Suzuki 1989 GS500EK User manual

Dimensions andWeights. . . . . . . . . . . . . . . . . . .REF-1
Tools REF-2
Maintenance Techniques. . . . . . . . . . . . . . . . . . .REF-4
Motorcycle Chemicals and Lubricants. . . . . . . . .REF-S
MOTTestChecks REF-6
Storage REF-10
Dimensions and
"..'!i r' ,
Wheelbaee(W) 1 1410nvn
Overaillength(L) I ;... 2O75nWT1
Overallwidth I
Kmodels .
L, M. N, P and R models . . .. . .
S.TandVmodels
Overall height (H) ,. ~.~ ,!Seat height (S) };;: ;...
Minimumgroundclearance. .. .,.. . ... , ,.... ... ....... .. .
::c : ;',.
Weight (dry) .............. .. ,. """:':'~ ",..!,..,.,.,,!,::,
Reference REF-1
FaultFinding REF-12
FaultFindingEquipment. . . . . ...i . . . . . . . . .REF-20
Technical Terms Explained. . . . ... . . . . . . . . .REF-24
Conversion Factors REF-28
Index. . . . . . . . . . . . . . . . . . . . ...... . . . . . . . .REF-29
Weights
725 mm
755 mm
745mm
1045 mm
790 mm
155 mm
169 kg

Tools
REF.2
Buyingtools .& Warning:Toavoidtheriskofa the HaynesMotorcycle WorkshopPractice
A t Ik"t"f d t I I t f ,poor qualitytool breaking in use, Manual (Bk. No. 1454).
.?O I IS a u~. amen a requ remen or . causing Injuty or damage to the
servicing and repaJnnga motorcycle. Although com ent befi worked on M,.
therewill beaninitial.e~pens~in ~uildingup alwaysaimto:rchase t::1s which~t anufacturer s service tools
enoughtoolsfor.servicing,this will soon.be therelevantnationalsafetystandBtUs. Inevitablycertaintasksrequirethe use of a
offset by thesavingsmadeby doingthe Job servicetool. Where possible an alternative
yourself. Asexperienceandconfidencegrow, The following lists of tools do not represent tool or method of approach is recommended,
additional tools can be addedto enablethe themanufacturer'sservicetools, butserveas but sometimesthere is no optionif personal
repairand overf1aulof the motorcycle. Many of a guide to help the owner decide which tools injury or damage to the component is to be
the specialisttoolsareexpensiveandnotoften areneededfor thislevelof work. Inaddition, avoided.Whererequired,servicetools are
usedsoitmaybepre!erabletohirethem,orfor itemssuchas an electric drill, hacksaw, files, refetTedto intherelevantprocedure.
a group of friends or motorcycleclub to join in hammers, soldering iron and a workbench Service tools can usually only be purchased
the putdtase. equipped with a vice, may be needed. from a motorcycle dealer and are identifiedby
Asarule,it Isbetterto buy more expensive, Althoughnot classedastools,a selectionof a partnumber.Someof the commonly-used
goodqualitytools. Cheaper toolsare likely to bolts, screws, nuts, washers and pieces of tools, such as rotor pullers, are available in
wear out faster and need to be renewed more tubing always come in useful. aftermarket form from mail-order motorcycle
often, nullifying theoriginalsaving. For more information about tools, refer to tool and accessory suppliers.
Maintenance and minor repair tools
2 3' 4 5
--~ c ,..,
--,-
- 1- ... '
t_.~ ~.c.,,:==4;
..
(!) , ,'
~;;;;;;~~~;II.t
1 Setofflat-~
SCf8Wdrivefs
2 Set of PhJNipsh..t
screwdrlVets
3~~
& ring spenners
4 Socket set (JIB inch
or 1/2 inch drive)
5 Setof Allen keysor bits
6 SetofTOf]( keysCN'a'ts 12 Feelergauges 16 FIIVIe/and
7 PIers 8nd se/f-locking 13 Spsrlcplug gap ,,-.u,;ng vessel
grtps(A.4oIegrips) measuringand 17 Stf8P~. chain
8 AtfustabI8 spsmer sdjustJngtool WlW'Chor oi ffIter
9 C-.".vw (kJesJ/y 14 Spstfc~ sp.-vw (A) tWnov8 tool
8dju$tabIetype) or deeppiJg soc#(et(8) 18 at drBintray
10 Tyrepressuregauge(A) 15 ~ Ixush and 19 Pun., type oi can
& tI88d depth gauge(8) emery~ 20 Gt88Ie gill
11 Cablept8SSUf8oiler
,~'" ... .
~' ~
..-A: ,
21 SteelI1J.IefA)and
st/ai9fJt-edge(8)
22 Continuitytester
23 BatterychBIger
24 Hydrometer(forbattery
specific gravitycheck)
25 Anti-f18ezetester(for
1kIuid-cooIedengines)

I
5 CiIC1ippliefs(lntemaiand
extema/.or combination)
6 Set of punches
sndctJdchisels
7SMctionofpullets
Specialist tools
. .
T0015 REF.3
-;
~I
8BtBBkBrb8ts(A)
and length of tutN7ng(8)
9 ChahJtxeekingl
rivetb'Ig~
10 WiI8crimper tool
11 A'*JItRneter (mea8Jres
~ ~ and ohms)
12 St1oboscope(for
dynwnictimingchecks)
13 Hoseclamp
(wingnuttypeshown)
14 Magneticarm
(te/escopk;I)'pe.thown)
15 One-mantxBk8/~
b/eederkit
7 PIastIgaugekit 10 PistaJringrerrW)va/~ 13 Studextractor
8 Valvespringcompressor insW8tiontad 14 Saewextractorset
(4-strokeengines) 11 PistaJringc/81rf' 15 Bearingdriverset
9 PIstonpindtawboIttad 12 Cylinderbotehone
(srooetypeshown)

REF-4 Maintenance Techniques
Basic maintenance spec~fictorque value, which is noted in the loosened by striking it with a soft-faced
. Specifications.Besuretofollowthetorquerec. hammernearthe matingsurfaces.A normal
techni q ues ommendatlons~losely:. hammer can be used if a block of wood is
Fasteners laId out In a pattem (Ie cylinder placed between the hamme d the art Dhead bolts engl b It )r an p. 0
Therearea numberof techniquesinvolvedin loosen d 'r h;e ~a~e 0 s, etc. must ~ not hammeron cast parts or parts that could be
maintenanceand repair that will be referred to Wine t~ c~ en In a.~equenceto avoId easilydamaged. With any particularlystubborn
throU~hout this manual. Application of these S~ldg go on ~:~~i I~~'allyitheNbo~~uts part, always recheck to make sure that every
techniqueswill enablethe amateurmechanicto should be tightened on~ fu~~~;n e:~h Ine~ fasten~r~ been remo~.
be more efficient,be~er organlsedand capable criss-cross or diagonal pattem. After each one Avoid uSInga scl9Wdnveror bar to pry apart
of.performIngthe varioustasks properly, which has been tightened one full tum retum to the components, as they can easily mark the
will ensure that the repair job is thorough and first one tightened and tighten th~m all half gasket sealing surfaces of the parts (which
complete. . one must . th) If . .
tum, followingthe samepattem. Finally,tighten remain smoo . prying ISabsolutely
each of them one quarter turn at a time until necessary, use a piece of wood, but keep In
Fastening systems each fastenerhas been tightened to the proper mindthat.extra clean-up will be necessaryIfthe
Fasteners basicall are nut I torque. To loosenand removethe fastenersthe wOOdsplInters.
screws used to hOI~'two ors~~etsp=~~ procedurewouldbe reversed. Afterthepartsareseparated,theoldgasket
together.Therearea few thingsto keep in mind must be carefully scraped off and the gasket
whenworking with fasteners.Almost allof them . surfacesC~ed. Stubbom gasketmaterialcan
usea locking device of some type (eithera lock Disassembly sequence be soaked with a gasket remover (available in
washer, locknut, locking tab or thread locking Component disassembly should be done aerosol cans) to soften it so it c~n be easily
compound). All threaded fasteners should be with care and purpose to help ensure that the sr:'aped off. A scraper ~anbe fashlon~ from a
clean, straight, have undamaged threads and parts go back together properly during piece ~f copper tubing by flattening and
undamagedcomers on the hex headwherethe reassembly.Alwayskeeptrack of the sequence sharpening.one end. Copper is recommended
spanner fits. Develop the habit of replacing all in which parts are removed. Take note of becauseIt ISusuallysofter than the surfacesto
damagednuts and bolts with newones. special characteristics or marks on parts that be scraped, which reduces the chance of
Rustednuts and bolts should be treated with can be installed more than one way (such as gouging the part. Some gaskets can be
a penetrating oil to ease removal and prevent convex washers and gear pinions). It's a good removed with a wire brush, but regardless of
breakage.After applying the rust penetrant, let Idea to lay the disassembled parts out on a the method used,the mating surfacesmust be
it work for a few minutes beforetrying to loosen clean surface in the order that they were left clean and smooth. If for some reason the
the nut or bolt. Badly rusted fasteners may removed. It may also be helpful to make gasketsurface isgouged, then a gasketsealant
have to be chiselled off or removed with a sketchesor take instant photos of components thick enough to fill scratches will have to be
specialnut breaker,availableat tool shops. beforeremoval. used during reassembly of the components.
If a bolt or stud breaks off in an assembly,it Whenremovingfastenersfrom acomponent, For most applications, a non-drying (or semi-
can be drilled out and removed with a special keep track of their locations. Sometimes drying)gasket sealantis best.
tool called an E-Zout (orscrew extractor). Most threading a bolt back in a part, or putting the
dealer service departments and motorcycle washers and nut back on a stud, can prevent
repair shops can perform this task, as well as mix-ups later. If nuts and bolts can't be Hose removal f
others (such asthe repairof threadedholes retumedto theiroriginallocations,theyshould IpS
that have been stripped out). be kept in a compartmented box or a series of Hose removal precautions closely parallel
Washers should always be replaced exactly small bo~es or la~led plastic bags. A box of gasket removal precautions. Avoid scratching
asremoved.Replaceanydamagedwashers thIS type IS especiallyhelpfulwhenworkingon or gougingthe surfacethat the hosemates
with new ones. Always use a flat washer assemblieswithverysmallparts(such asthe againstortheconnectionmayleak.Becauseof
betweena lock washerand any soft metal carburettors,tappets,shimsetc). variouschemicalreactions,the rubber in hoses
surface(suchasaluminium),thinsheetmetalor Whenever wiring looms, harnesses or canbonditselfto themetalunionthatthehose
plastic.Speciallocknuts can only be usedonce ~onn.ectorsare separated,it's a goodideato fits over.To removea hose, first loosenthe
or twicebefore they lose their locking ability Identitythetwohalveswithnumberedpiecesof hose clamps thatsecureit totheunion.Then,
and must be replaced. masking tape so they can be easily withslip joint pliers, grab the hoseat the clamp
reconnected. androtateitarolKldtheunion.WOI'kitbackand
forthuntilit is completely free, then pull it off
(silicone or other lubricants will ease removalIf
Tightening sequences and Gasket sealing surfaces they can be applied between the hose and the
procedures Gasketsare usedto sealthe mating surfaces outsid~ o~the union).Apply the same lubricant
between components and keep lubricants, to the InSIdeof the hoseand the outside of the
Whenthreaded fastenersare tightened, they fluids, vacuum or pressure contained in an unionto simplify installation.
are often tightened to a spe~ific torque value assembly. If the hose is particularly stubborn, slit the
(torqu~ IS basically a twisting force). Over- Many times these gaskets are coated with a hosewith a sharp knifeand peel it off the union.
~Ightenlng the fastener ca.n weakenit andcause liquid or paste type gasket seating compound The hose will obviously be destroyed uq this
It to break, while under-tighteningcan cause it before assembly. Age, heat and pressure can method.
to eventuallyco":e loose.Eachbolt, depending sometimes cause the two parts to stick If a hose clamp is broken or damaged, do
on the material it s made of, the diameter of its together so tightly that they are very difficult to not reuse it. Also do not reuse hoses that
shankandthematerialit isthreaded into, hasa separate. In most cases, the part can be cracked,split or t~m. are

