Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. Try to vary the throttle position. Polyurethane foam element Starter system Electric Lubrication system Wet multi-plate type Transmission Electronic ignition Transistorized Ignition timing Telescopic, coil spring, oil damped Rear suspension Swingarm type, coil spring, oil damped, spring pre-load 5-way adjustable Front fork stroke Disc brake Rear brake Drum brake Front tire size Maintenance intervals are expressed in terms of kilometers and months, and are dependant on whichever comes first.
NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions. Brake fluid I I I Replace every 2 years. Major lubrication points are indicated below. The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjusted, 1 at the time of periodic inspection, 2 when the valve mechanism is serviced, and 3 when the camshaft is disturbed by removing it for servicing.
The spark plug should be removed. Valve clearance when cold : IN. If the carbon is deposited, remove it with a spark plug cleaner machine or carefully using a tool with a pointed end. If not, adjust it to the following gap. Standard: Spark plug gap: 0. If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, etc.
If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result. Immerse the element in the cleaning solvent and wash it. The element should be wet but not dripping. A torn element must be replaced.
The surest way to accelerate engine wear is to use the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component! NOTE: When cleaning the air cleaner element, drain water from the air cleaner box by removing the drain plug.
NOTE: Make this adjustment when the engine is hot. Throttle cable play A: 2. After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.
Replace every 4 years. If any defects are found, the fuel hoses must be replaced. If accumulation of sediment or clogging is found, replace the fuel filter with a new one. Oil filter replacement at the above intervals, should be done together with the engine oil change. Suzuki automobile genuine oil filter is also not usable for the motorcycles. Clean and lubricate every 1 km.
Visually check the drive chain for the possible defects listed below. Support the motorcycle by a jack and a wooden block, turn the rear wheel slowly by hand with the transmission shifted to Neutral. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.
If the distance exceeds the service limit, the chain must be replaced. Drive chain pitch length: Service limit: The marks 2 on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned.
If the drive chain tends to rust quickly, the intervals must be shortened. Remember high durability comes from the presence of grease in that clearance. Replace hoses every 4 years. Replace fluid every 2 years. The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based.
Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period. Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. When the wear exceeds the grooved limit, replace the pads with new ones.
Fill the reservoir with new brake fluid to the upper line. Replace the reservoir cap to prevent dirt from entering. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the brake lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.
NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.
Fill the reservoir with brake fluid to the upper line. To check brake lining wear, perform the following steps. Make sure that the index mark 4 is within the range 5 embossed on the brake panel. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, and pull forward.
If play is found, perform steering bearing adjustment as described in page of this manual. Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes.
Replace any defective parts, if necessary. Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.
Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows. The use of tires other than those specified may cause instability.
Check that all chassis bolts and nuts are tightened to their specified torque. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service. Remove the parts concerned and test the compression pressure in the following manner.
Winter 20 min. Refer to page listed in each section for removal and reinstallation instructions. NOTE: When loosening the engine sprocket nut, depress the brake pedal. NOTE: If it is difficult to remove the engine sprocket, loosen the rear axle nut, rear torque link nuts and chain adjusters to provide additional chain slack. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use. NOTE: When removing the cylinder head covers, the piston must be at top dead center on the compression stroke.
Remove the piston pin circlips with long-nose pliers. NOTE: Scribe the cylinder position on the head of the respective pistons.
The generator rotor is used when removing the primary drive gear nut. Turning it counterclockwise, it may cause damage. The crankshaft and transmission components must remain in the left crankcase half. Cylinder head cover distortion: Service Limit: 0. Measure diameter of rocker arm shaft. Rocker arm shaft O. When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked.
Rocker arm I. Measure the cam height H with a micrometer. Replace the camshaft if found worn down to the service limit. Camshaft journal oil clearance: Service Limit: 0. Camshaft journal holder I. Camshaft journal O. If the clearance does not come to the standard range, replace both the camshaft and cylinder head with new ones. If the runout exceeds the service limit, replace the camshaft. Camshaft runout: Service Limit: 0. If it does not slide smoothly or the ratchet mechanism is worn or damaged, replace the cam chain tension adjuster with a new one.
