 in)
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#
5C43
←
#
←
←
E-03, 28, 33
P-37
Carburetor type
Bore size
I.D. No.
Idle r/min
Fuel level
Float height
Main jet
Jet needle
Needle jet
Throttle valve
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
MIKUNI BS36SS (No. 1)
36 mm
48EK
1 200 ± 100 r/min
7.3 ± 0.5 mm
(0.29 ± 0.02 in)
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#105
5D105-3
P-3
#115
#70
PRE-SET (2 and 1/2 turns back)
2.0 – 4.0 mm
(0.08 – 0.16 in)
6/9
MIKUNI BDS36SS (No. 2)
←
←
←
15.0 ± 0.5 mm
(0.59 ± 0.02 in)
9.1 ± 1.0 mm
(0.36 ± 0.04 in)
#95
5C29-4
P-7
←
#42.5
PRE-SET (2 and 3/8 turns back)
←
E-03, 28, 33
P-37
120
ELECTRICAL
ITEM
Firing order
Spark plug
Type
Gap
Spark performance
Signal coil resistance
Ignition coil resistance
Primary
1·2
NGK: DPR8EA-9
DENSO: X24EPR-U9
0.8 – 0.9
(0.031 – 0.035)
Over 8 (0.3) at 1 atm.
170 – 280 Ω
2–6Ω
Secondary
Generator coil resistance
Generator no-load voltage
(when engine cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Fuse size
Unit: mm (in)
NOTE
SPECIFICATION
G – Bl
tap – tap
Plug cap –
tap
Y–Y
0.2 – 1.5 Ω
More than 75 V (AC) at 5 000 r/min
250 W at 5 000 r/min
13.5 – 15.5 V at 5 000 r/min
3–6Ω
Type
designation
Capacity
Standard
electrolyte S.G.
FTX12-BS
12V 36 kC (10Ah)/10HR
Signal
Ignition
Tail
Main
A
A
A
A
A
A
Rear
—
Rear
—
Brake disc thickness
Front
Brake light/Taillight
Turn signal light
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Wheel rim runout
Axial
—
Radial
—
Front
—
Wheel rim size
SPECIFICATION
E-03, 28, 33
60
55
21/5
21/5
21
1.7
1.7
3.4
1.7
3.4
1.7
Front
Rear
Speedometer light
Water temp. warning light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil pressure warning light
Tire tread depth
P37
←
←
←
21
←
←
←
←
←
←
←
7/9
TIRE PRESSURE
ITEM
Front fork stroke
Front fork damper free length
FRONT
REAR
SOLO RIDING
kg/cm2
2.00
2.25
FUEL + OIL + COOLANT
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil capacity
Front fork oil type
Front fork oil capacity
(each leg)
Brake fluid type
Coolant capacity
P
M
E-03, 28, 33
P-37
A
S
psi
29
33
kPa
200
225
DUAL RIDING
kg/cm2
2.00
2.25
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
13.0 L
(3.4/2.9 US/lmp gal)
3.0 L
(0.8/0.7 US/lmp gal)
SAE 10W-40, API SF or SG
1 700 ml
Change
(1.8/1.5 US/lmp qt)
2 100 ml
Filter change
(2.2/1.8 US/lmp qt)
2 500 ml
Overhaul
(2.6/2.2 US/lmp qt)
Fork oil #15
838 ml
(28.3/29.5 US/lmp oz)
DOT 4
1 500 ml
(1.6/1.3 US/lmp qt)
9/9
– 12.743
– 0.5017)
– 12.684
– 0.4993)
– 30.306
– 1.1931)
– 30.200
– 1.1890)
Rear
—
Front
Rear
Front
Rear
J16 × MT3.00, J16M/C × MT3.00
J15M/C × MT3.50
130/90-16 67H, 130/90-16 M/C 67H
150/90-15 74H, 150/90-15 M/C 74H
Front
—
Rear
—
psi
29
33
NOTE
E-03, 28, 33
The others
E-03, 28, 33
P-37
STANDARD
LIMIT
140
(5.5)
—
—
156
(6.1)
154
(6.1)
102
(4.0)
—
—
0.3
(0.01)
E
L
Front fork oil level
(At outer tube 177 mm up position)
Rear wheel travel
NORMAL RIDING
kPa
200
225
12.700
(0.5000
12.657
(0.4983
30.230
(1.1902
30.150
(1.1870
SUSPENSION
Swingarm pivot shaft runout
COLD INFLATION
TIRE PRESSURE
4.5 ± 0.2
(0.18 ± 0.01)
Brake disc runout
Tire size
HI
LO
—
—
Brake drum I. D.
Unit: W
ITEM
20 – 30
(0.8 – 1.2)
60
(2.4)
Brake lining thickness
Wheel axle runout
WATTAGE
Headlight
Unit: mm (in)
LIMIT
STANDARD
1.32 at 20 °C (68 °F)
10
10
10
10
10
30
(HI)
(LO)
Headlight
ITEM
Rear brake pedal free travel
Rear brake pedal height
15 – 30 kΩ
Changing
BRAKE + WHEEL
8/9
1.5
(0.06)
180.7
(7.11)
4.0
(0.16)
0.30
(0.012)
—
—
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
1.6
(0.06)
2.0
(0.08)
Unit: mm (in)
NOTE
—
E-03, 28, 33
P-37
121
VZ1600
ENGINE TOP END
Unit: mm (in)
ITEM
Cam height
STANDARD
33.928 – 34.044
(1.33575 – 1.34031)
33.741 – 33.857
(1.32839 – 1.33295)
0.020 – 0.062
(0.000787 – 0.00244)
0.016 – 0.055
(0.000630 – 0.00217)
24.959 – 24.980
(0.982638 – 0.983465)
16.966 – 16.984
(0.667953 – 0.668661)
25.000 – 25.021
(0.984252 – 0.985079)
17.000 – 17.021
(0.669291 – 0.670118)
IN.
EX.
Camshaft/rocker case clearance
φ 25
φ 17
Camshaft journal diameter
φ 25
φ 17
Rocker case bearing inside
diameter
φ 25
φ 17
Camshaft runout
TIR 0.02 (0.00079) or less
Rocker arm inside diameter
16.000 – 16.018
(0.629921 – 0.630630)
15.966 – 15.984
(0.628583 – 0.629291)
340 – 590 kPa
(3.5 – 6.0 kgf/cm2, 50 – 85 psi)
@ 300 r/min with electric starter
—
Non-adjustable (Auto-adjuster)
Rocker shaft diameter
Cylinder compression usable range
Cylinder head warp
Valve clearance
Valve head thickness
IN.
0.9 – 1.1
(0.035 – 0.0433)
EX.
Valve stem bend
TIR 0.01 (0.00039) or less
Valve stem diameter
6.965 –
(0.27421 –
6.955 –
(0.27382 –
IN.
EX.
6.980
0.27480)
6.970
0.27441)
LIMIT
33.83
(1.3319)
33.64
(1.3244)
0.15
(0.00591)
0.14
(0.00551)
24.93
(0.98150)
16.93
(0.66654)
25.08
(0.98740)
17.08
(0.67244)
TIR 0.1
(0.0039)
16.05
(0.63189)
15.94
(0.62756)
ITEM
Valve guide inside diameter
Valve/valve guide clearance
(Wobble method)
STANDARD
7.000 – 7.015
(0.27559 – 0.27618)
0.05 – 0.13
(0.0020 – 0.00512)
0.08 – 0.16
(0.0031 – 0.0063)
45°, 32°, 55°
36.4 – 36.6
(1.433 – 1.441)
31.9 – 32.1
(1.256 – 1.264)
0.5 – 1.0
(0.020 – 0.039)
0.8 – 1.2
(0.031 – 0.047)
IN. & EX.
IN.
EX.
Valve seat cutting angle
Valve outside diameter
IN.
EX.
Valve width
IN.
EX.
Valve spring free length
Outer
(IN. & EX.)
Inner
(IN. & EX.)
Cylinder inside diameter
Piston/cylinder clearance
—
0.05 (0.0020)
—
0.5
(0.020)
0.7
(0.028)
TIR 0.05
(0.0020)
6.95
(0.2736)
6.94
(0.2732)
Top
Second
Piston ring groove width
Top
Second
Piston ring thickness
Piston ring end gap
Top &
Second
Top
Oil
A
S
CRANKSHAFT/TRANSMISSION
ITEM
Connecting rod bend
STANDARD
—
Connecting rod twist
—
Connecting rod big end side
clearance
Connecting rod big end bearing
insert/crankpin clearance
Crankpin diameter
Marking
Connecting rod big end bore
diameter
Marking
Connecting rod big end bearing
insert thickness
None
None
Brown
Black
Blue
Crankshaft side clearance
Crankshaft web length
Crankshaft runout
Crankshaft main bearing/journal
clearance
Crankshaft main journal diameter
Crank case main bearing bore
diameter
Shift fork ear thickness
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
0.16 – 0.46
(0.0062 – 0.0181)
0.026 – 0.057
(0.001024 – 0.0022)
54.981 – 55.000
(2.1646 – 2.1654)
54.981 – 54.991
(2.1646 – 2.16500)
54.992 – 55.000
(2.16504 – 2.1654)
58.000 – 58.020
(2.2835 – 2.2843)
58000 – 58.010
(2.2835 – 2.28386)
58.011 – 58.020
(2.28390 – 2.2843)
1.483 – 1.487
(0.05839 – 0.05854)
1.487 – 1.491
(0.05854 – 0.05870)
1.491 – 1.495
(0.05870 – 0.05886)
0.05 – 0.55
(0.00197 – 0.0217)
96.85 – 96.95
(3.8130 – 3.8169)
TIR 0.02 (0.0008) or less
0.025 – 0.052
(0.00098 – 0.00205)
54.986 – 55.000
(2.1648 – 2.1654)
55.025 – 55.038
(2.1663 – 2.1669)
5.9 – 6.0
(0.232 – 0.236)
6.05 – 6.15
(0.238 – 0.242)
7.9 – 8.0
(0.311 – 0.315)
8.05 – 8.20
(0.317 – 0.323)
3/9
P
M
E-02, 03, 19, 24, 28, 33
Unit: mm (in)
LIMIT
TIR 0.2/100 mm
(0.08/3.94 in)
TIR 0.2/100 mm
(0.08/3.94 in)
0.7
(0.028)
0.10
(0.0039)
54.97
(2.1642)
ITEM
Clutch fluid grade
Clutch lever position
Clutch lever free play
Clutch spring free height
Spring plate gap (usable range)
Friction plate thickness
Friction plate/steel plate warp
FINAL DRIVE
—
ITEM
Final gear case oil
—
—
—
—
Final bevel gear backlash
Preload for pinion gear bearing
Propeller shaft joint grease
Front bevel gear backlash
Preload for front bevel gear bearing
—
0.75
(0.0295)
96.6
(3.803)
TIR 0.05
(0.0020)
0.10
(0.00394)
54.96
(2.1638)
55.07
(2.1681)
5.8
(0.228)
6.3
(0.248)
7.8
(0.307)
8.3
(0.327)
E-02, 03, 19, 24, 28, 33
—
—
43.2 (1.700)
39.82 (1.5677) Orange
38.3 (1.508)
2/9
102.10
(4.01969)
101.79
(4.00748)
—
—
0.19
(0.00748)
0.17
(0.00669)
1.34
(0.05276)
1.32
(0.05197)
1.10
(0.0433)
0.7
(0.028)
0.8
(0.031)
1.2
(0.0472)
E-02, 03, 19, 24, 28, 33
CLUTCH
—
—
—
44.76 (1.7622) Orange
E
L
Second
1/9
—
102.000 – 102.012
(4.015748 – 4.016220)
101.942 – 101.957
(4.013457 – 4.014047)
0.043 – 0.070
(0.00169 – 0.00276)
+ 0.5 (0.020)
0.05 – 0.09
(0.00197 – 0.00354)
0.03 – 0.07
(0.0012 – 0.0028)
1.24 – 1.26
(0.048819 – 0.049606)
1.22 – 1.24
(0.04803 – 0.04882)
1.17 – 1.19
(0.04606 – 0.04685)
0.25 – 0.35
(0.0098 – 0.0138)
0.40 – 0.55
(0.0157 – 0.0217)
0.3 – 0.9
(0.012 – 0.035)
Piston diameter
Oversize piston and rings
Piston ring groove clearance
LIMIT
7.08
(0.2787)
0.27
(0.0106)
0.30
(0.0118)
—
Unit: mm (in)
STANDARD
DOT 4 (provided when shipping)
No.1 (to suit rider)
Non-adjustable
4.3 (0.235)
1.95 – 2.45
(0.0768 – 0.0965)
3.3 – 3.5
(0.130 – 0.138)
0.2 (0.0079) or less
LIMIT
—
—
—
4 (0.16)
—
3.1
(0.122)
0.3 (0.012)
STANDARD
API service classification: GL-5 hypoid gear oil
When above 5 °C (41 °F) SAE90
Viscosity
When below 5 °C (41 °F) SAE80
Oil level
Filler opening bottom
Amount
200 mL (6.76 US oz)
0.06 – 0.09 mm (0.0024 – 0.0035 in) (at gear hub splines)
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)
20 mL (0.68 US oz), high-temperature grease
0.10 – 0.15 mm (0.0039 – 0.0059 in) (at gear teeth)
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)
Grade
FUEL SYSTEM
ITEM
Throttle grip free play
Air cleaner element
DFI (Digital Fuel Injecton) system
make
Idle speed
Throttle assy
ECU (Electronic Control Unit)
ISC valves
(Idle speed control valve or fast idle
solenoid valve)
STANDARD
2 – 3 mm (0.079 – 0.118 in)
Paper filter
NOTE
—
—
Mitsubishi Electric
Type × bore
Type
Usable engine
speed
Maximum air
flow rate
Solenoid
resistance
4/9
—
950 ± 50 r/min
Two barrel type ×
φ 40 mm (1.57 in)
Digital memory type, with built in
IC igniter, sealed with resin
—
100 – 6 300 r/min
—
75 ± 7 L/min
—
13.6 – 20.4 Ω
—
—
—
E-02, 03, 19, 24, 28, 33
122
ITEM
Fuel filter
Fuel pressure (high pressure line)
Pressure regulator
Throttle sensor
Filtration area
Rated flow
Right after
ignition SW ON
After pump runs
3 sec. and stops
With engine
idling
With engine
running at
full throttle
Regulated fuel
pressure
Type
STANDARD
More than 200 cm2
1.0 L/min
310 kPa (3.2 kgf/cm2, 46 psi)
with fuel pump running
280 kPa (2.9 kgf/cm2, 41 psi)
with fuel pump stopped
260 kPa (2.7 kgf/cm2, 38 psi)
with fuel pump running
260 – 280 kPa
(2.7 – 2.9 kgf/cm2, 38 – 41 psi)
with fuel pump running
294 ± 4.9 kPa
(3.00 ± 0.05 kgf/cm2,
43 ± 0.73 psi)
Non-adjustable
and non-removable
Input voltage
Output voltage at
idle throttle
opening
Output voltage at
full throttle
opening
Resistance
Atmospheric pressure sensor
Inlet air pressure sensor
Water temperature sensor
resistance
Vehicle-down sensor
4 – 6 kΩ
Input voltage
4.75 – 5.25 V DC
3.74 – 4.26 V DC at standard
atmospheric pressure
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)
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)
Detection
Magnetic flux detection method
method
More than 45° ± 5°
Detection angle
for each bank
Detection time
Within 0.5 – 1.0 sec.