Motorcycle Chemicals and Lubricants REF-S
A number of chemicals and variety of additives to prevent corrosion brushed on and, depending on the type,
lubricants are available for use in and reduce foaming and wear. Motor oil are rinsed with either water or solvent,
motorcycle maintenance and repair. comes in various weights (viscosity .SItd I '
, ",oven s are use a one or In
They Include a wide variety of products ratings) of from 5 to 80, The bl t ' ' th d t I" "com na Ion WI egreasers 0 c ean
ranging from cleaning solvents and recommended weight of the 011depends rt d bl 'd . ' d" pa s an assem les urlng repair an
degreasers to lubricants and protective on the seasonal temperature and the h I Th h h ' h Idf bbe I t '
d ' I d h ' , . 1 ' over au, e ome mec anlc s ou
sprays or ru r, pas ICan vlny. deman s on t e engine. Ught 01 ISused I I t th t fl abl, Id I. t d d I' h I d use on y so ven s a are non- amm e
. Contact point/spark plug cleaner is In co,. c Ima es an . u.n er Ig ,t oa and that do not produce irritating fumes.
a solv t used to clean oily film and dirt conditions; heavy 011 IS used In hot
f en, t 'f I t 'I climates and where high loads are. Gasket sealing compounds may be
rom poln s, grime rom eec rica ' , , '
t d 'I d 't f k encountered. Multi-viscosity oils are used In conjunction with gaskets, to
connec ors an 01 eposl s rom spar . " ' , ,
plugs. It is 011 free and leaves no residue. designed to have characteristics of both Improve their sealing capabllltl~S.' or
It can also be used to remove gum and light and heavy oils and are available in a alone, to seal metal-to-metal JOints.
varnish from carburettor jets and other number of weights from 5W-20 to 20W- Many gasket sealers c~n wit,hstand
'fj 50 extreme heat, some are Impervious to
on ICes. '. . petrol and lubricants, while others are
. Carburettorcleaneris similarto . P~troladdrtl~esperfor,m sev~ral capable of filling and sealing large
contact poinVspark plug cleaner but it functions, depending on the~r chemical cavities. Depending on the intended use,
usually has a stronger solvent and may makeup. T~ey usually contain s~lvents gasket sealers either dry hard or stay
leave a slight oily reside. It is not that help dissolve gum and v~rnlsh that relatively soft and pliable. They are
recommended for cleaning electrical build up on carburettor and Inlet parts. usually applied by hand, with a brush, or
components or connections. They also serve to break down carbon are sprayed on the gasket sealing
, depositsthatformontheinsidesurfaces surfaces.
. Brake system cleaner ISused to of the combustion chambers, Some
remove grease or brake fluid from brake additives contain upper cylinder. Thread locking compound is an
system components (where clean lubricants for valves and piston rings. adhesive locking compound that
surfaces are absolutely necessary and prevents threaded fasteners from
petroleum-based solvents cannot be . Brake and clutch fluid is a specially loosening because of vibration. It is
used); it also leaves no residue. fo,rmulated hydraulic fluid that can available in a variety of types for different
. . . withstand the heat and pressure applications.
. SIlicone-basedlubrIcantsare used encountered in brake/clutch systems.
to protect rubber parts such as hoses Care must be taken that this fluid does. Moisture dispersants are usually
and, gromme~s, and are used as not come in contact with painted spray~ that can be used to dry out
lubricants for hinges and locks. surfaces or plastics. An opened electrical components such as the fuse
. Multi-purposegreaseis an all container should always be resealed to block and wiring connectors. Some
purpose lubricant used wherever grease prevent contamination by water or dirt. types can also be used as treatment for
, , ", rubber and as a lubricant for hinges,
IS more practical than a liquid lubricant. Chain lubricants are formulated bl dh 'I S It' ca esan locks,
~uc as 01, ome r:nu I-purpose grease especially for use on motorcycle final
IS coloured white and specially drive chains A good chain lube should. Waxes and polishes are used to
formulat~ to be more resistant to water adhere well ~nd have good penetrating help protect pajnt~ and plated surfac.es
than ordinary grease. qualities to be effective as a lubricant from the ~eather. Dlffere~t types of paint
. Gear oil (sometimes called gear lube) inside the chain and on the side plates, may req~lre the use of d~erent ~~ of
is a specially designed oil used in pins and rollers, Most chain lubes are wax ~ollsh. Some, polishes utilise a
transmissions and final drive units, as either the foaming type or quick drying chemical or abrasive clea~~r to help
well as other areas where high friction, type and are usually marketed as sprays. rer:nove the top la.yer of oxldlsed (dull)
high temperature lubrication is required. Take care to use a lubricant marked as paint on older vehl?les. In recent ye.ars'
It is available in a number of viscosities being suitable for O-ring chains. many non.-wax polishes, (that contain a
(weights) for various applications. wide variety of, ?hemlcals such as
. Degreasers are heavy duty solvents polymers and silicones) have been
. Motor oil, of course, is the lubricant used to remove grease and grime that introduced. These non-wax polishes are
specially formulated for use in the may accumulate on engine and frame usually easier to apply and last longer
engine. It normally contains a wide components. They can be sprayed or than conventional waxes and polishes.

REF-6 MOT Test Checks
About the MOT Test
Inthe UK, all vehicles more than three years
old are subject to an annual test to ensure that
they meet minimum safety requirements. A
current test certificate must be issued before
a machine can be used on public roads, and
is required before a road fund licence can be
issued. Riding without a current test
certificate will also invalidate your insurance.
For most owners, the MOT test is an annual
cause for anxiety, and this is largely due to
owners not being sure what needs to be
checked prior to submitting the motorcycle
for testing. The simple answer is that a fully
roadworthy motorcycle will have no difficulty
in passing the test.
This is a guide to getting your motorcycle
through the MOT test. Obviously it will not be
possible to examine the motorcycle to the
same standard as the professional MOT
ElectricalSystem
Lights, turn signals,horn and
reflector
V' With the ignition on, check the operation
of the following electrical components. Note:
The electrical components on certain small-
capacity machines are powered by the
generator, requiring that the engine is run for
this check.
a) Headlight and tail light. Check that both
illuminate in the low and high beam
switch positions.
b) Position lights. Check that the front
position (orsidelight) and taillight
illuminate in this switch position.
c) Tum signals. Check that all flash at the
correct rate, and that the warning light(s)
function correctly. Check that the tum
signal switch wo'*$ correctly.
c) Hazard waming system (wherefitted).
Check that all four tum signals flash in this
switch position.
d) Brake stop light. Check that the light
comes on when the front and rear brakes
are independently applied. Models first
used on or after 1stApril 1986must have
a brake light switch on each brake.
e) Hom. Check that the sound is continuous
and of reasonable volume.
V' Check that there is a red reflector on the
rear of the machine. either mounted
separately or as part of the taillight lens.
V' Check the condition of the headlight. tail
lightandtumsignallenses.
tester, particularly in view of the equipment
required for some of the checks. However,
working through the following procedures will
enable you to identify any problem areas
before submitting the motorcycle for the test.
It has only been possible to summarise the
test requirements here, based on the
regulations in force at the time of printing. Test
standards are becoming Increasingly stringent,
although there are some exemptions for older
vehicles. More Information about the MOT test
can be obtained from the HMSO publications,
How Safe is your Motorcycle and The MOT
Inspection Manual for Motorcycle Testing.
Many of the checks require that one of the
wheels is raised off the ground. If the
motorcycle doesn't have a centre stand, note
that an auxiliary stand will be required.
Additionally, the help of an assistant may
prove useful.
Certain exceptions apply to machines
under 50 cc, machineswithout a lighting
system,andClassicbikes- if in doubtabout
any of the requirementslisted below seek
confirmation from an MOT tester prior to
submittingthemotorcycleforthetest.
Check that the frame number is clearly
visible.
Headlight beam height
tI' The MOT tester will perform a headlight
beam height check using specialised beam
setting equipment (see Illustration 1). This
equipment will not be available to the home
mechanic, but if you suspect that the
headlight is incorrectly set or may have been
maladjusted in the past, you can perform a
rough test as follows.
tI' Position the bike in a straight line facing a
brick wall. The bike must be off its stand,
upright and with a rider seated. Measure the
height from the ground to the centre of the
headlight and mark a horizontal line on the
wall at this height. Position the motorcycle
3.8 metres from the wall and draw a vertical
Headlight beam height checking
equipment
line up the wall central to the centreline of the
motorcycle. Switch to dipped beam and
check that the beam pattern falls slightly
lower than the horizontal line and to the left of
theverticalline(seeillustration 2).

