Valve and guide sleeve
Units: mm (in).
Name | Specification | Tolerance | |
Valve diameter | Inlet | 28.5 (1.12) | - |
Release | 25.0 (0.98) | - | |
Disc gap («when cold») | Inlet | 0.10 – 0.20 (0.004 – 0.008) | - |
Release | 0.20 – 0.30 (0.008 – 0.012) | - | |
Clearance between valve guide and stem | Inlet | 0.010 – 0.037 (0.0004 – 0.0015) | |
Release | 0.030 – 0.057 (0.0012 – 0.0022) | - | |
Valve stem deflection | Inlet and outlet | - | 0.35 (0.014) |
Valve guide (inner diameter) | Inlet and outlet | 4.500 – 4.512 (0.1772 – 0.1776) | - |
Valve guide (external diameter) | Inlet | 4.475 – 4.490 (0.1762 – 0.1768) | - |
Release | 4.455 – 4.470 (0.1754 – 0.1760) | - | |
Valve stem wear | Inlet and outlet | - | 0.05 (0.002) |
Valve head thickness | Inlet and outlet | - | 0.5 (0.02) |
Valve seat width | Inlet and outlet | 0.9 – 1.1 (0.035 – 0,043) | - |
Radial wear of valve head | Inlet and outlet | - | 0.03 (0.001) |
Valve spring free length (Inlet and outlet) | internal | - | 38.6 (1.52) |
external | - | 40.6 (1.60) | |
Valve spring tension (Inlet and outlet) | internal | 48 – 58 N (4.8 – 5.8 kgf, 10.6 – 12.8 lbs) at a length of 29.9 mm (1.18 in) | - |
external | 133 – 153 N (13.3 – 15.3 kgf, 29.3 – 33.7 lbs) at a length of 33.4 mm (1.32 in) | - |
Camshaft and cylinder head
Name | Specification | Tolerance | |
Cam height | Inlet | 35.32 – 35.36 (1.391 – 1.392) | 35.02 (1.379) |
Release | 35.22 – 35.26 (1.387 – 1.388) | 34.92 (1.375) |
Name | Specification | Tolerance |
Camshaft holder oil clearance | 0.032 – 0.066 (0.0013 – 0.0026) | 0.150 (0.0059) |
Camshaft holder (inner diameter) | 22.012 – 22.025 (0.8666 – 0.8671) | - |
Camshaft holder (external diameter) | 21.959 – 21.980 (0.8645 – 0.8654) | - |
Camshaft wear | - | 0.10 (0.004) |
Timing chain pin (on the arrow «3») | 17th pin | - |
Cylinder head deformation | - | 0.05 (0.002) |
Cylinder, piston and piston ring
Units: mm (in).
Name | Specification | Tolerance | |
Compression pressure | 1300 kPa (13 kgf/cm2, 185 psi) | 910 kPa (9.1 kgf/cm2, 129 psi) | |
Clearance between piston and cylinder | 0.015 - 0.025 (0.0006 – 0.0010) | 0.120 (0.0047) | |
Cylinder inner diameter | 73.000 – 73.015 (2.8740 – 2.8746) | Burrs and scratches | |
Piston diameter | 72.980 – 72.995 (2.8732 – 2.8738) measured 15mm from the edge of the skirt | 72.880 (2.8693) | |
Cylinder deformation | - | 0.05 (0.002) | |
Piston ring cut gap in free state | 1st | Approximately 7.6 (0.30) | 6.1 (0.24) |
2nd | Approximately 7.7 (0.31) | 6.2 (0.25) | |
Piston ring cut gap | 1st and 2nd | 0.08 – 0.20 (0.003 – 0.008) | 0.50 (0.02) |
Gap between piston ring and groove | 1st and 2nd | - | 0.180 (0.007) |
Piston ring groove width | 1st and 2nd | 1.01 – 1.03 (0.040 – 0.041) | - |
oil | 2.01 – 2.03 (0.079 – 0.080) | - | |
Piston ring thickness | 1st and 2nd | 0.97 – 0.99 (0.038 – 0.039) | - |
Inner diameter of the piston pin hole | 19.002 – 19.008 (0.7481 – 0.7483) | 19.030 (0.7492) | |
Piston pin outer diameter | 18.992 – 19.000 (0.7477 – 0.7480) | 18.980 (0.7472) |
Connecting rod and crankshaft
Name | Specification | Tolerance |
Top inner diameter (small) connecting rod heads | 19.006 – 19.014 (0.7483 – 0.7486) | 19.040 (0.7496) |
Connecting rod bend | - | 3.0 (0.12) |