If it is worn or damaged, replace it with a new one. If any defects are found, replace it with a new one. Check the cam chain guide for wear and damage. If it is found to be damaged, replace it with a new one. If distortion exceeds the service limit, repair or replace the cylinder head. Cylinder head distortion: Service Limit: 0. Place the valve on V-blocks and measure runout.
If the service limit is exceeded or abnormal condition exists, replace the valve. Valve stem runout: Service Limit: 0. If the service limit is exceeded, replace the valve. Valve head radial runout: Service Limit: 0. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve head T. If it is out of specification replace the valve with a new one. Valve head thickness T: Service Limit: 0. If pitting or wear is present, resurface the valve stem end.
Make sure that the length 1 is not less than the service limit. If this length becomes less than the service limit, replace the valve. If the diameter measured is within the standard range, replace the valve guide.
Valve stem O. Part No. A Valve guide B Cylinder head! Be sure to clean and oil the guides after reaming. If the valve face has worn abnomally, replace the valve.
Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. Check that the transferred blue on the valve face is uniform all around and in center of the valve face. If the seat width W measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter.
Valve seat width W Standard: 0. Rotate the cutter one or two turns. NOTE: Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle. If so, re-cut the valve seat to the correct width.
The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation. NOTE: After servicing the valve seats, be sure to check the valve clearance after the cylinder head has been reinstalled. Check that no gasoline leaks though the valve seat.
If leakage is found, correct the sealing surface. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism.
Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace both the inner and outer springs as a set. NOTE: To facilitate assembly, apply a little grease to the valve cotter when fitting into the valve stem groove. If the distortion exceeds the service limit, replace the cylinder.
Cylinder distortion: Service limit: 0. At three positions, top, middle and bottom, measure the bore diameter. At each position, take two measurements, one parallel with and the other perpendicular to the crankshaft axis. Cylinder bore: Standard: If the measurement is found less than the service limit, replace the piston.
Piston diameter: Standard: Piston-to-cylinder clearance Standard: 0. If the measurement exceeds the service limit, replace the piston. Piston pin bore: Standard: If any of the measurements is found less than the service limit, replace the pin.
Piston pin O. If the gap is less than the service limit, replace the ring. Piston ring free end gap: Standard: 1st Approx. Measure the end gap with a thickness gauge. If the gap exceeds the service limit, replace the piston ring. Piston ring end gap: Standard: 1st 0. Fit the piston ring into the groove. With the ring compressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.
Piston ring-to-Groove clearance: Limit: 1st 0. They bear the following identification numbers. Piston ring 1st and 2nd 0. They bear the following identification marks. Oil ring side rail 0. If any of the measurements exceeds the service limit, replace the conrod. Conrod small end I. Measure the amount of deflection. Turn the conrod and see if it moves smoothly without play and noise. Conrod deflecition: Service Limit: 3.
If the measurement is out of standard value, measure the conrod big end and the crank pin widths individually to determine which one is to be replaced. Conrod big end side clearance Standard: 0. At this time, measure the crankshaft end runout using a dial gauge.
If the runout exceeds the service limit, replace the crankshaft. Crankshaft runout: Service Limit: 0. STD width between webs: The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch.
Also, inspect the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the defective part -s. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
If any spring is not within the service limit, replace all of the spring. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced.
Smooth engagement and disengagement of the clutch depends on the condition of this bearing. If any abnormal condition are found, replace the primary driven gear. This oil pump is available only as an assembly. If any abnormal condition is found, replace the oil pump with a new one. The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.
If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both. NOTE: Before installing the gears, coat lightly engine oil to the driveshaft and countershaft. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
Fit it to the side where the thrust is as shown in figure. Replace the bearing in the following procedure if there is anything unusual.
NOTE: Before installing the oil nozzle, check or clean its oil passage. However, the following points must be observed in the reassembly operation.
Piston No. Generator rotor 10 N. NOTE: Fit steel plates between the crankcase and the special tool when installing the crankshaft with the special tool. NOTE: Apply engine oil to the inside surface of the primary driven gear bearing. NOTE: Make sure that the clutch pressure plate is installed correctly. Use nonflammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry. Be sure to bring the stamped mark side to the top when assembling to the piston.