Exhaust System and Final Drive
II' Check that the exhaust mountingsare
secureandthatthesystemdoesnotfoulany
oftherearsuspensioncomponents.
II' Startthe motorcycle.Whenthe revsare
increased.checkthat the exhaustis neither
holednorleakingfrom anyof itsjoints.Ona
linkedsystem.checkthatthecollectorboxis
notleakingduetocorrosion.
SteeringandSuspension
!!: testerwill~ acheckofthesteeringhead .
Steering bearinglower~ bymountingthefrontwheel Front suspenSIon
on a surfaceplate,thenperforminga lockto
lockcheckwiththeweightofthemachineon
thelowerbearing(seeillustration3).
II' Withthefrontwheelraisedofftheground, II' Graspthe fork sliders (lowerlegs)and II' Withthe motorcycleoff the stand, hold
rotate the steering from lock to lock. The attemptto push and puli on the forks (see thefrontbrakeonandpumpthefrontforksup
handlebaror switchesmust not contact the illustration 4). Anyplayinthe steeringhead and down (S88illustration 5). Checkthat
fueltankorbecloseenoughtotraptherider's bearingswili be felt. Note that in extreme theyareadequatelydamped.
hand.Problemscan becausedby damaged cases,wearof thefront fork bushescanbe II' Inspectthe areaaboveand aroundthe
lockstopsontheloweryokeandframe,or by misinterpretedforheadbearingplay. frontfork oil seals(seeIllustration 8).There
thefittingof non-standardhandlebars. II" Checkthat the handlebarsaresecurely should be no sign of oil on the fork tube
II' Whenperformingthe lockto lock check, mounted. (stanchion)norleakingdownthe slider(lower
also ensurethat the steeringmoves freely II' Checkthatthehandlebargriprubbersare leg).Onmodelssoequipped,checkthatthere
witOOutdragornotd1iness.Steeringmov«nent secure.Theyshouldbybondedtothebarleft isnooilleakingfromtheanti-diveunits.
canbeimpairedbyPOOI1yroutedcables,orby end and to the throttle cable puliey on the II' On models with swingarm front
overtightheadbearingsor wornbearings.The rightend. suspension,checkthatthereIsnotreeplayin
thelinkagewhenmovedfromsidetoside.
Frontwheelmountedon a surfaceplate
for steeringheadbearinglowerracecheck
Hold the front brake on and pump the front
forks up and down to check operation
MOT Test Checks REF-?
II' Note that the exhaust decibel level
("loudness" of the exhaust) is assessed at the
discretion of the tester. If the motorcycle was
first used on or after 1st January 1985 the
silencer must carry the BSAU 193 stamp, or a
marking relating to its make and model, or be
of OE (original equipment) manufacture. If the
silencer is marked NOT FOR ROAD USE,
RACING USE ONLY or similar. it will fail the
MOT.
Finaldrive
t! On chainor belt drive machines.check
that the chain/beltis in good conditionand
does not haveexcessiveslack. Also check
thatthe sprocketis securelymountedonthe
rear wheel hub. Check that the chain/belt
guardisinplace.
t! Onshaftdrivebikes.checkfor oil leaking
fromthedriveunitandfoulingthereartyre.
Rear suspension
tI' Withthe motorcycleoff thestandandan
assistantsupporting the motorcycle by its
handlebars.bouncetherearsuspension(see
illustration 7). Check that the suspension
componentsdo not foul on anyof the cycle
parts and check that the shock absorber(s)
provideadequatedamping.
Checking the steering head bearings
for freeplay
Bounce the rear of the motorcycle
to check rear suspension operation

Checkingfor rearsuspensionlinkageplay
tI Visuallyinspecttheshockabsorber(s)and
checkthatthereisnosignof oilleakagefrom
its damper.This is somewhatrestricted on
certain single shock models due to the
locationoftheshockabsorber.
tI With the rear wheel raised off the
ground,graspthe wheelat the highestpoint
Brakes, Wheels and Tyres
tI' On disc brakes, examine the flexible systems are properly maintained. For
Brakes hosesfromtop to bottom.Haveanassistant hydraulicdisc brakes,checkthe fluid level,
holdthebrakeonsothatthefluidinthehose lever/pedalfeel(bleedof airif its spongy)and
is underpressure,andcheckthatthereis no pad material. For drum brakes, check
. . sign of fluid leakage,bulgesor cracking. If adjustment,cableor rod operationandshoe
tI' With the wheel rals~ off the ground, there are any metalbrake pipes or unions, liningthickness.
applythebrakethenfreeit off,andcheckthat checkthat thesearefreefromcorrosionand
the wheelis aboutto revolvefreelywithout damage. Where a brake-linked anti-dive
brakedrag. systemisfitted,checkthehosesto theanti- "
tI' On disc brakes,examinethe disc itself. diveinasimilarmanner. Wheels and tyres
Checkthat it is securelymountedand not tI' Checkthat the rearbraketorque armis
cracked. secureandthat its fastenersaresecuredby
tI' On disc brakes,view the pad material self-lockingnutsorcastellatednutswithsplit-
throughthecalipermouthandcheckthatthe pinsor A-pins(seeillustration13). tI' Checkthe wheelcondition.Castwheels
padsarenotwomdownbeyondthelimit(see tI' OnmodelswithABS,checkthatthe self- shouldbefreefromcracksandif of thebullt-
IHustI'ation11). checkwarninglight in the instrumentpanel up design, all fastenersshould be secure.
tI' On drum brakes,check that when the wOf1<s. Spoked wheels should be checked for
brake is applied the angle between the tI' TheMOTtesterwillperformatestof the broken,corroded,looseorbentspokes.
operatingleverand cable or rod is not too motorcycle's brakingefficiencybasedon a tI' Withthewheelraisedofftheground,spin
great(see illustration 12).Check also that calculation of rider and motorcycleweight. thewheelandvisuallycheckthatthetyr8end
the operating lever doesn't foul any other Althoughthis cannotbecarriedout at home, wheelruntrue.Checkthat the tyre does not
components. you can at least ensure that the braking foulthesuspensionormudguards.
Brakepadwearcanusuallybeviewed
without removingthe caliper.Most pads
havewear indicatorgrooves(1)andsome
alsohaveindicator tangs (2)
Wornsuspensionlinkagepivots(arrows)
areusuallythe causeof playinthe rear
suspension
andattemptto pullit up (seeIllustration 8).
Anyplayintheswingarmpivotorsuspension
linkagebearingswill be felt as movement.
Note: Do not confuse play with actual
suspensionmovement.Failureto lubricate
suspension linkage bearings can lead to
bearingfailure(seeillustration9).
Grasp the swingarmat the endsto check
for play in its pivot bearings
With the rear wheel raised off the ground,
grasp the swingarm ends and attempt to
move the swingarm from side to side and
forwards and backwards - any play indicates
wear of the swingarm pivot bearings (see
illustration 10).
Ondrumbrakes,checktheangleof the
operatingleverwith the brakefully applied.
Mostdrum brakeshaveawearindicator
pointerandscale.
Brake torque am1 must be properly
secured at both ends

Checkfor wheelbearingplaybytrying to
movethewheelaboutthe axle(spindle)
Castellatedtypewheelaxle(spindle)nut
mustbesecuredbya split pin or A-pin
t' With the wheel raised off the ground,
graspthewheelandattemptto moveit about
the axle(spindle)(see illustration 14).Any
playfelthereindicateswheelbearingfailure.
t' Check the tyre tread depth, tread
Generalchecks andcondition
II' Checkthe securityof all major fasteners.
bodypanels. seat, fairings (where fitted) and
~udguards.
Sidecars
A motorcyclefitted with a sidecarrequires
additionalchecksrelatingto the stability of
the machineand securityof attachmentand
MOT Test Checks REF-9
Tyre direction of rotation arrow can be
found on tyre sidewall
USE, COMPETITION USE ONLY or similar,
will fail the MOT.
., If the tyre sidewall carries a direction of
rotation arrow, this must be pointing In the
direction of normal wheel rotation (...
illustration 16).
., Checkthatthe wheel axle (spindle) nuts
(where applicable) are properly secured. A
self-locking nut or castellated nut with a split-
pin or A-pin can be used (see Illustration 17).
., Wheel alignment is checked with the
motorcycle off the stand and a rider seated.
With the front wheel pointing straight ahead,
two perfectly straight lengths of metal or wood
and placed against the sidewalls of both tyres
(see ilklSb'ation 18).The gap each side of the
front tyre must be equidistant on both sides.
Incorrect wheel alignment may be due to a
cocked rear wheel (often as the result of poor
chain adjustment) or in extreme cases, a bent
frame.
Twostraightedgesareusedto check
wheelalignment
condition and sidewall condition (see
illustration15).
'" Checkthe tyretype. Frontand reartyre
typesmustbecompatibleandbesuitablefor
road use. Tyres marked NOT FOR ROAD
81' Checkfor corrosionon the frameor any
load-bearingcomponents.If severe,this may
affectthestructure,particularlyunderstress.
V Check that the rider and pillion footrests,
handlebar leyers and brake DedaJare securely
mounted.
swivel joints, plus specific wheel alignment
(toe-in) requirements. Additionally, tyre and
lighting requirements differ from conventional
motorcycle use.Ownersareadvisedto check
MOTtest requirementswith an official test
centre.

