2004_Service data_01E.book

Transcription

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.
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© 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
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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
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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
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NOTE:
These service data are current as of APRIL 2004, and they are subject to change without
notice.
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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
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
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
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
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
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
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)
IN.
EX.
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.
IN.
EX.
––
––
¬22
¬17.5
––
––
¬22
¬17.5
––
––
¬22
¬17.5
––
Camshaft runout
––
Rocker arm shaft I.D.
IN. & EX.
IN. & EX.
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
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
STANDARD
20.006 – 20.014
(0.7876 – 0.7880)
Conrod deflection
––
0.10 – 0.75
(0.004 – 0.030)
21.95 – 22.00
(0.864 – 0.866)
59.9 – 60.1
(2.358 – 2.366)
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.
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
Reduction ratio
Secondary reduction
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)
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)
––
ITEM
Injector resistance
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
Injector voltage
HO2 sensor resistance
HO2 sensor output voltage
3/8
0.35
0.014)
0.50
0.020)
2nd
––
––
––
0.05
(0.002)
STANDARD
2nd
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
1st
––
Piston diam.
ITEM
––
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 – 5.5 V
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
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
Regulated voltage
Battery
E-33
15G1
←
←
←
←
←
←
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
ITEM
resistance
Engine coolant type
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)
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
––
Turn signal light
License light
Oil change indicator light
FI indicator light
Brake-lock indicator light
Trunk light
ELECTRICAL
ITEM
Spark plug
Spark performance
0.2 – 0.6 Ω
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
Front
Rear
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 oil type
Front fork oil capacily (each leg)
Rear wheel travel
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)
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
––
: W
: Ground
Y–Y
150 and more
Charging
BRAKE + WHEEL
––
3–5Ω
17 – 30 kΩ
Primary
Secondary
5/8
ITEM
––
HI
LO
G – BI
: G/W
: BI
4.5 V and more
(When cold)
Headlight
Unit: mm (in)
NOTE
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
Front
––
Rear
––
Front
Rear
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
SPECIFICATION
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)
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.
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.
IN. & EX.
—
Valve stem runout
IN. & EX.
—
ITEM
Cam height
—
IN.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam chain pin (at arrow “3”)
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
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)
15th pin
—
ITEM
1 500 – 1 900 kPa
(15.0 – 19.0 kgf/cm2, 213 – 270 psi)
—
—
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
1st
E
L
—
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
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
ITEM
Injector resistance
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
—
STANDARD
Below 550 kPa (5.5 kgf/cm2)
at 3 000 r/min
LIMIT
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
—
AP sensor input voltage
AP 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)
—
1st
—
0.10
(0.004)
—
0.10
(0.004)
—
—
ITEM
—
—
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.)
SPECIFICATION
0.9 – 1.7 kΩ
More than 0.5 V (When cranking)
150 – 300 Ω
4.5 – 5.5 V
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
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
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
More than 5 V at idle speed
sensor peak voltage
ITEM
resistance
Eclectic fan thermo-switch operating temperature
Engine coolant type
: Y, : W
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
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
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
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
More than 80 V
(When cold)
Regulated voltage
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
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
Turn signal light
License light
Engine coolant temp. indicator light
FI indicator light
Engine oil pressure 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
E-03, 24, 28, 33
60 × 2
55 × 2
←
←
←
←
←
←
←
←
←
←
←
←
←
←
Front
Rear
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)
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)
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
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
#1 : W/Bl,
: Ground
#2 : B/Y,
: Ground
G – BI
Y–Y
14.0 – 15.5 V at 5 000 r/min
3–6Ω
BRAKE + WHEEL
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
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.
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)
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.
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.
ITEM
Cam height
Camshaft runout
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
—
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
Crank pin width
Crank pin O.D.
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
at 3 000 r/min
2/7
LIMIT
—
E-02, 19
8
CLUTCH
ITEM
Driven plate No. 2 thickness
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)
—
set pressure
Injector voltage
SPECIFICATION
0.9 – 1.7 kΩ
150 – 300 Ω
4.5 – 5.5 V
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
4.5 – 5.5 V
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
3/7
Type
Gap
Spark performance
Primary
Secondary
More than 80 V
(When cold)
Regulated voltage
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
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
ITEM
resistance
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
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
ratio of 50:50.
Reverse
Approx. 250 ml
tank side
Engine side
Approx. 1 350 ml
WATTAGE
NOTE
: Bl, :G
E
L
#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
sensor resistance
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
: B/Y, : Br
Unit: mm
ITEM
Firing order
Spark plug
NOTE
A
S
ELECTRICAL
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
Idle speed
3 000 r/min
CVT primary pulley position sensor
output voltage
ITEM
Injector resistance
ITEM
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
Turn signal light
License light
FI indicator light
Engine oil pressure 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 runout
10 A
15 A × 2
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 oil type
110
—
SUZUKI FORK OIL G-10 (#10) or
458 ml
151
100
—
341
2nd
—
Rear wheel travel
adjuster
—
—
—
—
TIRE
ITEM
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
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
Engine oil capacity
Oil change
2.6 L
Filter change
2.9 L
Overhaul
3.4 L
Oil change
360 ml
Overhaul
400 ml
Final gear oil type
Hypoid gear oil SAE #90 API grade GL-5
Oil change
300 ml
Overhaul
430 ml
NOTE
Fuel type
7/7
DL650
ITEM
Valve diam.
EX.
Valve clearance (when cold)
IN.
EX.
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
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
Cam height
IN.
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
—
—
—
0.10
(0.004)
—
0.05
(0.002)
—
16th pin
—
—
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
(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)
17.0 – 19.6 kgf
(37.48 – 43.21 lbs)
—
ITEM
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
—
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)
Cylinder distortion
—
Piston ring end gap
—
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.
OUTER
ITEM
—
Valve seat width
INNER
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
(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
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)
Crank pin width
Crank pin O.D.
Crankshaft runout
—
—
No. 1 & No. 2
0.05
(0.002)
Fuel pressure regulator operating set
pressure
LIMIT
TO sensor voltage
GP switch voltage
Injector voltage
STP sensor input voltage
STP sensor resistance
STP sensor output voltage
STV actuator resistance
ITEM
—
—
2.62
(0.103)
12.9
(0.507)
0.10
(0.004)
50.5
(1.99)
53.1
(2.09)
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)
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
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
(When cold)
Regulated voltage
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
5/9
—
Approx. 88 °C (190 °F)
4/9
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
116 links
—
—
—
—
319.4
(12.57)
—
ITEM
Injector resistance
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
—
—
—
Type
Drive chain slack (on side-stand)
0.080
(0.0031)
CLUTCH
No. 1 & No. 2
Shift fork thickness
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
STANDARD
at 3 000 r/min
Clutch release screw
Shift fork groove width
0.080
(0.0031)
—
ITEM
Clutch cable play
Shift fork to groove clearance
Drive chain
OIL PUMP
ITEM
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
TRANSMISSION + DRIVE CHAIN
ITEM
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
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
Turn signal light
License light
Speedometer 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
STANDARD
15 – 25 (0.59 – 0.98)
5
(0.20)
5
(0.20)
Front
Rear
Brake disc runout
—
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
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
(Solo riding)
Front
—
Rear
—
Rear
(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
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 oil level (without spring,
outer tube fully compressed)
Front fork spring adjuster
Front fork oil type
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
Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33
methanol with appropriate cosolvents and corrosion
inhibitor is permissible.
Others
22 L (5.8/4.8 US/lmp gal)
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.
IN.
EX.
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.
—
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
—
Cam drive idle gear/sprocket thrust
clearance
—
—
IN. & EX.
—
Valve stem runout
IN. & EX.
—
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)
—
IN. & EX.
—
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)
LIMIT
ITEM
(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)
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
RN
1st
—
E
L
2nd
ITEM
1st
2nd
Oil
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
Crank pin width
Crank pin 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
STANDARD
at 3 000 r/min
LIMIT
—
—
—
—
CLUTCH
Unit: mm (in)
ITEM
—
—
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
No.1
No. 2 and 3
—
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
CONROD + CRANKSHAFT
—
0.10
(0.004)
—
1/10
—
—
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
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
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
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
—
—
INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR
ITEM
Injector resistance
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
ECT sensor reisitance
IAT sensor input volatage
TO sensor voltage
GP switch voltage
Injector voltage
Heated oxygen sensor output voltage
Heated oxygen sensor resistance
SPECIFICATION
More than 3.7 V
130 – 240 Ω
4.5 – 5.5 V
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
19.1 – 19.7 kΩ
Approx. 0.4 – 1.4 V
More than 1.0 V (From 1st to top)
Battery voltage
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
Crankshaft position sensor peak
voltage
(When engine is cold)
Regulated voltage
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
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)
2.0 – 4.0 r/min
(0.08 – 0.16 in)
6/10
WATTAGE
Unit: W
SPECIFICATION
ITEM
Headlight
Turn signal light
License light
Speedometer 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
More than 75 V (AC) at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
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)
—
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
Front
Rear
Front
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
Front
—
Rear
—
SUSPENSION
ITEM
Front fork stroke
inner tube fully compressed)
Front fork oil type
adjuster
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
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.
17 L
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
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.
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
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.
—
—
—
IN. & EX.
—
IN. & EX.
Camshaft runout
IN. & EX.
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
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)
—
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
—
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
Cylinder head cover distortion
Valve stem O.D.
IN.
Valve seat width
IN. & EX.
0.9 – 1.1
(0.04 – 0.05)
—
IN. & EX.
—
(IN. & EX.)
INNER
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
OUTER
(IN. & EX.)
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
INNER
OUTER
—
—
Cylinder bore
Piston diam.
Piston ring end gap
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)
—
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)
ITEM
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
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
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
Crank web to web width
Crankshaft runout
LIMIT
ITEM
Gear ratios
—
—
16.030
(0.6311)
15.980
(0.6291)
1 pc.
5 pcs.
—
—
—
ITEM
Spark plug
Type
Gap
Spark performance
Signal coil resitance
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
Turn signal light
Speedometer 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
Brake drum I.D.
Rear
—
Brake lining thickness
Rear
—
Front
3.5 ± 0.2
(0.138 ± 0.008)
Brake disc runout
Front
—
Front
Front
Front
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)
Charging
0.1 – 1.5 Ω
150 W at 5 000 r/min
Regulated voltage
13.0 – 16.0 V at 5 000 r/min
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
LIMIT
—
—
—
—
—
—
—
CARBURETOR
—
Unit: mm (in)
Clutch plate thickness
No.1, 2, 3
Drive chain slack
LIMIT
—
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
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
OIL PUMP
ITEM
Oil pump reduction ratio
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)
pre-set length
Rear wheel travel
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
Brake fluid type
SPECIFICATION
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)
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
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.
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
—
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.
—
—
—
IN. & EX.
—
IN. & EX.
Camshaft runout
IN. & EX.
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
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)
—
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
—
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
2.6
(0.1)
Valve stem O.D.
IN.
Valve seat width
IN. & EX.
0.9 – 1.1
(0.04 – 0.05)
—
IN. & EX.
—
(IN. & EX.)
INNER
—
0.03
(0.001)
35.1
(1.38)
40.6
(1.60)
OUTER
(IN. & EX.)
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
INNER
OUTER
—
—
Cylinder bore
Piston diam.
Piston ring end gap
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)
—
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)
ITEM
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
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
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.09 ± 0.004)
Crankshaft runout
LIMIT
ITEM
Gear ratios
—
—
16.030
(0.6311)
15.980
(0.6291)
STANDARD
2.000 (30/15)
at 3 000 r/min
LIMIT
—
—
Unit: mm (in)
Clutch plate thickness
1 pc.
5 pcs.
—
—
LIMIT
—
ITEM
Spark performance
Signal coil resitance
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
125 – 195 V
Charging
0.1 – 1.5 Ω
Regulated voltage
13.0 – 16.0 V at 5 000 r/min
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
Turn signal light
(For South Africa)
Speedometer light
(Fpr South Afriaca)
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)
Brake drum I.D.
Rear
LIMIT
—
—
—
—
Rear
—
Front
3.5 ± 0.2
(0.138 ± 0.008)
Brake disc runout
Front
—
Front
Front
Front
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
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)
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)
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
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
OIL PUMP
ITEM
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
pre-set length
Rear wheel travel
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
Brake fluid type
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or
13.0 L
(3.4/2.9 US/lmp qt)
2.5 L
(0.7/0.5 US/lmp qt)
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.
clearance
IN.
EX.
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.
—
IN. & EX.
—
Unit: mm (in)
LIMIT
—
—
—
0.35
(0.014)
Right &
Center
Right &
Center
Left
Left
Right &
Center
Left
—
Rocker arm I.D.
IN. & EX.
IN. & EX.
—
IN. & EX.
—
(IN. & EX.)
INNER
—
0.03
(0.001)
34.4
(1.35)
38.1
(1.50)
OUTER
Camshaft runout
IN. & EX.
INNER
IN.
—
—
12.000
(0.4724
11.973
(0.4714
—
—
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
(Automatic decomp. actuated)
—
LIMIT
0.120
(0.0047)
Nicks or
Scratches
Cylinder distortion
—
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)
—
E-03, 24, 28, 33
– 12.018
– 0.4731)
– 11.984
– 0.4718)
ITEM
Unit: mm (in)
LIMIT
33.410
(1.3154)
33.400
(1.3150)
0.150
(0.0059)
0.150
(0.0059)
0.10
(0.004)
—
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)
13.8 – 15.8 kg
(30.4 – 34.8 lbs)
ITEM
—
Valve seat width
OUTER
—
0.05
(0.002)
0.5
(0.02)
2.7
(0.11)
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
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
LIMIT
0.180
(0.0071)
0.150
(0.0059)
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
0.10
(0.004
24.95
(0.982
Crankshaft runout
– 0.65
– 0.026)
– 25.00
– 0.984)
—
—
CLUTCH
ITEM
Clutch lever play
STANDARD
10 – 15
(0.4 – 0.6)
2.9 – 3.1
(0.11 – 0.12)
No. 1 &
No. 2
—
—
—
—
DRIVE TRAIN
—
ITEM
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)
—
—
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
Primary
Secondary
Regulated voltage
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
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
Turn signal light
Speedometer 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
Front
Rear
Brake disc runout
—
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
Front
Rear
B–W
Front
Bl – G
Rear
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)
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
—
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
—
2.6
(0.10)
0.10
(0.004)
33.0
(1.30)
LIMIT
—
STANDARD
2.178 (61/28)
E-03, 28,
33
E-24
Gear ratios
Low
2nd
3rd
4th
Top
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)
pre-set length
Rear wheel travel
—
Engine oil type
Engine oil capacity
Low seat
—
Front fork oil type
—
—
Fuel tank capacity
Low seat
Brake fluid type
SPECIFICATION
the reserch method.
Gasoline containing MTBE (MethyI Tertiary ButyI
12 L
(3.2/2.6 US/Imp gal)
Including
reserve
13 L
Only
3.0 L
reserve
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.
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.
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
Top
Second
—
0.05
(0.002)
8/8
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
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
Radial
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)
(fully compressed, spring removed)
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
Valve stem runout
Valve seat width
(IN. & EX.)
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
—
INNER
—
OUTER
(IN. & EX.)
INNER
OUTER
—
76 – 90 N
(7.8 – 9.2 kgf, 17.2 – 20.3 lbs)
186 – 219 N
(18.9 – 22.3 kgf, 41.7 – 49.2 lbs)
1/8
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
1st
—
2nd
1st
2nd
Oil
1st
2nd
Piston pin bore
Piston pin 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.
—
12.018
0.4731)
11.995
0.4722)
—
—
LIMIT
32.83
(1.29)
0.150
(0.0059)
—
—
0.10
(0.004)
—
12.000 –
(0.4724 –
11.977 –
(0.4715 –
IN. & EX.
—
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.
—
—
—
—
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
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)
Unit: mm (in)
ITEM
E-28, 33
ITEM
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
Unit: mm (in)
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
15.95 – 16.00
(0.628 – 0.630)
53.0 ± 0.1
(2.09 ± 0.004)
Crankshaft runout
—
LIMIT
14.040
(0.5528)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
OIL PUMP
ITEM
STANDARD
at 3 000 r/min
CLUTCH
—
—
—
—
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
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
No. 1
No. 2
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
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)
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
—
—
—
—
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
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
Brake drum I.D.
Brake disc runout
11.000 –
(0.4331 –
10.957 –
(0.4314 –
30.230 –
(1.1902 –
30.150 –
(1.1870 –
DOT 4
Front
Front
Front
Brake fluid type
Wheel rim runout
Axial
Wheel axle runout
Front
Rear
Front
Rear
Tire tread depth
—
Front
Tire size
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
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 oil type
pre-set length
Rear wheel travel
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
6.6 L (1.7/1.5 US/lmp qt)
1.7 L (0.4/0.4 US/lmp qt)
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.
IN.
EX.
clearance
IN.
EX.
LIMIT
—
—
—
—
—
—
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.
—
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
OUTER
(IN. & EX.)
INNER
OUTER
Cylinder bore
—
—
—
48 – 58 N
(4.8 – 5.8 kgf, 10.6 – 12.8 lbs)
133 – 153 N
(13.3 – 15.3 kgf, 29.3 – 33.7 lbs)
—
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)
Piston diam.
Cylinder distortion
—
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
—
Crankshaft runout
1st & 2nd
Piston pin O.D.