Rear brake light switch timing
Engine oil pressure switch
connections
Radiator fan switch
Water temperature switch
Fuel level switch resistance
BL/W – BR/BK
: BL/W –
: BR/BK
: BL/Y –
: BR/BK
: BL/W –
: BR/BK
: W/BL –
: BR/BK
ITEM
Coolant provided when shipping
Radiator cap relief pressure
Thermostat
Front
Rear
208 V or more
192 V or more
273.1 – 289.4 mL/min
ITEM
Battery
Alternator type
—
—
Two spray type with four holes ×
0.3 mm (0.012 in)
14.2 – 14.8 Ω
In-tank pump (friction pump)
Type
75 mL or more for 3 seconds
(90 L or more/h) with the filter
Discharge
installed at 12 V
atmospheric pressure
18 – 22 Ω at 20 °C (68 °F)
—
—
—
P
M
—
—
—
—
—
—
—
STANDARD
Permanent type antifreeze (soft water and
ethylene glycol plus corrosion and rust inhibitor
chemicals for aluminum engines and radiators)
Color
Green
Mixed ratio
Soft water 50 %, coolant 50 %
Freezing point
– 35 °C (– 31 °F)
2.3 L (2.4 US qt, reserve tank full level
Total amount
including radiator and engine)
93 – 123 kPa (0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)
Valve opening
58 – 62 °C (136 – 144 °F)
temperature
Valve full
8 mm (0.3 in) or more @ 75 °C (167 °F)
opening lift
STANDARD
Type
Sealed battery
Model name
FTZ16-BS
Capacity
12 V 18 Ah
Voltage
12.6 V or more
Three-phase AC with delta connectoin,
and rare-earth single magnet rotor
14.2 – 15.2 V @ 3 000 r/min
64 – 96 V @ 3 000 r/min
NOTE
—
—
—
—
—
—
—
0.33 – 0.49 Ω
—
Load dumping regulator with full-wave rectifier
—
6/9
E-02, 03, 19, 24, 28, 33
BRAKES
ITEM
Brake lever position
Brake lever free play
Brake pedal free play
Brake pedal position
Brake fluid grade
Brake pad lining thickness
Brake disc thickness
—
Brake disc runout
Unit: mm (in)
STANDARD
No.1
Non-adjustable
Non-adjustable
About 110 (4.33)
(height from pedal top to footpeg top)
DOT 4
Front
4.0 (0.157)
Rear
7.5 (0.295)
4.8 – 5.1
Front
(0.19 – 0.20)
6.8 – 7.2
Rear
(0.268 – 0.283)
Front &
TIR 0.15 (0.0059) or less
Rear
LIMIT
5-way adjustable
—
—
—
—
1 (0.04)
1 (0.04)
4.5
(0.18)
6.0
(0.24)
TIR 0.3 (0.01)
WHEELS/TIRES
—
12 mm (0.47 in)
—
—
Type
(recommended)
E
L
DC battery charging voltage
Alternator output voltage (no load)
Stator coil (battery charging coil)
resistance
Regulator/rectifier type
—
Commutator
28 mm (1.1 in)
diameter
ON after about 10 mm (0.39 in) pedal travel
When engine is
ON
stopped
When engine is
OFF
running
Rising
From OFF to ON
temperature
@ 102 – 108 °C (212 – 226 °F)
Falling
From ON to OFF
temperature
@ 97 – 103 °C (207 – 217 °F)
ON
Less than 0.5 Ω
Resistance
OFF
More than 1 MΩ
Rising
From OFF to ON
temperature
@ 113 – 117 °C (235 – 243 °F)
From ON to OFF @
Falling
108 °C (226 °F) – temperature
temperature
less than ON temperature
ON
Less than 0.5 Ω
Resistance
OFF
More than 1 MΩ
FULL position
4 – 10 Ω
EMPTY position
90 – 100 Ω
NOTE
—
—
ELECTRICAL SYSTEM
—
NOTE
: BK –
: Ground
: BK/G –
: Ground
3 needle arcing
6 mm (0.24 in) or more
distance
Ignition coil
primary winding
1.9 – 2.9 Ω
resistance
Ignition coil secondary winding
18 – 28 kΩ
resistance
0.8 – 0.9 mm (0.031 – 0.035 in)
3.75 – 6.25 kΩ
Front
2.2 V or more
Peak voltage
Rear
2.0 V or more
1.0 mm (0.04 in)
Air gap
(Non-measurable and
non-adjustable)
Resistance
380 – 560 Ω
7/9
—
A
S
STANDARD
Brush length
Air swiching valve resistance
STANDARD
INP-786
60° BTDC at each cylinder
COOLING SYSTEM
E-02, 03, 19, 24, 28, 33
)
Starter motor
—
: Y/W –
: BR/BK
5/9
Spark plug gap
Spark plug cap resistance
Pickup coil
Fuel pump
—
4.29 – 4.59 V DC
3.74 – 4.26 V DC at standard
atmospheric pressure
Primary peak
voltage
—
: Y/W –
: BR/BK
Output voltage
ITEM
—
0.584 – 0.604 V DC
4.75 – 5.25 V DC
Type
Injection timing
Static injection
quantity
Nozzle type ×
diameter
Resistance
—
: BL/W –
: BR/BK
Input voltage
Ignition coil
ITEM
Fuel injectors
4.75 – 5.25 V DC
Output voltage
Inlet air temperature sensor
resistance
NOTE
—
—
—
Service limit
8.5 mm (0.33 in)
Service limit
27 mm (1.06 in)
—
—
ITEM
Wheel rim runout
Axle runout/100 mm
Wheel balance
Balance weight
Tire air pressure (when cold)
Unit: mm (in)
STANDARD
Axial
—
Radial
—
TIR 0.05 (0.002) or less
10 g (0.35 oz) or less
10 g (0.35 oz), 20 g (0.71 oz), 30 g (1.1 oz)
Front &
Up to 184 kg (405 lb) load:
Rear
250 kPa (2.5 kgf/cm2, 36 psi)
Tire thread depth
Front
DUNLOP: 4.4 (0.17)
Rear
DUNLOP: 6.9 (0.27)
Type
Size
Type
Size
DUNLOP D220F ST G
130/70R17 M/C 62H
DUNLOP D220 ST G
170/60R17 M/C 72H
—
—
—
—
—
Front tire
—
Rear tire
—
—
1 (0.04)
[AT, CH, DE
1.6 (0.063)]
Up to 130 km/h
(80 mph):
2 (0.08)
Over 130 km/h
(80 mph):
3 (0.1)
—
—
—
—
AT: Republic of Austria
CH: Swiss Confederatoin
DE: Federal Republic of Germany
—
—
—
—
E-02, 03, 19, 24, 28, 33
LIMIT
TIR 0.5 (0.02)
TIR 0.8 (0.03)
TIR 0.2 (0.008)
—
—
8/9
E-02, 03, 19, 24, 28, 33
123
SUSPENSIONS
ITEM
Front fork inner tube diameter
Front fork spring setting
Front fork air pressure
Front fork rebound damper setting
Front fork oil viscosity
Front fork oil capacity
Front fork oil level
(Fully compressed, without fork
spring, below from inner tube top)
Front fork spring free length
Rear shock absorber rebound
damper setting
Rear shock absorber air pressure
Unit: mm (in)
STANDARD
φ 43 (φ 1.7)
Non-adjustable
Atmospheric pressure (Non-adjustable)
Non-adjustable
SAE 10W-20
507 ± 2.5 mL (17.1 ± 0.085 US oz)
(Completely disassembled and dry)
Right fork
Approx. 430 mL (14.5 US oz)
leg
(When changing oil)
Left fork
601 ± 2.5 mL (20.3 ± 0.085 US oz)
leg
(Completely disassembled and dry)
Right fork
142 (5.59)
leg
Left fork
136 (5.35)
leg
LIMIT
—
—
—
—
—
333.7 (13.14)
327 (12.9)
No.II of 4 positions
Standard
Usable
renge
—
—
—
—
—
Atmospheric pressure
Atmospheric pressure –
290 kPa (3.0 kgf/cm2, 43 psi)
—
—
ENGINE LUBRICATOIN SYSTEM)
ITEM
Engine oil type
Engine oil viscosity
Engine oil capacity
STANDARD
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
When filter is not
2.9 L (3.1 US qt)
removed
When filter is
removed
When engine is
completely
disassembled
and dry
Engine oil level
(Wait 2 – 3 minutes after idling or
running)
Engine oil pressure
[2 000 r/min, oil temperature 90 °C
(194 °F)]
NOTE
—
—
—
3.1 L (3.3 US qt)
—
3.5 L (3.7 US qt)
—
Between upper and lower lines
—
340 – 440 kPa (3.5 – 4.5 kgf/cm2, 50 – 64 psi)
—
9/9
P
M
E-02, 03, 19, 24, 28, 33
A
S
E
L
124
A100X/XS
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
STANDARD
0.035 – 0.045
50.000 – 50.015
Measure at 20 mm from the top surface.
49.960 – 49.975
Measure at 21 mm from the skirt end.
—
—
T
Approx. 4.5
1st &
2nd
RN
Approx. 5.0
0.15 – 0.35
1st &
0.04 – 0.08
2nd
14.002 – 14.010
13.995 – 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
STANDARD
18.003 – 18.011
—
50.0 ± 0.1
—
Unit: mm
LIMIT
0.120
50.095
0.05
0.05
3.6
4.0
0.80
—
Unit: mm
LIMIT
18.040
3.0
—
0.05
ITEM
Clutch cable play
Clutch release screw
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
10 – 15
1/4 – 1/2 turn back
2.9 – 3.1
9.8 – 10.0
—
—
Unit: mm
LIMIT
—
—
2.6
9.0
0.10
34.5
1/5
ITEM
Ignition timing
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
22° B.T.D.C. at 4 000 r/min
ND: W20FP
NGK: BP6HS
0.6 – 0.7 mm
Over 8 mm at 1 atm.
Secondary
Magneto coil resistance
15 – 25 kΩ
120 – 200 Ω
0.1 – 1.0 Ω
0.1 – 1.5 Ω
Primary
Lighting
Charging
Magneto no-load voltage
(when engine is cold)
Regulated voltage
Resistor resistance
Battery
Type designation
Capacity
Standard electrolyte
S.G.
Fuse size
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Main air jet
Jet needle
Needle jet
Cut-away
Pilot jet
By-pass
Pilot outlet
Air screw
Starter jet
Valve seat
Thottle cable play
2/5
P-42
Plug cap –
Ground
B/R – B/W
Y/W – B/W
W/R – B/W
A100XS
A100XS
A100XS
Front
Rear
Front
Rear
Front
Front
Front
A100XS
Front
12.657 – 12.684
—
A100XS
Front
27.000 – 27.050
—
A100XS
Front
26.900 – 26.950
—
Axial
Radial
Front
Rear
Front
Rear
Front
Rear
—
—
—
—
2.50-18 4PR
2.75-18 4PR
—
—
2.0
2.0
0.25
0.25
—
—
1.6
1.6
Brake lining thickness
A100X
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston
diam.
Brake caliper cylinder
bore
Brake caliper piston
diam.
Wheel rim runout
Wheel axle runout
Unit: W
SPECIFICATION
25
25
5/18
10
3.4
3.4
1.7
3.4
3.4
Unit: mm
LIMIT
—
—
110.7
110.7
1.5
1.5
3.0
0.30
—
STANDARD
3–7
20 – 30
—
—
—
—
4.0 ± 0.2
—
12.700 – 12.743
15 A
Tail/Brake light
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
Oil level indicator light
—
E
L
1.28 at 20 °C
HI
LO
259.0
SPECIFICATION
MIKUNI VM20SC
20 mm
12630
1300 ± 100 r/min
25.1 ± 1.0 mm
#100
0.5 mm
4FM37-4th
O-4
2.5
# 20
1.0 mm
0.7 mm
2 and 1/8 turns back
# 50
2.0 mm
3 – 6 mm
(M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(C.A.)
(P.J.)
(B.P.)
(P.O.)
(A.S.)
(G.S.)
(V.S.)
ITEM
Front brake cable play
Rear brake pedal free travel
Brake drum I.D.