REF.10 Storage
Preparing for storage
remove the spark plugs and fit them back in
their caps; ensure that the plugs are earthed
(grounded) against the cylinder head when the
starter is operated (see illustration 3).
Warning: It is important that the
/:\ plugs areearthed(grounded)
ili awayfrom the sparkplug holes
otherwisethereis arisk of
atomisedfuel from the
cylindersigniting.
Before you start
If repairs or an overhaul is needed, see that
this is carried out now rather than left until you
want to ride the bike again.
Give the bike a good wash and scrub all dirt
from its underside. Make sure the bike dries
completely before preparing for storage.
Engine
. Remove the spark plug(s) and lubricate the
cylinder bores with approximately a teaspoon
of motor oil using a spout-type oil can (see
Illustration 1). Reinstall the spark plug(s).
Crank the engine over a couple of times to
coat the piston rings and bores with oil. If the
bike has a kickstart. use this to tum the engine
over. If not. flick the kill switch to the OFF
position and crank the engine over on the
starter (see illustration 2). If the nature on the
ignition system prevents the starter operating
with the kill switch in the OFF position,
Squirta drop of motor oil into each
cylinder
...and ensure that the metal bodies of the
plugs (arrows) are earthed against the
cylinder head
=Onasinglecylinderfour-
. strokeengine,youcanseal
HIN thecombustionchamber
completelybypositioning
thepistonatroc onthecompression
stroke. Battery
. Removeitfromthe bike -in extreme cases
of cold the battery may freeze and crack its
case (seeIllustration6).
Connectahoseto the carburettorfloat
chamberdrain stub (arrow)andunscrew
the drain screw
. Drainthe carburettor(s)otherwise there is a
risk of jets becoming blocked by gum
deposits from the fuel (see ilklsb'8tlon4).
. If the bike is going into long-term storage,
consider adding a fuel stabiliser to the fuel in
the tank. If the tank Is drained completely,
corrosion of its internal surfaces may occur if
left unprotected for a long period. The tank
can be treated with a rust preventative
especially for this purpose. Alternatively,
remove the tank and pour half a litre of motor
011into it, install the filler cap and shake the
tank to coat its intemals with oil before
draining off the excess. The same effect can
also be achieved by spraying WD40 or a
similar water-dispersant around the inside of
the tank via its flexible nozzle.
. Make sure the cooling system contains the
correct mix of antifreeze. Antifreeze also
contains important corrosion inhibitors.
. The air Intakes and exhaust can be sealed
off by covering or plugging the openings.
Ensure that you do not seal in any
condensation; run the engine until it is hot.
then switch off and allow to cool. Tape a piece
of thick plastic over the silencer end(s) (see
illustration 5). Note that some advocate
pouring a tablespoon of motor oil into the
silencer(s)beforesealingthemoff.
Disconnect the negative lead (A)first,
followed by the positive lead (8)
. Checktheelectrolytelevel and top up if
necessary (conventional refillable batteries).
Clean the terminals.
. Store the battery off the motorcycle and
away from any sources of fire. Position a
wooden block under the battery if it is to sit on
the ground.
. Give the battery a trickle charge for a few
hours every month (seeillustration7).

Tyres
. Placethe bike on its centrestandor an
auxiliary stand which will support the
motorcyclein an upright position. Position
woodblocksunderthetyresto keepthemoff
the ground and to provide insulationfrom
damp.If the bikeis beingput Intolong-term
storage,ideallyboth tyresshouldbe off the
ground;notonlywillthisprotectthetyres.but
will alsoensurethat no loadis placedonthe
steeringheadorwheelbearings.
. Deflateeachtyreby 5 to 10 psi. no more or
the beadsmayunseatfromthe rim, making
subsequent inflation difficult on tubeless
tyres.
Storage REF.11
Pivots and controls
. Lubricateall lever,pedal,standand
footrest pivot points. If greasenipplesare
fitted to the rear suspensioncomponents.
not compressthe forks otherwisethe seals
willrotfromcontactwiththeVaseline.
. Applyavinylcleanerto theseat.
Storage ns
apply lubricant to the pivots.
. Lubricate all control cables. . Aimto storethe bike ina shedor garage
whichdoesnotleakandisfreefromdamp.
. Drapean old blanketor bedspreadover
the bike to protect it from dust and direct
contactwith sunlight(whichwill fadepaint).
This also hides the bike from prying eyes.
Bewareof tight-fitting plastic coverswhich
mayallowcondensationto formandsettleon
thebike.
Cycle components
. Applya wax protectant to all painted and
plastic components. Wipe off any excess, but
don't polish to a shine. Wherefitted, clean the
screen with soap and water.
. Coat metal parts with Vaseline (petroleum
jelly). When applying this to the fork tubes, do

REF.12 FaultFinding
This Section provides an easy reference-guide to the more common
faults that are likely to afflict your machine. Obviously, the
opportunities are almost limitless for faults to occur as a result of
obscure failures, and to try and cover all eventualities would require a
book. Indeed, a number have been written on the subject.
Successful troubleshooting is not a mysterious 'black art' but the
application of a bit of knowledge combined with a systematic and
logical approach to the problem. Approach any troubleshooting by first
accurately identifying the symptom and then checking through the list
1Engine doesn't start or Is difficult to start
0 Startermotordoesn'trotate
0 Startermotorrotatesbutenginedoesnottumover
0 Starterworksbutenginewon'ttumover(seized)
0 Nofuelflow
0 Engineflooded
0 Nosparkorweakspark
0 Compressionlow
0 Stallsafterstarting
0 Roughidle
2Poor running at low speed
0 Sparkweak
0 Fuel/airmixtureincorrect
0 Compressionlow
0 Pooracceleration
3 Poor running or no power at high speed
0 FIringincorrect
0 FueValrmixtureincorrect
0 Compressionlow
0 Knockingor pinging
0 Miscellaneouscauses
4 Overheating
0 Engineoverheats
0 FIringIncorrect
0 FueVairmixtureJncorrect
0 ComPfMSiontoohigh
p engine1089excessive-
0 Lubricationinadequate
0 Miscellaneouscauses
5 Clutch problems
Clutch slipping
Clutch not disengaging completely
shifting problems
Doesn'tgointogear,orleverdoesn'treturn
Jumpsoutof gear
Overshifts
:0
Q
of possiblecauses,startingwith the simplestor most obviousand
progressinginstagesto themostcomplex.
Takenothingfor granted,but aboveall apply liberalquantitiesof
commonsense.
Themainsymptomofafaultisgiveninthetextasa majorheading
belowwhicharelistedthevarioussystemsorareaswhichmaycontain
thefault.Detailsof eachpossiblecausefor a faultandthe remedial
actionto betakenaregiven,in brief,in the paragraphsbeloweach
heading.FurtherinformationshouldbesoughtintherejevantChapter.
7Abnonnal engine noise
0 Knockingor pinglng
0 Pistonslaporrattling
0 Valvenoise
0 Othernoise
8 Abnonnal driveline noise
0 Clutchnoise
0 Transmissionnoise
0 Finaldrivenoise
9Abnormal frame and suspension noise
0 Frontendnoise
0 Shockabsorbernoise
0 Brakenoise
10011pressure indicator light comes on
0 Enginelubricationsystem
0 Electricalsystem
11 excessive exhaust smoke
0 Whitesmoke
0 Blacksmoke
0 Brownsmoke
12 Poor handling or stability
0 Handlebarhardto tum
0 Handlebarshakesorvibratesexcessively
0 Handlebarpullstooneside
0 Poorshockabsorbingqualities
13 Braking problems
0 Brakesarespongy.don'thold
0 Brakeleverorpedalpulsates
0 Brakesdrag
14 Electrical problems
0 Batterydeadorweak
0 Batteryovercharged