E
L
ITEM
Drive chain
20-pitch length
—
STANDARD
1.571 (33/21)
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
—
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
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)
—
—
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
ITEM
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)
0.08 – 0.20
(0.003 – 0.008)
Oil
Unit: mm (in)
ITEM
Approx. 7.7 (0.31)
E-03, 28, 33
CONROD + CRANKSHAFT
Approx. 7.6 (0.30)
R
—
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
0.10
(0.004)
—
0.05
(0.002)
—
ITEM
—
—
INNER
—
17th pin
—
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
(IN. & EX.)
LIMIT
0.150
(0.0059)
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 O.D.
ITEM
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
SPECIFICATION
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
0.1 – 1.5 Ω
Primary
Secondary
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
Regulated voltage
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
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
Axial
—
Radial
—
Front
—
Rear
—
Front
Rear
J21 × 1.60
J18 × 2.15
TIRE
ITEM
(Solo riding)
Front
Rear
BRAKE + WHEEL
Unit: mm (in)
ITEM
Brake lever play
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)
Brake disc runout
—
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
Front
Rear
Front
Rear
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 type
(each leg)
Front fork damping force adjuster
—
—
—
—
Rear shock absorber gas
pressure
pre-set length
force adjuster
—
Rear wheel travel
—
—
100/100-18 59M
SUSPENSION
—
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
octane (R/2 + M/2).
10.5 L
2.4 L
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)
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
285
(11.2)
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.
IN.
EX.
clearance
IN.
EX.
LIMIT
—
—
—
—
—
—
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.
—
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
OUTER
(IN. & EX.)
INNER
OUTER
Cylinder bore
—
—
—
48 – 58 N
(4.8 – 5.8 kgf, 10.6 – 12.8 lbs)
133 – 153 N
(13.3 – 15.3 kgf, 29.3 – 33.7 lbs)
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)
Piston diam.
Cylinder distortion
—
—
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
—
Crankshaft runout
1st & 2nd
Piston pin O.D.
E
L
P
M
ITEM
Drive chain
20-pitch length
—
—
STANDARD
1.571 (33/21)
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
—
Drive chain slack
30 – 45
(1.2 – 1.8)
LIMIT
0.5
(0.02)
—
—
—
—
319.4
(12.57)
—
CARBURETOR
OIL PUMP
ITEM
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)
—
—
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
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
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
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)
0.08 – 0.20
(0.003 – 0.008)
Oil
Unit: mm (in)
ITEM
Approx. 7.7 (0.31)
E-24
CONROD + CRANKSHAFT
Approx. 7.6 (0.30)
R
—
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
0.10
(0.004)
—
0.05
(0.002)
—
ITEM
—
—
INNER
—
17th pin
—
0.9 – 1.1
(0.035 – 0.043)
IN. & EX.
(IN. & EX.)
LIMIT
0.150
(0.0059)
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 O.D.
ITEM
Type
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
E-24
SPECIFICATION
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
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
Regulated voltage
Battery
Type designation
Capacity
Fuse size
SPECIFICATION
More than 5 V
More than 1.2 V
NOTE
: G, : Bl
: W, : B
ITEM
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
Turn signal light
Speedometer light
License plate light
BRAKE + WHEEL
Wheel axle runout
Wheel rim size
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)
Brake disc runout
—
12.700 –
(0.5000 –
14.000 –
(0.5512 –
12.657 –
(0.4983 –
13.957 –
(0.5495 –
Front
Rear
Front
Rear
12.743
0.5017)
14.043
0.5529)
12.684
0.4994)
13.984
0.5506)
ITEM
(Solo riding)
Tire size
—
Tire type
Rear wheel travel
Tire tread depth
ITEM
Front fork stroke
—
—
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
including
reserve
reserve
Front fork oil type
(each leg)
P
M
LIMIT
—
—
—
—
—
—
0.3
(0.01)
SPECIFICATION
10.5 L
2.4 L
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
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)
280
(11.0)
502.6
(19.79)
143
(5.6)
526 ml
(17.8/18.5 US/Imp oz)
Rebound
8 clicks turns back
Compression
7 clicks turns back
E
L
—
FUEL + OIL
Fuel type
—
Rear
SUSPENSION
—
A
S
Front
Front
Rear
Front
Rear
—
3.0
(0.118)
3.5
(0.138)
0.3
(0.012)
E-24
1 000 kPa
(10 kgf/cm2, 142 psi)
269.4
(10.6)
Rebound
3 turns back
Compression
285
(11.2)
—
—
Rear
LIMIT
5/7
ITEM
Rear shock absorber gas
pressure
pre-set length
force adjuster
Axial
Radial
LIMIT
TIRE
Unit: mm (in)
ITEM
Brake lever play
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.
IN.
EX.
clearance
IN.
EX.
Cam height
—
E-01, 03,
28
—
—
—
IN. & EX.
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)
—
—
0.05
(0.002)
0.5
(0.02)
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
—
OUTER
(IN. & EX.)
INNER
OUTER
—
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
ITEM
Except for DR-Z400
Cylinder bore
—
Piston diam.
—
1st
2nd
Oil
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
ITEM
LIMIT
—
—
—
—
—
Unit: mm (in)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
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)
(No. 1 & No. 2)
(No. 1 & No. 2)
—
—
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
—
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
STANDARD
2.220 (74/25 × 20/16 × 12/20)
at 3 000 r/min
3/9
LIMIT
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
ITEM
Gear ratios
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)
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
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)
—
Piston ring end gap
ITEM
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
15th pin
De-compression cable play
(DR-Z400)
1/9
—
—
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)
—
(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.
—
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
Rear
—
Front
Rear
Front
Rear
Front
Rear
Brake fluid type
Wheel rim runout
#
#
LIMIT
Wheel rim size
Axial
—
Radial
—
Front
—
—
Front
Rear
1.60 × 21
2.15 × 18
ITEM
(Solo riding)
Front
P
M
E-01, 03
E-01, 03, 28, 33
A
S
288
(11.3)
510.6
(20.1)
122
(without spring)
(4.8)
Front fork oil type
720 ml
(each leg)
(24.3/25.4 US/lmp oz)
Rebound
15th clicks turn back
Compression
Rear shock absorber gas pressure
900 kPa
(9.0 kgf/cm2, 128 psi)
Rear shock absorber oil type
SUZUKI REAR SUSPENSION OIL SS-25 or
an equivalent suspension oli
Rear shock absorber oil capacity
380 ml
(12.8/13.4 US/lmp oz)
258.0
pre-set length
(10.2)
Rebound
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
Rear wheel travel
295
(11.6)
—
Unit: mm (in)
LIMIT
—
Front
—
Rear
—
6/9
ITEM
Spark plug
Type
Gap
Spark performance
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
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
More than 10.0 V (: Bl, : G)
More than 5.0 V (: Bl, : G)
More than 1.0 V (: B, : W)
More than 1.4 V (: B, : W)
(Y – Y)
(Y – Y)
Regulated voltage
12.5 – 14.0 V at 5 000 r/min
13.5 – 15.0 V at 5 000 r/min
150 W at 5 000 r/min
200 W at 5 000 r/min
3–5Ω
Battery
Type designation
YT7B-BS
Capacity
12 V 21.6 kC (6 Ah)/10 HR
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)
—
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
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
ratio of 50:50.
1 250 ml
(1.3/1.1 US/lmp qt)
Front
5
(0.2)
3.0 ± 0.2
(0.118 ± 0.008)
4.5 ± 0.2
(0.177 ± 0.008)
Brake disc runout
RADIATOR + ENGINE COOLANT
ITEM
Engine coolant type
Unit: mm (in)
ITEM
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
octane (R/2 + M/2).
10.0 L
(2.6/2.2 US/lmp qt)
2.3 L
(0.6/0.5 US/lmp qt)
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 guide I.D.
P
M
LIMIT
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
0.05
(0.002)
0.5
(0.02)
EX.
—
—
IN. & EX.
—
IN. & EX.
—
(IN. & EX.)
INNER
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
INNER
OUTER
—
15th pin
—
—
—
0.9 – 1.1
(0.035 – 0.043)
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
ITEM
Cylinder bore
Piston diam.
—
—
Piston ring end gap
—
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
—
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)
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.
Valve seat width
(IN. & EX.)
EX.
—
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
0.35
(0.014)
Valve stem runout
Unit: mm (in)
ITEM
—
—
IN.
—
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.
clearance
E-01
Unit: mm (in)
ITEM
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
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
—
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
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)
at 3 000 r/min
LIMIT
—
(No. 1 & No. 2)
(No. 1 & No. 2)
—
—
ITEM
Carburetor type
Bore size
ITEM
Engine coolant type
Front
Rear
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
—
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
Front
Rear
Front
Rear
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
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
(M.J.)
(J.N.)
(N.J.)
LIMIT
A
S
BRAKE + WHEEL
Main jet
Jet needle
Needle jet
E-24
95 – 125 kPa
(0.95 – 1.25 kgf/cm², 13.5 – 17.8 psi)
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
OIL PUMP
ITEM
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
—
Unit: mm (in)
ITEM
ITEM
Gear ratios
—
LIMIT
—
SUSPENSION
—
ITEM
Front fork stroke
288
(11.3)
510.6
(20.1)
122
(without spring)
(4.8)
Front fork oil type
720 ml
(each leg)
(24.3/25.4 US/lmp oz)
Rebound
Compression
900 kPa
(9.0 kgf/cm2, 128 psi)
SUZUKI REAR SUSPENSION OIL SS-25
or an equivalent suspension oli
380 ml
(12.8/13.4 US/lmp oz)
258.0
pre-set length
(10.2)
Rebound
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
Rear wheel travel
295
(11.6)
—
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
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
0.1 – 1.0 Ω
Primary
Secondary
Regulated voltage
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
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
10.0 L
(2.6/2.2 US/lmp qt)
2.3 L
(0.6/0.5 US/lmp qt)
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
Turn signal light
Speedometer 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.
IN.
EX.
clearance
IN.
EX.
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.
– 5.012
– 0.1973)
– 4.990
– 0.1965)
– 4.970
– 0.1957)
—
—
IN. & EX.
IN. & EX.
—
Camshaft runout
15th pin
—
—
—
—
0.05
(0.002)
0.5
(0.02)
IN. & EX.
—
IN. & EX.
—
(IN. & EX.)
INNER
—
0.03
(0.001)
32.6
(1.28)
36.3
(1.43)
OUTER
ITEM
Cylinder bore
Piston diam.
—
—
Piston ring end gap
—
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
—
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)
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)
—
—
INNER
IN. & EX.
—
—
—
EX.
0.9 – 1.1
(0.035 – 0.043)
56 – 64 N
(5.6 – 6.4 kgf, 12.3 – 14.1 lbs)
126 – 145 N
(12.6 – 14.5 kgf, 27.7 – 32.0 lbs
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.
IN. & EX.
OUTER
Cam height
—
0.35
(0.014)
E-24
Unit: mm (in)
ITEM
—
—
8/8
LIMIT
Valve seat width
(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
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
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
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
STANDARD
2.220 (74/25 × 20/16 × 12/20)
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)
(No. 1 & No. 2)
(No. 1 & No. 2)
—
—
3/8
Engine coolant type
—
(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
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
(Solo riding)
—
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.A.J.)
(P.S.)
E
L
TIRE
Rear
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
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
Approx. 75 °C (167 °F)
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
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)
ratio of 50:50.
1 250 ml (1.3/1.1 US/lmp qt)
ITEM
Brake lever play
—
A
S
BRAKE + WHEEL
LIMIT
ITEM
Gear ratios
E-03, 28, 33
THERMOSTAT + RADIATOR + FAN + ENGINE COOLANT
—
Unit: mm (in)
ITEM
Clutch cable play
ITEM
Engine coolant temp. switch operating temperature
LIMIT
—
Front
Rear
Front
Rear
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
288
(11.3)
573.2
(22.57)
129
(without spring)
(5.07)
Front fork oil type
710 ml
(24.0/25.0 US/lmp oz)
Rebound
Compression
900 kPa
(9.0 kgf/cm2, 128 psi)
258.0
pre-set length
(10.2)
Rebound
force adjuster
High speed
1 and ¼ turns out
Compression
Low speed
Rear wheel travel
295
(11.6)
—
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
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 – 0.8
(0.028 – 0.031)
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
Regulated voltage
Battery
Type designation
Capacity
Fuse size
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
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)
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
Turn signal light
Speedometer light
21/5
21
LED
LED
LED
LED
LED
Water temp. indicator light
7/8
GS125T
ITEM
Valve diam.
clearance
Valve guide I.D.
Valve stem O.D.
stem deflection
stem runout
head thickness
stem end length
Valve seat width
(IN. & EX.)
(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
ITEM
Cam height
Camshaft runout
Rocker arm I.D.
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
Piston-to-cylinder clearance
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
Piston pin bore
Piston pin O.D.
—
CONROD + CRANKSHAFT
P-31
E-03, 28, 33
—
Unit: mm
LIMIT
33.35
33.00
0.150
—
—
0.10
—
—
0.05
0.05
8/8
ITEM
Conrod deflection
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
—
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
STANDARD
2.000 (30/15)
at 3 000 r/min
2/6
LIMIT
—
—
P-31
35
CLUTCH
ITEM
Clutch lever play
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
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
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
Regulated voltage
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
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 oil type
adjuster
Rear wheel travel
Exciting coil peak voltage
WATTAGE
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
P-31
A
S
BRAKE + WHEEL
14 – 19 kΩ
Position light
Turn signal light
Speedometer light
Tachometer 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
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
higher. An unleaded gasoline type is recommended.
Fuel tank capacity including reserve
12.0 L
reserve
2.3 L
Engine oil type
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.
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.
ITEM
Cam height
—
IN.
EX.
—
—
—
—
—
IN. & EX.
IN. & EX.
IN. & EX.
Camshaft runout
IN. & EX.
—
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
—
ITEM
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)
—
Valve stem runout
IN. & EX.
—
IN. & EX.
Valve seat width
IN. & EX.
IN. & EX.
(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
(IN. & EX.)
—
10.9 – 12.5 kgf
(24.0 – 27.6 lbs)
20.3 – 23.3 kgf
(44.8 – 51.4 lbs)
INNER
OUTER
—
Piston ring end gap
—
ITEM
1st
2nd
Oil
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
Crank pin width
Crank pin O.D.
Crankshaft thrust bearing
thickness
Crankshaft runout
Balancer journal oil clearance
Balancer journal O.D.
Balancer spring free length
—
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
—
—
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)
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)
Low
2nd
3rd
4th
5th
Top
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
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
—
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)
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
—
0.10
(0.004)
—
0.10
(0.004)
18th pin
Valve stem O.D.
—
—
—
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
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
Front
Rear
Brake disc runout
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
Front
Rear
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 oil type
(each leg)
Front fork inner tube O.D.
—
336
(13.2)
—
—
—
—
adjuster
Rear wheel travel
4th position among 7
115
(4.5)
—
—
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
Turn signal light
Tachometer light
Speedometer light
Oil pressure indicator light
Unit: mm (in)
LIMIT
—
Rear
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
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
Regulated voltage
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
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
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)
250 – 420 Ω
SPECIFICATION
octane (R/2 + M/2) or 91 octaneor higher rated by
19 L
20 L
4.3 L
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.
IN.
EX.
clearance
IN.
EX.
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.
—
IN. & EX.
—
Unit: mm (in)
LIMIT
—
IN. & EX.
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
Rocker arm I.D.
IN. & EX.
IN. & EX.
0.35
(0.014)
—
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)
ITEM
STANDARD
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
—
Cylinder bore
Piston diameter
—
Cylinder distortion
—
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
A
S
2nd
Oil
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Crank pin width
Crank pin O.D.
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
—
—
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
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)
STANDARD
1.898 (75/43 × 37/34)
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 drive plate thickness
OIL PUMP
ITEM
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 end gap
1/8
– 12.018
– 0.4731)
– 11.984
– 0.4718)
—
—
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
—
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
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)
Type
Gap
Spark performance
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
Type
designation
Capacity
Standard
electrolyte S.G.
HI
Headlight
LO
Turn signal
Ignition
Meter
Main
Fuse size
Headlight
Turn signal light
Speedometer light
Tachometer light
Neutral position indicator light
License plate light
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 oil type
Rear wheel travel
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
—
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
Brake fluid type
ITEM
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
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
Including
20 L (5.3/4.4 US/lmp gal)
reserve
NOTE
Reserve only
4.5 L (1.2/1.0 US/lmp gal)
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
(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.
IN.
EX.
clearance
IN.
EX.
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)
5.6 – 6.6 kgf
(12.3 – 14.6 lbs)
12.8 – 15.0 kgf
(28.2 – 33.1 lbs)
INNER
OUTER
Camshaft runout
IN. & EX.
Rocker arm I.D.
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
1st
2nd
Oil
1st
2nd
Piston pin bore
Piston pin O.D.
ITEM
Crank pin width
Crank pin O.D.
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
—
—
—
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)
—
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)
—
—
—
—
—
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
Gear ratios
0.080
(0.0031)
—
No. 2
—
—
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
No. 1&
No. 3
Type
Links
20-pitch
length
—
Drive chain slack
25 – 35
(0.98 – 1.38)
55 (2.2)
STANDARD
1.898 (75/43 × 37/34)
Above 300 kPa (3.0 kgf/cm2, 43 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
OIL PUMP
ITEM
—
0.20
(0.008)
—
Cylinder distortion
—
LIMIT
—
—
—
A
S
CONROD + CRANKSHAFT
IN. & EX.