A100X
13 – 16 V at 5 000 r/min
2.0 ± 0.5 Ω
GM2.5 A-3C-2H
12 V 9 kC (2.5 Ah)/10 HR
ITEM
—
10 – 15
BRAKE + WHEEL
NOTE
—
—
CARBURETOR
P
M
27 V and more (AC) at 5 000 r/min
WATTAGE
Headlight
Drive chain slack
P-42
A
S
ELECTRICAL
Unit: mm Except ratio
LIMIT
—
—
—
—
—
—
0.6
—
—
STANDARD
3.125 (50/16)
3.000 (39/13)
2.909 (32/11)
1.800 (27/15)
1.277 (23/18)
0.954 (21/22)
0.2 – 0.4
5.6 – 5.7
5.3 – 5.4
D.I.D.: DID 428
TAKASAGO: RK428M
108
Links
20-pitch
length
14.030
13.980
SPECIFICATION
5.729 (50/16 × 26/18 × 33/26)
1.5 – 1.8 ml
for 2 minutes at 2 000 r/min
CLUTCH
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Type
49.880
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate (full open)
TRANSMISSION + DRIVE CHAIN
Tire size
Tire tread depth
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Rear shock absorber spring
adjuster
Swingarm pivot shaft runout
STANDARD
90
297
137
Unit: mm
LIMIT
—
291
—
1st set
—
—
0.6
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
3/5
P-42
SOLO RIDING
kPa
kgf/cm2
175
1.75
200
2.00
4/5
DUAL RIDING
kPa
kgf/cm2
175
1.75
225
2.25
P-42
125
FUEL + OIL
ITEM
Fuel type
Fuel tank including reserve
reserve
Engine oil type
Engine oil tank capacity
Transmission oil type
Transmission oil capacity
Front fork oil type
Front fork oil capacity (eah leg)
Brake fluid type
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or
higher. An unleaded gasoline is recommended.
10.5 L
2.0 L
Use SUZUKI CCI or CCI SUPER OIL or an equivalent good quality synthetic based 2-cycle oil.
1.2 L
SAE 10W-40
Change
650 ml
Overhaul
700 ml
Fork oil #10
101 ml
DOT 4
NOTE
A100XS
5/5
AY50
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
STANDARD
0.06 – 0.07
41.005 – 41.020
Measure at 20 mm from the top surface.
40.940 – 40.955
Measure at 15 mm from the skirt end.
—
—
1st
R
Approx. 4.0
2nd R
Approx. 4.3
1st & R
0.10 – 0.25
2nd
1st
0.03 – 0.07
2nd
0.02 – 0.06
10.002 – 10.010
9.995 – 10.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
P
M
P-42
A
S
CYLINDER + PISTON + PISTON RING
E
L
STANDARD
14.003 – 14.011
—
36.0 ± 0.05
—
Unit: mm
LIMIT
0.120
41.075
TRANSMISSION
ITEM
Reduction ratio
Final reduction ratio
Drive belt width
40.885
0.05
0.05
3.2
3.4
0.80
—
—
10.030
9.980
Unit: mm
LIMIT
14.040
3.0
—
0.05
Driven face spring free length
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Pilot jet
Air screw
Throttle cable play
CLUTCH
Clutch
Clutch
Clutch
Clutch
ITEM
wheel I.D.
shoe thickness
engagement
lock-up
STANDARD
110.00 – 110.15
3.0
3 300 ± 200 r/min
4 500 ± 300 r/min
1/4
SPECIFICATION
KEIHIN PWS14
14 mm
35EJ
1 900 ± 200 r/min
5.1 ± 0.5 mm
#65
N5GJ-3rd
#40
1 and 3/4 turns back
2 – 4 mm
(M.J.)
(J.N.)
(P.J.)
(A.S.)
ELECTRICAL
ITEM
Spark plug
Type
Gap
SPECIFICATION
30.000 (30/1)
0.9 – 1.1 ml
for 5 minutes at 3 000 r/min
Spark performance
Ignition coil resistance
SPECIFICATION
NGK: BPR6HS
DENSO: W20FPR-U
0.6 – 0.7
Over 8 at 1 atm.
Secondary
Unit: mm
LIMIT
110.50
2.0
—
—
P-02, 19
Unit: mm Except ratio
LIMIT
—
—
15.9
17.4
104.5
CARBURETOR
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
STANDARD
Variable 2.768 – 1.005
14.960 (51/15 × 66/15)
16.9
18.4
110
Generator coil resistance
Regulated voltage
Generator Max. output
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
Charging
Pick-up
4 – 10 kΩ
0.2 – 1.5 Ω
100 – 270 Ω
13.5 – 15.5 V at 5 000 r/min
100 W at 5 000 r/min
50 – 90 Ω
Unit: mm
NOTE
Plug cap –
B/W lead wire
terminal
Y – Ground
R – Ground
YT4L-BS
12 V 10.8 kC (3 Ah)/10 HR
10 A
2/4
P-02, 19
126
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
35
35
21/5
10
1.2 × 2
1.2
2
2
1.7
2
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Fuel meter light
Turn signal indicator light
Oil level indicator light
High beam indicator light
Trunk light
BRAKE + WHEEL
ITEM
Brake lever play
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Rear
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
ITEM
Front fork stroke
Front fork spring free length
Rear wheel travel
ITEM
Piston to cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
Unit: mm
LIMIT
0.120
41.105
40.890
0.05
0.05
3.6
2.4
0.80
—
12.030
11.980
Unit: mm
LIMIT
16.040
3.0
—
0.05
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
SPECIFICATION
30.000 (30/1)
0.8 – 1.0 ml
for 5 minutes at 3 000 r/min
CLUTCH
Clutch
Clutch
Clutch
Clutch
ITEM
wheel I.D.
shoe thickness
engagement
lock-up
STANDARD
110.00 – 110.15
3.0
4 000 ± 200 r/min
5 600 ± 300 r/min
1/5
Engine oil tank capacity
Final gear oil type
Final gear oil capacity
kPa
125
230
DUAL RIDING
kgf/cm2
1.25
2.30
psi
18
33
Unit: mm
LIMIT
110.50
2.0
—
—
P-02, 19
NOTE
E
L
P
M
P-02, 19
STANDARD
16.003 – 16.011
—
38.0 ± 0.05
—
psi
18
25
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
6.8 L
Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke oil rated FC under
JASO classification.
1.2 L
SAE 10W-40
130 ml
Fuel tank capacity
Engine oil type
Unit: mm
LIMIT
—
122
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
ITEM
Fuel type
STANDARD
77
124.7
60
STANDARD
0.035 – 0.045
41.010 – 41.025
Measure at 20 mm from the top surface.
40.970 – 40.985
Measure at 23 mm from the skirt end.
—
—
T
Approx. 4.5
1st &
2nd N
Approx. 3.0
1st & T&
0.08 – 0.18
2nd N
1st & 2nd
0.01 – 0.05
12.002 – 12.010
11.996 – 12.000
SOLO RIDING
kgf/cm2
1.25
1.75
FUEL + OIL
A
S
CYLINDER + PISTON + PISTON RING
kPa
125
175
FRONT
REAR
Unit: mm
LIMIT
—
120.7
3.5
0.30
—
—
—
—
—
2.0
2.0
0.25
—
—
—
—
—
—
1.6
1.6
3/4
AY50W
COLD INFLATION
TIRE PRESSURE
STANDARD
15 – 20
—
4.0 ± 0.2
—
11.000 – 11.043
10.957 – 10.984
30.230 – 30.306
30.150 – 30.200
DOT 4
—
—
—
J12 × MT3.50
J12 × MT3.50
120/70-12 51L
130/70-12 56L
MICHELIN: DEXTER
MICHELIN: DEXTER
—
—
SUSPENSION
TIRE PRESSURE
4/4
P-02, 19
THERMOSTAT + RADIATOR + ENGINE COOLANT TEMP. SWITCH +
ENGINE COOLANT
ITEM
STANDARD/SPECIFICATION
Thermostat valve opening temperApprox. 65 °C
ature
Thermostat valve lift
Over 3 mm at 80 °C
Radiator reservoir cap valve open100 kPa (1.0 kgf/cm2)
ing pressure
Engine coolant temp. switch ON
Approx. 125 °C
operating temperature
OFF
Approx. 118 °C
Engine coolant type
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
Engine coolant including reserve
1 200 ml
TRANSMISSION
ITEM
Reduction ratio
Final reduction ratio
Drive belt width
Driven face spring free length
STANDARD
Variable 2.975 – 1.033
16.271 (51/15 × 67/14)
18.4
110
LIMIT
—
—
—
—
—
—
—
Unit: mm Except ratio
LIMIT
—
—
17.4
104.5
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min.
Float height
Main jet
Jet needle
Pilot jet
Air screw
Throttle cable play
SPECIFICATION
KEIHIN PWS14
14 mm
35EA
1 900 ± 200 r/min
5.1 ± 0.5 mm
#62
N5GJ-2nd
#45
1 and 1/2 turns back
2 – 4 mm
(M.J.)
(J.N.)
(P.J.)
(A.S.)
2/5
P-02, 19
127
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
NGK: BPR6HS
DENSO: W20FPR
0.6 – 0.7
Over 8 at 1 atm.
Secondary
Generator coil resistance
Charging
Pick-up
Regulated voltage
Generator Max. output
Starter relay resistance
Battery
Type
designation
Capacity
Fuse size
4 – 10 kΩ
0.2 – 1.5 Ω
100 – 270 Ω
13.5 – 15.5 V at 5 000 r/min
100 W at 5 000 r/min
50 – 90 Ω
Unit: mm
NOTE
Brake fluid type
Wheel rim runout
SPECIFICATION
35
35
21/5
10
1.2 × 2
1.2
2
2
2
1.2
2
HI
LO
Brake light/Taillight
Turn signal light
Speedometer light
Fuel meter light
Turn signal indicator light
Oil level indicator light
Water temp. indicator light
High beam indicator light
Trunk light
Master cylinder piston diam.
Brake caliper piston diam.
12 V 10.8 kC (3 Ah)/10 HR
10 A
ITEM
Master cylinder bore
Brake caliper cylinder bore
Unit: W
Headlight
ITEM
Brake disc thickness
Brake disc runout
Plug cap –
B/W lead wire
terminal
Y – Ground
R – Ground
YT4L-BS
WATTAGE
BRAKE + WHEEL
Wheel axle runout
Wheel rim size
Tire size
Tire type
Tire tread depth
STANDARD/SPECIFICATION
Front
4.0 ± 0.2
Rear
4.0 ± 0.2
Front &
—
Rear
Front
11.000 – 11.043
Rear
12.000 – 12.043
Front
10.957 – 10.984
Rear
11.957 – 11.984
Front
30.230 – 30.306
Rear
30.230 – 30.306
Front
30.150 – 30.200
Rear
30.150 – 30.200
DOT 4
Axial
—
Radial
—
Front
—
Front
J12 × MT3.50
Rear
J13MC × MT3.50
Front
120/70-12 51L
Rear
130/60-13 M/C 53L
Front
METZELER: ME 7 TEEN
Rear
METZELER: ME 7 TEEN
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Rear wheel travel
Unit: mm
LIMIT
3.5
3.5
0.30
—
—
—
—
—
—
—
—
—
2.0
2.0
0.25
—
—
—
—
—
—
1.6
1.6
Unit: mm
LIMIT
—
122
—
STANDARD
77
124.7
60
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
3/5
A
S
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil tank capacity
Final gear oil type
Final gear oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
6.8 L
Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke oil rated FC under
JASO classification.
1.2 L
SAE 10W-40
130 ml
5/5
NOTE
P-02, 19
SOLO RIDING
kgf/cm2
1.25
1.75
E
L
P
M
P-02, 19
kPa
125
175
4/5
psi
18
25
kPa
125
230
DUAL RIDING
kgf/cm2
1.25
2.30
psi
18
33
P-02, 19
128
JR50
CYLINDER + PISTON + PISTON RING
Unit: mm (in)
CLUTCH
ITEM
Piston to cylinder clearance
STANDARD
0.065 – 0.075
(0.0026 – 0.0030)
41.000 – 41.015
(1.6142 – 1.6148)
Measure at 20 mm (0.8 in) from the top surface.
40.930 – 40.945
(1.6114 – 1.6120)
Measure at 23 mm (0.9 in) from the skirt end.
LIMIT
0.120
(0.0047)
ITEM
Clutch release screw
Drive plate thickness
41.065
(1.6167)
Drive plate claw width
40.880
(1.6094)
Driven plate distortion
—
0.05
(0.002)
0.05
(0.002)
3.6
(0.14)
3.6
(0.14)
3.3
(0.13)
4.0
(0.16)
0.75
(0.030)
Clutch engagement
Clutch lock-up
Clutch spring free length
Cylinder bore
Piston diam.
Cylinder distortion
Cylinder head distortion
—
Piston ring free end gap
R
Approx. 4.5 (0.18)
T
Approx. 4.5 (0.18)
1st
R
Approx. 4.1 (0.16)
T
Approx. 5.0 (0.20)
2nd
Piston ring end gap
Piston ring to groove clearance
1st & 2nd
Piston pin bore
Piston pin O.D.
0.10 – 0.25
(0.004 – 0.010)
0.03 – 0.07
(0.0012 – 0.0028)
12.002 – 12.010
(0.4725 – 0.1728)
11.996 – 12.000
(0.4723 – 0.4724)
Unit: mm (in)
STANDARD
1/4 turn back
2.5 – 2.7
(0.10 – 0.11)
15.65 – 15.95
(0.616 – 0.628)
—
2 500 – 2 900 r/min
2 700 – 3 100 r/min
—
TRANSMISSTION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Shift fork to groove clearance
Shift fork groove width
—
Shift fork thickness
12.030
(0.4736)
11.980
(0.4717)
DRIVE CHAIN
Unit: mm (in)
Drive chain
ITEM
Conrod small end I.D.
