Suzuki DR600S User manual

SUZUKI
ORGOO"
SERVICE MANUAL
|
4

gr i tien key No ios 2.& #
FOREWORD
The SUZUKI DR6O00S was designed to offer superior performance through lightweight
design,
four
stroke-power
(TSCC
engine),
engine
counter-balancers
and
full-floating
suspen-
sion.
This
service
manual
has
been
produced
primarily
for
experienced
mechanics
whose
job
is
to
inspect,
adjust,
repair
and
service
Suzuki
Motorcycles.
Apprentice
mechanics
and
do-it-
yourself
mechanics
will
also
find
this
manual
to
be
an
extremely
useful
repair
guide.
This
manual
contains
up-to-date
information
at
the
time
of
publication.
The
rights
are
reserved
to
update
or
make
corrections
to
this
manual
at
any
time.
SUZUKI MOTOR CO.,LTD.
Motorcycle
Technical
Service
Department
© COPYRIGHT SUZUKI MOTOR CO., LTD. 1985

VIEW OF SUZUKI DR6OOSF (‘85—MODEL)
RIGHT SIDE
LEFT SIDE

GROUP INDEX
GENERAL
INFORMATION
—lc
ile
FUEL
AND
LUBRICATION
SYSTEM
PERIODIC MAINTENANCE AND
TUNE-UP
PROCEDURES
SERVICING
ENGINE
ELECTRICAL
SYSTEM
ee.
CHASSIS
EE
SERVICING
INFORMATION
DR600SG/
DR500SG
(‘86—MODEL)
DR600RG/
DR500RG
(‘86—MODEL)
Bo
DR600RH/DR500RH
DR600SH/DR500SH
(87—MODEL)
|
10
ie
DR600SJ/DR600RJ ,.
DR500SJ/DR500RJ(
88—MODEL)
HE
APPENDIX
J
i20
DR600SK/RK
(‘'89-MODEL)
Ei

GENERAL INFORMATION
CONTENTS
SERIAL NUMBER LOCATIONS 4h: 0- on --ae e
FUEL AND OIL RECOMMENDATIONS 0000000000000: eee
BREAKING-IN PROCEDURES «+++++>--2520s--22++0duestutabrties soxsUnass-onseas
SPECIAL IVA TERIA LS 305: 0-8 ss res scarey ane eogeeae ee Cee eaeaamatae> ae
PRECAUTIONS AND GENERAL INSTRUCTIONS
SPECTFICA TIONS 005+ -02 fo 0cthies sce accatduaretant dnensltses ans ues: atv Sena

1-1 GENERAL INFORMATION
SERIAL NUMBER LOCATIONS
The frame serial number or V.I.N. (Vehicle Identi-
fication Number) @ is stamped on the steering
head pipe. The engine serial number (2) is located
on the crankcase. These numbers are required
especially for registering the machine and ordering
spare parts.
FUEL
AND
OIL
RECOMMENDA-
TIONS
FUEL
Gasoline
used
should
be
graded
85
—
95
octane
or
higher.
An
unleaded
or
low-lead
type
gasoline
is
recommended.
ENGINE OIL
Be
sure
that
the
engine
oil
you
use
comes
under
API
classification
of
SE
or
SF
and
that
its
viscosity
rating
is
SAE
10W-40.
If
SAE
10W-40
motor
oil
is
not
available,
select
the
oil
viscosity
according
to
_
the
following
chart:
-% -20 -10 0
10 20 30 40
=22_-4
14
32
SO
68
86
104
FRONT FORK OIL
Use fork oil # 10.
BRAKE FLUID
SAE J1703, DOT 3
or DOT 4
Specification and
classification:
WARNING:
* Since the brake system of this motorcycle
is filled with a glycol-based brake fluid by
the manufacturer, do not use or mix differ-
ent types of fluid such as silicone-based
and petroleum-based fluid for refilling the
system, otherwise serious damage will
result.
* Do not use any brake fluid taken from old
or used or unsealed containers.
Never re-use brake fluid left over from the
previous servicing and stored for a long
Period.
*
BREAKING-IN
PROCEDURES
During
manufacture
only
the
best
possible
ma-
terials
are
used
and
all
machined
parts
are
finished
to
a
very
high
standard
but
it
is
still
necessary
to
allow
the
moving
parts
to
‘‘BREAK-IN”
before
subjecting
the
engine
to
maximum
stresses.
The
future
performance
and
reliability
of
the
engine
depends
on
the
care
and
restraint
exercised
during
its
early
life.
The
general
rules
are
as
follows.
1.
Keep
to
this
break-in
throttle
position.
Below 4/5 throttle
2.
After
the
engine
has
been
operated
for
1
600
km
(1
000
miles)
the
motorcycle
can
be
subjected
to
full
throttle
operation
for
short
periods
of
time.
Up to 1 600 km
(1 000 miles)

SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the DR6OOS, and should be kept on hand
for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the
GENERAL INFORMATION 1-2
like. How to use them and where to use them are described in the text of this manual.
Material
Part
Part
SUZUKI
SUPER GREASE “A”
99000-25010
Oil seals
Throttle grip
Brake pedal shaft
Gearshift lever and shaft
Speedometer cable, gear-
box and dust seal
Wheel bearings
Steering stem bearings
Sprocket drum bearing
Brake camshaft, oil seal,
spacer, dust seals, bearing
and bushing
Brake cam and pin
Shock absorber dust seals
Cushion lever dust seals,
spacers and bearings
Swingarm dust seals,
spacers and bearings
SUZUKI SILICONE
GREASE
99000-25100
Caliper axle
SUZUKI MOLY PASTE
99000-25140
Valve stems
De-comp. camshaft
Countershaft and drive-
shaft gears
Piston pin
Camshaft journals
Rocker arm shafts
De-comp. shafts
SUZUKI BOND No. 1207B
99000-31140
Mating surfaces of left
and right halves of crankcase
Magneto lead wire grommet
Cylinder base and head
gaskets
Cylinder head cover
THREAD LOCK SUPER
1303”
99000-32030
2nd drive gear
Crankcase bearing
retainers
Kick starter pawl guide/
stopper bolt and screw
Gearshift arm stopper
Cam sprocket bolts

Material
1-3 GENERAL INFORMATION
Part
Part
Page
*
THREAD LOCK SUPER
“1360”
99000-32130
@ Gearshift cam stopper 3-48 Magneto stator coil 5-2
bolt securing screws
@ Gearshift cam guide/paw! 3-50 Front fork damper rod 6-16
lifter screws bolts
@ Engine oil pump mounting 3-54
screws
THREAD LOCK “1342”
99000-32050
| @ Magneto rotor bolt 3-53
THREAD LOCK SUPER
"1305"
99000-32100 if
© Disc mounting bolts 6-8
v
SUZUKI BRAKE FLUID
99000-23021 (0.5 L)
|e Front brake

GENERAL INFORMATION 1-4
PRECAUTIONS AND GENERAL INSTRUCTIONS
Observe the following items without fail when disassembling and reassembling motorcycles.
e Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones.
CAUTION.
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken not to expand the end gap larger than required to
slip the circlip over the shaft.
After
installing
a
circlip,
always
insure
that
it is
completely
seated
in
its
groove
and
securely
fitted.
®
Tighten
bolts
and
nuts
from
the
ones
of
larger
diameter
to
those
of
smaller
diameter,
and
from
inside
to
outside
diagonally,
with
specified
tightening
torque.
e Use special tools where specified.
e Use specified genuine parts and recommended oils.
e
When
more
than
2
persons
perform
work
in
cooperation,
pay
attention
to
the
safety
of
each
other.
e
After
the
reassembly,
check
parts
for
tightening
condition
and
operation.
e
Treat
gasoline,
which
is
extremely
flammable
and
highly
explosive,
with
greatest
care.
Never
use
gaso-
line as cleaning solvent.
Warning,
Caution
and
Note
are
included
in
this
manual
occasionally,
describing
the
following
contents.
MOORS
INNINGS
5
cha.
sere
oe
Personal
safety
of
the
rider
is
involved,
and
disregard
of
the
information
could
result
in
injury.
GATHON
oodce
te
ones
sews
For
the
protection
of
the
motorcycle,
the
instruction
or
rule
must
be
strictly
adhered
to.
DUNN
eri
tics
wesc
veoe
«tose
Advice
calculated
to
facilitate
the
repair
of
the
motorcycle
is
given
under
this
heading.
USE OF SUZUKI GENUINE PARTS
To
replace
any
part
of
the
machine,
use
a
genuine
SUZUKI
replacement
part
or
an
equivalent.
Imita-
tion
parts
or
parts
supplied
from
any
other
source
than
SUZUKI,
if
used
to
replace
SUZUKI
Parts,
can
reduce
the
machine’s
performance
and,
even
worse,
could
induce
costly
mechanical
troubles.