– 12.018
– 0.4731)
– 11.984
– 0.4718)
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
ITEM
—
0.10
(0.004)
—
Piston ring end gap
1/9
—
—
—
—
IN. & EX.
—
—
—
IN. & EX.
INNER
IN. & EX.
IN. & EX.
OUTER
—
—
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
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
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)
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)
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)
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
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
Turn signal light
Speedometer light
Tachometer 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
STANDARD
50 (2.0)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
voltage
Generator
Generator Maximum output
Regulated voltage
Battery
Fuse size
Rear
Brake disc runout
—
—
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
Front
Rear
Front
Rear
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
Primary
6/9
ITEM
Wheel rim size
STANDARD
17 M/C × MT3.50
17 M/C × MT4.50
Front
Rear
Rear wheel travel
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)
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
(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)
Secondary
P
M
Unit: mm (in)
ITEM
Type
Spark performance
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
SPECIFICATION
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)
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 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.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
Rocker arm I.D.
IN. & EX.
IN. & EX.
—
24th pin
12.000
(0.4724
11.973
(0.4714
—
—
– 12.018
– 0.4731)
– 11.984
– 0.4718)
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
(IN. & EX.)
INNER
—
OUTER
—
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
ITEM
STANDARD
1 250 kPa
(12.5 kgf/cm2, 178 psi)
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 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)
—
—
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.
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
OUTER
Cam height
—
53 – 65 N
(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)
131 – 151 N
(13.1 – 15.1 kgf, 28.9 – 33.3 lbs)
ITEM
—
IN. & EX.
INNER
—
Valve stem runout
(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
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
1st
2nd
Oil
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
Crank pin width
Crank pin O.D.
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 pressure (at 60°C,140°F)
—
—
—
—
CLUTCH
—
ITEM
STANDARD
2.92 – 3.08
(0.115 – 0.121)
—
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.
—
diam.
—
ITEM
Gear ratios
—
0.080
(0.0031)
1st (low)
2nd
3rd
4th
5th (top)
Gearshift-fork to gearshift-forkgroove clearance
—
—
—
—
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
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)
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)
play
5/9
ITEM
—
—
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)
Type
Gap
Spark performance
Primary
Unit: mm (in)
NOTE
Approx. 130 – 200 Ω
Tester range:
(× 100 Ω)
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
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)
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
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
Generator
CARBURETOR
—
14.043
0.5529)
13.984
0.5506)
35.762
1.4079)
35.675
1.4045)
0.080
(0.0031)
LIMIT
—
—
0.05
(0.002)
—
STANDARD
1.703 (72/46 × 37/34)
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
Turn signal light
Speedometer light
Tachometer light
License plate light
E-02, 19
←
←
5
←
←
←
←
←
←
←
←
←
21/5 × 2
21 × 4
LED
LED
LED × 2
LED
LED
LED
5
BRAKE + WHEEL
ITEM
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
—
Front
Rear
Front
Rear
Leading
Front
Trailing
Rear
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
Brake fluid type
SPECIFICATION
(MethyI Tertiary ButyI Ether), less than 10% ethanol, or less than 5% methanol with appropriate
Including
20 L (5.3/4.4 US/lmp gal)
reserve
Reserve
4.4 L
only
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)
Rear wheel travel
Unit: mm (in)
LIMIT
—
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
(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.
IN.
EX.
Valve-guide to valve-stem
clearance
IN.
EX.
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.
—
IN. & EX.
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
Rocker arm I.D.
IN. & EX.
IN. & EX.
0.35
(0.014)
IN. & EX.
—
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
—
(IN. & EX.)
INNER
OUTER
53 – 65 N
(5.3 – 6.5 kgf, 11.7 – 14.3 lbs)
131 – 151 N
(13.1 – 15.1 kgf, 28.9 – 33.3 lbs)
ITEM
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)
Cylinder distortion
—
—
—
A
S
—
2nd
1st
2nd
Oil
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
Crank pin width
Crank pin O.D.
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
STANDARD
1.703 (72/46 × 37/34)
at 3 000 r/min
LIMIT
—
—
—
—
CLUTCH
—
ITEM
STANDARD
2.92 – 3.08
(0.115 – 0.121)
—
—
—
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)
—
—
—
—
14.000 –
(0.5511 –
13.957 –
(0.5495 –
35.700 –
(1.4055 –
35.650 –
(1.4035 –
Clutch master cylinder piston
diam.
diam.
14.043
0.5529)
13.984
0.5506)
35.762
1.4079)
35.675
1.4045)
ITEM
Gear ratios
1st (low)
2nd
3rd
4th
5th (top)
Gearshift-fork to gearshift-forkgroove clearance
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)
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)
—
Drive chain slack
3/9
—
0.20
(0.008)
STANDARD
1 250 kPa
(12.5 kgf/cm2, 178 psi)
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)
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
(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)
ITEM
Cam height
—
—
5.000
(0.1969
4.965
(0.1955
4.945
(0.1947
4/9
—
—
—
—
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)
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)
voltage
Generator
←
←
Regulated voltage
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)
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
Turn signal light
Speedometer light
Tachometer light
License plate light
BRAKE + WHEEL
ITEM
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)
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
Leading
Front
Trailing
Rear
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
Rear wheel travel
ITEM
(Solo/Dual riding)
Tire size
—
—
Front
Rear
—
—
—
—
TIRE
Tire type
Tire tread depth
(Recommended depth)
Unit: mm (in)
NOTE
STANDARD
130
(5.1)
—
—
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
Tester range:
(× 100 Ω)
More than 1.0 V
tap – tap
Approx. 2 – 4 Ω
E
L
E-02, 03, 19, 24, 28, 33
WATTAGE
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
Primary
Secondary
CARBURETOR
ITEM
Type
Spark performance
←
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)
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
Brake fluid type
SPECIFICATION
octane or 91 octane (R/2 + M/2) or higher rated by
the Research Method.
19 L
Including
reserve
20 L
Reserve
4.4 L
only
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
ITEM
STANDARD
—
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)
—
IN. & EX.
IN. & EX.
—
0.35
(0.014)
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)
—
Rocker arm I.D.
IN. & EX.
IN. & EX.
IN.
EX.
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)
—
IN. & EX.
—
(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)
12.8 – 15.0 kgf
(28.2 – 33.1 lbs)
INNER
OUTER
Others
24th pin
12.000
(0.4724
11.973
(0.4714
STANDARD
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
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)
—
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
—
E-02, 03, 19, 28, 33
– 12.018
– 0.4731)
– 11.984
– 0.4718)
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.
(IN. & EX.)
E-18
EX.
—
—
Others
—
—
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
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
2nd
Oil
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)
Crank pin width
Crank pin O.D.
Crankshaft jounal width
—
—
No. 2
18.030
(0.7098)
17.980
(0.7079)
—
—
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
—
—
0.080
(0.0031)
1st (low)
2nd
3rd
4th
5th
6th (top)
Gearshift fork-to-gearshift fork
groove clearance
—
—
1.898 (75/43 × 37/34)
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)
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
Main jet
(M.J.)
Jet needle
(J.N.)
Needle jet
(N.J.)
Throttle valve
(Th.V.)
Pilot jet
(P.J.)
Pilot screw
(P.S.)
5/9
Primary
More than 1.0 V
tap – tap
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)
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
#
2.0 – 4.0 mm
(0.08 – 0.16 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
play
Approx. 135 – 200 Ω
Secondary
Generator
—
1·2·4·3
NGK: CR9EK
DENSO: U27ETR
0.6 – 0.7
(0.024 – 0.028)
Type
—
E-02, 03, 19, 28, 33
STD/SPEC.
Generator maximaum output
Regulated voltage
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
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
3/9
CABURETOR
STANDARD
No. 2
—
STANDARD
No. 1 &
No. 2
ITEM
Gear ratios
OIL PUMP
ITEM
No. 1
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
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
Brake light/taillight
Turn signal light
Speedometer light
Tachometer light
Fuel meter light
Turn signal indicator lights
License plate light
SPECIFICATION
The other countries
55
55
←
←
←
←
←
←
←
←
←
←
←
BRAKE + WHEEL
ITEM
54
(2.1)
4.5 ± 0.2
(0.177 ± 0.008)
5.0 ± 0.2
(0.197 ± 0.008)
Front
Rear
Brake disc runout
Front
Rear
Front
Rear
Front
Front
Rear
Rear
7/9
ITEM
Fuel tank capacity
Engine oil type
Engine oil capacity
Fuel fork oil type
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
Rear wheel travel
—
—
LIMIT
STANDARD
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
Gasoline used should be graded 91 octone or
18.5 L
Including
reserve
20 L
5.0 L
Reserve only
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.
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
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
Rocker arm I.D.
IN. & EX.
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.
—
IN. & EX.
—
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
(IN. & EX.)
(IN. & EX.)
INNER
—
OUTER
—
6.0 – 6.8 kgf
(13.2 – 15.0 lbs)
15.4 – 17.8 kgf
(34.0 – 39.2 lbs)
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
2nd
Oil
1st
ITEM
2nd
Piston pim bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Crank pin width
Crank pin O.D.
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)
at 3 000 r/min
3/9
—
0.20
(0.008)
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.
—
—
—
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
—
18.030
(0.7098)
17.980
(0.7079)
—
—
Unit: mm (in)
LIMIT
18.040
(0.7102)
0.30
(0.01)
—
0.080
(0.0031)
—
0.080
(0.0031)
ITEM
Gear ratios
1st (low)
2nd
3rd
4th
5th
6th (top)
Gearshift fork-to-gearshift fork
groove clearance
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
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)
—
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
Unit: mm (in)
LIMIT
800 kPa
200 kPa
(2 kgf/cm2, 28 psi)
1 000 – 1 500 kPa
(10 – 15 kgf/cm2, 142 – 213 psi)
OIL PUMP
ITEM
—
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)
E-02, 03, 19, 24, 28, 33
P-37
STANDARD
—
0.10
(0.004)
—
—
2nd
1st
—
—
Piston ring-to-piston ring groove
clearance
ITEM
– 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 O.D.
Unit: mm (in)
LIMIT
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
47.6
(1.87)
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.)
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
Generator
←
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.)
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)
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
Turn signal light
Speedometer light
Tachometer light
Fuel meter light
License plate light
A
S
55
55
←
←
←
←
←
←
←
←
←
←
←
ITEM
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
—
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
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
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
Slip ring
O.D.
Brush
length
Generator maximaum output
Regulated voltage
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)
Approx. 135 – 200 Ω
More than 1.0 V
Type
Spark performance
←
Unit: mm (in)
NOTE
SPECIFICATION
Front
Rear
Front
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
(N2 gas)
force adjuster
—
359
(14.13)
—
—
—
—
—
Rear wheel travel
—
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
Brake fluid type
SPECIFICATION
Gasoline used should be graded 91 octone or
18.5 L
Including
reserve
20.0 L
5.0 L
Reserve only
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.
IN.
EX.
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
—
ITEM
Cam height
—
EX.
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
—
—
—
0.10
(0.004)
—
0.20
(0.008)
—
15th pin
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
ITEM
—
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Cylinder bore
IN. & EX.
—
Piston diam.
(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)
15.5 – 17.9 kgf
(34.17 – 39.46 lbs)
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)
Cylinder distortion
—
—
STD/SPEC.
Piston ring end gap
—
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
—
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.
—
(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
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
Crank pin width
Crank pin O.D.
thickness
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
STD/SPEC.
Right side
Left side
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
—
—
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
resistance
Radiator cap valve opening preessure
Engine coolant type
Type
Links
20-pitch
length
P
M
A
S
—
—
ITEM
TO sensor voltage
GP switch voltage
Injector voltage
Heated oxygen sensor output voltage
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)
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)
—
—
—
—
—
—
—
—
—
—
—
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)
—
—
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
Unit: mm (in)
LIMIT
2.62
(0.103)
3.42
(0.135)
13.05
(0.514)
13.10
(0.516)
STD/SPEC.
No. 2
ITEM
Gear ratios
STD/SPEC.
at 3 000 r/min
—
DRIVE TRAIN
0.05
(0.002)
CLUTCH
ITEM
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
diam.
—
—
0.080
(0.0031)
LIMIT
0.10
(0.004)
27.6
(1.09)
—
Low
2nd
3rd
4th
5th
Top
0.080
(0.0031)
—
STD/SPEC.
Clutch spring free hength
—
20.030
(0.7886)
19.980
(0.7866)
CONROD + CRANKSHAFT
ITEM
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
60 – 64 kΩ
Approx. 2.5 V
More than 0.6 V (From 1st to top without neutral)
Battery voltage
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)
ITEM
Injector resistance
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
—
—
—
ELECTRICAL
ITEM
Firing order
Spark plug
1·2·4·3
NGK: CR9E
DENSO: U27ESR-N
0.7 – 0.8
(0.028 – 0.031)
180 – 280 Ω
More than 3 V
Type
Gap
FI SENSORS + INTAKE AIR CONTROL VALVE
ITEM
STD/SPEC.
0.9 – 1.3 kΩ
More than 0.7 V
180 – 280 Ω
More than 3 V
4.5 – 5.5 V
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
1.0 – 1.6 Ω
Primary
Secondary
(When cold)
Regulated voltage
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
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
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
Front
Rear
Front
WATTAGE
Unit: W
STD/SPEC.
ITEM
Headlight
E-03, 24, 28, 33
65 + 55W
55 W
HI
LO
Turn signal light
License light
Tachometer light
Speedometer light
Fuel meter light
Engine coolant temp. meter light
FI indicator light
Fuel level 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 oil type
Front fork damping force
adjuster
pre-set length
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.
the research Method.
19 L
(50/4.2 US/lmp gal)
Including
reserve
21L
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.
(Dual riding)
—
FUEL + OIL
ITEM
Wheel rim size
Rear
4.5
(0.177)
4.5
(0.177)
0.30
(0.012)
STD/SPEC.
Fuel type
—
—
ITEM
(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
Brake fluid type
Wheel rim runout
Unit: mm (in)
ITEM
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)
IN. & EX.
—
Valve stem runout
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
INNER
—
0.03
(0.001)
38.6
(1.52)
40.6
(1.60)
IN.
EX.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
(IN. & EX.)
OUTER
(IN. & EX.)
—
49 – 59 N
(4.9 – 5.9 kgf, 10.8 – 13.0 lbs)
136 – 156 N
(13.6 – 15.6 kgf, 30.0 – 34.4 lbs)
INNER
OUTER
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.
—
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
—
24th pin
—
ITEM
STD/SPEC.
1 180 kPa
(11.8 kgf/cm2, 168 psi)
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)
Cylinder distortion
—
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
STD/SPEC.
Crank pin width
Crank pin O.D.
thickness
Right side
Left side
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
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)
—
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
diam.
diam.
Clutch fluid type
—
0.080
(0.0031)
—
—
—
—
0.05
(0.002)
DRIVE TRAIN
ITEM
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
LIMIT
Drive chain
—
Type
Links
20-pitch
length
—
20 – 30
(0.79 – 1.18)
30 – 40
(1.2 – 1.6)
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
ITEM
– 0.20
– 0.008)
– 0.30
– 0.012)
—
2nd
STD/SPEC.
—
0.10
(0.004)
—
0.20
(0.008)
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
1st
—
—
2nd
ITEM
– 35.33
– 1.391)
– 34.22
– 1.347)
– 0.066
– 0.0026)
– 24.025
– 0.9459)
– 23.980
– 0.9441)
—
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
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.57)
—
—
E-02, 19, 24
E-19
56
ITEM
Injector resistance
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
NOTE
STD/SPEC.
More than 3.7 V
134 – 202 Ω
More than 2.7 V
4.5 – 5.5 V
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
EOT sensor input voltage
EOT sensor resistance
Approx. 2.6 kΩ at 20 °C (68 °F)
TO sensor voltage
GP switch voltage
Injector voltage
W–W
Terminal –
Terminal
Regulated voltage
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
Turn signal light
Speedometer light
Tachometer light
FI indicator light
BRAKE + WHEEL
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
—
Front
Rear
Front
Rear
Front
Rear
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
(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
(Solo riding)
Unit: mm (in)
NOTE
Wheel rim size
Unit: mm (in)
ITEM
Secondary
E
L
STD/SPEC.
5/9
2–4Ω
More than 150 V
4.5 – 5.5 V
60 – 64 kΩ
Approx. 3.8 V
More than 0.6 V (From 1st to Top)
Battery voltage
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
THROTTLE BODY
Headlight
1·2·4·3
NGK: CR8EK
DENSO: U24ETR
0.6 – 0.7
(0.024 – 0.028)
134 – 202 Ω
More than 2.7 V
Type
FI SENSORS + SECONDARY THROTTLE VALVE ACTUATOR
ITEM
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.
adjuster
130
(5.12)
322.6
(12.70)
108
(4.25)
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
adjuster
force adjuster
Rebound
Compression
Front fork oil type
1.5
—
—
—
—
—
—
—
—
—
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.
Including
22 L
reserve
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.
IN.
EX.
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.
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
Cam height
IN.
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Camshaft runout
—
—
—
0.10
(0.004)
—
0.20
(0.008)
—
12th pin
—
—
—
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
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)
146 – 168 N
(14.9 – 17.1 kgf, 32.8 – 37.7 lbs)
—
ITEM
STANDARD
1 100 – 1 500 kPa
(11 – 15 kgf/cm², 156 – 213 psi)
difference
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)
Cylinder distortion
—
Piston ring end gap
—
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.