STANDARD
16.003 – 16.011
(0.6300 – 0.6304)
Conrod deflection
—
Crank web to web width
LIMIT
16.040
(0.6315)
3.0
(0.12)
ITEM
Oil pump reduction ratio
Oil pump discharge rate
—
CARBURETOR
STANDARD
60.950 (53/20 × 23/1)
0.8 – 1.1 ml
(0.027/0.028 – 0.037/0.039 US/lmp oz)
for 5 minutes at 3 000 r/min
LIMIT
—
ITEM
Carburetor type
Bore size
I.D. No
Idle r/min
Fuel level
1/4
ITEM
Main jet
Jet needle
Needle jet
Pilot jet
Air screw
Throttle cable play
A
S
SPECIFICATION
#56.3
3D23-3rd
E-6
#15
1 and 1/4 turns out
2 – 4 mm
(0.08 – 0.16 in)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(A.S.)
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
SPECIFICATION
NGK: BPR4HS
DENSO: W14FPR-UL
0.6 – 0.7
(0.024 – 0.028)
Over 8 (0.3) at 1 atm.
Secondary
Generator coil peak voltage
11 – 20 kΩ
More than 120 V
100 – 160 Ω
Generator coil resistance
BRAKE + WHEEL
ITEM
Front brake cable play
STANDARD
15 – 25
(0.6 – 1.0)
20 – 30
(0.8 – 1.2)
Rear brake pedal free travel
Brake drum I.D.
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
P
M
Unit: mm (in)
NOTE
Plug cap –
Ground
: B/Y
: Ground
B/Y – Ground
Front fork spring free length
Rear wheel travel
Swingarm pivot shaft runout
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
2/4
P-03, 28
STANDARD
70
(2.8)
173.0
(6.81)
192.5
(7.58)
52
(2.1)
LIMIT
—
0.6
(0.02)
Unit: mm (in)
NOTE
—
169.0
(6.65)
188.0
(7.40)
Upper
Lower
—
ITEM
Fuel type
Fuel tank capacity
—
Axial
—
Radial
—
Front
—
Rear
—
Front &
Rear
Front &
Rear
1.40 × 10
—
—
4.0
(0.16)
4.0
(0.16)
P-03, 28
kPa
kg/cm2
psi
150
150
1.50
1.50
22
22
FUEL + OIL
—
Rear
3/4
ITEM
Front fork stroke
—
90.7
(3.57)
90.7
(3.57)
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
Rear
SPECIFICATION
MIKUNI VM12SC
12 mm
0445
1 700 ± 100 r/min
3.5 – 4.5 mm
(0.14 – 0.18 in)
24.5 – 25.0 mm
(0.96 – 1.00 in)
SUSPENSION
Unit: mm (in)
LIMIT
—
2.50-10 2PR
—
TIRE PRESSURE
Front
Front
E
L
Float height
P-03, 28
Unit: mm (in)
LIMIT
—
—
259.0
(10.20)
20 – 25
(0.8 – 1.0)
0.05
(0.002)
—
—
—
Drive chain slack
—
OIL PUMP
—
STANDARD
D.I.D.: DID 420
78
Type
Links
20-pitch
length
32.0 ± 0.1
(1.260 ± 0.004)
Crankshaft runout
Unit: mm (in) Except ratio
LIMIT
—
—
—
0.50
(0.020)
STANDARD
2.650 (53/20)
2.153 (28/13)
2.230 (29/13)
0.10 – 0.30
(0.004 – 0.012)
6.50 – 6.60
(0.250 – 0.260)
6.30 – 6.40
(0.248 – 0.252)
ITEM
CONROD + CRANKSHAFT
LIMIT
—
2.2
(0.09)
14.85
(0.585)
0.15
(0.006)
—
—
10.1
(0.4)
Engine oil type
Engine oil tank capacity
Transmission oil type
Transmission oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
2.0 L
(0.5/0.4 US/lmp gal)
Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality systhetic based 2-stroke engine oil rated FC under the
JASO classification.
Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke oil rated FC under
JASO classification.
0.3 L
(0.3/0.3 US/lmp qt)
SAE 10W-40
450 ml
Change
(0.5/0.4 US/lmp qt)
500 ml
Overhaul
(0.5/0.4 US/lmp qt)
4/4
NOTE
P-03, 28
P-03
P-28
P-03, 28
129
JR80
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
STANDARD
0.040 – 0.050
(0.0016 – 0.0020)
49.000 – 49.015
(1.9291 – 1.9297)
Measure at 15 mm (0.6 in) from the top surface.
48.955 – 48.970
(1.9274 – 1.9279)
Measure at 18 mm (0.7 in) from the skirt end.
Cylinder bore
Piston diam.
Cylinder distortion
—
Cylinder head distortion
—
Piston ring free end gap
1st &
2nd
T
Piston ring end gap
Piston ring to groove clearance
1st & 2nd
Piston pin bore
Piston pin O.D.
4.5
Approx. (0.18)
0.15 – 0.35
(0.006 – 0.014)
0.03 – 0.07
(0.0012 – 0.0028)
12.002 – 12.010
(0.4725 – 0.4728)
11.995 – 12.000
(0.4722 – 0.4724)
CONROD + CRANKSHAFT
Unit: mm (in)
LIMIT
0.120
(0.0047)
CLUTCH
49.090
(1.9327)
Drive plate thickness
No. 1
Drive plate claw width
No. 1 & 2
48.880
(1.9244)
0.05
(0.002)
0.05
(0.002)
3.6
(0.14)
0.80
(0.031)
—
12.030
(0.4736)
11.980
(0.4717)
Unit: mm (in)
ITEM
Conrod small end I.D.
STANDARD
16.003 – 16.011
(0.6300 – 0.6304)
Conrod deflection
—
Crank web to web width
Crankshaft runout
LIMIT
16.040
(0.6315)
3.0
(0.12)
40.0 ± 0.1
(1.575 ± 0.004)
—
—
0.05
(0.002)
Unit: mm (in)
ITEM
Clutch cable play
STANDARD
10 – 15
(0.4 – 0.6)
2.9 – 3.1
(0.11 – 0.12)
2.92 – 3.08
(0.11 – 0.12)
11.8 – 12.0
(0.46 – 0.47)
No. 2
Driven plate distortion
—
Clutch spring free length
—
TRANSMISSION
Shift fork groove width
Shift fork thickness
STANDARD
3.842 (73/19)
2.833 (34/12)
2.333 (35/15)
1.684 (32/19)
1.318 (29/22)
1.083 (26/24)
0.923 (24/26)
0.10 – 0.30
(0.004 – 0.012)
4.45 – 4.55
(0.175 – 0.179)
4.25 – 4.35
(0.167 – 0.171)
76.0 +– 00.1
(2.992 –+ 00.004 )
No. 1, 2
&3
No. 1, 2
&3
No. 1, 2
&3
Countershaft length
(Low to 2nd)
DRIVE CHAIN
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
(Full open)
Drive chain
STANDARD
D.I.D.: 428
96
Type
Links
20-pitch length
Drive chain slack
1/5
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Air screw
Throttle cable play
SPECIFICATION
MIKUNI VM20SS
20 mm
03410
1 500 ± 150 r/min
21.4 ± 1.0 mm (0.84 ± 0.04 in)
#87.5
4L27-3rd
O-4
#25
1 and 1/4turns out
2 – 4 mm (0.08 – 0.16 in)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(A.S.)
ELECTRICAL
Spark plug
NOTE
Secondary
25 – 35 kΩ
Primary
Lighting
120 – 200 Ω
0.2 – 1.5 Ω
Plug cap –
Ground
B/R – B/W
Y/R – B/W
: B/Y
: Ground
Type
Gap
Spark performance
Ignition coil resistance
Generator coil resistance
Ignition coil primary peak voltage
More than 140 V
BRAKE + WHEEL
STANDARD
20 – 30
(0.8 – 1.2)
20 – 30
(0.8 – 1.2)
10
(0.4)
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Front
—
Rear
—
Wheel rim runout
Axial
—
Radial
—
Front
—
Rear
—
Wheel axle runout
3/5
Wheel rim size
Tire tread depth
Front fork spring free length
Front fork oil level
Front fork oil capacity (each leg)
LIMIT
—
—
—
P-03, 28
STANDARD
2.50-14 4PR
3.00-12 4PR
14 × 1.40
12 × 1.60
Front
Rear
Front
Rear
Front
—
Rear
—
SUSPENSION
Front fork oil type
Unit: mm (in)
ITEM
Front brake cable play
—
LIMIT
—
—
259.0
(10.20)
2/5
ITEM
Tire size
ITEM
Front fork stroke
SPECIFICATION
NGK: BR7ES
DENSO: W22ESR
NGK: 0.7 – 0.8 (0.028 – 0.031)
DENSO: 0.6 – 0.7 (0.024 – 0.028)
Over 8 (0.3) at 1 atm.
—
35 – 40
(1.37 – 1.57)
P
M
Unit: mm (in)
ITEM
—
—
E
L
P-03, 28
A
S
CARBURETOR
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
Unit: mm (in)
ITEM
SPECIFICATION
6.461 (73/19 × 29/22 × 37/29)
0.9 – 1.2 ml
for 3 minutes at 2 000 r/min
—
2.6
(0.10)
2.62
(0.10)
11.0
(0.43)
0.1
(0.004)
33.7
(1.33)
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
LIMIT
Rear shock absorber spring
pre-set length
Rear wheel travel
Swingarm pivot shaft runout
LIMIT
—
—
—
—
3.0
(0.12)
3.0
(0.12)
Unit: mm (in)
STANDARD
100
(3.9)
322.4
(12.7)
LIMIT
107
(4.2)
—
NOTE
—
315
(12.4)
Compress inner
tube without
spring
SUZUKI FORK OIL SS-08 (#10) or
an equivalent fork oil
83 ml
(2.8/2.9 US/lmp oz)
2/5
—
110
(4.3)
—
—
0.6
(0.02)
TIRE AIR PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
100
125
1.00
1.25
14
18
—
110.7
(4.36)
110.7
(4.36)
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
P-03, 28
4/5
P-03, 28
130
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil tank capacity
Transmission oil type
Transmission oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (MethyI Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
4.1 L
(1.1/0.9 US/lmp gal)
Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the
JASO classification.
Use SUZUKI CCI SUPER OIL or an equivalent
good quality synthetic based 2-stroke oil rated FC
under the JASO classification.
0.9 L
(1.0/0.8 US/lmp qt)
SAE 10W-40
650 ml
Change
(0.69/0.57 US/lmp qt)
700 ml
Overhaul
(0.74/0.62 US/lmp qt)
5/5
Cylinder distortion
Cylinder head distortion
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
P-03
For the others
A
S
CYLINDER + PISTON + PISTON RING
Piston diam.
P-03, 28
E
L
P
M
P-03, 28
LT50
ITEM
Piston to cylinder clearance
Cylinder bore
NOTE
Unit: mm
STANDARD
0.065 – 0.075
41.000 – 41.015
Measure at 20 mm from the top surface.
40.930 – 40.945
Measure at 23 mm from the skirt end.
—
—
Approx. 4.5
1st & R
2nd
T
Approx. 5.0
0.10 – 0.25
1st
0.020 – 0.060
2nd
0.020 – 0.060
11.998 – 12.006
11.996 – 12.000
LIMIT
0.120
41.065
TRANSMISSTION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
0.05
0.05
3.6
4.0
0.75
—
—
12.030
11.980
Unit: mm
ITEM
Conrod small end I.D.
Conrod deflection
Crank web to web width
Crankshaft runout
STANDARD
16.003 – 16.011
—
32.0 ± 0.1
—
LIMIT
16.040
3.0
—
0.05
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
STANDARD
60.95 (53/20 × 23/1)
0.8 – 1.1 ml
for 5 minutes at 3 000 r/min
CLUTCH
ITEM
Clutch wheel I.D.
Clutch shoe O.D.
Clutch engagement
Clutch lock-up
Clutch spring free length
STANDARD
87.00 – 87.15
—
2 600 ± 200 r/min
3 500 ± 200 r/min
—
1/3
LIMIT
—
—
—
STANDARD
D.I.D.: DID 420
64
Unit: mm
LIMIT
—
—
40.880
DRIVE CHAIN
ITEM
Drive chain
Type
Links
20-pitch
length
Unit: mm
LIMIT
87.40
No goove at
any part
—
—
Over 28.0
P-01, 02, 37, 43, 71
—
Drive chain slack
259.1
15 – 25
—
CARBURETOR
ITEM
CONROD + CRANKSHAFT
STANDARD
2.650 (53/20)
3.364 (37/11)
2.416 (29/12)
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Air screw
Starter jet
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(A.S.)
(G.S.)
SPECIFICATION
P-01, 02, 43, 71
MIKUNI VM12SC
12 mm
04431
1 550 ± 50 r/min
24.5 – 25.0 mm
#57.5
3E3-3rd
E-6
#15
1 and 1/2 turns back
#50
3 – 5 mm
ELECTRICAL
ITEM
Spark plug
Spark performance
Ignition coil resistance
Type
Gap
SPECIFICATION
NGK: BPR4H
0.5 – 0.6
Over 8 at 1 atm.
B/Y – Ground
120 – 160 Ω
2/3
P-37
←
←
0444
←
←
←
←
←
←
←
←
←
Unit: mm
NOTE
P-01, 02, 37, 43, 71
131
BRAKE + WHEEL
ITEM
Parking brake lever free travel
Brake drum I.D.