Also, do not expand the piston ring more than necessary as the ring can break. Front No. Rear No. NOTE: Do not rotate the generator rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket. Gasoline must be handled carefully in an area well ventilated and away from fire or sparks. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.
When the needle valve closes, the pressure of the fuel in the hose connecting the carburetor and the fuel pump increases, and when the set pressure is reached, the operation of the fuel pump is stopped by the fuel pressure to prevent excessive supply. As positive pressure is applied, the diaphragm backs, pushing the fuel through the outlet to the carburetor. A series of check valves 1 and 2 is used in the fuel flow route to allow the fuel to move in only one direction, through the pump body.
Gasoline is very explosive. Extreme care must be taken. Clean the fuel filter with compressed air. Also check the fuel cock for cracks. Check the fuel flow when cranking the engine for few seconds by pressing the starter button. If the fuel flow is not found, check the fuel cock. The carburetor I. In this system, air is taken in from the clean side of air cleaner and guided into the slow system through the air control valve. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4.
Part of the mixture is discharged into the main bore through bypass ports 6. The mixture is metered by the pilot screw 5 and sprayed into the main bore through the pilot outlet port 7. This causes the piston valve 2 to move upward. The metered fuel enters the needle jet 5, mixes with the air admitted through the main air jet 6 and forms an emulsion. The emulsified fuel then passes through the clearance between the needle jet 5 and jet needle 7 and is discharged into the venturi A, where it meets the main air stream being drawn by the engine.
The clearance through which the emulsified fuel must flow ultimately depends on throttle position. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less.
The rod 4 pushes plunger 5. Except for E NOTE: Before removing the pilot screw, determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw. This counted number is important when reassembling pilot screw to original position. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screw.
Carefully drill through the plug. Pull on the screw head with pliers to remove the plug. Carefully clean any metal shavings from the area. Make a note of how many turns were made so the screw can be reset correctly after cleaning. If damage or clogging is found, replace the part with a new one. Some carburetor cleaning chemicals, especially diptype soaking solutions, are very corrosive and must be handled carefully.
Clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if necessary, to loosen dirt and varnish. Blow the body dry using compressed air. A wire can damage the jets and passageways. If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip-type cleaning solution and allow them to soak. Throttle position sensor resistance: Approx.
This inspection must be performed in an area well ventilated, away from fire or sparks since gasoline, an explosive fluid, is used in this operation. Meniscus is approximately 1 mm. Measure the float height A while the float arm is just contacting the needle valve using vernier calipers.
When reassembling, carefully observe the following instructions. If the runout exceeds the limit, replace the front axle. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel. Wheel runout: Service Limit axial and radial : 2.
Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. The sealed cover of the bearing must face outside. If any abnormal condition is noted, replace the caliper. Do not wipe off brake fluid after washing the components. Measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if damage is found.
Replace the brake disc if the runout exceeds the service limit. Inspect the piston surface for any scratches or other damage. Inspect the primary cup, secondary cup and dust seal for wear or damage. Never use different types of fluid or cleaning solvents such as gasoline, kerosine, etc. If the length is found shorter than the service limit, replace the spring.
Insufficient washing can result in oil leakage or premature wear of the parts. If dirt is on the installer, the inner tube may possibly be damaged during press-fitting work.
NOTE: Hold the steering stem lower bracket to prevent from falling. Check the bearing and race for corrosion, nick or other damage. However, operate the work taking care for the following points. NOTE: This adjustment will vary from motorcycle to motorcycle. Make sure that the steering turns smoothly and easily in both directions without play. Finally, check to make sure that the steering stem moves freely from left to right with its own weight.
If play or stiffeness is noticeable, readjust the steering stem nut. NOTE: Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts.
Replace the rear sprocket damper if there is anything unusual. If they are worn, replace the sprocket and drive chain as a set. Replace the brake drum if the measurement exceeds the service limit. The value of this limit is indicated inside the brake drum. If grease gets on the lining, brake slippage will result.
Left Right 29 N. If any defects are found, replace the rear shock absorber with a new one. It is unserviceable. If any defects are found, replace the swingarm with a new one. If any defects are found, replace the chain buffer with a new one. If the pivot shaft exceeds the service limit, replace it with a new one. If any defects are found, replace the spacer with a new one. If there is anything usual, replace the bearing -s with a new one.