IN. & EX.
EX.
ITEM
—
Valve seat width
IN.
—
0.25
(0.001)
0.05
(0.002)
0.5
(0.02)
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
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 O.D.
LIMIT
CLUTCH
ITEM
Clutch lever play
—
—
14.030
(0.5524)
13.980
(0.5504)
No. 1, 2 and 3
No. 1, 2 and 3
CONROD + CRANKSHAFT
ITEM
Crank pin width
Crank pin O.D.
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 runout
—
—
—
0.080
(0.0031)
—
Shift fork-to-groove clearance
—
—
—
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
E
L
P
M
E-02, 03, 19, 24, 28, 33
E-19
E-19
A
S
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)
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
ITEM
SPECIFICATION
0.9 – 1.7 kΩ
NOTE
0.7 V and more
When
cranking
142 – 194 Ω
When
cranking
0.5 V and more
—
—
—
—
—
—
—
—
—
TO sensor voltage
ITEM
Injector resistance
Fuel discharge amount
Fuel pressure regulator operating set
pressure
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)
—
Radiator cap valve opening
pressure
Cooling fan thermo-switch
operating temperature
Type
Links
3/10
ITEM
temperature
Low
2nd
3rd
4th
5th
Top
0.05
(0.002)
—
OIL PUMP
ITEM
54.15
(2.132)
0.080
(0.0031)
—
—
2.62
(0.103)
12.90
(0.5079)
0.10
(0.004)
51.5
(2.028)
—
ITEM
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
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
16.5 – 22.3 kΩ
Normal
0.4 – 1.4 V
Leaning
NOTE
0.6 V and more
Injector voltage
Battery voltage
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
Secondary
Terminal –
Terminal
Plug cap –
Terminal
10.8 – 16.2 kΩ
85 V and more
0.2 – 0.9 Ω
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
Turn signal light
License plate light
Combination meter light
FI indicator light/Oil pressure indicator
light/Engine coolant temp. indicator
light
Engine RPM indicator light
E-03, 24, 28, 33
Others
60/55 W
←
55/55 W
55 W
5W
LED
←
18 W × 4
←
5W
←
LED
←
LED
←
LED
←
LED
←
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
(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
(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 oil type
Front fork inner tube outside diam.
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)
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)
—
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
—
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
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
Generator no-load performance
Regulated voltage (charging output)
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)
142 – 194 Ω
0.5 V and more
SPECIFICATION
NOTE
Others
16.5 L
E-33
(4.4/3.6
US/lmp
gal)
Including
reserve
17 L
Others
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.
IN.
EX.
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
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
—
—
—
Cylinder bore
—
Piston diam.
—
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
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)
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.
IN. & EX.
IN. & EX.
IN. & EX.
ITEM
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)
Crank pin width
Crank pin O.D.
Crankshaft thrust bearing thickness Right side
Left side
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
RN
1st
Unit: mm (in)
LIMIT
36.48
(1.436)
34.98
(1.377)
0.150
(0.0059)
—
1st
2nd
Oil
1st
2nd
—
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
—
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)
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
336.5
(13.25)
20 – 30
(0.8 – 1.2)
60 – 70
(4 – 8)
71.880
(2.8299)
—
—
0.120
(0.0047)
Nicks or
Scratches
E-02, 13, 19, 24, 28, 33
E-19
—
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
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
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)
—
—
A
S
CONROD + CRANKSHAFT
—
Cylinder distortion
E-02, 13, 19, 24, 28, 33
E-19
1/9
14th pin
—
—
LIMIT
0.10
(0.004)
—
0.20
(0.008)
—
—
Valve stem runout
STANDARD
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
ITEM
Camshaft runout
—
—
—
CLUTCH
ITEM
Clutch lever play
No. 1, 2 and 3
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)
—
55.11
(2.170)
—
Unit: mm (in)
LIMIT
ITEM
—
—
2.62
(0.103)
12.90
(0.5079)
0.10
(0.004)
52.4
(2.063)
Engine coolant type
Engine coolant
3/9
E-02, 13, 19, 24, 28, 33
E-19
NOTE
Approx. 88 °C (190 °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
ITEM
Injector resistance
Fuel discharge amount
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
ITEM
SPECIFICATION
0.9 – 1.7 kΩ
0.7 V and more
142 – 194 Ω
0.5 V and more
4.5 – 5.5 V
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
16.5 – 22.3 kΩ
Normal
0.4 – 1.4 V
TO sensor voltage
Leaning
GP switch voltage
Injector voltage
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
ITEM light
Turn signal indicator
Firingbeam
orderindicator light
High
Spark
plug
FI indicator light/Oil pressure indicator light/Engine coolant temp.
indicator light
Sparklevel
performance
Fuel
indicator light
CKP sensor
Engine
RPMresistance
indicator light
Ignition coil+resistance
BRAKE
WHEEL
ITEM
Brake
disc coil
thickness
Generator
resistance
Regulated
Brake
disc voltage
runout
GP switch
voltage
Master
cylinder
bore
Battery
Type designation
Capacity
Master
cylinder
piston
diam
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
Brake fluid type
ELECTRICAL
ITEM
When cranking
When cranking
Firing order
Spark plug
Gap
Spark performance
When
leaning 65°
From 1st to Top
3.7 – 4.4 V
When cranking
Regulated voltage
GP switch voltage
Battery
Type designation
Capacity
Fuse size
HI
Headlight
LO
Signal
Ignition
Fuel
Fan
Main
P
M
A
S
Unit: W
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
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
Wheelsignal
axle runout
Turn
light
License plate light
TIRE
ITEM
Neutral indicator
light
Cold
inflation
tire pressure
FI
indicator
light/Oil
pressure indi(Solo light/Engine
riding)
cator
coolant temp.
indicator light
Cold inflation
tire pressure
Engine
RPM indicator
light
(Dual riding)
BRAKE + WHEEL
ITEM
Tire size
Tire type
Brake
discdepth
runout
Tire tread
(Recommended depth)
—
E-03, 24,
— 28, 33
E-02, 19
—
—
—
—
—
—
—
—
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
14.0 – 15.5 V at 5 000 r/min
3–5Ω
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)
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
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
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
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)
60 – ZR17
70 M/C (73 W)
Rear
180/55
—
(2.4—
– 2.8)
0.3
Tire type
DUNLOP: D218F
E-03,
28, 33
(0.01)
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).
19.050 – 19.093
2.0
Front
—
Gasoline
containing
MTBE
(Methyl
Tertiary
Butyl
Rear
(0.7500 —
– 0.7517)
E-03,
28, 33
(0.08)
14.000 – 14.043
Rear
—
methanol with appropriate
cosolvents
(0.5512
– 0.5529)and corrosion inhibitor is permissible.
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)
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
Brake
light/Taillight
outer tube
fully compressed)
Wheelsignal
axleoilrunout
Turn
light
Front
fork
type
License
plate
light
Front fork
oil capacity
(each leg)
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem runout
Valve seat width
----
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)
ITEM
EX.
IN. & EX.
ITEM
STANDARD
24.012 – 24.025
(0.9454 – 0.9459)
23.959 – 23.980
(0.9433 – 0.9441)
IN. & EX.
----
IN. & EX.
---Camshaft runout
------0.10
(0.004)
---0.20
(0.008)
----
----
----
----
14th pin
----
ITEM
1 000 kPa
1 300 – 1 700 kPa
(13 – 17 kgf/cm², 185 – 242 psi)
-------
Unit: mm (in)
LIMIT
STANDARD
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)
0.120
(0.0047)
Nicks or
Scratches
----
----
Unit: mm (in)
LIMIT
36.71
(1.445)
35.68
(1.405)
0.150
(0.0059)
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
---1st
R
Approx 8.0 (0.31)
2nd
RN
Approx 10.2 (0.40)
1st
R
2nd
RN
1st
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)
Cam height
P
M
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
IN. & EX.
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
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 O.D.
CONROD + CRANKSHAFT
ITEM
Crank pin width
Crank pin O.D.
thickness
Right side
Left side
Crankshaft runout
---0.080
(0.0031)
pressure
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
No. 1, 2 and 3
No. 1, 2 and 3
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)
ITEM
Gear ratios
----
----
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
Drive chain
Type
Links
E
L
20-pitch length
----
P
M
E-02, 03, 19, 24, 28, 33
E-19
A
S
NOTE
Approx. 82 °C (180 °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)
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)
-------
70 – 220 Ω
-------
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.
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
EXCVA position sensor
input voltage
resistance
output voltage
When
cranking
4.5 – 5.5 V
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
19.1 – 19.7 kΩ
Normal
0.4 – 1.4 V
Injector voltage
NOTE
0.5 V and more
NOTE
E-02, 03, 19, 24, 28, 33
E-19
----
0.5 V and more
GP switch voltage
----
E-02, 03, 19, 24, 28, 33
E-19
SPECIFICATION
0.9 – 1.7 kΩ
----
----
---------319.4
(12.57)
----
ITEM
----
----
----
----
LIMIT
------------------------0.50
(0.020)
20 – 30
(0.79 – 1.18)
60 – 70
(2.36 – 2.76)
4/11
Leaning
5/11
----
----
----
ITEM
Injector resistance
set pressure
LIMIT
CLUTCH
----
ITEM
temperature
ITEM
----
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)
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)
70 – 220 Ω
0.5 V and more
Type
Gap
Spark performance
Secondary
Regulated voltage
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
Turn signal light
License plate light
FI indicator light/Oil pressure
indicator light/Engine coolant
temp. indicator light
Engine RPM indicator light
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
Front
Rear
14.0 – 15.5 V at 5 000 r/min
3–5Ω
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
Front &
Rear
Front
Rear
Front
E
L
ITEM
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 oil type
adjuster
pre-set length
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
(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)
509 ml
(17.2/17.9 US/Imp oz)
4.5 th groove from top
Rebound
Compression 11 clicks out from stiffest position
179.6
(7.07)
Rebound
Compression
130
(5.1)
-------------------
E-02, 03, 19, 24, 28, 33
E-19
SUSPENSION
TIRE
ITEM
(Solo riding)
---5.0
(0.177)
4.5
(0.177)
0.30
(0.012)
----
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
octane (R/2 + M/2).
E-03, 28, 33
Others
Including
18 L
reserve
Fuel level
Approx. 4.2 L
indicator light
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.
clearance
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
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
INNER
OUTER
ITEM
Cam height
Camshaft runout
Rocker arm I.D.
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
—
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 deflection
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
—
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
STANDARD
2.000 (30/15)
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
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
—
2.9 – 3.1
11.8 – 12.0
—
—
—
2.6
11.0
0.10
29.5
2/5
P-02, 19
P-19
66
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
Countershaft length
(Low to 2nd)
Drive chain
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
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
reserve
Engine oil type and grade
Engine oil capacity
SPECIFICATION
13.0 L
2.9 L
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
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
—
—
—
—
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
Turn signal light
Speedometer light
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
More than 4.0 V
175 W at 5 000 r/min
Regulated voltage
13.5 – 15.0 V at 5 000 r/min
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 oil type
Rear wheel travel
3 – 5Ω
ITEM
3/5
Axial
Radial
Front
Rear
Front
Rear
Primary
Brake disc runout
Brake fluid type
Brake drum I.D.
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.
IN.
EX.
clearance
IN.
EX.
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
—
R. side
L. side
—
—
R. side
0.35
(0.014)
L. side
—
Camshaft runout
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
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)
—
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
40.1
(1.58)
18.4 – 21.6 kgf
(40.56 – 47.62 lbs)
IN.
—
12.000
(0.4724
11.966
(0.4711
—
—
ITEM
Cylinder bore
—
Piston diam.
2nd
Oil
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
STANDARD
18.006 – 18.014
(0.7089 – 0.7092)
Conrod deflection
—
0.10 – 0.65
(0.004 – 0.026)
20.95 – 21.00
(0.825 – 0.827)
60.0 ± 0.1
(2.362 ± 0.004)
Crankshaft web to web width
Crankshaft runout
—
—
—
—
CLUTCH
ITEM
Clutch cable play
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
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
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
Drive chain
Type
Links
20-pitch
length
—
0.05
(0.002)
10.0
(0.39)
71.880
(2.8299)
—
ITEM
Gear ratios
—
Unit: mm (in)
LIMIT
800 kPa
0.120
(0.0047)
72.085
(2.8380)
—
Unit: mm (in)
LIMIT
18.040
(0.7102)
3.0
(0.12)
1.0
(0.04)
—
STANDARD
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)
at 3 000 r/min
Approx. 10.0 (0.39)
N
—
OIL PUMP
ITEM
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)
1st
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
—
ITEM
—
—
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
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.)
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.)
Fuse size
HI
Headlight
LO
Turn signal
Ignition
Taillight
Spark plug
Gap
Spark performance
Regulated voltage
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
Turn signal light
Front turn signal light/Running light
Speedometer light
Bl – G
Y–Y
21/5
21 (rear)
21/5
1.7
3.4
3.4
1.7
ITEM
Brake disc runout
E
L
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
—
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 oil type
Rear wheel travel
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
—
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
—
←
←
←
←
—
←
←
←
←
←
←
Front
Brake fluid type
Brake drum I.D.
Axial
P-09
←
←
20 – 30
(0.8 – 1.2)
50
(2.0)
5.0 ± 0.2
Front
(0.20 ± 0.01)
5/8
SPECIFICATION
P-19
←
←
4
←
10
BRAKE + WHEEL
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
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
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)
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
14 L
2.9 L
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.
clearance
IN. & EX.
IN.
EX.
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
—
Left
Right &
Center
—
—
Left
Right &
Center
—
0.35
(0.014)
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
—
IN. & EX.
—
—
IN. & EX.
—
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)
—
IN. & EX.
—
(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)
16.4 – 18.8 kgf
(36.2 – 41.4 lbs)
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.
—
INNER
ITEM
Cam height
—
Valve stem runout
12.000
(0.4724
11.966
(0.4711
ITEM
Cylinder bore
Piston diam.
—
ITEM
1st
2nd
Oil
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
—
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
70.0 ± 0.1
(2.756 ± 0.004)
Crankshaft runout
—
—
LIMIT
—
—
CLUTCH
ITEM
Clutch lever play
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
—
—
—
—
DRIVE TRAIN
Unit: mm (in)
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.039)
Low
2nd
3rd
4th
Top
—
—
0.05
(0.002)
10.0
(0.39)
Drive belt
LIMIT
15.0
(0.591)
15.1
(0.594)
0.1
(0.004)
33.0
(1.30)
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
Gear ratios
93.880
(3.6961)
E-03, 28, 33
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
STANDARD
2.203 (68/36 × 35/30)
Below 75 kPa (0.75 kgf/cm2, 10.7 psI)
at 3 000 r/min
—
—
OIL PUMP
ITEM
ITEM
—
—
T
E
L
P
M
—
3–5
(0.12 – 0.20)
1st
2nd
E-03, 28, 33
—
LIMIT
800 kPa
0.120
(0.0047)
94.080
(3.7039)
Cylinder distortion
—
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)
—
—
0.05
(0.002)
0.05
(0.002)
Piston ring end gap
1/8
– 12.018
– 0.4731)
– 11.984
– 0.4718)
—
De-comp. cable play
—
0.10
(0.004)
—
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
Rear
Front
Brake disc runout
Front
Front
Front
Front
Front
Wheel rim runout
Axial
E
L
E-03, 28, 33
STANDARD
20 – 30
(0.8 – 1.2)
60
(2.4)
Tire tread depth
O/G
O/W – Ground
Plug cap –
Ground
20 A
ITEM
Tire size
NOTE
1.28 at 20 °C (68 °F)
BRAKE + WHEEL
Wheel rim size
5
3
3
1.7
3
8
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)
0.1 – 1.0 Ω
170 – 270 Ω
1–7Ω
Secondary
Regulated voltage
Battery
Type designation
Voltage
Capacity
Standard
electrolyte S.G.
Fuse size
HI
LO
Unit: mm (in)
ITEM
Spark performance
Solenoid resistance
SPECIFICATION
60
55
Parking or City light
Turn signal light
Running light
(within front turn signal light)
Speedometer 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
Rear wheel travel
—
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
the reserch method.
Including
10.5 L
reserve
Only
2.5 L
reserve
(0.66/0.55 US/lmp gal)
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
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.
IN.
EX.
clearance
IN.
EX.
Unit: mm (in)
LIMIT
—
ITEM
Cam height
IN.
P-03
EX.
—
IN.
—
P-33
EX.
—
—
IN. & EX.
—
IN. & EX.
IN. & EX.
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)
—
IN. & EX
Valve stem runout
IN. & EX.
—
IN. & EX.
—
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)
—
IN. & EX.
—
0.03
(0.001)
39.5
(1.56)
Valve stem O.D.
IN.
—
18.4 – 21.6 kgf
(40.6 – 47.6 lbs)
12.000
(0.4724
11.977
(0.4715
—
—
ITEM
Cylinder bore
—
Piston diam.