Side clearance bottom (big) connecting rod heads | 0.10 – 0.55 (0.004 – 0.022) | 1.0 (0.04) |
Bottom width (big) connecting rod heads | 19.95 – 20.00 (0.785 – 0.787) | - |
Width between crankshaft cheeks | 64.0 +/- 0.1 (2.52 +/- 0.004) | - |
Crankshaft wear | - | 0.08 (0.003) |
Oil pump
Name | Specification | Tolerance |
Oil pump transmission ratio | 1.571 (33/21) | - |
Oil pressure (600°C, 1400°F) | More than 50 kPa (0.5 kgf/cm2, 7.1 psi) Less than 150 kPa (1.5 kgf/cm2, 21.3 psi) at 3000 rpm | - |
Clutch
Name | Specification | Tolerance |
Clutch handle play | 10 – 15 (0.4 – 0.6) | - |
Drive disc thickness | 2.92 – 3.08 (0.115 – 0.121) | 2.62 (0.103) |
Drive tooth width | 13.7 – 13.8 (0.539 – 0.543) | 12.9 (0.51) |
Drive disc deformation | - | 0.10 (0.004) |
Clutch spring free length | - | 39.0 (1.54) |
Transmission and drive chain
Units: mm (in) except for the gear ratio.
Name | Specification | Tolerance | |
Main gear ratio | 3.190 (67/21) | - | |
Final gear ratio | 3.769 (49/13) | - | |
Gearbox ratios | low | 2.416 (29/12) | - |
2nd | 1.733 (26/15) | - | |
3rd | 1.333 (24/18) | - | |
4th | 1.111 (20/18) | - | |
5th | 0.952 (20/21) | - | |
high | 0.826 (19/23) | - |
Name | Specification | Tolerance | |
Shift fork clearance | 0.1 – 0.3 (0.004 – 0.012) | 0.5 (0.02) | |
Groove width for gear shift fork | No. 1, No. 2 and No. 3 | 5.0 – 5.1 (0.197 – 0.201) | - |
Gear fork thickness | No. 1, No. 2 and No. 3 | 4.8 - 4.9 (0.189 – 0.193) | - |
Drive chain | Type | D.I.D. 520V2 | - |
Links | 112 | - | |
Length for 20 teeth | - | 319.4 (12.57) | |
Drive chain slack | 30 – 45 (1.2 – 1.8) | - |
Carburetor
Name | Specification | |
E-03,28 | E-33 | |
Carburetor type | TM28SS | BSR32 |
Channel diameter | 28 mm | 32 mm |
ID number | 13E3 | 13E4 |
Revolutions H.H. | 1600 +/- 100 rpm | 1500 +/- 100 rpm |
Float height | 14.2 +/- 1.0 (0.56 +/- 0.04) | 13.0+/- 1.0 (0.51 +/- 0.04) |
Main jet | #127.5 | #132.5 |
Jetting needle | 6FN3-3rd | 5DH46 |
Additional jet needle | P6M | P-0M |
Idle jet | #37.5 | #12.5 |
Idle speed screw | 1.25 turns back | 2.75 turns back |
Throttle cable play | 2 – 4 mm (0.08 – 0.16in) | 2 – 4 mm (0.08 – 0.16 in) |
Electrical equipment
Name | Specification | Note | |
Spark plug | Type | NGK:CR9E DENSO:U27ESR-N | |
Gap | 0.7 – 0.8 (0.028 – 0.031) | ||
Candle effectiveness | More than 8 (0.3) at sea level | ||
Ignition coil resistance | Primary | 0.1 – 1.5 Ohm | Terminal - Ground |
Secondary | 12 – 20 kOhm | Plug - Terminal | |
Primary ignition voltage | More than 150 V | +: Black/White -: White blue | |
Generator winding resistance | Charger | 0.7 – 1.5 Ohm | Yellow - Yellow |
Signal | 0.1 – 1.2 Ohm | White black | |
Crankshaft position sensor coil | 390 – 620 Ohm | Green - Blue |
Name | Specification | Note |
Maximum voltage of the crankshaft position sensor winding | More than 5 V | +: Green -: Blue |
Maximum signal voltage | More than 1.2 V | +: White -: Black |
Generator open circuit voltage (cold engine) | More than ~75 V (variable). at 5000 rpm | |
Adjustable voltage | 14.0 – 15.5 V (fast). at 5000 rpm | |
Starter relay resistance | 3 – 5 Ohm | |
Battery Capacity | FTZ5L-BS | |
Battery Type | 12 V 16.2 kC (4.5 Ah) /10 hours | |
Fuse current | 10 A |
Power consumption
Units: Watt.