1 Engine doesn't start or is difficult to start
-
Stalter motor doesn't rotate [J Startingtechniqueincorrect.UndernormalcircumstancesO.e.,if
0 Enginekill switch OFF. all the carburettor functions are sound) the machine should start
0 Fuse blown. Check fuse (Chapter 8). with little or no throttle. When the engine is cold, the choke should
0 Battery voltage low. Check and recharge battery (Chapter8). be operated a~d ~heengine started without opening the th~ttle.
0 Startermotordefective.Makesurethewiringto thestarteris WhentheengineISatoperatingtemperature,only.averyslight
secure.Makesurethestarterrelayclickswhenthestartbuttonis amountofthrottleshould,ben~sary. Ifth~eng,".eis.flooded
pushed.Iftherelayclicks,thenthefaultisinthewiringormotor. hol~~hethr?ttleopenwhilecrankingtheengine.Thiswillallow
0 Starterrelayfaulty.CheckitaccordingtotheprocedureinChapter8. additionalairto reachthecytind9'S.
0 Starterswitchnotcontacting.Thecontactscouldbewet, No spark or weak spark
co:~ordirty.Disassembleand~~eantheswitch(Chapt~8), 0 IgnitionswitchOFF.
0 Wiringopenorshorted.CheckallWIringconnectionsand 0 E 'k'il 't ht edt th OFF it,
, nglne I SWI C urn 0 e pos Ion.
harnessesto makesurettlattheyaredry,tightandnotcorroded. 0 Batt Ita 10 Ch kand ech th batt
Alsocheckforbrokenorfrayedwiresthatcancauseashortto (Cherr v~) ge w. ec r arge e eryasnecessary
ground(earth)(seewiringdiagram,Chapt~8), aper .
0 Ignition(main)switchdefective.Checktheswitchaccordingtothe 0 Sparkpl~gsdirty,defective~ wornout,Locatereasonforfouled
procedureinChapter8. Replacetheswitchwithanewoneifit is plugsuSIngsparkplugconditIonchartandfollowtheplug
defecti maintenanceprocedures(Chapter1).
0 EngineV~ilswitchdefective.Checkforwet,dirtyorcorroded 0 Sparkpl~ capsorsecondary(HT)":firingfaulty.C~k ~Ition.
contacts.Cleanorreplacetheswitchasnecessary(Ch ter8). R~placeeitherorbothcomponentsIfcracksat detenoratlOOare
. ,ap evident(Chapter4).
0 Faulty neutral or side stand switch. Check the wiring to each 0 Sp kit makJ ood tact M k hat the
switch and the switch itself according to the procedures in ,..j ar p ugficapst nly°thnggl codn . a esuret
Chapter8. ~u~.caps I snug, over .epugen s'. .
0 Faultysidestandrelayordiode,Checkaccordingtotheprocedure 0 Ignition~ntrol Unitdefective.CheckttleUnit,refemngto Chapter
,Ch t 8 4fordetails.
In aper . 0 Pulsegeneratorcoilsdefective.Checkthecoils,referringto
Statter motor rotates but engine does not turn over Chapter4fordetails.
0 Starterclutchdefective.Inspectandrepairorreplace(Chapter2). 0 IgnitionHTcoilsdefective.Checkthecoils,referringto Chapter4
0 Damagedidle/reductiongearorstartergears.Inspectandreplace fordetaJls.
thedamagedparts(Chapter2), 0 Ignitionorkillswitchshorted.Thisisusuallycausedbywat~,
corrosion,damageorexcessivewear.Theswitchescanbe
Starter works but engine won't turn over (seized) disassembledandcleanedwithelectricalcontactcleaner.If
0 Seizedenginecausedbyoneor moreinternallydamaged cl~ning doesnothelp,replacetheswitches(Chapter8).
components.Failuredueto wear,abuseorlackoflubrication, 0 Wlnngshortedorbrokenbetween:
Damagecanincludeseizedvalves,followers,camshafts,pistons, a) Ignition(main)switchandenginekillswitch(orblownfuse)
crankshaft,connectingrodbearings,ortransmissiongearsor b) Ignitioncontrolunitandenginekillswitch
bearings.Referto Chapter2forenginedisassembly, c) IgnitioncontrolunitandignitionHTcoils
d)IgnitionHTcoilsandSparlcplugs
No fuel flow e) Ignitioncontrolunitandpulsegeneratorcoils
0 No,fuelintank, 0 Makesurethatallwiringconnectionsareclean,dryandtight.
0 Mainfuelcockfilterclogged.Removethefuelcockandcleanit Lookforchafedandbrokenwk'es(Chapters4and8).
andthefilter(Chapter3). .
0 Fuellineclogged.Pullthefuellinelooseandcarefullyblow CompressIon low
ttlroughit. [] Sparkplugsloose.Removetheplugsandinspecttheirthreads.
0 Floatneedlevalveclogged.Forbothofthevalvesto beclogged, Reinstallandtightentottlespecifiedtorque(Chapter1).
eitheraverybadbatchoffuelwithanunusuaJadditivehasbeen 0 Cylinderheadnotsufficientlytighteneddown.Ifthecylinderhead
used,orsomeotherforeignmaterialhasenteredthetank.Many issuspectedof beingloose,thenthere'sachancethatthegasket
timesafteramachinehasbeenstoredformanymonthswithout orheadisdamagediftheproblemhaspersistedforanylengthof
running,thefuelturnstoavarnish-likeliquidandformsdeposits time.Theheadboltsshouldbetightenedtothepropertorquein
ontheInletneedlevalvesandjets.Thecarburettorsshould be the correctsequence(Chapter2).
removedandoverhauledifdraJningthefloatchambersdoesn't 0 Impropervalveclearance.Thismeansthatthevalveisnotclosing
solvetheproblem(Chapter3). completelyandcompressionpressureisleakingpastthevalve.
Engln flooded Checkandadjustthevalveclearances(Chapter1).
e 0 Cylinderand/orpistonworn.Excessivewearwillcause
0 Float height incorrect. Check and adjust as necessary(Chapter3). compression pressure to leak past the rings. This is usually
0 Float needle valve worn or stuck open. A piece of dirt, rust or other accompanied by worn rings as well. A top-end overhaul is
debriscancausethevalvetoseatimproperly, causingexcessfuel necessary(Chapt~2).
to be admitted to the float chamber. In this case, the float chamber 0 Piston rings worn, weak, broken, or sticking. Brok«1 or sticking
shouldbecleanedandtheneedlevalveandseatinspected.Ifthe piston ringsusuallyindicatealubricationorCBl'burationproblem
needle and seat are worn, then the leaking will persist and the parts that causes excess carbon deposits or seizures to form on the
shouldbereplacedwithnewones(Chapter3). pistons and rings. Top-endoverhaulisnecessary(Chapter2).
Fault Finding REF.13

REF.14 Fault Finding
doesn't start or is difficult to start
1 Engine
Carburettormalfunction(Chapter3).
Fuelcontaminated.Thefuelcanbecontaminatedwitheitherdirt
orwater,orcanchangechemicallyifthemachineIsallowedtosit
forseveralmonthsormore.Drainthetankandfloatcham~
(Chapter3).
Intakeairleak.Checkforloosecarburettor-to-intakemanifold
connections,looseormissingvacuumgaugeadaptercaps,or
loosecarburettortops(Chapter3).
Engineidlespeedincorrect.Turnidleadjustingscrewuntilthe
engineidlesatthespecifiedrpm(Chapter1).
improperlytightenedheadbolts.Machineshopresurfacingor Rough Idle
headreplacementisnecessary(Chapter2).
0 Valvespringbrokenorweak.Causedbycomponentfailureor 0 Ignitionmalfunction(Chapter4).
wear;thespringsmustbereplaced(Chapter2). 0 Idlespeedincorrect(Chapter1).
0 Valvenotseatingproperly.Thisiscausedbyabentvalve(from 0 Carburettorsnotsynchronlsed.Adjustcarburettorswithvacuum
over-rewingorimpropervalveadjustment),bumedvalveorseat gaugeormanometerset(Chapter1).
(impropercarburation)oranaccumulationofcarbondepositson 0 Carburettormalfunction(Chapter3).
theseat(fromcarburationorlubricationproblems).Thevalves 0 Fuelcontaminated.Thefuelcanbecontaminatedwitheitherdirt
mustbecleanedand/orreplacedandtheseatsservicedif orwater,orcanchangechemicallyifthemachineisallowedto sit
possible(Chapter2). forseveralmonthsormore.Drainthetankandfloatchambers
0 Pistonring-to-grooveclewanceexcessive.Thisiscausedby
excessivewearofthepistonringlands.Pistonreplacementis
necessary(Chapter2).
0 Cylind« headgasketdamaged.Iftheheadisallowedto become
loose,orifexcessivecarbonbuild-uponthepistoncrownand
combustionchambercausesextremelyhighcompression,the
headgasketmayleak.Retorquingtheheadisnotalways
sufficientto restoretheseal,sogasketreplacementisnecessary
(Chapter2).
0 Cylinderheadwarped.Thisiscausedbyovett1eatingor
Stalls after starting
0 Improper choke action. Make surethe choke linkage shaft is
getting a full stroke and staying in the out position (Chapter 3).
0 Ignition malfunction (Chapter 4).
2 Poorrunningat low speeds
Battery voltage low. Check and recharge battery (Chapter 8).
Spark plugs fouled, defective or worn out (Chapter 1)
Spark plug cap or HT wiring defective (Chapters 1 and 4).
Spark plug caps not making contact. Make surethey are properly
connected.
Incorrect spark plugs. Wrong type, heat range or cap
configuration. Check and install correct plugs (Chapter 1).
Ignition control defective (Chapter 4).
Pulsegenerator coils defective (Chapter 4).
Ignition HT coils defective (Chapter 4).
Pilot screws out of adjustment (Chapter 3).
Pilot jet or air passage clogged. Remove and overhaulthe
carburettors (Chapter 3).
Air bleed holes clogged. Remove carburettor and blow out all
passages (Chapter 3).
Air filter clogged, poorly sealed or missing (Chapter 1).
Air filter housing poorly sealed. Look for cracks, holes or loose
clamps and replace or repair defective parts (Chapter3).
Fuel leveltoo high or too low. Check the float height (Chapter 3).
Carburettor intake manifolds loose. Check for cracks, breaks,
tears or loose clamps. Replacethe rubber intake manifold joints if
split or perished (Chapter 3).
Compression low
0 Spark plugs loose. Remove the plugs and inspect their threads.
Reinstalland tighten to the specified torque (Chapter 1).
0 Cylinder head not sufficiently tightened down. If the cylinder head
is suspected of being loose, then there's a chance that the gasket
or head is damaged if the problem has persisted for any length of
time. The head boits should be tightened to the proper torque in
the correct sequence (Chapter 2).
Fuel/air mixture incorrect
a
(continued)
e
a
0
0
(Chapter3).
0 Intake air leak. Check forloosecarburettor-to-intake manifold
connections,loose or missingvacuumgaugeadaptercaps, or
loose carburettor tops (Chapter 3).
0 Air filter clogged. Replacethe air filter element (Chapter 1).
0 Improper valve clearance. This means that the valve Is not closing
completely and compression pressure Is leaking past the valve.
Check and adjust the valve clearances (Chapter 1).
0 Cytinder and/or piston worn. Excessivewear will cause
compression pressure to leak past the rings. This Is usually
accompanied by worn rings as well. A top-end overhaul is
necessary (Chapter2).
0 Piston rings wom, weak, broken, or sticking. Broken or sticking
piston rings usually indicate a lubrication or carburation problem
that causes excess carbon deposits or seizures to form on the
pistons and rings. Top-end overhaul is necessary (Chapter 2).
0 Piston rlng-to-groove clearance excessive. This is caused by
excessive wear of the piston ring lands. Piston replacement Is
necessary (Chapter2).
0 Cytinder head gasket damaged. If the head is allowed to become
loose,or if excessive carbon build-up on the piston crown and
combustion chamber causes extremely high compression, the
head gasket may leak. Retorquing the head is not always
sufficient to restore the seal. so gasket replacement is neOe68ary
(Chapter2).
0 Cylinder head warped. This Is caused by overheating or
improperly tightened head bolts. Machine shop resurfacing or
head replacement is necessary (Chapter 2).
0 Valvespring broken or weak. Caused by component failure or
wear; the springs must be replaced (Chapter 2).
0 Valvenot seating PfOPefiy.This Iscaused by a bent valve (from
over-revving or improper valve adjustment). burned valve or seat
(Impropercarburation) or an accumulation of carbon deposita on
the seat (from carbu~ion or lubrication problems). The valves
must be cleaned and/or replaced and the seats serviced if
possible (Chapter 2).