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
STANDARD
14.004 – 14.012
(0.5513 – 0.5517)
Conrod deflection
—
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
at 3 000 r/min
LIMIT
CLUTCH
ITEM
STANDARD
0 – 1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
—
—
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
Gear ratios
Low
2nd
3rd
4th
Top
Reverse
No. 1, No. 2
& No. 3
No. 1, No. 2
& No. 3
Reverse
Reverse
Drive chain
Type
Links
20-pitch
length
Drive chain slack
—
2/7
Unit: mm (in)
LIMIT
800 kPa
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
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
R
R
Oil
—
—
1st
2nd
E
L
LIMIT
—
0.05
(0.002)
0.05
(0.002)
—
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)
Piston ring end gap
1st & 2nd
—
0.10
(0.004)
ITEM
—
—
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
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
Magneto coil resistance
Regulated voltage
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)
Primary
0.1 – 1.0 Ω
Secondary
10 – 25 kΩ
BRAKE + WHEEL
ITEM
Front brake lever 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
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
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)
—
—
—
—
—
Turning radius
Toe-in (with 75 kg, 165 lbs)
Caster
Trail
Wheel axle runout
WATTAGE
Headlight
30
(1.2)
20 – 30
(0.8 – 1.2)
—
—
SUSPENSION
ITEM
setting
Front wheel travel
Rear wheel travel
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
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
8.5 L
1.1 L
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
Valve stem O.D.
IN. & EX.
IN.
EX.
IN. & EX.
—
Valve stem runout
IN. & EX.
—
LIMIT
¬ 17.5
—
¬ 17.5
—
Camshaft runout
—
—
—
—
IN. & EX.
—
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
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)
—
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.
¬ 22
¬ 17.5
¬ 22
¬ 17.5
1/7
ITEM
1st
2nd
Piston pin bore
Piston pin O.D.
ITEM
STANDARD
20.006 – 20.014
(0.7876 – 0.7879)
—
0.10 – 0.55
(0.004 – 0.022)
21.95 – 22.00
(0.864 – 0.866)
60.0 ± 0.1
(2.362 ± 0.004)
Crankshaft runout
LIMIT
32.830
(1.2925)
32.830
(1.2925)
0.150
(0.0059)
0.150
(0.0059)
—
ITEM
(Automatic-decomp. actuated)
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)
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
High/Low
Reverse
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
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
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
—
—
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
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
at 3 000 r/min
STANDARD
140.0 – 140.2
(5.512 – 5.520)
—
—
0.080
(0.0031)
ITEM
Clutch wheel I.D.
ITEM
Automatic transmission ratio
Secondary reduction ratio
Front
Rear
Transfer gear ratio
Low
High
Reverse
Oil
—
CLUTCH
Clutch engagement r/min
Clutch lock-up r/min
—
—
OIL PUMP
ITEM
—
0.10
(0.004)
12.000 –
(0.4724 –
11.973 –
(0.4714 –
—
Unit: mm (in)
Conrod deflection
IN. & EX.
IN. & EX.
A
S
CONROD + CRANKSHAFT
Rocker arm I.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
¬ 22
—
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)
ITEM
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
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
Regulated voltage
Unit: mm (in)
ITEM
Rear brake cable play
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
13.5 – 15.0 V at 5 000 r/min
: Ground
: W/BI
: G, : BI
: Y, : W
More than 180 V
Power source coil peak voltage
Battery
Type designation
Capacity
Fuse size
Main
Power source
Headlight (HI)
Headlight (LO)
Taillight
Ignition
Fan
BRAKE + WHEEL
0.1 – 1.0 Ω
Primary
Unit: mm (in)
NOTE
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
(0.028 – 0.031)
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
Front
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
Front
Front
Front
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
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
Speedometer light
Engine oil temp. 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
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
15.0 L
3.3 L
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Unit: mm (in)
LIMIT
ITEM
Cam height
—
IN.
—
«22
«17.5
—
—
«22
«17.5
—
—
«22
«17.5
—
—
Camshaft runout
Rocker arm I.D.
IN. & EX.
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.
—
IN. & EX.
—
IN. & EX.
Valve seat width
IN. & EX.
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
38.3
(1.53)
IN. & EX.
18.6 – 21.4 kgf
(41.0 – 47.2 lbs)
—
—
ITEM
—
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)
Nicks or
Scratches
1st
R
Approx. 11.2 (0.44)
2nd
R
Approx. 11.9 (0.47)
1st
1st
2nd
Oil
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
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
71.0 ± 0.1
(2.795 ± 0.004)
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
STANDARD
at 3 000 r/min
CLUTCH
ITEM
Clutch wheel I.D.
STANDARD
140.0 – 140.2
(5.512 – 5.520)
Clurch shoe
—
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
Front
Rear
Transfer gear ratio
Low
High
Reverse
Drive belt width
length
Shift fork groove
width
High/Low
Reverse
CONROD + CRANKSHAFT
0.10 –
(0.004 –
0.10 –
(0.004 –
High/Low
Reverse
backlash
Front drive (defferential) gear backlash
STANDARD
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
E
L
P-24, 28, 33
A
S
2nd
—
0.05
(0.002)
0.05
(0.002)
STANDARD
2nd
—
—
—
Piston ring end gap
STANDARD
– 12.018
– 0.4731)
– 11.984
– 0.4718)
1st
—
—
0.10
(0.004)
12.000
(0.4724
11.973
(0.4714
Cylinder distortion
ITEM
—
—
—
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.
—
P-24, 28, 33
LIMIT
—
—
—
—
—
—
—
35.7
(1.41)
145.4
(5.72)
0.50
(0.020)
—
—
—
—
—
—
—
ITEM
switch operating temperature
Engine coolant type
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)
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.)
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)
Type
Gap
Spark performance
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
Regulated 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
Camber
Caster
Wheel rim size
Tire size
Tire type
Auxiliary light
Speedometer light
Parking indicator light
Hight beam indicator light
BRAKE + WHEEL
ITEM
Terminal –
Ground
Plug cap –
Terminal
Bl – G
Y–W
B–B
Front
Rear
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
—
13.5 – 15.0 V at 5 000 r/min
Battery
Type designation
Capacity
ITEM
NOTE
SPECIFICATION
30 × 2 pcs.
30 × 2 pcs.
40
21/5
LED
LED
LED
LED
LED
LED
HI
LO
More than 150 V
Front
Rear
Front
Rear
Front
Rear
: Ground
: W/Bl
: G, : Bl
: Y, : W
—
—
Front
Rear
E
L
Front
Rear
—
P
M
—
—
—
—
Fuel tank including
A
S
Tire tread depth
Front
Rear
P-24, 28, 33
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
capacity
SPECIFICATION
19.0 L
4.2 L
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
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
IN. & EX.
—
Valve stem runout
IN. & EX.
—
IN. & EX.
—
IN. & EX.
—
Valve seat width
0.88 – 1.08
(0.035 – 0.043)
IN. & EX.
IN. & EX.
—
IN. & EX.
—
IN. & EX.
256 – 294 N
(25.6 – 29.4 kgf, 56.4 – 64.8 lbs)
Unit: mm (in)
LIMIT
ITEM
Cam height
—
IN.
EX.
—
—
—
—
—
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
IN. & EX.
—
—
—
ITEM
—
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)
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
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
CONROD + CRANKSHAFT
ITEM
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.087 ± 0.004)
Crankshaft runout
P
M
LIMIT
—
—
—
—
—
—
0.08
(0.003)
STANDARD
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
ITEM
—
Unit: mm (in)
LIMIT
16.040
(0.6315)
3.0
(0.12)
1.0
(0.04)
Clutch wheel I.D.
—
2/7
ITEM
Transmission gear
Low
ratio
2nd
3rd
4th
Top
Reverse
Secondary bevel gear backlash
Rear drive (final) bevel gear backlash
STANDARD
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
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
ITEM
—
0.05
(0.002)
0.05
(0.002)
—
1/7
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
Cylinder distortion
—
—
0.10
(0.004)
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
—
—
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
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
Secondary
←
←
More than 120 V
80 – 155 Ω
0.5 – 1.5 Ω
Pick-up
Charging
Regulated voltage
Battery
Type designation
Capacity
Fuse size
More than 4.0 V
kPa
25
20
FUEL + OIL
TEM
reserve
Engine oil type
Engine oil capacity
Rear drive (final) gear oil type
Rear drive (final) gear oil capacity
←
ITEM
Unit: mm (in)
NOTE
Terminal –
Terminal
Plug cap –
Ground
: B/W,
: W/Bl
B/Y – G/W
Y–Y
: G/W,
: B/Y
Rear
Front
Front
Front
Front
A
S
psi
SPECIFICATION
10.6 L
2.6 L
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
Camber
Caster
Wheel rim size
Front
Rear
Front
Rear
E
L
P
M
E-17, 24, 28, 33
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
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
Backup 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)
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.
IN.
EX.
IN.
EX.
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 runout
0.35
(0.014)
Rocker arm I.D.
IN. & EX.
IN. & EX.
—
—
—
—
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
0.03
(0.001)
35.1
(1.38)
39.9
(1.57)
—
7.1 – 9.2 kgf
(15.7 – 20.3 lbs)
17.3 – 21.3 kgf
(38.1 – 47.0 lbs)
INNER
OUTER
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
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
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
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
STANDARD
17.006 – 17.014
(0.6695 – 0.6698)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
55.0 ± 0.1
(2.165 ± 0.004)
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
STANDARD
1.566 (47/30)
at 3 000 r/min
CLUTCH
ITEM
STANDARD
1/8 turn back
2.7 – 2.9
(0.106 – 0.114)
11.8 – 12.0
(0.46 – 0.47)
—
Clutch wheel I.D.
—
116.00 – 116.15
(4.567 – 4.573)
Clutch shoe
—
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
—
—
—
Unit: mm (in)
LIMIT
800 kPa
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)
—
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)
Cylinder distortion
—
12.000
(0.4724
11.977
(0.4715
ITEM
Unit: mm (in)
LIMIT
33.820
(1.3315)
33.490
(1.3185)
0.150
(0.0059)
0.10
(0.004)
—
—
—
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
(IN. & EX.)
Cam height
—
No. 1, No. 2
& No. 3
Subtransmission
No. 1, No. 2
Reverse
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
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
#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)
Type
Gap
Spark performance
0.1 – 0.5 Ω
Primary
Secondary
12 – 20 kΩ
More than 100 V
90 – 140 Ω
0.1 – 1.0 Ω
More than 2.5 V
Pick-up
Charging
(When the engine is cold)
Regulated voltage
Battery
Type designation
Capacity
S.G.
Fuse size
Main
Power source
Fan
Headlight
Front
Rear
Unit: mm (in)
NOTE
Front
Brake disc runout
Front
Front
Terminal –
Ground
Plug cap –
Ground
Front
Brake hluid type
Brake drum I.D.
Rear
B/Y – G/W
Y–Y
Rear
Front
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
FUEL + OIL
ITEM
Fuel type
reserve
Engine oil type
Engine oil capacity
Differential gear oil type
Differential gear oil capacity
Brake fluid type
SPECIFICATION
12 L
2.0 L
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)
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
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)
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
Cooling fan indicator light
More than 60 V (AC)
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.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
EX.
—
—
« 17.5
Camshaft runout
—
IN. & EX.
—
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)
IN. & EX.
—
« 22
—
—
« 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
LIMIT
Rocker arm I.D.
IN. & EX.
IN. & EX.
12.000 –
(0.4724 –
11.973 –
(0.4714 –
—
—
ITEM
—
Cylinder bore
A
S
2nd
1st
2nd
Oil
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 deflection
—
0.10 – 0.55
(0.004 – 0.022)
21.95 – 22.00
(0.864 – 0.866)
60.0 ± 0.1
(2.362 ± 0.004)
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
—
ITEM
—
—
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
ITEM
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
Transmission
Unit: mm (in)
STANDARD
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
at 3 000 r/min
LIMIT
—
ITEM
OIL PUMP
ITEM
—
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)
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)
1st
Piston ring end gap
STANDARD
—
STANDARD
2nd
1st
—
Cylinder distortion
ITEM
—
—
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
backlash
Front drive (differential) 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
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
3 – 5 mm
(0.12 – 0.20 in)
P-33
←
←
38FC
←
ITEM
Spark plug
Type
Gap
Spark performance
Regulated 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
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
Camber
Caster
Wheel rim size
Front
Rear
Front
Rear
Tire size
Tire tread depth
Front
Brake disc runout
Front
Brake drum I.D.
Rear
—
Front
14.000 –
(0.5512 –
13.957 –
(0.5495 –
32.030 –
(1.2610 –
31.948 –
(1.2578 –
DOT 4
A
S
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
Front
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
Brake fluid type
P-17, 24, 28, 33
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)
Right
Left
Unit: mm (in)
Pick-up
Power
source
Charging
Others
←
←
←
←
←
←
←
—
—
BRAKE + WHEEL
ITEM
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
Speedometer light
Reverse light
Terminal –
Terminal
Plug cap –
Terminal
Bl – G
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)
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
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)
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
kPa
kgf/cm2
psi
NOTE
32.5
30
0.325
0.30
4.7
4.4
LOAD CAPACITY
LT-F400F
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
SPECIFICATION
15.0 L
3.3 L
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.
IN.
EX.
clearance
IN.
EX.
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
—
Right &
Center
Right &
Center
Left
—
Left
—
0.35
(0.014)
Right &
Center
Left
—
—
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
IN. & EX.
—
IN. & EX.
—
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)
—
IN. & EX.
—
0.03
(0.001)
38.3
(1.53)
—
IN.
—
12.000
(0.4724
11.973
(0.4714
—
—
ITEM
—
R
1st
E
L
R
Approx. 12.0 (0.47)
0.08 –
(0.003 –
0.08 –
(0.003 –
1st
2nd
Oil
1st
2nd
Piston pin bore
Piston pin O.D.
A
S
—
CONROD + CRANKSHAFT
ITEM
STANDARD
23.006 – 23.014
(0.9057 – 0.9061)
Conrod deflection
—
0.10 – 0.65
(0.004 – 0.026)
24.95 – 25.00
(0.982 – 0.984)
70.9 – 71.1
(2.791 – 2.799)
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
Drive plate tickness
STANDARD
2.92 – 3.08
(0.115 – 0.121)
—
—
—
—
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)
—
Front
Rear
Low
High
Transmission gear
Low
ratio
2nd
3rd
4th
Top
Reverse
Transfer gear ratio
—
0.08
(0.003)
STANDARD
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
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
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
—
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)
2nd
– 12.018
– 0.4731)
– 11.984
– 0.4718)
1st
Piston ring end gap
—
—
0.10
(0.004)
—
STANDARD
—
STANDARD
Cylinder distortion
1st
—
Piston diam.
ITEM
—
—
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)
ITEM
Cam height
—
Valve stem runout
(IN. & EX.)
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
—
—
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
—
ITEM
Engine coolant type
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)
ratio of 50:50.
2 000 ml
(2.1/1.8 US/lmp qt)
—
—
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
Front
Rear
A
S
Front
Rear
Front
Rear
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)
—
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
Front
Rear
Brake fluid type
Steering angle
Right
Left
Turning radius
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
Auxiliary light
Speedometer light
Parking indicator light
Hight beam indicator light
←
Throttle cable play
Terminal –
Ground
Plug cap –
Terminal
Bl – G
Y–W
B–B
ITEM
Headlight
←
#
150 – 300 Ω
0.05 – 1.0 Ω
0.1 – 1.5 Ω
NOTE
WATTAGE
←
#
Pick-up
Power source
Charging
Regulated voltage
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
—
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)
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
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
capacity
SPECIFICATION
19.0 L (5.0/4.2 US/lmp gal)
4.2 L (1.1/0.9 US/lmp gal)
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)
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 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
(Electric starter)
Cylinder head warp
Valve clearance
IN.
EX.
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
clearance (Wobble method)
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
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
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
IN. & EX.
IN. & EX.
Piston diameter
Top
Second
0.05 (0.002)
—
Top
Second
—
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
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
0.9 L (0.95 US qt)
0.07 – 0.14
(0.003 – 0.006)
at pinion gear spline
—
—
—
—
(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
ITEM
Coolant color
Coolant mixing ratio
Coolant freezing point
Coolant total amount
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
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)
—
—
—
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 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
clearance
Piston pin bore
Piston pin O.D.
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.
IN.
Conrod deflection
EX.
Valve stem runout
IN. & EX.
IN. & EX.
IN. & EX.
Valve
seat width
Crankshaft
runout
IN. & EX.
IN. & EX.
A
S
Unit:
mm (in)
LIMIT
LIMIT
—
—
—
—
—
—
—
—
—
—
16.030
(0.6311)
—
15.980
(0.6291)
0.35
(0.014)
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)
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
0.08
—
(0.003)
0.03
(0.001)
43.0
LIMIT
(1.69)
—
—
ITEM
Cam height
STANDARD
2.7 – 2.9
(0.106 – 0.114)
11.9 – 12.0
(0.469 – 0.472)
—
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 runout
—
—
– 12.018
– 0.4731)
– 11.995
– 0.4722)
STANDARD
1 400 kPa
(14.0 kgf/cm2, 199 psi)
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)
Cylinder distortion
Piston ring end gap
—
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)
ITEM
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
CLUTCH
ITEM
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
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
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
1st
2nd
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
STANDARD
16.006 – 16.014
(0.6302 – 0.6305)
Conrod deflection
—
0.10 – 0.45
(0.004 – 0.018)
17.95 – 18.00
(0.707 – 0.709)
53.0 ± 0.1
(2.087 ± 0.004)
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
Gear ratios
1st
2nd
3rd
4th
5th
Reverse
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)
—
—
—
0.08
(0.003)
STANDARD
at 3 000 r/min
LIMIT
Secondary bevel gear
backlash
Rear drive (final) bevel gear
backlash
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
—
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
STANDARD
2.7 – 2.9
(0.106 – 0.114)
11.9 – 12.0
(0.469 – 0.472)
—
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)
Type
Gap
Spark performance
0.05 – 1.0 Ω
Primary
10.5 – 19.0 kΩ
Ω
Secondary
Regulated voltage
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
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
←
21G1
←
←
#
←
E
L
Pilot screw
#
#
PRE-SET
Throttle cable play
3 – 5 mm
(0.12 – 0.20 in)
←
play
0.5 – 1.0 mm
(0.02 – 0.04 in)
←
4/7
E-19, 28, 33
BRAKE + WHEEL
ITEM
Rear brake lever play
Front
Brake disc runout
Front
Brake drum I.D.