Brake lining thickness
Steering angle
Turning radius
Toe-in
Camber
Trail
Kingpin inclination
Caster
Wheel rim runout
Tire size
Tire tread depth
Unit: mm
LIMIT
—
90.7
1.5
—
—
—
—
—
—
—
—
3.0
3.0
STANDARD
5
—
—
35°
21.5°
Approx. 2 m
4.0 ± 1.5
1°
10
10°
3° 30’
—
—
Rear
Inside
Outside
Axial
Radial
Front &
Rear
Front &
Rear
145/70-6
—
—
4.0
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
25
25
0.25
0.25
3.6
3.6
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Engine oil tank capacity
Transmission oil type
Transmission oil capacity
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is reccomended.
1.5 L
Use SUZUKI CCI SUPER OIL or an equivalent
good quality synthetic based 2-stroke oil rated FC
under the JASO classification.
0.5 L
SAE 10W-40
Charge
500 ml
Overhaul
550 ml
3/3
LT80
Cylinder bore
Piston diam.
STANDARD
0.080 – 0.090
(0.0031 – 0.0035)
50.000 – 50.015
(1.9685 – 1.9691)
Measure at 20 mm (0.8 in) from the top surface.
49.915 – 49.930
(1.9652 – 1.9657)
Measure at 20 mm (0.8 in) from the skirt end.
Cylinder distortion
—
Cylinder head distortion
Piston ring free end gap
—
1st
T
2nd
T
Piston ring end gap
Piston ring to groove clearance
1st
2nd
Piston pin bore
Piston pin O.D.
Approx. 4.0 (0.16)
Approx. 4.0 (0.16)
0.15 – 0.35
(0.006 – 0.014)
0.020 – 0.060
(0.0008 – 0.0024)
0.020 – 0.060
(0.0008 – 0.0024)
12.002 – 12.010
(0.4725 – 0.4728)
11.994 – 12.000
(0.4722 – 0.4724)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
P
M
Unit: mm (in)
CLUTCH
LIMIT
0.120
(0.0047)
ITEM
Clutch wheel I.D.
50.050
(1.9705)
Clutch shoe thickness
49.880
(1.9638)
0.05
(0.002)
0.05
(0.002)
3.2
(0.13)
3.2
(0.13)
0.80
(0.031)
STANDARD
16.000 – 16.008
(0.6299 – 0.6302)
Crank web to web width
Crankshaft runout
Unit: mm (in)
STANDARD
110.00 – 110.15
(4.331 – 4.337)
4.0
(0.16)
2 500 – 2 900 r/min
3 000 – 3 600 r/min
Clutch engagement
Clutch lock-up
Clutch spring free length
—
TRANSMISSION + DRIVE CHAIN
ITEM
Final reduction ratio
Gears
Chain
Gear ratios
Drive belt width
—
Driven face spring free length
—
Drive chain
12.030
(0.4736)
11.980
(0.4717)
Unit: mm (in)
Conrod deflection
E
L
P-01, 02, 37, 43, 71
A
S
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
NOTE
—
LIMIT
16.040
(0.6315)
3.0
(0.12)
38.0 ± 0.1
(1.50 ± 0.004)
—
—
0.05
(0.002)
Unit: mm (in) Except ratio
STANDARD
7.197 (33/12 × 27/14 × 19/14)
2.200 (22/10)
Variable, 2.341 – 0.851
17.6 – 18.6
(0.69 – 0.73)
107.5
(4.23)
Type
RK520SMO
Links
36
LIMIT
—
—
—
16.7
(0.66)
102.1
(4.02)
—
—
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Throttle cable play
SPECIFICATION
MIKUNI VM16SH
16 mm
41B10
1 600 ± 150 r/min
18.5 ± 1.0 mm
(0.73 ± 0.04 in)
#92.5
3J17-2nd
E-0
#20
3 – 5 mm
(0.12 – 0.20 in)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
OIL PUMP
ITEM
Oil pump reduction ratio
Oil pump discharge rate
(Full open)
LIMIT
110.50
(4.350)
2.5
(0.10)
—
—
34.2
(1.35)
SPECIFICATION
6.500 (13/2)
1.0 – 1.3 ml
(0.03/0.04 – 0.04/0.05 US/lmp oz)
for 3 minutes at 3 000 r/min
1/4
P-02, 03, 19, 28
2/4
P-02, 03, 19, 28
132
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
DENSO: W22FPR
NGK: BPR7HS
0.60 – 0.80
(0.024 – 0.031)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Primary
0.01 – 1.0 Ω
Secondary
10 – 20 kΩ
Generator coil resistance
Generator no-load voltage
Generator Max. output
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
Circuit breaker
Charging
0.5 – 0.8 Ω
Primary
139 – 207 Ω
More than 28 V (AC) at 5 000 r/min
30 W at 5 000 r/min
72 – 88 Ω
YTX5L-BS
12 V 14.4 kC (4 Ah)/10 HR
5A
30 A
BRAKE + WHEEL
STANDARD
15 – 25
(0.59 – 0.98)
5
(0.2)
Rear brake pedal height
Wheel axle runout
Wheel rim size
Tire size
SUSPENSION
ITEM
Front suspension stroke
—
8 × 5.5 AT
—
Front wheel travel
Rear suspension stroke
CYLINDER + PISTON + PISTON RING
—
Fuel tank capacity
—
—
—
—
Engine oil type
including
reserve
reserve
Engine oil tank capacity
Transmission oil type
Transmission oil capacity
P
M
A
S
OIL PUMP
LIMIT
0.120
(0.0047)
ITEM
Oil pump reduction ratio
Oil pump discharge rate
Cylinder distortion
—
Cylinder head distortion
—
0.05
(0.002)
0.05
(0.002)
3.6
(0.14)
3.6
(0.14)
3.3
(0.13)
4.0
(0.16)
0.80
(0.031)
Piston diam.
Piston ring free end gap
R
Approx. 4.5 (0.18)
1st
T
Approx. 4.5 (0.18)
R
Approx. 4.1 (0.16)
T
Approx. 5.0 (0.20)
2nd
Piston ring end gap
Piston ring to groove clearance
1st
2nd
Piston pin bore
Piston pin O.D.
0.10 – 0.25
(0.004 – 0.010)
0.020 – 0.060
(0.0008 – 0.0024)
0.020 – 0.060
(0.0008 – 0.0024)
12.002 – 12.010
(0.4725 – 0.4728)
11.996 – 12.000
(0.4723 – 0.4724)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
—
—
—
kPa
kgf/cm2
psi
15
20
0.15
0.20
2.2
2.9
2.0 L (0.53/0.44 US/lmp gal)
Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the
JASO classification.
Use SUZUKI CCI SUPER OIL or an equivalent
good quality synthetic based 2-stroke oil rated FC
under the JASO classification.
1.2 L (1.27/1.06 US/lmp qt)
SAE 10W-40
Change
80 ml (2.7/2.8 US/lmp oz)
80 – 90 ml
Overhaul
(2.7/2.8 – 3.0/3.2 US/lmp oz)
—
—
12.030
(0.4736)
11.980
(0.4717)
P-03, 28
For the others
P-03
For the others
4/4
P-02, 03, 19, 28
SPECIFICATION
60.95 (53/20 × 23/1)
0.6 – 0.8 ml
(0.020/0.021 – 0.027/0.030 US/lmp oz)
for 5 minutes at 2 000 r/min
41.065
(1.6167)
40.880
(1.6094)
NOTE
6.0 L (1.58/1.32 US/lmp gal)
E
L
—
—
—
—
—
Unit: mm (in)
Cylinder bore
—
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel type
STANDARD
0.065 – 0.075
(0.0026 – 0.0030)
41.000 – 41.015
(1.6142 – 1.6148)
Measure at 20 mm (0.8 in) from the top surface.
40.930 – 40.945
(1.6114 – 1.6120)
Measure at 20 mm (0.8 in) from the top surface.
ITEM
Piston to cylinder clearance
Unit: mm (in)
NOTE
LIMIT
VEHICLE LOAD CAPACITY: 60 kg (132 lbs)
P-02, 03, 19, 28
LT-A50
STANDARD
31
(1.22)
50
(1.97)
55
(2.17)
57.4
(2.26)
ITEM
—
Rear
3/4
—
FUEL + OIL
—
80.7
(3.18)
130.7
(5.15)
3.0
(0.12)
Inside
Outside
Front
Rear
Rear
LIMIT
4.0
(0.16)
4.0
(0.16)
LIMIT
—
Turning radius
Camber
Kingpin inclination
Caster
Trail
—
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
—
8
(0.31)
2.1 m (6.89 ft)
1°
15°
3°
11.6
(0.46)
35°
27° 30’
AT19 × 7.00-8✩
✩
AT19 × 7.00-8✩
✩
STANDARD
Front
TIRE PRESSURE
Rear
Front
&Rear
ITEM
Tire tread depth
Rear wheel travel
Front
Toe-in (with 60 kg load)
Steering angle
Terminal –
Terminal
Plug cap –
Terminal
W/R – Ground
B/R – Ground
Unit: mm (in)
ITEM
Rear brake pedal free travel
Brake drum I.D.
NOTE
CLUTCH
ITEM
Clutch wheel I.D.
STANDARD
87.00 – 87.15
(3.425 – 3.431)
Clutch shoe thickness
—
Clutch engagement
Clutch lock-up
2 200 – 2 600 r/min
2 500 – 2 900 r/min
Unit: mm (in)
LIMIT
87.50
(3.445)
No goove at
any part
—
—
TRANSMISSTION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STANDARD
2.650 (53/20)
3.700 (37/10)
2.416 (29/12)
DRIVE CHAIN
ITEM
Drive chain
STANDARD
D.I.D.: DID 420
78
Type
Links
20-pitch
length
—
Drive chain slack
20 – 30
(0.8 – 1.2)
LIMIT
—
—
—
Unit: mm (in)
LIMIT
—
—
259.0
(10.20)
—
Unit: mm (in)
STANDARD
16.003 – 16.011
(0.6300 – 0.6304)
Conrod deflection
—
Crank web to web width
Crankshaft runout
LIMIT
16.040
(0.6315)
3.0
(0.12)
32.0 ± 0.1
(1.260 ± 0.004)
—
—
0.05
(0.002)
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Air screw
Throttle cable play
1/4
P-02, 03, 19, 28
SPECIFICATION
MIKUNI VM12SC
12 mm
43F0
1 800 ± 100 r/min
24.5 – 25.0 mm
(0.96 – 0.98 in)
#55
3E3-4th
E-6
#15
1 and 1/8 turns out
3 – 5 mm
(0.12 – 0.20 in)
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(A.S.)
2/4
P-02, 03, 19, 28
133
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
NGK: BPR4H
0.50 – 0.60
(0.020 – 0.024)
Over 8 (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Generator coil resistance
Ignition coil primary peak voltage
Secondary
13 – 20 Ω
Primary
100 – 160 Ω
More than 100 V
BRAKE + WHEEL
ITEM
Front brake lever play
Brake drum I.D.
Wheel axle runout
Wheel rim size
—
Rear
—
80.7
(3.18)
110.7
(4.36)
3.0
(0.12)
7 × 6.0 AT
—
1.5 ± 3
(0.06 ± 0.12)
2.0 m
(6.6 ft)
0°
3°
10
(0.39)
33° 40’
24°
AT16 × 8.00-7✩
AT16 × 8.00-7✩
Camber
Caster
Trail
Tire size
Tire tread depth
Inside
Outside
Front
Rear
Front
—
Rear
—
Rear wheel travel
ITEM
Fuel type
Fuel tank capacity
Engine oil type
—
—
—
—
Engine oil tank capacity
—
—
—
—
–
4.0
(0.16)
4.0
(0.16)
kPa
kgf/cm2
psi
20
20
0.20
0.20
2.9
2.9
Transmission oil type
Transmission oil capacity
A
S
ENGINE TOP END
ITEM
Cylinder compression
Cylinder head warp
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/groove clearance
Piston ring groove width
Piston ring thickness
Piston ring end gap
Piston pin diameter
Piston pin hole diameter
Small end inside diameter
Unit: mm
STANDARD
(Usable range)
770 – 1 200 kPa
(7.7 – 12 kgf/cm2, 109 – 171 psi)
—
43.000 – 43.015
42.965 – 42.980
0.030 – 0.040
0.02 – 0.06
1.01 – 1.03
0.97 – 0.99
0.15 – 0.35
11.995 – 12.000
12.000 – 12.006
16.002 – 16.013
ENGINE BOTTOM END/TRANSMISSION
ITEM
Transmission oil grade
Transmission oil viscosity
Transmission oil amount
Connecting rod bend and twist
Connecting rod big end radial
clearance
Connecting rod big end side clearance
Crankshaft runout
Transmission gear backlash
Shift fork finger thickness
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
P
M
P-02, 03, 19, 28
RM60
LIMIT
—
0.03
43.10
42.83
—
0.16
1.10
0.90
0.70
11.96
12.07
16.05
Unit: mm
STANDARD
SE class
SAE 10W-30 or 10W-40
0.6 L
Not more than 0.03 mm/100 mm
LIMIT
—
—
—
0.2 mm/100 mm
0.021 – 0.033
0.08
0.35 – 0.45
0.7
Not more than 0.03 mm
0.02 – 0.19
3.9 – 4.0
4.05 – 4.15
5.9 – 6.0
6.05 – 6.20
0.10
0.26
3.8
4.25
5.85
6.25
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
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.
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
2.6 L
(0.7/0.6 US/lmp gal)
Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the
JASO classification.
Use SUZUKI CCI SUPER OIL. If they are not available, use a good quality 2-stroke engine oil rated
FC under the JASO classification.