Pay attention to the following points: Left Right 72 N. Neglecting proper procedure may cause damage to this part. Therefore, do not bring fire near the battery while it is being charged. Do not replace with an ordinary battery.
Sub-tract that resistance from the resistance measured under load in order to get the true resistance. If voltage is applied, the tester may be damaged. D is below 0. The AC current generated from the generator is rectified by the rectifier and is turned into DC current, then it charges the battery. When leakage is found, look for the part where the tester reads under 3 mA through the couplers and connectors by removing them one by one.
If the tester reads under NOTE: When making this test, be sure that the battery is in fully-charged condition. Measure the resistance between the three lead wires. Also check that the stator core is insulated.
If the resistance is not specified value, replace the stator with a new one. Using the multi circuit tester, measure the voltage between three lead wires. If the tester reads under the specified value, replace the generator with a new one. Using the multi circuit tester, measure the voltage between the lead wires in the following table. Pressing the starter button on the right handlebar switch energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
The starter motor draws about 80 amperes to start the engine. The transmission is in neutral. Check the side-stand switch. If the brush has failed, replace the brush sub assy. If the commutator is abnormally worn, replace the armature. When surface is discolored, polish it with sand paper and clean it with dry cloth.
If there is no undercut, scrape out the insulator 1 with saw blade. Check for continuity between each segment and the armature shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the starter motor with a new one. If any damage is found, replace the housing end. Apply 12 volts to A and B terminals, inspect the continuity between the terminals, positive and negative.
If continuity is found, the starter relay is in sound condition. The coil is in good condition if the resistance is as follows. If any abnormality is found, replace the component with a new one. Refer to the following table. The ignition timing is programmed and stored in the ignitor.
The induced signal in the pick-up coil is sent to the wave-form arrangement circuit and the CPU receives this signal and calculates the best ignition timing, throttle position sensed by throttle position sensor and data stored in the ROM.
NOTE: Be sure that all couplers and spark plugs are connected properly and the battery used is in fully-charged condition. Inspect the No. Do not touch the tester probes and speak plugs to prevent an electric shock while testing. If the windings are in sound condition, their resistance should be close to the specified values. Ignition coil resistance Primary: 1. Signal generator peak voltage: More than 4. If the resistance is not specified value, the signal generator must be replaced.
Check that voltage varies between about 0 — 2 V when turning the rear wheel by hand. If any abnormal condition is noted, check each coupler at both end of circuit or replace the sensor or wiring harness.
The headlight uses a halogen bulb which operates at a high temperature. Therefore, handle the bulb after sufficiently cooled. If the bulb is contacted with bare hand, wipe clean with a cloth damped with alcohol or detergent.
If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If any abnormality is found, replace the respective switch assemblies with new ones. Take precaution not to allow any of the fluid to spill. Never remove the container from the battery. Wait for around 20 minutes. The tester should indicate more than If the battery voltage is lower than the specification, charge the battery with a battery charger.
Refer to the recharging operation NOTE: Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one.
If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper. If the voltage reading is less than the NOTE: Do not remove the caps on the battery top while recharging. Recharging time: 3 A for one hour or 0. Engine stalls easily. Compression too low 1.
Worn cylinder. Worn piston ring. Worn valve guide or improper valve seating. Loose spark plug. Broken, cracked, or damaged piston. Slow cranking starter motor. Mistimed valves. Valve clearance out of adjustment. Spark plug not sparking 1. Damaged spark plug. Damaged spark plug cap. Fouled spark plug. Wet spark plug. Defective ignition coil.
Open or short in high-tension cord. Defective pick-up coil or ignitor unit. No fuel reaching the carburetor 1. Clogged hole in the fuel tank cap. Defective fuel pump. Clogged or defective fuel valve. Defective carburetor needle valve. Clogged fuel hose. Clogged fuel filter. Defective signal coil or ignitor unit. Clogged carburetor jet. Repair or replace. See electrical section. Clean or replace. Clean and dry or replace.