2 Poor running at low speeds (continued)
-
Poor acceleration 0 Engineoilviscositytoo high. Usingaheavier oil than that
recommended in Chapter 1 can damage the 011pump or
0 Carburettors leakingor dirty. Overhaulthecarburettors(Chapter3). lubricationsystemandcausedragontheengine.
0 Timingnotadvancing.Faultypick-upcoils or ignitOf'unit(Chapter4). 0 Brakesdragging.UsuaHycausedbydebriswhichhasenteredthe
0 Cartxnttors notsynchronised.Adjustthem with a vacuum gauge brakepistonseals,orfromawarpeddiscorbentaxle.Repairas
set or manometer(Chapter1). necessary(Chapter6).
3 Poor running or no power at high speed
-
FIring incorrect 0 Pistonring-to-grooveclearanceexcessive.Thisiscausedby
0 Airfilterrestricted.Cleanorreplacefilter(Chapter1). excessivewearofthepistonringlands.PIstonreplacementis
0 Sparkplugsfouled,defectiveorwornout(Chapter1). nec:essary(Chapter2).
0 SparkplugcaporHTwiringdefective(Chapters1and4). 0 Cylinderhead~et damaged"Iftheheadis~Iowedto become
0 Spark lugcapsnotmakingcontact.Makesuretheyareproperty loose,or.ifexcessIVecarbonbuild-upon~hepistonCfO';Nnand
con~ed combustionchambercausesextremelyhighcompresSIon,the
0 Incon'ect spark plugs. Wrong type, heat range or cap head.gasketmay leak. Retorquing the head is not al~ays
configuration. Check and install correct plugs (Chapter 1). sufficient to restore the seal, so gasket replacement ISnecessary
0 Ignitioncontrolunitdefective(Chapter4). (Ch.apter2). ,
0 Pulsegeneratorcoilsdefective(Chapter4). 0 Cytlnderheadwarped.ThisIScausedbyoverheatingor
0 IgnitionHTcoilsdefective(Chapter4). improperlytightenedheadbolts.Machineshopresurfacingor
headreplacementisnecessary(Chapter2).
FueValr mixture Incorrect 0 Valvespringbrokenorweak.Causedbycomponentfailureor
0 Airbleedholesclogged.Removecarburettorandblowoutall wear;thespringsmustbereplaced(Chapter2).
passages(Chapter3). 0 Valvenotseatingproperly.Thisiscausedbyabentvalve(from
0 Airfilterclogged,poorlysealedor missing(Chapter1). over-rewingorimpropervalveadjustment),burnedvalveorseat
0 Airfilterhousingpoor1ysealed.Lookforcracks,holesorloose Qmpropercarburation)oranaccumulationof carbondepositson
clampsandreplaceorrepairdefectiveparts(Chapter3), theseat(fromcarburationorlubricationproblems).Thevalves
0 Fueileveltoo highortoo low.Checkthefloatheight(Chapter3). mustbecleanedand/orreplacedandtheseatsservicedif
0 Carburettorintakemanifoldsloose.Checkforcracks,breaks, possible(Chapter2).
tearsorlooseclamps.Replacetherubberintakemanifoldjointsif
splitorperished(Chapter3), Knocklng or plnglng
0 JetneedleincorrectlypositionedorwomCheckandadjustor
replace(Chapter3). 0 Carbonbuild-upincombustionchamber.Useofafueladditive
0 Mainjetclogged.Dirt,waterorothercontaminantscanclogthe thatwilldissolvetheadhesivebondingthecarbonparticlesto the
mainjets,Cleanthefueltapfilter,thein-linefilter,thefloat crownandchamberistheeasiestwayto removethebuild-up.
chamberarea,andthejetsandcarburettororifices(Chapter3). Otherwise,thecylinderheadwillhaveto beremovedand
D Mainjetwrongsize.Thestandardjettingisforsealevel decarbonized(Chapter2).
atmosphericpressureandoxygencontent.Checkjetsize 0 Incorrectorpoorqualityfuel.Oldorimpropergradesoffuelcan
(Chapter3). causedetonation.Thiscausesthepistonto rattle,thusthe
0 Throttleshaft-to-carburettorbodyclearanceexcessive.Overhaul knockingorpinglngsound.Drainoldfuelandalwaysusethe
carburettors,reJ)iacingwornpartsorcompletecarburettorif recommendedfuelgrade(Chapter3).
necessary(Chapter3), 0 Sparkplugheatrangeincorrect.Uncontrolleddetonationindicates
. theplugheatrangeistoohot.Theplugineffectbecomesaglow
CompressIon /ow plug,raisingcylindertemperatures.Installtheproperheatrange
0 Sparkplugsloose,Removetheplugsandinspecttheirthreads. plug(Chapter1).
Reinstallandtightentothespecifiedtorque(Chapter1). 0 Improperair/fuelmixture.Thiswillcausethecylindertorunhot,
0 Cylinderheadnotsufficientlytighteneddown.Ifthecylinderhead whichleadsto detonation.Cloggedjetsoranairleakcancause
issuspectedofbeingloose,thenthere'sachancethatthegasket thisimbalance(Chapter3).
or head is damaged if the problem has persisted for any length of
time.Theheadboltsshookibetightenedto thepropertorquein .., "thecorrectsequence(Chapter2). ...,sce ,aneous causes
D Impropervalveclearance.Thismeansthatthevalveisnotclosing 0 Throttlevalvedoesn'topenfully.Adjustthethrottlegripfreeplay
completelyandcompressionpressureisleakingpastthevalve. (Chapter1).
Checkandadjustthevalveclearances(Chapter1). 0 Clutchslipping.Maybecausedbylooseorwomclutch
0 Cytinderand/orpistonwom.Excessivewearwillcause components.Overhaulclutch(Chapter2).
compressionpressureto leakpasttherings.Thisisusually 0 Timingnotadvancing.Ignitioncontrolunitfaulty(Chapter4).
accompaniedbywomringsaswell.Atop-endoverhaulis D Engineoilviscositytoohigh.Usingaheavier011thantheone
necessary(Chapter2). recommendedinChapter1candamagetheoilpumpor
0 Pistonringswom,weak,broken,orsticking.Brokenorsticking lubricationsystemandcausedragontheengine.
pistonringsusuallyindicatealubricationorcarburationproblem 0 Brakesdragging.Usuallycausedbydebriswhichhasenteredthe
thatcausesexcesscarbondepositsorseizurestoformonthe brakepistonseals,orfromawarpeddiscor bentaxle.Repairas
pistonsandrings.Top-endoverhaulisnecessary(Chapter2). necessary.
Fault Finding REF-15