Rear
Front
Front
Front
Front
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
Unit: W
Headlight
Float height
Main jet
Jet needle
Needle jet
Pilot jet
P
M
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
5/7
E-19, 28, 33
6/7
E-19, 28, 33
89
FUEL + OIL
ITEM
Fuel type
Reserve
Engine oil type
Engine oil capacity
Final gear oil type
SPECIFICATION
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.
10.6 L
2.6 L
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)
190 ml
(6.4/6.7 US/lmp oz)
7/7
LT-Z400
ITEM
IN.
IN.
EX.
clearance
IN.
EX.
Valve guide I.D.
The others
P
M
Unit: mm (in)
LIMIT
—
IN. & EX.
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
—
EX.
IN. & EX.
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
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)
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.
—
Cam height
Valve stem runout
ITEM
—
IN. & EX.
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)
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.
E-28, 33
A
S
VALVE + GUIDE
Valve diam.
NOTE
15th pin
—
—
—
—
0.05
(0.002)
0.5
(0.02)
ITEM
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)
Cylinder distortion
—
—
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
1st
—
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)
—
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
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
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Crankshaft runout
—
—
LIMIT
ITEM
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)
(No. 1 & No. 2)
(No. 1 & No. 2)
—
—
3/7
Engine coolant type
—
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)
Type
Gap
Spark performance
Regulated voltage
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
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
4/7
Headlight
HI
LO
—
—
Front
Rear
Front
Rear
Brake fluid type
←
#
PRE-SET
←
←
E-19, 28, 33
Front
Rear
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)
—
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
Front
Rear
Turning radius
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
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
—
LIMIT
—
—
—
—
—
—
—
—
0.5
(0.020)
CARBRETOR
E-19, 28, 33
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)
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
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
LIMIT
ITEM
—
0.08
(0.003)
10.3
(0.41)
STANDARD
at 3 000 r/min
Low
2nd
3rd
4th
Top
Reverse
Drive chain slack
OIL PUMP
ITEM
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
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
FUEL + OIL
ITEM
Fuel type
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
10.0 L (2.6/2.2 US/lmp qt)
2.7 L (0.7/0.6 US/lmp qt)
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 inside diameter
Camshaft journal runout
Cylinder head warp
Valve clearance
(Wobble method)
TIR 0.01 (0.0004) or less
IN.
IN. & EX.
IN.
EX.
Valve seat surface outside
diameter
IN.
EX.
Valve seat surface width
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.
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
Piston diameter
Piston ring/ring groove clearance
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)
ITEM
clearance
clearance
Crankshaft runout
—
—
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)
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
Friction plate/clutch housing
clearance
FINAL DRIVE
ITEM
Drive chain
Drive chain slack
Engline 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
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
(Fully compressed, spring
removed)
Rear shock absorber rebound
damping adjustment
(From the seated position; adjuster
turned fully clockwise)
preload adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear shock absorber spring free
length
Gas reservoir compression
damping adjustment
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
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
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
Unit: mm (in)
ITEM
Carburetor type
Starter jet
Leak jet
Main jet
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 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)
(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
Front fork compression damping
adjustment
Unit: mm (in)
STANDARD
Atmospheric pressure
LIMIT
—
12 clicks counterclockwise (EU)
(Adjustable
range)
16 clicks
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 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
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
clearance
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve seat width
(IN. & EX.)
(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 runout
Rocker arm I.D.
STANDARD
1 300 – 1 700 kPa
(13 – 17 kgf/cm2, 185 – 242 psi)
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
Piston pin bore
Piston pin O.D.
0.040 – 0.055
57.000 – 57.015
56.955 – 56.970
—
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 deflection
Crankshaft runout
1/6
ITEM
Low
2nd
3rd
4th
5th
Top
A
S
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
Primary
1.6 – 2.7 Ω
Secondary
18 – 26 kΩ
0.4 – 0.8 Ω
∞Ω
More than 2.0 V
More than 200 V
172 – 288 Ω
∞Ω
Regulated voltage
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
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
88.0 +0.1
-0
DID 428
132
Type
Links
20-pitch
length
Drive chain slack
Unit: mm (Except ratio)
LIMIT
—
—
—
—
—
—
—
—
0.50
—
—
—
—
Unit: mm
LIMIT
14.040
3.0
1.0
—
—
0.08
STANDARD
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
ITEM
Gear ratios
56.880
OIL PUMP
CLUTCH
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
—
Cam height
(M.J.)
(J.N.)
(N.J.)
(Th.V.)
(P.J.)
(P.S.)
3/6
Position light
Turn signal light
Speedometer light
E-02, 19
HI
LO
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
Brake drum I.D.
Brake disc runout
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
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
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 oil type
Rear wheel travel
FUEL + OIL
ITEM
Fuel type
Fuel tank including
reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
higher. An unleaded gasoline type is recommended.
7.5 L
1.8 L
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.
clearance
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
ITEM
Cam height
Rocker arm I.D.
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
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
—
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 deflection
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
STANDARD
at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
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
ITEM
Gear ratios
Low
2nd
3rd
Top
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
—
LIMIT
—
—
—
—
—
—
0.50
—
—
—
—
ELECTRICAL
ITEM
Spark plug
Type
Gap
Spark performance
Secondary
ITEM
Front brake cable play (SD110)
Brake drum I.D.
4.0 V and more
Brake disc thickness (SD110S)
Brake disc runout (SD110S)
Master cylinder bore (SD110S)
(SD110S)
(SD110S)
(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 oil type
adjuster
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.
10.5 L
2.0 L
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
Turn signal light
Speedometer light
DOT 4
ITEM
0.5 – 2.0 Ω
ITEM
Headlight
Fuel type
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
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
Regulated voltage
Battery
3/6
BRAKE + WHEEL
10 – 20 kΩ
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.
IN.
EX.
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.
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
IN. & EX.
IN. & EX.
—
IN. & EX.
—
Camshaft runout
IN. & EX.
—
IN. & EX.
—
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
(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)
166 – 192 N
(17.0 – 19.6 kgf, 36.60 – 42.33 lbs)
16th pin
—
ITEM
STANDARD
1 500 kPa
(15 kgf/cm2, 213 psi)
—
—
0.055 – 0.065
(0.0022 – 0.0026)
81.000 – 81.015
(3.1890 – 3.1896)
80.940 – 80.955
(3.1866 – 3.1872)
Cylinder bore
Piston diam.
Cylinder distortion
—
—
Piston ring end gap
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
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
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
at 3 000 r/min
LIMIT
Crank pin width
Crank pin O.D.
Crankshaft runout
2/10
ITEM
Gear ratios
Unit: mm (in)
ITEM
—
0.10
(0.004)
—
0.05
(0.002)
—
—
IN. & EX.
SV650
SV650S
SV650SU
SV650U
—
—
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)
(IN. & EX.)
SV650S
SV650
Low
2nd
3rd
4th
5th
Top
—
—
Drive chain
20-pitch
length
—
0.080
(0.0031)
—
Type
Links
0.080
(0.0031)
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
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
CLUTCH
—
Unit: mm (in)
ITEM
Clutch cable play
No. 1 & No. 2
No. 1 & No. 2
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)
—
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
ITEM
resistance
Cooling fan thermo-switch operating
temperature
Engine coolant type
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)
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)
—
—
—
—
—
—
—
—
—
—
—
ITEM
Injector resistance
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
TO sensor voltage
GP switch voltage
Injector voltage
NOTE
SPECIFICATION
130 – 240 Ω
3.7 V (When cranking) and more
4.5 – 5.5 V
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
SPECIFICATION
1.2
NGK: CR8E
DENSO: U24ESR-N
0.7 – 0.8 mm
(0.028 – 0.031 in)
130 – 240 Ω
2–5Ω
Primary
Secondary
Crankshaft position sensor peak voltage
(When cold)
Regulated voltage
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
Unit: W
ITEM
Headlight
ITEM
60 W × 2
55 W × 2
5W
LED
21 W
5W
LED
LED
LED
LED
LED
LED
SV650
Front
Rear
Brake disc runout
—
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
Front
Rear
Front
Rear
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
SPECIFICATION
SV650
E-03, 24, 28, 33
60 W
55 W
SV650S
HI
LO
Turn signal light
License light
Speedometer 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
SV650S
SV650
SV650S
SV650
SPECIFICATION
17G0 (Others), 17G1 (For E-33)
39 mm
1 800 – 2 400 r/min at 25 °C (77 °F)
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
SV650
SV650S
TIRE
ITEM
(Solo riding)
Front
(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 oil type
—
SV650S
—
—
—
—
1.6
(0.06)
2.0
(0.08)
pre-set length
Rear wheel travel
Engine oil type
Engine oil capacity
ITEM
Valve diam.
IN.
EX.
IN.
EX.
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)
IN. & EX.
—
Valve stem runout
IN. & EX.
—
—
—
—
—
—
—
—
—
IN. & EX.
—
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
0.03
(0.001)
41.2
(1.62)
IN. & EX.
—
IN. & EX.
197 – 227 N
(20.1 – 23.1 kgf, 44.3 – 51.0 lbs)
ITEM
Cam height
IN.
EX.
IN. & EX.
IN. & EX.
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
—
—
—
—
—
—
—
—
ITEM
STANDARD
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
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)
Cylinder distortion
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
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
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)
—
Unit: mm (in)
LIMIT
37.48
(1.476)
36.08
(1.420)
0.150
(0.0059)
SV650
SV650S
SV650SU
SV650U
10/10
—
0.35
(0.014)
0.05
(0.002)
0.5
(0.02)
—
STD/SPEC.
NOTE
Others
16 L (4.2/3.5 US/lmp gal)
E-33
17 L (4.5/3.7 US/lmp gal)
Others
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
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
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
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)
Crank pin width
Crank pin O.D.
Crankshaft runout
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
0.05
(0.002)
—
OIL PUMP
ITEM
STANDARD
at 3 000 r/min
LIMIT
No. 1
No. 2 and 3
No. 1
No. 2 and 3
STANDARD
2.92 –
(0.115 –
3.72 –
(0.146 –
13.85 –
(0.545 –
13.90 –
(0.547 –
—
28.1
(1.11)
14.000 – 14.043
(0.5512 – 0.5528)
13.957 – 13.984
(0.5495 – 0.5505)
diam.
3/9
ITEM
Drive chain
Type
Links
20-link
length
A
S
20 – 30
(0.8 – 1.2)
—
55 – 65
(2.2 – 2.6)
—
ITEM
Injector resistance
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
TO sensor voltage
GP switch voltage
Injector voltage
SPECIFICATION
3.7 V and more
130 – 240 Ω
4.5 – 5.5 V
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
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
—
—
—
—
—
—
—
—
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)
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)
Type
Gap
Spark performance
Crankshaft position sensor
resistance
voltage
Regulated voltage
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
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
—
—
—
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
Heated oxygen sensor output
voltage
NOTE
LIMIT
ITEM
Gear ratio
Low
2nd
3rd
4th
5th
Top
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)
—
—
ITEM
STANDARD
Thermostat valve opening tem86.5 – 89.5 °C
perature
(188 – 193 °F)
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
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
50:50.
Engine coolant
Reservoir
Approx. 250 ml
(0.3/0.2 US/lmp qt)
tank side
—
LIMIT
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
diam.
Clutch fluid type
—
CLUTCH
ITEM
ITEM
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
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)
Turn signal light
Speedometer/Tachometer light
Coolant temperature/oil pressure/FI indicator light
License light
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
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
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
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)
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)
(without spring, inner tube fully
compressed)
Front fork oil type
LIMIT
—
298
(11.7)
147
(5.8)
—
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
Rebound
force adjuster
Compression
—
FUEL + OIL
Engine oil type
Engine oil capacity
Rear
Wheel rim size
adjuster
—
NOTE
—
TIRE PRESSURE
kPa
250
250
—
STANDARD
130
(5.1)
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
—
—
5
Front
Brake disc runout
(Front & Rear)
LIMIT
Wheel axle runout
LED
ITEM
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
ITEM
202
(8.0)
—
—
—
—
—
—
—
8/9
E-02, 03, 19, 24, 28, 33
E-19
101
SV1000SD/SF
VALVE + GUIDE
ITEM
Valve diam.
IN.
EX.
IN.
EX.
IN.
EX.
Valve guide I.D.
IN. & EX.
Valve stem O.D.
IN.
EX.
Valve stem runout
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.
—
—
—
—
ITEM
—
—
—
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.
—
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)
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.
IN. & EX.
IN. & EX.
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
1st
Crank pin width
2nd
Crank pin O.D.
Crankshaft runout
P
M
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
0.05
(0.002)
STANDARD
at 3 000 r/min
LIMIT
OIL PUMP
ITEM
ITEM
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
No. 1
No. 2 and 3
diam.
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)
—
Drive chain
—
LIMIT
—
—
—
—
—
—
—
—
—
—
—
—
ITEM
Gear ratio
Low
2nd
3rd
4th
5th
Top
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)
3/9
—
ITEM
STANDARD
Thermostat valve opening tem86.5 – 89.5 °C
perature
(188 – 193 °F)
Over 8.0 mm (0.31 in) at 100 °C (212 °F)
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
50:50.
Engine coolant
Reservoir
Approx. 250 ml
(0.3/0.2 US/lmp qt)
tank 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)
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)
2nd
—
A
S
ITEM
—
—
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)
ITEM
LIMIT
STANDARD
—
Valve seat width
STANDARD
0.15 – 0.29
(0.006 – 0.011)
—
ITEM
Cam drive idle gear/sprocket
thrust clearance
4/9
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
319.4
(12.6)
—
—
E-02, 03, 19, 24, 28, 33
E-19
102
ITEM
Injector resistance
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
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)
2.0 – 4.0 mm
(0.08 – 0.16 in)
FI-SENSORS
ITEM
TO sensor voltage
GP switch voltage
Injector voltage
SPECIFICATION
3.7 V and more
130 – 240 Ω
4.5 – 5.5 V
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
19.1 – 19.7 kΩ
1.4 V and less
0.6 V and more (From 1st to top)
Battery voltage
Heated oxygen sensor output
voltage
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
Turn signal light
Speedometer/Tachometer light
Coolant temperature/oil pressure/FI indicator light
License light
5
BRAKE + WHEEL
ITEM
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)
—
Front
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
MICHELIN: PILOT SPORT E
MICHELIN: PILOT SPORT L
Front
—
Rear
—
Tire size
Unit: mm (in)
(without spring, inner tube fully
compressed)
Front fork oil type
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
Radial
Unit: mm (in)
LIMIT
—
When cranking
Wheel axle runout
Tire type
LED
5.0 V and more
200 V and more
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
voltage
Regulated voltage
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)
Type
Spark performance
Crankshaft position sensor
resistance
4.5 – 5.5 V
Approx. 0.58 kΩ
Approx. 4.38 kΩ
7 – 14 Ω
0.4 V and less at idle speed
0.6 V and more at 3 000 r/min
5/9
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)
—
—
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
Rebound
force adjuster
Compression
Rear wheel travel
199.3
(7.85)
—
—
—
—
—
—
—
—
—
—
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
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
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)
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 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
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
ITEM
Camshaft runout
Rocker arm I.D.
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
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
Piston pin bore
Piston pin O.D.
CONROD + CRANKSHAFT
ITEM
Conrod deflection
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
STANDARD
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
---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
Drive belt width
length
STD/SPEC.
9.965 (45/17 × 64/17)
22.1
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
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.)
More than 1.3 V
Primary
0.09 – 0.13 Ω
Secondary
15.4 – 18.1 kΩ
More than 150 V
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
Engine coolant temperature switch
resistance
Electric fan thermo-switch operating temperature
Engine coolant type
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 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 oil type
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.
10.0 Liter
Full
4 – 10 Ω
Empty
90 – 100 Ω
Change
1 200 ml
Filter
1 300 ml
change
Overhaul
1 500 ml
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
Turn signal light
License light
Speedometer light
Fuel meter light
Water temp. meter 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
Generator Max.output
(When cold)
Regulated voltage
Battery
NOTE
E-02, 19
6/6
E-02, 19
105
UH150
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (When cold)
Lash-adjuster plunger stroke
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
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
IN. & EX.
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.
—
Valve seat width
ITEM
Cam height
Camshaft
clearance
Valve headjournal
radial oil
runout
Valve spring
free length
Camshaft
journal
holder I.D.
(INTAKE)
(EXHAUST)
Camshaft
runout
Valve spring
tension (INTAKE)
Rocker
arm I.D.
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)
20.3 – 23.3 kgf
(44.75 – 51.37 Ibs)
IN.
IN.
EX.
EX.