0.5 L
(0.53/0.44 US/lmp qt)
SAE 10W-40
500 ml
Charge
(0.53/0.44 US/lmp qt)
550 ml
Overhaul
(0.58/0.48 US/lmp qt)
E
L
VEHICLE LOAD CAPACITY: 38 kg (841 lbs)
3/4
Unit: mm (in)
LIMIT
—
—
—
—
FUEL + OIL
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
STANDARD
31
(1.22)
52
(2.0)
31
(1.22)
51
(2.0)
Rear suspension stroke
—
—
Front &
Rear
ITEM
Front suspension stroke
—
Rear
Turning radius
Steering angle
Plug cap –
Terminal
B/Y – Ground
: B/Y
: Ground
Front
Toe-in (with 30 kg load)
SUSPENSION
Front wheel travel
Unit: mm (in)
LIMIT
STANDARD
3–7
(0.12 – 0.28)
4–6
(0.16 – 0.24)
Rear brake lever play
Unit: mm (in)
NOTE
4/4
LIMIT
—
25.3
2.9
0.9
0.3
Unit: mm
Type
Links
20-link length
STANDARD
DAIDO: D.I.D. 420M
104 links
254.0
15 – 30
44.71 – 44.91 mm/13T
170.3 – 170.8 mm/44T
under 0.4 mm
FUEL SYSTEM
Reed valve warp
For the others
0.35 – 0.60
Drive chain slack
ITEM
Throttole grip free play
Carburetor type
Main jet
Needle jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Pilot jet
Servise fuel level
Bore center
Float height
Air cleaner element oil
P-03
Not more than 0.15 mm
ITEM
Engine sprocket diameter
Rear sprocket diameter
Rear sprocket warp
For the others
Unit: mm
STANDARD
2–3
26.6
3.1 – 3.3
FINAL DRIVE
Drive chain
P-03, 28
P-02, 03, 19, 28
ENGINE RIGHT SIDE
ITEM
Clutch lever free play
Clutch spring free length
Friction plate thickness
Friction plate/clutch housing clearance
Friction and steel plate warp
NOTE
LIMIT
—
—
259
Less than 15 mm
More than 35 mm
44.0
170
0.5
Unit: mm
STANDARD
2–3
MIKUNI VM24SS
#200
N-8
2.0
5I14-3
3rd groove from the top
#30
1.5 ± 1
26
21.1 ± 2
2-stroke racing oil or
high-quality foam-air filter oil
—
LIMIT
—
—
—
—
—
—
—
—
—
—
—
0.2
COOLING SYSTEM
ITEM
Coolant type
Coolant color
Coolant mixed ratio
Coolant total amount
Radiator cap relief pressure
1/4
P-03, 24, 28
STANDARD
Permanent type antifreeze for aluminum engines and radiators
Green
Soft water 50%, coolant 50%
0.5 L
95 – 125 kPa
(0.95 – 1.25 kgf/cm2, 14 – 18 psi)
2/4
P-03, 24, 28
134
ELECTRICAL SYSTEM
ITEM
Ignition timing
Ignition coil
Spark plug
Unit: mm
STANDARD
18.5° BTDC at 6 000 r/min (rpm)
3 needle
arcing dis7 mm or more
tance
Primary
winding
0.25 – 0.37 Ω
resistance
Secondary wind2.5 – 3.7 kΩ
ing
resistance
Type
NGK B9EG (AS)(CN)(EU) BR9EG
Gap
0.5 – 0.6
BRAKES
Brake
Brake
Brake
Brake
Brake
Brake
ITEM
lever free play
pedal position
pedal play
cam lever angle
shoe lining thickness
shoe spring free length
Brake drum inside diameter
Front
Rear
Front &
Rear
STANDARD
4–5
Adjustable (to suit rider)
20 – 30
80 – 90°
2.1 – 3.0
30.8 – 31.2
32 – 33
Axle runout/100 mm
Tire type
Tire air pressure
90.000 – 90.087
12.18
11.83
Axial
Radial
Front &
Rear
Front
Rear
Front
Rear
Front &
Rear
Piston ring thickness
Piston ring end gap
Piston pin diameter
Piston pin hole diameter
Small end inside diameter
Transmission oil viscosity
Transmission oil capacity
Connecting rod bend
Connecting rod twist
Connecting rod big end radial
clearance
Connecting rod big end side clearance
Crankshaft runout
Shift fork ear thickness
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
Front fork spring free length
Rear shock absorber spring adjusting sleeve position
487.9
181 ± 2.5 ml
132 ± 5
—
—
—
(Adjustable
range)
100 – 165
478
(Adjustable
range)
1–5
LIMIT
2
2
Under 0.10 mm
0.2
60/100-14
80/100-12
DUNLOP K195
DUNLOP K195
100 kPa
(1.0 kgf/cm2, 14 psi)
—
—
—
—
E
L
—
P
M
A
S
Unit: mm
STANDARD
(Usable range)
755 – 1 177 kPa
(7.70 – 12.0 kgf/cm2, 109 – 171 psi)
—
LIMIT
—
0.03
44.500 – 44.515
44.64
44.460 – 44.475
0.042 – 0.052
44.31
—
Top &
Second
Top &
Second
Top &
Second
Top &
Second
0.02 – 0.06
0.16
1.01 – 1.03
1.11
0.97 – 0.99
0.90
0.15 – 0.35
0.65
4/4
P-03, 24, 28
STANDARD
2–3
3.1 – 3.3
1.47 – 1.73
Not more than 0.2 mm
Not more than 0.15 mm
28.1
LIMIT
—
2.9
1.37
0.3
0.3
26.7
0.3 – 0.6
0.9
ENGINE RIGHT SIDE
ITEM
Clutch lever free play
Friction plate thickness
Steel plate thickness
Friction plate warp
Steel plate warp
Clutch spring free length
Friction plate/clutch housing clearance
Unit: mm
FINAL DRIVE
Unit: mm
ITEM
11.995 – 12.000
12.001 – 12.011
16.002 – 16.013
ENGINE BOTTOM END/TRANSMISSION
ITEM
Transmission oil type
SHOWA SS-8 or SAE 5W-20
P-03, 24, 28
ENGINE TOP END
Piston ring groove width
Atmospheric pressure
Front fork oil viscosity
Front fork oil capacity
(completely dry)
Front fork oil level
(fully compressed, spring removed)
LIMIT
40 kPa
(0.4 kgf/cm2, 6 psi)
Unit: mm
STANDARD
Under 0.5 mm
Under 0.8 mm
RM65
Cylinder head warp
Cylinder inside diameter (15 mm
below from the cylinder top end)
Piston diameter
Piston/cylinder clearance
Piston ring/groove clearance
Unit: mm
STANDARD
90.75
11.957 – 11.984
3/4
ITEM
Cylinder compression
ITEM
Front Air pressure
LIMIT
—
—
—
—
1.2
32.8
34.5
12.000 – 12.027
WHEELS/TIRES
Tire size
SUSPENSIONS
Unit: mm
Brake camshaft hole inside diameter
Brake camshaft diameter
ITEM
Wheel rim runout
NOTE
11.96
12.08
16.05
Unit: mm
STANDARD
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
0.5 L
Not more than 0.05 mm/100 mm
Not more than 0.05 mm/100 mm
LIMIT
—
—
—
0.2 mm/100 mm
0.2 mm/100 mm
0.025 – 0.037
0.09
0.35 – 0.45
0.65
Not more than 0.03 mm
3.90 – 4.00
4.05 – 4.15
5.90 – 6.00
6.05 – 6.20
0.05
3.80
4.25
5.80
6.25
1/4
E-03, 21, 24, 28
Drive chain
Type
Links
20-link length
Drive chain slack
Engine sprocket diameter
Rear sprocket diameter
Rear sprocket warp
STANDARD
DAIDO: D.I.D. 420MBK1
110 links
254.0 – 254.6
44 – 54
44.70 – 44.90/13T
182.38 – 182.88/47T
under 0.4 mm
FUEL SYSTEM
ITEM
Throttole grip free play and cable
Carburetor type
Main jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Needle jet
Slow jet
Air screw
Main air jet
Servise fuel level (below the bottom
edge of the carburetor body)
Float height
Air cleaner element oil
Reed valve warp
LIMIT
—
—
259
44 mm or less
59 mm or more
44.0
182.1
0.5
Unit: mm
STANDARD
2–3
MIKUNI VM24SS
#190
#1.5
WY-3
4th groove from the top
O-0
#25
1 and 1/2 (turns out)
0.8 (Pressed in)
LIMIT
—
—
—
—
—
—
—
—
—
0.5 ± 1
—
21.1 ± 1
High quality foam air filter oil
—
—
—
0.5
2/4
E-03, 21, 24, 28
135
COOLING SYSTEM
WHEELS/TIRES
ITEM
STANDARD
Permanent type antifreeze for aluminum engines and radiators
Green
Soft water 50%, coolant 50%
0.4 L
108 – 137 kPa
(1.1 – 1.4 kgf/cm2, 16 – 20 psi)
Coolant type
Coolant color
Coolant mixed ratio
Coolant total amount
Radiator cap relief pressure
ELECTRICAL SYSTEM
ITEM
Stator coil resistance
Ignition timing
Ignition coil
Spark plug
C.D.I. unit
STANDARD
214 Ω ± 20%
20.5° BTDC at 6 000 r/min (rpm)
3 needle arcing
7 mm or more
distance
Primary winding
0.31
Ω ± 15% (at 20 °C)
resistance
Secondary winding
3.1
kΩ
± 15% (at 20 °C)
resistance
Type
NGK BR10EG (US) B10EG
Gap
0.5 – 0.6
Ignition coil primary
115 V or above
peak voltage
Stator coil primary
100 V or above
peak voltage
BRAKES
ITEM
Brake lever free play
Brake fliud type
Brake pad lining thickness
Brake disc thickness
Brake disc runout
STANDARD
Adjustable (to suit rider)
DOT 3 or DOT 4
Front &
Rear
Front &
Rear
Front &
Rear
Cylinder distortion
Piston ring to groove clearance
Piston ring end gap
Piston pin bore
Piston pin O.D.
: Ground
: O
: B/R
: B/W
LIMIT
—
—
4.5
0.7
2.80 – 3.20
2.5
Not more than 0.15 mm
0.3
STANDARD
0.040 – 0.050
(0.0016 – 0.0020)
48.000 – 48.015
(1.8898 – 1.8904)
Measure 15 mm (0.59 in) from the top surface.
47.955 – 47.970
(1.8880 – 1.8886)
Measure 16 mm (0.63 in) from the skirt end.
—
Cylinder head distortion
Piston ring free end gap
Tire type
—
N
Approx. 4.0 (0.16)
0.020 – 0.060
(0.008 – 0.0024)
0.20 – 0.40
(0.008 – 0.016)
14.002 – 14.008
(0.5513 – 0.5515)
13.995 – 14.000
(0.5510 – 0.5512)
Reed valve clearance
—
Front &
Rear
Front &
Rear
Front &
Rear
Front
Rear
Front
Rear
Nicks or
scratches
47.880
(1.8850)
0.05
(0.002)
0.05
(0.002)
3.2
(0.13)
0.80
(0.031)
14.030
(0.5524)
13.980
(0.5504)
0.2
(0.008)
ITEM
Conrod small end I.D.
Crank web to web width
Unit: mm (in)
STANDARD
18.003 – 18.011
(0.7088 – 0.7091)
44.9 – 45.1
(1.767 – 1.775)
LIMIT
18.040
(0.7102)
—
0.05
(0.002)
Crankshaft runout
—
2
0.1
0.2
98 kPa
(1.0 kgf/cm2, 14 psi)
60/100-14 30M
80/100-12 41M
DUNLOP D755F, Tube
DUNLOP D755, Tube
—
—
—
—
—
Unit: mm
LIMIT
—
252 ± 2.5 ml
—
132 ± 2
(from top of inner tube)
(Adjustable
range)
98 – 142
487.2
Front fork spring free length
Rear shock absorber spring preload adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear shock spring free length
Reservoir gas pressure
497.1
(Adjustable
range)
72.4 – 80.4
76.4
211.1
980 kPa
(10 kgf/cm2, 142 psi)
17.989 – 18.000
under 0.1 mm
Tie-rod sleeve outside diameter
Rocker arm mounting bolt runout
197.3
—
17.96
0.2
E
L
4/4
E-03, 21, 24, 28
TRANSMISSION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
STANDARD
3.444 (62/18)
3.357 (47/14)
3.615 (47/13)
2.545 (28/11)
1.933 (29/15)
1.571 (22/14)
1.333 (20/15)
1.166 (21/18)
1.045 (23/22)
No. 1, No. 2
0.05 – 0.25
& No. 3
(0.002 – 0.010)
3.95
– 4.05
No. 1
(0.156 – 0.159)
No. 2 &
4.45 – 4.55
No. 3
(0.175 – 0.179)
3.80 – 3.90
No. 1
(0.150 – 0.154)
No. 2 &
4.30 – 4.40
No. 3
(0.169 – 0.173)
Unit: mm (in) Except ratio
LIMIT
—
RM85
—
RM85L
—
—
—
—
—
—
—
0.45
(0.018)
—
—
—
—
DRIVE CHAIN
Unit: mm (in)
ITEM
CONROD + CRANKSHAFT
1.0 mm or less
STANDARD
SS-8 or 10W-20
P
M
Unit: mm (in)
LIMIT
0.120
(0.0047)
LIMIT
SUSPENSIONS
Front fork oil capacity
(completely dry)
Front fork oil level
(fully compressed, spring removed)
A
S
CYLINDER + PISTON + PISTON RING
Piston diam.
Tire air pressure
Tire size
E-03, 21, 24, 28
RM85/L
Cylinder bore
Axle runout/100 mm
STANDARD
ITEM
Front fork oil viscosity
Unit: mm
3/4
ITEM
Piston to cylinder clearance
Unit: mm
NOTE
: B/R
: B/W
Unit: mm
ITEM
Wheel rim runout (Axial & Radial)
Drive chain
STANDARD
D.I.D. 428G2
118
112
Type
Links
20-pitch
length
RM85
RM85L
—
Drive chain slack
40 – 50
(1.6 – 2.0)
LIMIT
—
—
—
259
(10.2)
—
CARBURETOR
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Unit: mm (in)
STANDARD
10 – 15
(0.4 – 0.6)
2.7 – 2.9
(0.106 – 0.114)
Driven plate distortion
—
Clutch spring free length
—
LIMIT
—
2.4
(0.094)
0.10
(0.004)
39.5
(1.56)
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Slow jet
Air screw
Throttle cable play
(M.J.)