Clutch drags. Transmission will not shift. Transmission will not shift back. Excessive valve chatter 1. Excessive valve clearance. Turning it counterclock- wise, it may cause damage. The crankshaft and transmission com- ponents must remain in the left crankcase half. Cylinder head cover distortion: Service Limit: 0. Measure the cam height H with a micrometer. Replace the camshaft if found worn down to the service limit.
If the runout exceeds the service limit, replace the camshaft. Camshaft runout: Service Limit: 0. If distortion exceeds the service limit, repair or replace the cylin- der head. Cylinder head distortion: Service Limit: 0.
Part No. If the valve face has worn abnomally, replace the valve. Coat the valve seat with Prussian Blue and set the valve in place. Rotate the valve with light pressure. Check that the transferred blue on the valve face is uniform all around and in center of the valve face.
Rotate the cutter one or two turns. A weak- ened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
If the measurement is found less than the service limit, replace the piston. If the gap is less than the service limit, replace the ring. Piston ring free end gap: Standard: 1st Approx. They bear the following identification numbers. Piston ring 1st and 2nd 0. If any of the measurements exceeds the service limit, replace the conrod.
STD width between webs: The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Inspect the starter driven gear bearing for smooth rotation and any abnor- mal noise.
If a clutch drive plate is not within the service limit, replace the clutch plates as a set. If any abnormal condition are found, replace the primary driven gear.
NOTE: Before installing the gears, coat lightly engine oil to the driveshaft and countershaft. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. Replace the bearing in the following procedure if there is any- thing unusual. NOTE: Before installing the oil nozzle, check or clean its oil passage.
However, the following points must be observed in the reassembly operation. NOTE: Fit steel plates between the crankcase and the special tool when installing the crankshaft with the special tool. Make sure to replace the gasket with a new one.
If crankshaft is turned without drawing the camshaft drive chain upward, the chain will be caught between crankcase and cam chain drive sprocket.
Page Speed Sensor Front No. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open. Extreme care must be taken. Clean the fuel filter with compressed air. Also check the fuel cock for cracks. In this system, air is taken in from the clean side of air cleaner and guided into the slow system through the air control valve.
The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4. This causes the piston valve 2 to move upward.
The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel enters the needle jet 5, mixes with the air admitted through the main air jet 6 and forms an emulsion. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less.
Do not use a wire to clean the valve seat. Except for E NOTE: Before removing the pilot screw, determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw. This counted number is important when reassembling pilot screw to original position.
Mea- sure the float height A while the float arm is just contacting the needle valve using vernier calipers. If the runout exceeds the limit, replace the front axle. Rotate the inner race by finger to inspect for abnor- mal noise and smooth rotation. Pay attention to the following points: Left Right " N. Measure the thick- ness using the micrometer.
Replace the brake disc if the thickness is less than the service limit or if damage is found. Place a rag under the union bolt so that brake fluid may not contact the parts. Page Master Cylinder Inspection When installing the circlip, make sure that the sharp edge of the circlip faces outside. If the length is found shorter than the service limit, replace the spring. Insufficient washing can result in oil leakage or premature wear of the parts.
Left Right 29 N. If any defects are found, replace the swingarm with a new one. Page Reassembly And Remounting 72 N. The AC current generated from the generator is rectified by the rectifier and is turned into DC current, then it charges the battery. Measure the resistance between the three lead wires. Also check that the stator core is insulated.
If the resistance is not specified value, replace the stator with a new one. The transmission is in neutral. If any abnormality is found, replace the component with a new one. The ignition timing is programmed and stored in the ignitor. The pick-up coil is mounted in the generator. The induced signal in the pick-up coil is sent to the wave-form arrangement circuit and the CPU receives this signal and calculates the best ignition timing, throttle position sensed by throttle position sensor and data stored in the ROM.
NOTE: Be sure that all couplers and spark plugs are connected prop- erly and the battery used is in fully-charged condition. If Signal generator the resistance is not specified value, the signal generator must coupler be replaced.
Check that voltage varies between about 0 — If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If any abnormality is found, replace the respective switch assemblies with new ones. Never remove the container from the battery.
If the voltage reading is less than the Worn cylinder. Worn piston ring. Worn valve guide or improper valve seating. Repair or replace. Excessive valve chatter 1. Excessive valve clearance.
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