1/6
1/8
Camshaft
journal holder I.D.
Cylinder distortion
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
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 —
Cylinder bore
Camshaft
journal oil clearance
Piston
diam.
Piston ringjournal
end gap
Camshaft
O.D.
Camshaft runout
2nd
Oil
1st
2nd
Rocker arm I.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
Cylinder bore
Piston diam.
CLUTCH
ITEM
Cylinder
distortion
Clutch wheel
I.D.
Clutch engagement
Clutch lock-up
STANDARD
0.02 – 0.03
Above(0.0008
120 kPa
(1.2 kgf/cm2)
– 0.0012)
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
16.006 —
– 16.014
Conrod deflection
---Conrod big end +
side
clearance+ PISTON RING
0.10 – 0.45
CYLINDER
PISTON
16.95 – 17.00
ITEM
STANDARD
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
peak voltage
ITEM
Generator
Max.
output bore
Clutch master
cylinder
(Whenmaster
cold) cylinder piston
Clutch
diam.
Regulated
voltage
Clutch release
cylinder bore
Starter
relay resistance
Battery
diam.
Fuse size
DRIVE
TRAIN
WATTAGE ITEM
ITEM
Headlight
HI
LO
Gear ratios
Low
2nd
3rd
Turn signal light
4th
License light
Top
Speedometer light
Fuel meter light
Water
temp.
meter
light
Shift fork
groove
width
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)
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
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
—
82
(3.23)
0.03 – 0.15
(0.001 – 0.006)
0.03 – 0.64
(0.001 – 0.025)
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
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
–
23.015 – 23.0234.0 mm
(0.9061 – 0.9064)
0.10 – 0.20
THERMOSTAT
+ RADIATOR + FAN + ENGINE
COOLANT
(0.004 – 0.008)
ITEM
STD/SPEC.
21.95 – 22.00
Thermostat valve opening temper(0.864
0.866)
Approx.– 82
°C
ature
Crank pin width
22.10 – 22.15
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
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
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
CAMSHAFT++PISTON
CYLINDER
CYLINDER
+ PISTON
HEAD RING
A
S
REDUCTION
GEAR + DRIVE BELT
ITEM
Piston ring endITEM
gap
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
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 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.
ITEM
Cam height
IN.
EX.
Camshaft runout
Rocker arm I.D.
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.
10.0 Liter
Full
4 – 10 Ω
Empty
90 – 100 Ω
Change
1 200 ml
Filter
1 300 ml
change
Overhaul
1 500 ml
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
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
←
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.)
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
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
—
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 deflection
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
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
No. 1
No. 2
No. 1 & 2
2.92 – 3.08
3.42 – 3.58
15.9 – 16.0
2.6
3.1
15.1
0.10
38.5
—
40.5
ITEM
Gear ratios
LIMIT
—
STANDARD
3.173 (73/23)
Low
2nd
3rd
4th
Top
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
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
NOTE
1.8 – 3.0 Ω
Primary
Secondary
18 – 28 kΩ
More than 250 V
Signal generator coil resistance
Regulated voltage
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
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
Turn signal light
Speedmeter light
E-19
←
←
4
←
←
←
←
←
←
BRAKE + WHEEL
Brake disc runout
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
(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
(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.
Including reserve
12.0 L
reserve
3.0 L
Change
1 800 ml
Filter change
1 900 ml
Overhaul
2 100 ml
NOTE
Unit: mm
ITEM
Front fork stroke
Front fork oil type
Rear wheel travel
4/6
TIRE
Tire type
Unit: mm
ITEM
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.
clearance
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
IN. & EX.
ITEM
Cam height
STANDARD
32.90 – 32.94
IN.
EX.
Camshaft runout
Rocker arm I.D.
Cylinder 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
2.92 – 3.08
3.42 – 3.58
15.9 – 16.0
—
43.0
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
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 – 4 mm
3/6
Piston ring end gap
Unit: mm (in)
LIMIT
—
2.6
3.1
15.1
0.10
40.9
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
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
Unit: mm (in)
LIMIT
15.040
3.0
1.0
—
—
0.080
STANDARD
15.006 – 15.014
Conrod deflection
Crankshaft runout
—
0.10 – 0.56
15.95 – 16.00
66.9 – 67.1
—
OIL PUMP
ITEM
STANDARD
20 – 70 kPa
(0.2 – 0.7 kgf/cm2)
at 3 000 r/min
LIMIT
—
E
L
P
M
CARBRETOR
ITEM
Cylinder bore
Piston diam.
E-19, 24
STANDARD
10 – 15
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
—
1/6
CLUTCH
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
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
More than 250 V
Signal generator coil resistance
Regulated voltage
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
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
Turn signal light
Speedmeter 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
Brake disc runout
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 oil type
Rear wheel travel
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.
IN.
EX.
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
—
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)
65 – 74 N
(12.09 – 13.91 kgf, 26.65 – 30.67 lbs)
12.000 –
(0.4724 –
11.966 –
(0.4711 –
—
—
ITEM
—
—
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)
—
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)
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
—
1/8
—
—
—
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)
IN. & EX.
INNER
ITEM
Rocker arm I.D.
—
—
—
—
—
1.6 mm
2.0 mm
E-19, 24
—
—
—
6/6
Camshaft runout
—
OUTER
STD/SPEC.
12.0 L
3.0 L
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
IN. & EX.
IN. & EX.
INNER
ITEM
Fuel type
Valve seat width
—
Front
FUEL + OIL
—
– 5.512
– 0.2170)
– 5.490
– 0.2161)
– 5.470
– 0.2154)
IN. & EX.
Tire tread depth
—
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)
Tire size
—
0.35
(0.014)
Front
Rear
—
—
EX.
Valve stem runout
(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
(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
STANDARD
1st
—
2nd
—
1st
2nd
Oil
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)
—
Crank pin width
Crank pin O.D.
—
—
—
Unit: mm (in)
LIMIT
20.040
(0.7890)
0.30
(0.012)
—
—
No.1
TRANSMISSION
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
No.1
No.1
No.2
—
—
ITEM
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)
Type
Gap
Spark performance
Primary
2–6Ω
Secondary
15 – 30 kΩ
LIMIT
—
—
(When engine cold)
Regulated voltage
Battery
Fuse size
160 – 300 Ω
0.2 – 1.5 Ω
More than 1.5 V
Pickup coil
Charging coil
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 →
temperature
ON
ON →
OFF
Engine coolant type
Use an antifreeze/coolant compatible with aluminum radiators, mixed with distilled water only, at the
ratio of 50:50
1 500 ml
(1.6 US qt, 1.3 lmp qt)
4/8
ITEM
—
—
58.5
(2.30)
—
5/8
Drive side
ITEM
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
3/8
LIMIT
—
—
—
—
—
—
—
—
0.50
(0.020)
0.50
(0.020)
SHAFT DRIVE
0.05
(0.002)
STANDARD
at 3 000 r/min
No.1
No.2
OIL PUMP
ITEM
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)
—
—
—
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
CLUTCH
—
—
WATTAGE
Unit: W
ITEM
E-03, 28, 33
60
55
—
Headlight
—
21/5
Turn signal light
21/5 (Front), 21 (Rear)
Speedometer light
LED
Engine coolant temp. warning light
LED
LED
LED
LED
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 oil level (without spring)
Front fork oil type
adjuster
Rear wheel travel
140
(5.51)
551.7
(21.73)
177
(6.96)
412 ml
(24.0 US oz, 25.0 lmp oz)
—
Brake drum I.D.
Rear
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
Front
Front
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.
—
reserve
(flicker)
—
Engine oil type
Engine oil capacity
—
—
2.0
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
—
—
—
—
EX.
Valve stem runout
IN. & EX.
—
IN. & EX.
—
IN.
—
0.05
(0.002)
0.5
(0.02)
2.5
(0.10)
2.2
(0.09)
Rocker arm I.D.
IN.
EX.
IN. & EX.
—
(INTAKE)
INNER
—
OUTER
—
0.03
(0.001)
35.0
(1.38)
37.8
(1.49)
40.6
(1.60)
—
OUTER
5.3 – 6.5 kgf
(11.68 – 14.33 Ibs)
14.0 – 14.2 kgf
(30.86 – 31.31 Ibs)
20.3 – 23.3 kgf
(44.75 – 51.37 Ibs)
1/8
—
IN.
EX.
—
—
ITEM
(Automatic de-compression
actuated)
Campression pressure difference
Cylinder bore
—
Cylinder distortion
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)
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
—
—
– 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
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
25.012
rear head right side
(0.9847
19.959
rear head left side
(0.7858
24.959
(0.9826
Front & Rear
—
(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
17.0 L
1.5 L
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
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)
—
—
—
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)
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)
Wheel axle runout
(Dual riding)
—
Unit: mm (in)
LIMIT
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)
ITEM
(Solo riding)
—
BRAKE + WHEEL
ITEM
—
TIRE
105
(4.13)
(4)
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)
—
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
2nd
1st
2nd
Oil
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
Crank pin width
Crank pin O.D.
Crankshaft journal I.D.
thickness
—
STANDARD
1.154 (76/51 × 31/40)
at 3 000 r/min
CLUTCH
—
—
—
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)
23.030
(0.9067)
22.980
(0.9047)
diam.
Unit: mm (in)
diam.
LIMIT
23.040
(0.9071)
0.3
(0.012)
—
0.05
(0.002)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
DRIVE TRAIN
—
—
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
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)
178 – 242 Ω
More than 2.4 V
1–7Ω
Type
Gap
Spark performance
Signal coil resistance
Primary
Secondary
Regulated voltage
De-comp. solenoid resistance
Fuel pump resistance
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
NOTE
Bl – G
tap – tap
Plug cap –
tap
B/Y – Ground
W – Ground
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
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
Turn signal light
5/8
—
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
—
—
LIMIT
—
Unit: mm (in)
STANDARD
2.90 – 3.10
(0.114 – 0.122)
15.6 – 15.8
(0.614 – 0.622)
—
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
ITEM
—
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
Fuel level warning 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
Front
Front
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
STANDARD
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Rocker arm I.D.
IN. & EX.
—
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)
—
—
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)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
IN. & EX.
—
INNER
—
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
EX.
Valve clearance
(when cold)
clearance
Valve stem O.D.
IN. & EX.
IN.
IN.
OUTER
—
6.51 – 7.49 kgf
(14.35 – 16.51 lbs)
12.09 – 13.91 kgf
(26.65 – 30.67 lbs)
INNER
OUTER
Cam height
—
—
—
—
—
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
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)
—
—
1st
R
Approx. 10.5 (0.413)
2nd
R
Approx. 11.8 (0.465)
0.20
(0.008
0.20
(0.008
1st
2nd
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
LIMIT
0.10
(0.004)
—
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
octane (R/2+M/2) or 91 octane or higher rated by
15.0 L
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)
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
set length
Rear wheel travel
—
Wheel axle runout
Tire size
LIMIT
—
Front
STANDARD
140
(5.5)
585
(23.03)
169.0
(6.65)
222.0
(8.74)
118
(4.6)
Unit: mm (in)
ITEM
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
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
1st
2nd
Piston pin bore
Piston pin O.D.
Crank pin width
Crank pin O.D.
Crankshaft runout
—
—
—
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)
—
—
0.080
(0.0031)
—
0.080
(0.0031)
—
—
—
diam.
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
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.)
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
←
←
←
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
←
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.)
36 mm
38E5
1 200 ± 50 r/min
27.7 ± 1.0 mm
(1.09 ± 0.04 in)
#
5D35-1st
←
←
←
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)
Approx. 50 – 200 Ω (G – Bl)
Primary
2–6Ω
Secondary
(When engine cold)
Regulated voltage
Starter motor brush length
Commutator under-cut
Battery
Fuse size
E-03, 28, 33
—
4/9
Spark performance
SPECIFICATION
E-28
ITEM
—
E
L
—
A
S
ITEM
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
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 –
diam.
—
—
ITEM
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
ITEM
—
CONROD + CRANKSHAFT
ITEM
CLUTCH
LIMIT
STANDARD
1st
Headlight
Signal
Ignition
Main
Power source
15 – 40 kΩ
NOTE
tap – tap
Plug cap –
tap
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
Turn signal light
Speedometer light
Water temp. meter light
License light
BRAKE + WHEEL
ITEM
STANDARD
20 – 30
(0.8 – 1.2)
40
(1.6)
Brake drum I.D.
Rear
—
Front
5.0 ± 0.2
(0.20 ± 0.01)
—
Front
Front
Front
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
reserve
Engine oil type
Engine oil capacity
Front fork oil type
(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
—
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
THERMOSTAT + RADIATOR + FAN
ITEM
temperature
Radiator cap valve release
pressure
Electric fan thermoswitch operating
temperature
Front
E-03, 28, 33
SPECIFICATION
11.0 L
12.0 L
3.0 L
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
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.
IN.
EX.
Valve guide I.D.
Valve stem runout
OUTER
—
—
ITEM
—
EX.
IN. & EX.
—
—
IN. & EX.
—
IN. & EX.
—
INNER
—
OUTER
—
(EXHAUST)
—
—
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.
—
—
—
(INTAKE)
IN.
EX.
0.9 – 1.3
(0.04 – 0.05)
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)
14.0 – 14.2 kgf
(30.86 – 31.31 lbs)
20.3 – 23.3 kgf
(44.75 – 51.37 lbs)
—
—
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 seat width
—
IN. & EX.
rear head left side
rear head left 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.
IN.
EX.
ITEM
1 000 – 1 400 kPa
(10 – 14 kgf/cm2, 142 – 199 psi)
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)
Cylinder distortion
Piston ring end gap
—
1st
T
Approx. 14.5 (0.57)
2nd
T
Approx. 11.5 (0.45)
1st
2nd
1st
2nd
1st
2nd
Oil
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
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)
Crank pin width
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)
at 3 000 r/min
LIMIT
—
OIL PUMP
ITEM
—
—
—
CLUTCH
—
ITEM
No. 1
23.030
(0.9067)
22.980
(0.9047)
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
—
No. 1
—
No. 2
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
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)
—
E-03, 28, 33
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
STANDARD
35.700 – 35.762
(1.4055 – 1.4079)
35.650 – 35.675
(1.4035 – 1.4045)
diam.
TRANSMISSION
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
STANDARD
No. 1
No. 2
No. 3
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)
Drive side
ITEM
Carburetor type
—
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
A
S
Primary
Secondary
Regulated voltage
Starter motor brush length
Commutator under-cut
De-comp. solenoid resistance
Side stand and neutral relay
Fuel pump resistance
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
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
HI
LO
Parking or city light
Turn signal light
Running light
Speedometer light
—
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
Front
Rear
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
License light
A
A
A
A
A
#110
#
PRE-SET
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
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)
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
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)
—
adjuster
Rear wheel travel
Unit: mm (in)
NOTE
LIMIT
STANDARD
2/5
105
(4.1)
—
—
0.30
(0.012)
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
reserve
Engine oil type
Engine oil capacity
Front fork oil type
(each leg)
Bevel gear oil type
Bevel gear oil capacity
Brake fluid type
SPECIFICATION
13.0 L
3.0 L
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)
—
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)
clearance
IN. & EX.
IN.
EX.
Valve stem runout
IN. & EX.
—
IN. & EX.
—
—
Camshaft runout
—
Rocker arm I.D.
IN. & EX.
IN. & EX.
IN. & EX.
—
IN. & EX.
—
0.03
(0.001)
38.3
(1.51)
40.1
(1.58)
6.51 – 7.49 kgf
(14.35 – 16.51 lbs)
12.09 – 13.91 kgf
(26.65 – 30.67 lbs)
INNER
OUTER
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
IN. & EX.
INNER
ITEM
—
Valve seat width
OUTER
—
0.05
(0.002)
0.5
(0.02)
3.1
(0.12)
E
L
E-03, 28, 33
A
S
VALVE + GUIDE
Valve diam.
NOTE
12.000
(0.4724
11.966
(0.4711
—
—
1 500 kPa
(15 kg/cm2, 213 psi)
Campression 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)
—
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
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)
ITEM
—
0.10
(0.004)
—
—
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
LIMIT
STANDARD
1st
2nd
Oil
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)
Crank pin width
Crank pin O.D.
Crankshaft journal bearing I. D.
—
—
—
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
pressure
TRANSMISSION
ITEM
Gear ratios
OIL PUMP
ITEM
LIMIT
—
STANDARD
1.364 (83/44 × 34/47)
at 3 000 r/min
—
Drive chain
Type
Links
20-pitch
length
E
L
Drive chain slack
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
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
←
←
←
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
—
—
—
—
—
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.)
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
←
←
←
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
—
—
2.62
(0.103)
3.12
(0.123)
15.1
(0.594)
0.10
(0.004)
24.6
(0.97)
23.3
(0.92)
—
Engine coolant temperature switch
—
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
CLUTCH
—
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
←
←
←
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.)
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
←
←
←
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
Primary
1·2
NGK: DPR8EA-9
DENSO: X24EPR-U9
0.8 – 0.9
(0.031 – 0.035)
170 – 280 Ω
2–6Ω
Secondary
(when engine cold)
Regulated voltage
Battery
Fuse size
Unit: mm (in)
NOTE
SPECIFICATION
G – Bl
tap – tap
Plug cap –
tap
Y–Y
0.2 – 1.5 Ω
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
—
Front
Turn signal light
—
Front
Front
Front
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
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
ITEM
Fuel type
reserve
Engine oil type
Engine oil capacity
Front fork oil type
(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
13.0 L
3.0 L
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
(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
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)
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
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
φ 25
φ 17
Rocker case bearing inside
diameter
φ 25
φ 17
Camshaft runout
TIR 0.02 (0.00079) or less
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
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
(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 outside diameter
IN.