Finding
REF.16 F au It
4 Overheating
FIring Incorrect 0 Engineoilleveltoohigh.Theadditionoftoomuchoilwillcause
0 Spar1<plugsfouled,defectiveorwomout(Chapter1). pressurisationofthecrankcaseandinefficientengineoperation.
0 Incorrectspar1<plugs(Chapter1). CheckSpecificationsanddrainto properlevel(Chapter1).
0 FaultyignitionHTcoils(Chapter4). 0 Engineoilviscositytoohigh.Usingaheavieroilthantheone
. recommendedinChapter1candamagetheoilpumpor
Fuel/air mixture Incorrect lubricationsystemaswellascausedragontheengine.
0 Mainjetclogged.Dirt,waterandothercontaminantscanclogthe 0 Brakesdragging.Usuallycausedbydebriswhichhasenteredthe
mainjets.Cleanthefueltapfilter.thefuelpumpin-linefilter,the brakepistonseals,orfromawarpeddiscor bentaxle.Repairas
floatchamberareaandthejetsandcarburettororifices(Chapter3). necessary.
D Mainjetwroogsize.Thestandardjettingisforsealevel D Excessivefrictioninmovingenginepartsdueto inadequate
atmosphericpressureandoxygencontent.Checkjetsize lubrication,wombearingsorincorrectassembly.Overhaulengine
(Chapter3). (Chapter2).
D Airfilterclogged,POOI1Ysealedormissing(Chapter1).
D Airfilterhousingpoorlysealed.Lookforcracks,holesorloose Lubrication inadequate
clampsandreplaceorrepair(Chapter3). !:J Engineoilleveltoolow.Frictioncausedbyintennittentlackof
D Fuelleveltoo low.Checkfloatheight(Chapter3). lubricationorfromoilthatisoverworkedcancauseoverheating.
D Carburettorintakemanifoldsloose.Checkforcracks,breaks, Theoilprovidesadefinitecoolingfunctionintheengine.Check
tearsorlooseclamps.Replacetherubberintakemanifoldjointsif theoillevel(Chapter1).
splitorperished(Chapter3). D PoorqualityengIne011orincorrectviscosityortype.011israted
Compression too high notonlyaccordingto viscositybutalsoaccordingto type.Some
." ,. oilsarenotratedhighenoughfor useinthisengine.Checkthe
D Carbo~ b~lld-up In combu~tlon cha~ber. Use of a fuel ,additive Specifications section and change to the correct 011(Chapter 1).
that WIll dissolve the adhesive bonding the carbon particles to the 0 W 'I logged 'I Check .1 d cI. ,~ om 01 pump or c 01 passages. 01 pump an ean
piston crown and chamber is the easiest way to remove the bUlld- (Ch t 2)
up.Otherwise,thecylinderheadwillhaveto beremovedand passages aper .
decarbonized(C~apter2). , , Miscellaneous causes
D ImproperlymachinedheadsurfaceorInstallationofInCOrrect
gasketduringengineassembly(Chapter2), 0 Enginecoolingfinscloggedwithdebris.
0 Modificationtoexhaustsystem.Mostaftermarketexhaust
Engine load excessive systemscausetheengineto runleaner,whichmakethemrun
0 Clutch slipping. Can be caused by damaged, loose or worn clutch hotter. When installing an accessory exhaust system, always rejet
components. Overhaul clutch (Chapter 2). the carburettors.
5 Clutch problems
Clutch slipping
0 Cablefreeplayinsufficient.Checkandadjustcable(Chapt«1).
0 Frictionplateswomorwarped.Overhaultheclutchassembly
(Chapter2).
0 Plainplateswarped(Chapter2).
0 Clutchspringsbrokenorweak.Oldorheat-damaged(from
slippingclutch)springsshouldbereplacedwithnewones
(Chapter2).
0 Clutchreleasemechanismdefective.Replaceanydefectiveparts
(Chapter2). 0
0 Clutchcentreorhousingunevenlyworn.Thiscausesimproper
engagementoftheplates.Replacethedamagedorwomparts
(Chapt«2).
Clutch not completelydisengaging
0 Cablefreeplayexcessive.Checkandadjustcable(Chapter1).
0 Clutchplateswarpedordamaged.Thiswillcauseclutchdrag,
whichinturnwillcausethemachinetocreep.Overhaultheclutch
assembly(Chapter2).
Clutch spring tension uneven. Usuallycaused by a sagged or
broken spring. Check and replace the springs as a set (Chapter2).
Engine011deteriorated. Old. thin, worn out 011will not provide
proper lubrication for the plates. causing the clutch to drag.
Replacethe 011and filter (Chapter 1).
Engineoil viscosity too high. Using a heavier oil than
recommended InChapter 1 can cause the plates to stick together,
putting a drag on the engine. Change to the correct weight oil
(Chapter 1).
Clutch housing seized on mainshaft. Lack of lubrication, severe
wear or damage can cause the guide to seize on the shaft.
Overhaulof the clutch. and perhaps transmission. may be
necessaryto repair the damage (Chapter 2).
Clutch releasemechanism defective. Overhaulthe clutch cover
components (Chapter 2).
Loose clutch centre nut. Causes drum and centre misalignment
putting a drag on the engine. Engagement adjustment continually
varies.Overhaulthe clutch assembly (Chapter 2).
Pr
Q!
~
~
~:

6 Gear shifting problems
Doesn't go Into gear or 'ever doesn't return
0 Clutchnotdisengaging.Seeabove.
0 Selectorfork(s)bentorseized.Oftencausedbydroppingthe
machineorfromlackof oil.Overhaulthetransmission(Chapter2).
0 ~s) stuckonshaft.Mostoftencausedbyalackof lubrication
orexcessivewearIntransmissionbearingsandbushings.
OveIt1aulthetransmission(Chapter2).
0 Gearselectordrumbinding.Causedbylubricationfailureor
excessivewear.Replacethedrumandbearing(Chapter2).
Gearcnangeleverreturnspringweakorbroken(Chapter2).
Gearchangeleverbroken.Splinesstrippedoutof leverorshaft,
causedbyallowingtheleverto get!<Joseorfromdroppingthe
machine.Replacenecessaryparts(Chapter2).
0
0
7 Abnormal engine noise
Knocking or plnglng 0 Connectingrodupperorlowerendclearanceexcessive.Caused
0 Carbonbuild-upincombustionchamber.Useofafueladditive byexcessiveweerorlackoflubrication.Replacewornparts
thatwilldissolvetheadhesivebondingthecarbonparticlestothe (Chapter2).
pistoncrownandchamberistheeasiestwayto removethebuild- Valve noIse
up.Otherwise,thecylinderheadwillhaveto beremovedand
decarbonized(Chapter2). 0 Incorrectvalveclearances.Adjusttheclearances(Chapter1).
0 Incorrectorpoorqualityfuel.Oldorimproperfuelcancause 0 Valvespringbrokenorweak.Checkandreplaceweakvalve
detonation.Thiscausesthepistonstorattle,thustheknockingor springs(Chapter2).
pingingsound.Draintheoldfuelandalwaysusethe 0 Camshaftorcylinderheadwornordamaged.Lackoflubrication
recommendedgradefuel(Chapter3). athighrpmisusuallythecauseofdamage.Insufficientoilor
0 Sparkplugheatrangeincorrect.Uncontrolleddetonationindicates failureto changetheoilattherecommendedintervalsarethe
thattheplugheatrangeistoohot.Theplugineffectbecomesa chiefcauses.Sincetherearenoreplaceablebearingsinthehead,
glowplug,raisingcylindertemperatures.Installtheproperheat theheaditselfwillhaveto bereplacedif thereisexcessivewear
rangeplug(Chapter1). ordamage(Chapter2).
0 Improperair/fuelmixture.Thiswillcausethecylindersto runhot .
andleadto detonation.Cloggedjetsoranairleakcancausethis Other noIse
imbalance(Chapter3). 0 Cylinderheadgasketleaking(Chapter1).
PIston slap or rattling 0 Exhaustpipeleakingatcylinderheadconnection.Causedby
., . . improperfit ofpipe(s)orlooseexhaustflange.Ailexhaust
0 Cyllnder-to-plstonclearanceexcesSIve.CausedbyImproper fastenersshouldbetightenedevenlyandcarefully.Failuretodo
assembly.Inspectandoverhaultop-endparts(Chapter2). tho 'ill dt I k(Chat 3)
0 Connectingrodbent.Causedbyover-rewing,tryingto starta ISWI ea 0 a ea .per.
badly flooded engine or from ingesting a foreign object into the 0 Cranksha~ runout excessIVe.Caused by a bent crankshaft (from
combustion chamber. Replace the damaged parts (Chapter 2). o~er-rewlng) or damag~ from an upper cylinder co~ponent
0 Pistonpinorpistonpinborewornorseizedfromwearorlackof failure.Canalsobeattnbutedto droppingthemachIneoneitherof
lubrication.Replacedamagedparts(Chapter2). thecrankshaftends(Chapter2).
0 Pistonring(s)worn,brokenorsticking.Overhaulthetop-end 0 Enginemountingboltsloose.TIghtenallenginemountbolts
(Chapter2). (Chapter2).
0 Pistonseizuredamage.Usuallyfromlackoflubricationor 0 Crankshaftbearingsworn(Chapter2).
overheating.Replacethepistonsandborethecylinders,as 0 Camchaintenslonerdefective.Replace(Chapter2).
necessary(Chapter2). 0 Camchain,sprocketsorguidesworn(Chapter2).
Fault Finding REF.17
0 Gearchangemechanismstopperarmbrokenorwom.Full
engagementandrotarymovementofshiftdrumresults.Replace
thearm(Chapter2).
0 Stopperarmspringbroken.Allowsarmto float,causingsporadic
shiftoperation.Replacespring(Chapter2).
Jumps out of gee'
0 Selector fork(S)worn. Overhaul the transmission (Chapter 2).
0 Gear groove(s)worn. Oveft)aulthe transmission (Chapter 2).
0 Gear dogs or dog slots worn or damaged. The gears should be
inspected and replaced. Don't service the wom parts (Chapter2).
Overshlfts
0 Stopperarmspringweakor broken(Chapter2).
0 Gearchangeshaftretumspringpostbrokenordistorted(Chapter2).