Name | Specification |
Head light: High beam | *60 |
Head light: Low | *55 |
Brake light/Tail light | *21/5 |
Turn signal | *21 |
Speedometer backlight | *LED |
Neutral indicator | *2 |
Turn signal indicator | *2 |
High beam indicator | *2 |
Number plate illumination | *5 |
Brakes and wheels
Units: mm (in).
Name | Specification | Tolerance | |
Brake handle play | 0.1 – 0.3 (0.004 – 0.010) | - | |
Rear brake pedal height | 5 (0.2) | - | |
Brake disc thickness | Front | * 3.5 +/- 0.2 (0.138 +/- 0.008) | 3.0 (0.118) |
Rear | 4.0 +/- 0.2 (0.157 +/- 0.008) | 3.5 (0.138) | |
Brake disc wear | - | 0.3 (0.12) | |
Master Cylinder Inner Diameter | Front | 12.700 – 12.743 (0.5000 – 0.5017) | - |
Rear | 14.000 – 14.043 (0.5512 – 0.5529) | - | |
Master cylinder piston diameter | Front | 12.657 – 12.684 (0.4983 – 0.4994) | - |
Rear | 13.957 – 13.984 (0.5495 – 0.5506) | - | |
Wheel rim wear | axial | - | 2.0 (0.08) |
radial | - | 2.0 (0.08) | |
Wheel axle wear | front | - | 0.25 (0.010) |
rear | - | 0.25 (0.010) | |
Wheel rim size | front | J21x1.60 | - |
rear | J18x2.15 | - |
Tire
Name | Specification | Tolerance | |
Air pressure in | front | 100 kPa (1.00 kgf/cm2, 14 psi) | - |
cold tires | rear | 100 kPa (1.00 kgf/cm2, 14 psi) | - |
Tire size | front | 80/100-21 51M | - |
rear | 100/100-18 59M | - | |
Tread height | front | - | 4 mm (0.16 in) |
rear | - | 4 mm (0.16 in) |
Suspension
Name | Specification | Tolerance |
Front fork travel | 280 (11.0) | - |
Free length of front fork spring | 502.6 (19.79) | 492 (19.4) |
Front fork oil level | 143 (5.6) | - |
Front fork oil type | SUZUKU SS-07 or equivalent | - |
Front fork oil volume (each rack) | 526 ml (17.8 US/18.5 UK ounces) | - |
Front fork stiffness adjuster | Release: 8 clicks counterclockwise | - |
Compression: 7 clicks counterclockwise | - | |
Rear shock absorber gas pressure | 1000 kPa (10.00 kgf/cm2, 142 psi) | - |
Rear shock absorber spring length specified | 269.4 (10.6) | - |
Rear fork stiffness adjuster | Rebound: 3 turns counterclockwise | |
Compression: 1.25 turns counterclockwise | ||
Rear wheel travel | 285 (11.2) | - |
Pendulum axle wear | - | 0.3 (0.01) |
Fuel and oil
Name | Specification | Note | |
Fuel type | Use only unleaded (free of tetraethyl lead) gasoline with an octane number of at least 90. It is allowed to use gasoline containing methyl tert-butyl ether, less than 10% ethanol or less than 5% ethanol with appropriate additives and corrosion inhibitors. | ||
Fuel tank capacity | Including reserve | 10.5 l (2.8 American gallons, 2.3 imperial. gallon) | |
Reserve | 2.4 l (0.6 US gallon, 0.5 imperial. gallon) | ||
Engine oil type | SAE 10W/40, API SF or SG | ||
Engine oil capacity | Replacement | 1100 ml (1.2 American quarts, 1.0 imperial quarts) | |
Replacing the filter | 1200 ml (1.3 American quarts, 1.1 british quarts) | ||
Complete replacement (overhaul) | 1600 ml (1.7 American quarts, 1.4 imperial quarts) |