(J.N.)
(S.J.)
(P.A.S.)
SPECIFICATION
KEIHIN PE28
28 mm
03B1
19.0 ± 0.5 mm (0.75 ± 0.02 in)
#125
24NAAH-3rd
#50
2 turns out
2 – 4 mm (0.08 – 0.16 in) at the throttle grip
RADIATOR
ITEM
Radiator cap valve opening pressure
STANDARD
110 kPa
(1.1 kgf/cm2, 16 psi)
1/5
LIMIT
—
P-03, 28
2/5
P-03, 28
136
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Ignition coil resistance
Primary
SPECIFICATION
NGK: BR10ES
0.7 – 0.8
(0.028 – 0.031)
Over 8 (0.3) at 1 atm.
0.2 – 1.0 Ω
Secondary
12 – 20 kΩ
100 – 160 Ω
140 – 230 Ω
240 – 380 Ω
Magneto coil resistance
Ignition coil primary peak voltage
More than 200 V
BRAKE + WHEEL
ITEM
Brake lever play
Brake disk thickness
STANDARD
5 – 20
(0.20 – 0.79)
2.8 – 3.2
(0.110 – 0.126)
2.85 – 3.15
(0.112 – 0.124)
Front
Rear
Brake disk runout
—
Master cylinder bore
Front
Master cylinder piston diam.
Front
11.000
(0.4331
12.700
(0.5000
10.957
(0.4314
12.657
(0.4983
30.230
(1.1902
27.000
(1.0630
30.150
(1.1870
26.920
(1.0600
Rear
Rear
Brake caliper cylinder bore
Front
Brake caliper piston diam.
Front
Rear
Rear
Wheel rim runout
Wheel axle runout
– 11.043
– 0.4348)
– 12.743
– 0.5017)
– 10.984
– 0.4324)
– 12.684
– 0.4994)
– 30.306
– 1.1931)
– 27.076
– 1.0660)
– 30.200
– 1.1890)
– 26.970
– 1.0618)
Axial
—
Radial
—
Front
—
Rear
—
3/5
Engine oil type
Engine coolant type
Engine coolant tank capacity
Transmission oil type
Transmission oil capacity
Brake fluid type
Front fork oil type
Front fork oil capacity (each leg)
Rear shock absorber oil type
Rear shock absorber oil capacity
Unit: mm (in)
LIMIT
5/5
STANDARD
70/100-17 40M
70/100-19 42M
90/100-14 49M
90/100-16 52M
Front
2.5
(0.10)
2.5
(0.10)
0.30
(0.012)
—
—
—
—
—
RM85
RM85L
RM85
RM85L
SUSPENSION
ITEM
Front fork stroke
STANDARD
275
(10.8)
Front fork spring free length
—
Front fork spring rate (each leg)
Front fork oil level
Front fork damping force adjuster
—
Rebound
Compression
2.6 N/mm (0.26 kgf/mm)
115
(4.53)
1 and 1/8 turns out
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)
Rear shock absorber spring pre-set RM85: 2 mm (0.08 in) compressed from spring
length
free length
RM85L: 5.5 mm (0.22 in) compressed from spring
free length
Rear shock absorber damping
RM85: 1 and 1/2 turns out
Rebound
force adjuster
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)
Rear wheel travel
277
(10.9)
Swingarm pivot shaft runout
—
LIMIT
—
—
—
—
Unit: mm (in)
LIMIT
—
445
(17.5)
—
—
—
—
—
—
—
—
—
—
—
0.3
(0.01)
—
TIRE PRESSURE
—
Front & Rear
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
NOTE
P-03, 28
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
E
L
P
M
P-03, 28
SPECIFICATION
Unleaded gasoline minumum 95 octane (RON)
5.0 L
(1.3/1.1 US/Imp gal)
MOTUL 800 2T or
equivalent Two Cycle Racing Lubricant
Use an anti-freeze & Summer engine coolant compatible with aluminum radiator, mixed with distilled
water only, at the ratio of 50:50.
570 ml
(1.20/1.00 US/Imp pt)
SAE 10W-40
550 ml
Change
(1.16/0.97 US/Imp pt)
650 ml
Overhaul
(1.37/1.14 US/Imp pt)
DOT 4
SUZUKI FORK OIL SS-05 or an equivalent fork oil
357 ml
(12.07/12.57 US/Imp oz)
SUZUKI REAR SUSPENSION OIL SS-15
or an equivalent rear suspension oil
150 ml
(5.07/5.28 US/Imp oz)
ITEM
Tire size
Rear
W/Bl – Ground
Plug cap –
Ground
B/R – R/W
R/W – B/W
B/R – B/W
: Ground
: W\Bl
A
S
FUEL + OIL + COOLANT
ITEM
Fuel type
Fuel tank capacity
Unit: mm (in)
NOTE
4/5
P-03, 28
137
RM100
ENGINE TOP END
ITEM
Cylinder compression
Cylinder head warp
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/groove clearance
Piston ring groove width
Piston ring thickness
Piston ring end gap
Unit: mm
STANDARD
(Usable range)
825 – 1 280 kPa
(8.4 – 13.0 kgf/cm2, 119 – 185 psi)
—
52.505 – 52.520
52.435 – 52.450
0.065 – 0.075
Top
0.040 – 0.080
Second
0.020 – 0.060
Top
1.03 – 1.05
Second
1.01 – 1.03
Top &
0.97 – 0.99
Second
Top &
0.30 – 0.50
Second
ENGINE BOTTOM END/TRANSMISSION
ITEM
Transmission oil type
Transmission oil viscosity
Transmission oil level
Transmission oil capacity
Connecting rod big end radial
clearance
Connecting rod big end side clearance
Crankshaft runout
Shift fork ear thickness
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
0.023 – 0.035
0.08
0.35 – 0.45
0.7
TIR 0.03 or less
3.9 – 4.0
4.05 – 4.15
5.9 – 6.0
6.05 – 6.20
TIR 0.08
3.8
4.3
5.8
6.3
STANDARD
2–3
2.8 – 2.9
0.15 or less
35.0
LIMIT
—
2.7
0.3
34.0
A
S
Unit: mm
3 needle
arcing distance
Primary
winding
resistance
Secondary winding
resistance
Peak voltage
6 mm or more
—
0.36 – 0.48 Ω
—
5.4 – 7.4 kΩ
—
110 V or more
—
0.7 – 0.8
3.75 – 6.25 kΩ
288 – 432 Ω
BRAKES
Front &
Rear
Front &
Rear
Front &
Rear
Tire air pressure
Tire size
Tire type
LIMIT
—
4.0
1
2.85 – 3.15
2.5
0.12 or less
0.3
DOT 4
—
STANDARD
LIMIT
WHEELS/TIRES
Axle runout/100 mm
—
—
—
Unit: mm
STANDARD
Adjustable (to suit rider)
Brake fliud type
ITEM
Wheel rim runout (Axial & Radial)
NOTE
—
—
—
—
STANDARD
DAIDO: D.I.D. 420DS
124 links, Endless
254.0
0.4 or less
LIMIT
—
—
259
Too tight less
than 54 mm
Too loose more
than 69 mm
0.5
STANDARD
2–3
KEIHIN PWK28
#138
#60
#3.5
NAPF
4th groove from the top
#45
1 and 3/8
#62
LIMIT
—
—
—
—
—
—
—
—
—
—
Type
Links
20-link length
Drive chain slack
60 – 70
Rear sprocket warp
FUEL SYSTEM
ITEM
Throttole grip free play and cable
Carburetor type
Main jet
Main air jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Pilot jet (Slow jet)
Air screw
Starter jet
Servise fuel level
(below the float bowl mating surface)
Float height
Air cleaner element oil
Reed valve warp
Unit: mm
1.0 ± 1
—
19 ± 1
High quality foam air filter oil
—
—
—
0.2
COOLING SYSTEM
ITEM
Coolant type
Coolant color
Coolant mixed ratio
Coolant freezing point
Coolant total amount
Radiator cap relief pressure
STANDARD
Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)
Green
Soft water 50%, coolant 50%
–35 °C (–31 °F)
0.67 L
93 – 123 kPa
(0.95 – 1.25 kgf/cm2, 14 – 18 psi)
E
L
P
M
E-03, 24, 28
STANDARD
16 V or more
0.4 – 0.6
396 – 594 Ω
4.0 V or more
Spark plug gap
Spark plug resistance
Magneto stator coil resistance
Brake disc runout
—
—
—
—
Unit: mm
ELECTRICAL SYSTEM
Brake disc thickness
0.80
Unit: mm
1/4
ITEM
Brake lever free play
Brake pad lining thickness
0.90
LIMIT
ITEM
Clutch lever free play
Friction plate thickness
Friction and steel plate warp
Clutch spring free length
ITEM
Magneto output voltage
Pickup coil air gap
Pickup coil resistance
Pickup coil peak voltage
Ignition coil
Drive chain
0.03
52.60
52.29
—
0.18
0.16
1.13
1.11
Unit: mm
ITEM
—
STANDARD
API SE, SF or SG
API SH or SJ with JASO MA
SAE 10W-40
in middle of level gauge
0.65 L
ENGINE RIGHT SIDE
FINAL DRIVE
LIMIT
2/4
E-03, 24, 28
STANDARD
Atmospheric pressure
LIMIT
—
SUSPENSIONS
ITEM
Front fork air pressure
Front fork compression damping
adjustment
Front fork oil viscosity
Front fork oil capacity
Front fork oil level
(fully compressed, spring removed)
Unit: mm
6 clicks
—
KAYABA 01 or SAE 5W
321 ± 4 ml
—
—
(Adjustable
range)
75 – 115
422
(Adjustable
range)
4 clicks
(Adjustable
range)
20 clicks
90 ± 2
Front fork spring free length
Rear shock absorber compression
damper setting (upper)
Rear shock absorber rebound
damper setting (lower)
Rear shock absorber standard
adjusting nut position
Rear shock absorber nut adjusting
range
Rear shock absorber standard
spring set length
Rear shock absorber oil type
Rear shock absorber oil total
amount
Rear shock absorber gas pressure
430
2nd position
11th click from fully clockwise position
76
—
63 – 95
—
244.5
—
KYB K-2C (SAE 5W or Bel-Ray SE2 #40)
—
161 ml
—
980 kPa
(10 kgf/cm2, 142 psi)
—
256
250
Rear shock absorber spring free
length
Unit: mm
Front &
Rear
Front &
Rear
Front &
Rear
Front
Rear
Front
Rear
1.0 or less
2
0.10 or less
0.2
100 kPa (1.0 kgf/cm2, 14 psi)
—
70/100-19, 70/100-19 42M (EU)
90/100-16, 90/100-16 52M (EU)
BRIDGESTONE M61
DUNLOP D752 (EU)
BRIDGESTONE M58
DUNLOP D752 (EU)
—
—
3/4
—
—
E-03, 24, 28
4/4
E-03, 24, 28
138
RM125
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
CLUTCH
STANDARD
0.030 – 0.040
(0.0012 – 0.0016)
54.000 – 54.015
(2.1260 – 2.1266)
Measure 20 mm (0.79 in) from the top surface.
53.965 – 53.980
(2.1246 – 2.1252)
Measure 19 mm (0.75 in) from the skirt end.
Cylinder bore
Piston diam.
Cylinder distortion
—
Cylinder head distortion
—
Piston ring free end gap
Approx. 4.3 (0.17)
Piston ring end gap
0.45 – 0.60
(0.018 – 0.024)
0.045 – 0.060
(0.0018 – 0.0024)
15.002 – 15.008
(0.5905 – 0.5907)
14.995 – 15.000
(0.5904 – 0.5906)
Piston ring to groove clearance
Piston pin bore
Piston pin O.D.
LIMIT
0.120
(0.0047)
STANDARD
19.003 – 19.011
(0.7481 – 0.7485)
Conrod deflection
—
Conrod big end side clearance
Crank web to web width
53.880
(2.1213)
0.05
(0.002)
0.05
(0.002)
3.4
(0.13)
0.80
(0.031)
No. 1, 2
Drive plate claw width
No. 1, 2
STANDARD
10 – 15
(0.40 – 0.60)
2.72 – 2.88
(0.107 – 0.113)
13.85 – 13.96
(0.545 – 0.550)
Driven plate distortion
LIMIT
—
2.42
(0.094)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
—
Clutch spring free length
39.78
(1.57)
RADIATOR
ITEM
Radiator cap valve release
pressure
STANDARD
95 – 125 kPa
(0.95 – 1.25 kgf/cm2, 13.5 – 17.8 psi)
LIMIT
—
—
15.030
(0.5917)
14.980
(0.5898)
LIMIT
19.040
(0.7496)
3.0
(0.12)
0.3 – 0.8
(0.0118 – 0.0315)
53.9 – 54.1
(2.12 – 2.13)
1.0
—
0.05
(0.002)
Crankshaft runout
Drive plate thickness
—
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
ITEM
Clutch lever play
—
TRANSMISSION
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Shift fork groove width
No. 1, 2 & 3
Shift fork thickness
No. 1, 2 & 3
STANDARD
3.368 (64/19)
4.167 (50/12)
2.071 (29/14)
1.687 (27/16)
1.444 (26/18)
1.200 (24/20)
1.052 (20/19)
0.950 (19/20)
0.05 – 0.25
(0.002 – 0.010)
4.95 – 5.05
(0.195 – 0.200)
4.80 – 4.90
(0.190 – 0.193)
Type
Links
STANDARD
D.I.D. 520DMA2
114
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
No. 1, 2 & 3
LIMIT
—
—
—
—
—
—
—
—
0.45
(0.018)
LIMIT
—
—
323.8
(12.7)
—
—
DRIVE CHAIN
ITEM
Drive chain
20-pitch length
E
L
Drive chain slack
1/5
A
S
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Pilot jet
Cut-away
Air screw
Throttle cable play
(M.J.)