REF.18 Fault Finding
9 Abnormalframe andsuspensionnoise
Front end noise
0 Lowfluidlevel or improper viscosity oil in forks. This can sound
like spurting and Is usually accompanied by irregularfork action
(Chapter5).
0 Springweakorbroken.Makesaclicking or scrapingsound.Fork
oil, when drained, will have alotof metal particlesinit(Chapter5).
0 Steeringheadbearingslooseor damaged.Clickswhenbraking.
Check and adjust or replaceasnecessary(Chapters1and5).
0 Fork yokes loose. Make sure all clamp pinch bolts aretight
(Chapter5).
0 Fork tube bent. Good possibility if machine has been dropped.
Replacetube with a new one (Chapter 5).
0 Front axle or axle clamp bolt loose. Tighten them to the specified
torque (Chapter 6).
Shock absorber noise
0 Fluid level incorrect. Indicates a leak caused by defective seal.
Shock will be covered with oil. Replace shock or seek advice on
repair from a Suzuki dealer (Chapter 5).
0 Defective shock absorber with internal damage. This is in the body
of the shock and can't be remedied. The shock must be replaced
with a new one (Chapter 5).
10 Oil pressure light comes on
EngIne lubrication system
0 Engineoilpumpdefective,blockedoilstrainergauze or failed
reliefvalve.Carryoutoilpressurecheck(Chapter2).
0 Engineoil level low. Inspect for leak or otherproblemcausinglow
oil levelandaddrecommendedoil(Chapter1).
0 Engineoil viscosity too low. Very old, thin oil or an improper
weightof oil used in the engine. Changeto correctoil(Chapter1).
0 Camshaftorjournalsworn.Excessivewearcausingdropinoil
pressure. Replace cam and/or/cylinder head. Abnormal wear
could be caused by oil starvation at high rpm from low oil level or
improper weight or type of oil (Chapter 1).
11 Excessive exhaust smoke
White smoke
0 Pistonoilringworn.TheringmaybebrokenordiM11aged,causing
oilfromthecrankcaseto bepulledpastthepistonIntothe
combustionchamber.Replacetheringswithnewones(Chapter2).
0 Cylindersworn,cracked,orscored.Causedbyoverheatingoroil
starvation.Thecylinderswillhaveto bereboredandnewpistons
installed(Chapter2).
0 Valveoilsealdamagedorworn.Replaceoilsealswithnewones
(Chapter2).
0 Valveguideworn.Performacompletevalvejob (Chapter2).
0 Engine011leveltoohigh,whichcausestheoilto beforcedpast
the rings. Drain 011to the proper level (Chapter 1).
0 Headgasketbrokenbetween011returnandcylinder.Causesoilto
bepulledintothecombustionchamber.Replacetheheedgasket
andchecktheheadforwarpage(Chapter2).
0 Abnormalcrankcasepressurisation,whichforcesoilpastthe
rings.Cloggedventilationsystemor breatherhose(Chapte.-2).
Black smoke
0 Airfilterclogged.Cleanorreplacetheelement(Chapter1).
0 Bent or damaged shock body. Replace the shock with a new one
(Chapter 5).
0 Loose or wom linkage components. Check and replace as needed
(Chapter5).
Brake noise
0 Squealcausedbypadshimnotinstalledorpositionedcorrectly
(Chapter6).
0 Squealcausedbydustonbrakepads.UsuallyfoundInoomt*'lation
withglazedpads.CleanuU1gbrakecleaningsolvent(Chapt«6).
0 Contaminationof brakepads.011,brakefluidordirtcausingbrake
tochatterorsqueal.Cleanorreplacepads(Chapter6).
0 Padsglazed.Causedbyexcessiveheatfromprolongeduseor
fromcontamination.Donotusesandpaper.emerycloth,
carborundumclothoranyotherabrasiveto roughenthepad
surfacesasabrasiveswillstayinthepadmaterialanddamagethe
disc.A veryfineflatfilecanbeused.butpadreplacementis
suggestedasacure(Chapter6).
0 Discwarped.Cancauseachattering,clickingorint~ittent
squeal.Usuallyaccompaniedbyapulsatingleveranduneven
braking.Replacethedisc(Chapter6).
0 Looseorwomwheelbearings.Checkandreplaceasneeded
(Chapter6).
0 Crankshaftand/orbearingsworn.Sameproblemsasparawaph4.
Checkandreplacecrankshaftand/orbearings(Chapter2).
Electrical system
0 Oilpressureswitchdefective.Checktheswitchaccordingtothe
procedureinChapter8.Replaceit ifit isdefective.
0 Oilpressureindicatorlightcircuitdefective.Checkforpinched,
shorted,disconnectedordamagedwiring(Chaptw8).
Mainjet too largeCM'~. Comparejet sizewith the Specifications
(Chapter3).
Choke cable or linkage shaft stuck, causing fuel to be pulled
through choke circuit (Chapter 3).
Fuelleveltoo high. Check and adjust the float height(s)as
necessary (Chapter 3).
Float needle valve held off needle seat. Clean the float chambers
and fuel line and replace the needles and seats if necessary
(Chapter3).
a~
"
\..a:
Q!
Q
Brown smoke
0 Mainjet too small or clogged. lean condition caused by wrong
size mainjet or by a restricted orifice. Clean float chambers and
jets and compare jet sizeto Specifications (Chapter 3).
0 Fuelflow insufficient. Float needle valve stuck closed due to
chemical reaction with old fuel. Aoat height Incorrect. Restricted
rue/line.Cleanlineandfloatchamberandadjustfloats if
necessary (Chapter3).
0 Carburettor intake manifoldclampsloose(Chapter3).
0 AIrfIlterpoorty sealed or not instaHed(Chapter 1).

REF-19
12 Poor handling or stability
- -
Handlebar hard to turn Handlebar pulls to one side
D Steering head bearing adjuster nut too tight. Check adjustment 0 Frame bent. Definitely suspect this If the machine has been
(Chapter 1). dropped. Mayor may not be accompanied by cracking near the
D Bearingsdamaged.Roughnesscanbefeltasthebarsaretumed bend.Replacetheframe(Chapter5).
fromside-to-side.Replacebearingsandraces(Chapter5). [J Wheelsoutofalignment.Causedbyimproperlocationofaxle
0 Racesdentedorworn.Dentingresultsfromwearinonlyone spacersorfrombentsteeringstemorframe(Chapter5).
position(e.g.,straightahead),fromacollisionorhittingapothole 0 Swingannbentortwisted.Causedbyage(metalfatigue)or
orfromdroppingthemachine.Replaceracesandbearings impactdamage.Replacethearm(Chapter5).
(Chapter5). 0 Steeringstembent.Causedbyimpactdamageorbydroppingthe
0 Steeringstemlubricationinadequate.Causesaregreasegetting motorcycle.Replacethesteeringstem(Chapter5).
hardfromageorbeingwashedoutbyhighpressurecarwashes. 0 Fori<tubebent.Disassembletheforksandreplacethedamaged
Disassemblesteeringheadandrepackbearings(Chapter5). parts(Chapter5).
0 Steeringstembent.Causedbyacollision,hittinga potholeorby D Fori<oilleveluneven.Checkandaddordrainasnecessary
droppingthemachine.Replacedamagedpart.Don'ttryto (Chapter5).
straightenthesteeringstem(Chapter5). . ..
0 Fronttireairpressuretoolow(Chapter1). Poor shock absorbIng qualitIes
Handlebar shakes or vIbrates excessively
0 Tyreswornoroutof balance(Chapter6).
0 Swlngarmbearingsworn.Replacewornbearings(Chapter5).
0 Rim(s)warpedordamaged.Inspectwheelsforrunout(Chapter6).
0 Wheelbearingsworn.Wornfrontorrearwheelbearingscan
causepoortracking.Wornfrontbearingswillcausewobble
(Chapter6).
0 Handlebarclampboltsloose(Chapter5).
0 Forkyokeboltsloose.Tightenthemtothespecifiedtorque
(Chapter5).
0 Enginemountingboltsloose.Willcauseexcessivevibrationwith
Increasedenginerprn(Chapter2).
Fault Finding
Toohard:
FOI1coil levelexcessi~ (Chapter 5).
Fork 01/viscosity too high. Use 8 lighter oil (seethe Specifications
in Chapter 5).
Fork tube bent. Causes8 harsh. sticking feeling (Chapl&r5).
Shock shaft or body bent or damaged (Chapter5).
Fork internal damage (Chapter 5).
Shock Internaldamage.
TIrepressure too high (Chapler 1).
Too soft:
FOI1cor shock oil insufficient and/or leaking (Chapter5).
Fork oil level too low (Chapter 5).
FOI1coil viscosity too light (Chapter 5).
Forksprings weak or broken (Chapter 5).
Shockintemafdamageorleakage(Chapter5).
0a}
b)
c)
d)
e)
f)
g)
0a)
b)
c)
d)
e)

REF.20 Fault Finding
14 Electrical problems
Battery dead or weak
0 Batteryfaulty.Causedbysulphatedplateswhichareshorted
throughsedimentation.Also.brokenbatteryterminalmakingonly
occasionalcontact(Chapter8).
0 Batterycablesmakingpoorcontact(Chapter1).
0 Loadexcessive.Causedbyadditionof highwattagelightsor
otherelectricalaccessories.
0 Ignition(main)switchdefective.Switcheithergrounds(earths)
internallyorfailsto shutoffsystem.Replacetheswitch(Chapter8).
0 Regulator/rectifierdefective(Chapter8).
0 Alternatorstatorcoilopenorshorted(Chapter8).
Fault Finding Equipment
Checking engine compression
. Low compressionwill result in exhaust
smoke, heavy 011consumption, poor starting
and poor performance. A compression test
will provide useful information about an
engine's condition and if performed regularly,
can give warning of trouble before any other
symptoms become apparent.
. A compression gauge will be required,
along with an adapter to suit the spark plug
hole thread size. Note that the screw-in type
gauge/adapter set up is preferable to the
rubber cone type.
Wiring faulty. Wiring grounded (earthed)or connections loose in
ignition, charging or lighting circuits (Chapter 8).
Battery overcharged
0 Regulator/rectifierdefective.Overchargingisnoticedwhenbattery
getsexcessivelywarm(Chapter8).
D Batterydefective.Replacebatterywitha newone(Chapter8).
D Batteryamperagetoo low,wrongtypeorsize.Install
manufacturer'sspecifiedamp-hourbatteryto handlecharging
load(Chapter8).
. Beforecarryingoutthetest,firstcheckthe
valveclearancesasdescribedinChapter1.
1 Run the engine until it reaches normal
operating temperature, then stop it and
removethe sparkplug(s),takingcarenot to
scaldyourhandsonthehotcomponents.
2 Installthegaugeadapterandcompression
gaugein No;1 cylindersparkplug hole(...
illustration 1).
3 Onkickstart-equippedmotorcycles,make
suretheignitionswitchisOFF,thenopenthe
throttlefullyandkicktheengineoveracouple
oftimesuntilthegaugereadingstabilises.
4 Onmotorcycleswithelectricstartonly,the
procedurewilldifferdependingonthe nature
of the ignition system.Flick the enginekill
switch(enginestopswitch)to OFFandturn