EX.
Valve width
IN.
EX.
Outer
(IN. & EX.)
Inner
(IN. & EX.)
—
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
Top
Second
Piston ring end gap
Top &
Second
Top
Oil
A
S
ITEM
Connecting rod bend
STANDARD
—
Connecting rod twist
—
clearance
insert/crankpin clearance
Crankpin diameter
Marking
Connecting rod big end bore
diameter
Marking
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
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
Spring plate gap (usable range)
Friction plate/steel plate warp
FINAL DRIVE
—
ITEM
Final gear case oil
—
—
—
—
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
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
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)
260 – 280 kPa
(2.7 – 2.9 kgf/cm2, 38 – 41 psi)
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
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
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 pedal free play
Brake pedal position
Brake fluid grade
—
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
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
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 rebound damper setting
(Fully compressed, without fork
spring, below from inner tube top)
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 –
290 kPa (3.0 kgf/cm2, 43 psi)
—
—
ENGINE LUBRICATOIN SYSTEM)
ITEM
Engine oil type
Engine oil capacity
STANDARD
API SE, SF or SG
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
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
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
—
—
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 deflection
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
STANDARD
10 – 15
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
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
15 – 25 kΩ
120 – 200 Ω
0.1 – 1.0 Ω
0.1 – 1.5 Ω
Primary
Lighting
Charging
Magneto no-load voltage
Regulated voltage
Resistor resistance
Battery
Type designation
Capacity
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
A100X
Brake disc runout
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
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
# 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
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
WATTAGE
Headlight
Drive chain slack
P-42
A
S
ELECTRICAL
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
Gear ratios
Low
2nd
3rd
Top
Drive chain
Type
49.880
OIL PUMP
ITEM
Oil pump discharge rate (full open)
Tire size
Tire tread depth
SUSPENSION
ITEM
Front fork stroke
adjuster
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
reserve
Engine oil type
Engine oil tank capacity
Transmission oil type
Front fork oil type
Front fork oil capacity (eah leg)
Brake fluid type
SPECIFICATION
Gasoline used should be graded 85 – 95 octane or
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
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
Piston pin bore
Piston pin O.D.
STANDARD
0.06 – 0.07
41.005 – 41.020
40.940 – 40.955
—
—
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 deflection
Crankshaft runout
P
M
P-42
A
S
E
L
STANDARD
14.003 – 14.011
—
36.0 ± 0.05
—
Unit: mm
LIMIT
0.120
41.075
TRANSMISSION
ITEM
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
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
Spark performance
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
LIMIT
—
—
15.9
17.4
104.5
CARBURETOR
OIL PUMP
ITEM
Oil pump discharge rate
STANDARD
Variable 2.768 – 1.005
14.960 (51/15 × 66/15)
16.9
18.4
110
Regulated voltage
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
Turn signal light
Speedometer light
Fuel meter light
Trunk light
BRAKE + WHEEL
ITEM
Brake lever play
Brake drum I.D.
Brake disc runout
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
Rear wheel travel
ITEM
Cylinder bore
Piston diam.
Cylinder distortion
Piston ring end gap
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
SPECIFICATION
30.000 (30/1)
0.8 – 1.0 ml
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
Final gear oil type
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
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 deflection
Crankshaft runout
ITEM
Fuel type
STANDARD
77
124.7
60
STANDARD
0.035 – 0.045
41.010 – 41.025
40.970 – 40.985
—
—
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
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
Thermostat valve opening temperApprox. 65 °C
ature
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
OFF
Approx. 118 °C
Engine coolant type
ratio of 50:50.
1 200 ml
TRANSMISSION
ITEM
Reduction ratio
Drive belt width
STANDARD
Variable 2.975 – 1.033
16.271 (51/15 × 67/14)
18.4
110
LIMIT
—
—
—
—
—
—
—
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
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
SPECIFICATION
NGK: BPR6HS
DENSO: W20FPR
0.6 – 0.7
Over 8 at 1 atm.
Secondary
Charging
Pick-up
Regulated voltage
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
Turn signal light
Speedometer light
Fuel meter light
Water temp. indicator light
Trunk light
12 V 10.8 kC (3 Ah)/10 HR
10 A
ITEM
Unit: W
Headlight
ITEM
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
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
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
Final gear oil type
SPECIFICATION
6.8 L
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
Unit: mm (in)
CLUTCH
ITEM
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)
LIMIT
0.120
(0.0047)
ITEM
41.065
(1.6167)
40.880
(1.6094)
—
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
Cylinder bore
Piston diam.
Cylinder distortion
—
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
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
Gear ratios
—
12.030
(0.4736)
11.980
(0.4717)
DRIVE CHAIN
Unit: mm (in)
Drive chain
ITEM
STANDARD
16.003 – 16.011
(0.6300 – 0.6304)
Conrod deflection
—
LIMIT
16.040
(0.6315)
3.0
(0.12)
ITEM
—
CARBURETOR
STANDARD
60.950 (53/20 × 23/1)
0.8 – 1.1 ml
(0.027/0.028 – 0.037/0.039 US/lmp oz)
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
SPECIFICATION
NGK: BPR4HS
DENSO: W14FPR-UL
0.6 – 0.7
(0.024 – 0.028)
Secondary
Generator coil peak voltage
11 – 20 kΩ
More than 120 V
100 – 160 Ω
BRAKE + WHEEL
ITEM
STANDARD
15 – 25
(0.6 – 1.0)
20 – 30
(0.8 – 1.2)
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
Rear wheel travel
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
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
SPECIFICATION
2.0 L
Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality systhetic based 2-stroke engine oil rated FC under the
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
ITEM
STANDARD
0.040 – 0.050
(0.0016 – 0.0020)
49.000 – 49.015
(1.9291 – 1.9297)
48.955 – 48.970
(1.9274 – 1.9279)
Cylinder bore
Piston diam.
Cylinder distortion
—
—
1st &
2nd
T
Piston ring end gap
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)
No. 1
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
STANDARD
16.003 – 16.011
(0.6300 – 0.6304)
Conrod deflection
—
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
—
—
TRANSMISSION
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
(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
More than 140 V
BRAKE + WHEEL
STANDARD
20 – 30
(0.8 – 1.2)
20 – 30
(0.8 – 1.2)
10
(0.4)
Brake drum I.D.
Front
—
Rear
—
Wheel rim runout
Axial
—
Radial
—
Front
—
Rear
—
Wheel axle runout
3/5
Wheel rim size
Tire tread depth
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
—
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)
—
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
—
2.6
(0.10)
2.62
(0.10)
11.0
(0.43)
0.1
(0.004)
33.7
(1.33)
ITEM
Gear ratios
Low
2nd
3rd
4th
Top
LIMIT
pre-set length
Rear wheel travel
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
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
SPECIFICATION
Gasoline containing MTBE (MethyI Tertiary Butyl
4.1 L
LUBRICANT or an equivalent good quality synthetic based 2-stroke engine oil rated FC under the
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
Piston ring end gap
Piston pin bore
Piston pin O.D.
P-03
For the others
A
S
Piston diam.
P-03, 28
E
L
P
M
P-03, 28
LT50
ITEM
Cylinder bore
NOTE
Unit: mm
STANDARD
0.065 – 0.075
41.000 – 41.015
40.930 – 40.945
—
—
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
Gear ratios
0.05
0.05
3.6
4.0
0.75
—
—
12.030
11.980
Unit: mm
ITEM
Conrod deflection
Crankshaft runout
STANDARD
16.003 – 16.011
—
32.0 ± 0.1
—
LIMIT
16.040
3.0
—
0.05
OIL PUMP
ITEM
STANDARD
60.95 (53/20 × 23/1)
0.8 – 1.1 ml
CLUTCH
ITEM
Clutch wheel I.D.
Clutch shoe O.D.
Clutch engagement
Clutch lock-up
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
#50
3 – 5 mm
ELECTRICAL
ITEM
Spark plug
Spark performance
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.
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
SPECIFICATION
higher. An unleaded gasoline is reccomended.
1.5 L
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)
49.915 – 49.930
(1.9652 – 1.9657)
Cylinder distortion
—
—
1st
T
2nd
T
Piston ring end gap
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
P
M
Unit: mm (in)
CLUTCH
LIMIT
0.120
(0.0047)
ITEM
Clutch wheel I.D.
50.050
(1.9705)
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)
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
—
ITEM
Gears
Chain
Gear ratios
Drive belt width
—
—
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
ITEM
NOTE
—
LIMIT
16.040
(0.6315)
3.0
(0.12)
38.0 ± 0.1
(1.50 ± 0.004)
—
—
0.05
(0.002)
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
(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)
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)
Type
Gap
Spark performance
Primary
0.01 – 1.0 Ω
Secondary
10 – 20 kΩ
Battery
Type designation
Capacity
Fuse size
Circuit breaker
Charging
0.5 – 0.8 Ω
Primary
139 – 207 Ω
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)
Wheel axle runout
Wheel rim size
Tire size
SUSPENSION
ITEM
Front suspension stroke
—
8 × 5.5 AT
—
Front wheel travel
Rear suspension stroke
—
Fuel tank capacity
—
—
—
—
Engine oil type
including
reserve
reserve
P
M
A
S
OIL PUMP
LIMIT
0.120
(0.0047)
ITEM
Cylinder 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.
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
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
—
—
—
kPa
kgf/cm2
psi
15
20
0.15
0.20
2.2
2.9
2.0 L (0.53/0.44 US/lmp gal)
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)
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
Fuel type
STANDARD
0.065 – 0.075
(0.0026 – 0.0030)
41.000 – 41.015
(1.6142 – 1.6148)
40.930 – 40.945
(1.6114 – 1.6120)
ITEM
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
Brake drum I.D.
NOTE
CLUTCH
ITEM
Clutch wheel I.D.
STANDARD
87.00 – 87.15
(3.425 – 3.431)
—
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
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
—
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)
Type
Gap
Spark performance
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
—
—
—
—
—
—
—
—
–
4.0
(0.16)
4.0
(0.16)
kPa
kgf/cm2
psi
20
20
0.20
0.20
2.9
2.9
A
S
ENGINE TOP END
ITEM
Cylinder head warp
Piston diameter
Piston ring end gap
Piston pin 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
clearance
Crankshaft runout
Transmission gear backlash
Shift fork finger thickness
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
2.6 L
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
Jet needle
Pilot jet
Servise fuel level
Bore center
Float height
P-03
ITEM
Engine 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
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
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
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 end gap
Piston pin diameter
Small end inside diameter
Connecting rod bend
Connecting rod twist
clearance
Crankshaft runout
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
28.1
LIMIT
—
2.9
1.37
0.3
0.3
26.7
0.3 – 0.6
0.9
ENGINE RIGHT SIDE
ITEM
Steel plate thickness
Friction plate warp
Steel plate warp
Friction plate/clutch housing clearance
Unit: mm
FINAL DRIVE
Unit: mm
ITEM
11.995 – 12.000
12.001 – 12.011
16.002 – 16.013
ITEM
SHOWA SS-8 or SAE 5W-20
P-03, 24, 28
ENGINE TOP END
(completely dry)
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
Unit: mm
STANDARD
90.75
11.957 – 11.984
3/4
ITEM
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
SAE 10W-40
0.5 L
LIMIT
—
—
—
0.2 mm/100 mm
0.2 mm/100 mm
0.025 – 0.037
0.09
0.35 – 0.45
0.65
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 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
Jet needle
Needle jet
Slow jet
Air screw
Main air jet
Servise fuel level (below the bottom
edge of the carburetor body)
Float height
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
—
—
—
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
0.4 L
108 – 137 kPa
(1.1 – 1.4 kgf/cm2, 16 – 20 psi)
Coolant type
Coolant color
Coolant mixed ratio
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 fliud type
Brake disc runout
STANDARD
DOT 3 or DOT 4
Front &
Rear
Front &
Rear
Front &
Rear
Cylinder distortion
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
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)
—
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
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
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
Gear ratios
Low
2nd
3rd
4th
5th
Top
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)
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
(completely dry)
A
S
Piston diam.
Tire air pressure
Tire size
E-03, 21, 24, 28
RM85/L
Cylinder bore
Axle runout/100 mm
STANDARD
ITEM
Unit: mm
3/4
ITEM
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
Unit: mm (in)
STANDARD
10 – 15
(0.4 – 0.6)
2.7 – 2.9
(0.106 – 0.114)
—
—
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
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
Primary
SPECIFICATION
NGK: BR10ES
0.7 – 0.8
(0.028 – 0.031)
0.2 – 1.0 Ω
Secondary
12 – 20 kΩ
100 – 160 Ω
140 – 230 Ω
240 – 380 Ω
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
—
Front
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
Front
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
Brake fluid type
Front fork oil type
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 rate (each leg)
—
Rebound
Compression
2.6 N/mm (0.26 kgf/mm)
115
(4.53)
1 and 1/8 turns out
7 clicks out
0 kPa
(0 kgf/cm2, 0 psi)
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
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)
—
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
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
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
ITEM
Fuel type
Fuel tank capacity
Unit: mm (in)
NOTE
4/5
P-03, 28
137
RM100
ENGINE TOP END
ITEM
Cylinder head warp
Piston diameter
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
ITEM
Transmission oil level
clearance
Crankshaft runout
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
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
Jet needle
Pilot jet (Slow jet)
Air screw
Starter jet
Servise fuel level
(below the float bowl mating surface)
Float height
Reed valve warp
Unit: mm
1.0 ± 1
—
19 ± 1
—
—
—
0.2
COOLING SYSTEM
ITEM
Coolant type
Coolant color
Coolant mixed ratio
Coolant freezing point
STANDARD
Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)
Green
–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
0.80
Unit: mm
1/4
ITEM
0.90
LIMIT
ITEM
Friction and steel plate warp
ITEM
Magneto output voltage
Pickup coil air gap
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
SAE 10W-40
in middle of level gauge
0.65 L
ENGINE RIGHT SIDE
FINAL DRIVE
LIMIT
2/4
E-03, 24, 28
STANDARD
LIMIT
—
SUSPENSIONS
ITEM
Front fork compression damping
adjustment
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
Rear shock absorber compression
damper setting (upper)
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 total
amount
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
ITEM
CLUTCH
STANDARD
0.030 – 0.040
(0.0012 – 0.0016)
54.000 – 54.015
(2.1260 – 2.1266)
53.965 – 53.980
(2.1246 – 2.1252)
Cylinder bore
Piston diam.
Cylinder distortion
—
—
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 pin bore
Piston pin O.D.
LIMIT
0.120
(0.0047)
STANDARD
19.003 – 19.011
(0.7481 – 0.7485)
Conrod deflection
—
53.880
(2.1213)
0.05
(0.002)
0.05
(0.002)
3.4
(0.13)
0.80
(0.031)
No. 1, 2
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)
LIMIT
—
2.42
(0.094)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
—
39.78
(1.57)
RADIATOR
ITEM
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
—
CONROD + CRANKSHAFT
ITEM
ITEM
Clutch lever play
—
TRANSMISSION
ITEM
Gear ratios
No. 1, 2 & 3
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
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
ITEM
Type
Gap
Spark performance
Pick-up peak voltage
Exciter peak voltage
SPECIFICATION
5° B.T.D.C. at 1 000 r/min
NGK: R6918B-8
0.55 – 0.65
(0.022 – 0.026)
75 – 125 Ω
3 V and more
30 V and more
0.15 – 0.45 Ω
12 – 21 kΩ
Primary
Secondary
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)
Front
Rear
Brake disc runout
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 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
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)
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)
—
—
—
—
—
length
6.7 (0.26)
—
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
—
NOTE
—
310
(12.6)
—
—
0.3
(0.01)
TIRE PRESSURE
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
Front & Rear
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Fuel and engine oil mixture ratio
Front fork oil type
(each leg)
Engine coolant type
SPECIFICATION
octane (R/2 + M/2 method).
Use only unleaded gasoline of at least 95 octane
(Research method).
8.0 L
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)
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.
—
—
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
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
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
—
—
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)
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
ITEM
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)
39.78
(1.57)
RADIATOR + COOLANT
ITEM
Radiator cap valve release pressure
Engine coolant type
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
—
—
—
ITEM
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
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)
000, E-03, 28
—
2.77
(0.109)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
—
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
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
Primary
Secondary
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
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
Front
Rear
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
length
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
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
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)
494 mm
(19.45 in)
Front fork spring rate
4.4 N/mm
(0.44 kgf/mm)
Front fork oil type
OUTER: 362 ml (12.24/12.75 US/Imp oz)
INNER: 180 ml (6.08/6.34 US/Imp oz)
Compression
6 clicks turns back
Rebound
13 clicks tuns back
0 kPa
(0 kgf/cm2, 0 psi)
981 kPa
(9.8 kgf/cm2, 139.5 psi)
SUZUKI REAR SUSPENSION OIL SS-25 or
an equivalent rear suspension oil
380 ml (12.84/13.38 US/Imp oz)
E
L
P
M
—
STD/SPEC.
octane (R/2 + M/2 method).
Use only unleaded gasoline of at least 95 octane
(Research method).
8.0 L
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
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

2004_Service data_01E.book

Transcription

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