(J.N.)
(P.J.)
(C.A.)
(A.S.)
P
M
000, E-03, 28
SPECIFICATION
USA, 000
Others
TMX38S
←
38 mm
←
36F4
36F5
8.7 ± 1.0 mm (0.34 ± 0.04 in)
←
#390
#460
6CHY16-62-3rd
6CHY17-62-4th
#42.5
#42.5
5.0
5.0
1 and 1/2 turns out
1 and 1/2 turns out
2 – 4 mm
(0.08 – 0.16 in) at the throttle grip
2/5
ITEM
Master cylinder piston diam.
Brake caliper cylinder bore
ITEM
Type
Gap
Spark performance
Pick-up coil resistance
Pick-up peak voltage
Exciter peak voltage
Ignition coil resistance
SPECIFICATION
5° B.T.D.C. at 1 000 r/min
NGK: R6918B-8
0.55 – 0.65
(0.022 – 0.026)
Over 8 (0.3) at 1 atm.
75 – 125 Ω
3 V and more
30 V and more
0.15 – 0.45 Ω
12 – 21 kΩ
Primary
Secondary
Ignition coil primary peak voltage
210 V and more
18 – 30 Ω
Exciter coil resistance
NOTE
R–G
G–R
R/W –
B/R
W/Bl – B/W
Plug cap – W/Bl
B/W –
W/Bl
R/W – B/R
STANDARD
11 – 15
(0.4 – 0.6)
0 – 10
(0 – 0.4)
3.0 ± 0.2
(0.118 ± 0.008)
4.0 ± 0.2
(0.157 ± 0.008)
Rear brake pedal height
Brake disc thickness
Front
Rear
Brake disc runout
Master cylinder bore
Front &
Rear
—
11.000 –
(0.4331 –
12.700 –
(0.5000 –
Front
Rear
3/5
11.043
0.4348)
12.743
0.5017)
LIMIT
Brake fluid type
Wheel rim runout
LIMIT
10.984
0.4324)
12.684
0.4994)
27.050
1.0650)
27.050
1.0650)
26.950
1.0610)
26.950
1.0617)
Axial
—
Radial
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
Wheel rim size
Front
Rear
1.60 × 21
1.85 × 19
Wheel axle runout
Front
—
Rear
—
Tire size
Front
Rear
80/100-21 51M
100/90-19 57M
0.25
(0.010)
0.25
(0.010)
—
—
SUSPENSION
ITEM
Front fork stroke
Front fork spring free
length
Front fork damping
force adjuster
Rebound
Compression
Front fork air pressure
—
Front fork spring rate
—
2.5
(0.10)
3.5
(0.14)
0.30
(0.01)
Front
Rear
BRAKE + WHEEL
ITEM
Brake lever adjuster length
Front
Rear
Brake caliper piston diam.
000, E-03, 28
STANDARD
10.957 –
(0.4314 –
12.657 –
(0.4983 –
27.000 –
(1.0630 –
27.000 –
(1.0630 –
26.900 –
(1.0591 –
26.900 –
(1.0598 –
DOT4
Front
Rear
ELECTRICAL
Ignition timing
Spark plug
—
40 – 50
(1.6 – 2.0)
Rear shock absorber gas pressure
STANDARD
310
(12.2)
494 ± 2.4
(19.45 ± 0.09)
MAX-11 clicks
turns back
MAX-9 clicks
turns back
0 kPa
(0 kgf/cm2, 0 psi)
4.2 N/mm
(0.42 kgf/mm)
981 kPa
(9.8 kgf/cm2, 139.5 psi)
LIMIT
NOTE
—
487 (19.17)
—
—
—
—
—
Rear shock absorber spring set
length
6.7 (0.26)
—
Rear shock absorber spring rate
50 N/mm
(5 kgf/mm)
—
6.7 mm compressed
from spring free
length
—
—
000, E-03, 28
4/5
000, E-03, 28
139
ITEM
Rear shock absorber
Rebound
damping force adjuster
Compression (High
speed)
Compression (Low
speed)
Rear wheel travel
STANDARD
MAX-11 clicks
turns back
LIMIT
MAX-2 and 1/8
turns back
—
MAX-8 clicks
turns back
—
Swingarm pivot shaft runout
NOTE
—
310
(12.6)
—
—
0.3
(0.01)
TIRE PRESSURE
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
Front & Rear
FUEL + OIL + COOLANT
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Fuel and engine oil mixture ratio
Transmission oil type
Transmission oil capacity
Front fork oil type
Front fork oil capacity
(each leg)
Engine coolant type
Engine coolant capacity
Rear shock absorber oil type
Rear shock absorber oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2 method).
Use only unleaded gasoline of at least 95 octane
(Research method).
8.0 L
(2.1/1.8 US/Imp gal)
SUZUKI CCI SUPER 2-CYCLE MOTOR LUBURICANT
or equivalent Two Cycle Racing Lubricant
MOTUL 800 2T
FACTORY LINE OFF ROAD
or equivalent Two Cycle Racing Lubricant
30 : 1
SAE 10W-40
750 ml
Change
(0.8/0.7 US/Imp qt)
800 ml
Overhaul
(0.9/0.8 US/Imp qt)
SUZUKI fork oil SS-05 or an equivalent fork oil
373 ml
(12.6/13.1 US/Imp oz)
180 ml
(6.08/6.33 US/lmp oz)
Use an anti-freeze & summer engine coolant compatible with aluminum radiator, mixed with distilled
water only, at the ratio of 50:50.
1 100 ml
(1.2/1.0 US/Imp qt)
SUZUKI rear suspension oil SS-25 or
an equivalent suspension oil
380 ml
(12.8/13.4 US/Imp oz)
5/5
RM250
Cylinder bore
Piston diam.
—
Cylinder head distortion
—
1st & 2nd
Piston ring to groove
clearance
Piston pin bore
1st & 2nd
1st & 2nd
Piston pin O.D.
R
Approx. 8.4 (0.33)
0.30 – 0.45
(0.012 – 0.018)
0.020 – 0.060
(0.0008 – 0.0024)
18.002 – 18.008
(0.7087 – 0.7090)
17.995 – 18.000
(0.7085 – 0.7087)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
E-03
The others
Outer tube oil
quantity
Damper rod
oil quantity
P
M
Unit: mm (in)
CLUTCH
LIMIT
0.120
(0.0047)
ITEM
Clutch lever play
Nicks or
scratches
Drive plate thickness
66.280
(2.6100)
0.05
(0.002)
0.05
(0.002)
6.7
(0.26)
0.50
(0.02)
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
STD/SPEC.
23.003 – 23.011
(0.9056 – 0.9059)
Conrod deflection
—
Conrod big end side clearance
—
Crank web to web width
Crankshaft runout
E
L
000, E-03, 28
STD/SPEC.
0.045 – 0.055
(0.0018 – 0.0022)
66.400 – 66.415
(2.6142 – 2.6148)
Measure 20 mm (0.79 in) from the top surface.
66.350 – 66.365
(2.6122 – 2.6128)
Measure 25.5 mm (1.00 in) from the skirt end.
Cylinder distortion
Piston ring free end
gap
Piston ring end gap
The others
A
S
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
NOTE
E-03, 28
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.04)
59.9 – 60.1
(2.358 – 2.366)
—
—
0.05
(0.002)
Unit: mm (in)
STD/SPEC.
10 – 15
(0.40 – 0.60)
3.07 – 3.23
(0.121 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
Drive plate claw width
Driven plate distortion
39.78
(1.57)
RADIATOR + COOLANT
ITEM
Radiator cap valve release pressure
Engine coolant type
Engine coolant capacity
STD/SPEC.
95 – 125 kPa
(0.95 – 1.25 kgf/cm2, 14 – 18 psi)
Use a anti-freeze & Summer coolant compatible
with aluminum radiator, mixed with distilled water
only, at the ratio of 50:50.
1100 ml
(1.2/1.0 US/Imp qt)
LIMIT
—
—
—
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STD/SPEC.
3.000 (63/21)
3.846 (50/13)
1.800 (27/15)
1.470 (25/17)
1.210 (23/19)
1.000 (21/21)
0.869 (20/23)
0.10 – 0.30 mm
(0.004 – 0.012 in)
4.80 – 4.90 mm
(0.189 – 0.193 in)
4.60 – 4.70 mm
(0.181 – 0.185 in)
DAIDO: D.I.D. 520DMA2
114 links
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Drive chain
Type
Links
20-pitch length
Drive chain slack
—
40 – 50 mm
(1.6 – 2.0 in)
0 – 5 mm below
(0 – 0.2 in)
Gearshift lever height
000, E-03, 28
—
2.77
(0.109)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
—
Clutch spring free length
Shift fork thickness
1/5
LIMIT
2/5
LIMIT
—
—
—
—
—
—
—
0.50 mm
(0.020 in)
—
—
—
—
323.8 mm
(12.75 in)
—
—
000, E-03, 28
140
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Cut-away
Slow jet
Air screw
Power jet
Throttle cable play
ITEM
Brake caliper piston diam.
STD/SPEC.
KEIHIN PWK38S
39 mm (1.54 in)
37F7
6.5 ± 1.0 mm (0.26 ± 0.04 in)
#172
NEDH-4th
#7
#50
1 and 1/2 turns out
#55
2 – 4 mm (0.08 – 0.16 in) at the throttle grip
(M.J.)
(J.N.)
(C.A.)
(S.J.)
(A.S.)
(PW.J.)
STD/SPEC.
26.930 –
(1.0602 –
26.918 –
(1.0598 –
DOT 4
Front
Rear
Brake fluid type
Wheel rim runout
Axial
LIMIT
26.950
1.0610)
26.968
1.0617)
—
Radial
—
Wheel rim size
Front
Rear
21 × 1.60
19 × 2.15
Wheel axle runout
Front
—
Rear
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
ELECTRICAL
ITEM
Spark plug
STD/SPEC.
NGK: BR8EG
0.5 – 0.6 mm
(0.020 – 0.024 in)
0.17 – 0.46 Ω
13 – 20 kΩ
78 – 122
28 – 46
Type
Gap
Ignition coil resistance
Primary
Secondary
Magneto coil resistance
BRAKE + WHEEL
STD/SPEC.
0 – 10 mm below
(0 – 0.39 in)
2.8 – 3.2
(0.11 – 0.13)
3.8 – 4.2
(0.15 – 0.17)
Front
Rear
Brake disc runout
Master cylinder bore
Front &
Rear
—
11.000
(0.4331
12.700
(0.5000
10.957
(0.4314
12.657
(0.4983
27.000
(1.0630
27.000
(1.0630
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
– 11.043
– 0.4348)
– 12.743
– 0.5017)
– 10.984
– 0.4324)
– 12.684
– 0.4994)
– 27.050
– 1.0650)
– 27.050
– 1.0650)
3/5
ITEM
Rear shock absorber spring set
length
Rear shock absorber spring rate
Rear shock absorber damping
force adjuster
W/Bl – B/W
W/Bl – Plug cap
G–R
R/W – B/R
Rebound
Compression
(High speed)
Compression
(Low speed)
Rear wheel travel
Swingarm pivot shaft runout
ITEM
2.5
(0.10)
3.5
(0.14)
0.30
(0.012)
—
—
—
—
—
A
S
LIMIT
—
Fuel tank capacity
Engine oil type
Fuel and engine oil mixture ratio
Transmission oil type
Transmission oil capacity
5/5
Tire size
Front
Rear
Tire tread depth
(Recomend depth)
—
—
—
7 clicks turns back
—
310 mm
(12.2 in)
—
—
0.3 mm
(0.01 in)
NOTE
For Canada
For other
countries
000, E-03, 28
LIMIT
—
—
—
—
4.0 mm
(0.16 in)
4.0 mm
(0.16 in)
SUSPENSION
ITEM
Front fork stroke
STD/SPEC.
310 mm
(12.2 in)
Front fork spring free length
494 mm
(19.45 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
Front fork air pressure
0 kPa
(0 kgf/cm2, 0 psi)
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)
E
L
P
M
—
1 and 7/8 turns back
STD/SPEC.
Use only unleaded gasoline of at least 90 pump
octane (R/2 + M/2 method).
Use only unleaded gasoline of at least 95 octane
(Research method).
8.0 L
(2.1/1.8 US/Imp gal)
MOTUL 800 2T FACTORY LINE OFF ROAD or
equivalent Two Cycle Racing Lubricant
30:1
SAE 10W-40
750 ml
Change
(0.8/0.7 US/Imp qt)
850 ml
Overhaul
(0.9/0.7 US/Imp qt)
Rear
—
—
FUEL + OIL
Fuel type
STD/SPEC.
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
80/100-21 51M
110/90-19 62M
Front
LIMIT
000, E-03, 28
STD/SPEC.
258 mm
(10.16 in)
52 N/mm
(5.2 kgf/mm)
11 clicks turns back
TIRE
ITEM
Tire air pressure
Unit: mm (in)
ITEM
Rear brake pedal height
Brake disc thickness
NOTE
4/5
LIMIT
—
487 mm
(19.17 in)
—
—
—
—
—
—
—
—
—
000, E-03, 28
Prepared by
P
M
March, 2004
Part No. 99563-01040-01E
A
S
E
L
140
2004
STROKE
E
L
P
M
A
S
SERVICE DATA
99563-01040-01E
K4

Similar documents

XT 125R XT 125X

XT 125R XT 125X engineers. This Manual cannot cover any aspect of mechanical knowledge; therefore, anyone who will refer to this manual is expected to have a basic knowledge of the mechanical skills required for s...

More information