1-5 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS
AND
DRY
MASS
CO
TANCE
8
Be
oe
ea
Overall
width
Overall
height
Wheelbase
Ground
clearance
ie
ES
GIGI
ess
oa
ENGINE
eS ee
Petre See eG be ose See a des
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
TRANSMISSION
Clutch
Gearshift pattern
Primary reduction
Final reduction
Drive chain
2 215 mm (87.2 in)
875 mm (34.4 in)
1 235 mm (48.6 in)
1 465 mm (57.7 in)
275 mm (10.8 in)
139
kg
(306
Ibs)
Four-stroke, air-cooled, OHC
94.0 mm (3.700 in)
85.0 mm (3.346 in)
589 cm?* (35.9 cu. in)
8.5:1
MIKUNI VM38SS, single
Polyurethane foam element
Primary kick
Wet sump
Wet multi-plate type
. 5-speed constant mesh
. 1-down, 4-up
2.310 (67/29)
2.625 (42/16)
2.416 (29/12)
1.625 (26/16)
1.263 (24/19)
1.000 (21/21)
0.826 (19/23)
TAKASAGO RK520KSO or DAIDO D.1.D.520VC-5,
108 links

GENERAL INFORMATION 146
ELECTRICAL
[GnithOn
AV
pees...
as
tee
ie
ee
SUZUKI
“PEI”
Kefothitelotadianttal tecture sce tay eee ee Ne 0° B.T.D.C. Below 2 200 r/min and
30° B.T.D.C. Above 4 300 r/min
Spark) PlUg- scx:.cke.ahernc ave «eect anode eee NGK DP9EA-9 or NIPPON DENSO X27EP-U9
(For E-01, 24, 25 and 34)
NGK DPR9EA-9 or NIPPON DENSO X27EPR-U9
(For others)
Battery
t.
aciewke-ce
a
no
eutsinaros
ei
ee
12V
18kC
(5
Ah)/10
HR
GON
GATOR
ratiig
ir
rua
cetera:
See
eee
Three-phase
A.C.
generator
FUSE
tenets
sc
Sehocos
Hatake
Ree
eh
ee
ees
15A
CHASSIS
PPVSME
SUMEMIPISID
oid.
ox
ny
edwin
ca
6
9:0
we
at
eoat
Telescopic,
pneumatic/coil
spring,
oil
dampened
FIGHT
AMMO
TMOM
irs
ding
case
5,
sieta
eta
Full
floating
suspension
system,
gas/oil
dampened,
spring
5-way
adjustable
BRUBEIN
rani
eid
a.
&
asia.
sin
gs
alain
tatareumme
ie
45°
(Right
&
Left)
(ATCT
RNEL
oe
Sle:
Sone
aap
mo
ueee
©
SOR
be
Y
@
60°
00’
BUG
SAL
Np
eipa
Accrtatss
5
ce
av
Sore.
wy
dyatee
revere
Rua
ree
eh
125
mm
(4.92
in)
PUL
CRONE:
ove
aie
g
charts
oophemte
w
Way
viatehaete
2.3
m
(7.5
ft)
FGrarit
BLAKE:
Gon
sevrteen.
cgchaceete-
ann
each
Disc
brake,
hydraulically
operated
ABA
DRE
KA
to.totii
cies:
bso
een
ome
cmtie
Internal
expanding
PONTE
MIZE
xo)
«
cugnatetetal
ceaeenereent
ont
ha
cet
aie
100/80-21
56S
say
Soe
othe
ROMs
Ce
130/80-17
65S
CAPACITIES
Fuel
tank
including
reserve...............
21L
(5.5/4.6
US/Imp
gal)
FORBUVE
rate
sata
ain
4.5
L
(4.8/4.0
US/Imp
qt)
ENGINE
Ol
cementing
To
RRitent
iss
+
oa).
2.3
L
(2.4/2.0
US/Imp
qt)
EQONUHORMVOH
tarexatiworee.cewle
es
kp
ean
wh
creas
475
ml
(16.1/16.7
US/Imp
oz)
These
specifications
are
subject
to
change
without
notice.

led 11 (0) 0) fom eV ea a eee
TUNE-UP PROCEDURES
CONTENTS
PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE AND TUNE-UP PROCEDURES °*°---:0+0-0000-""
1-9 W iy f 1) COPPER CREE RECEP, PREPS EE Tre Or re eS | CO
CYLINDER HEAD NUTS, EXHAUST PIPE BOLTS
AND MUFFLER CONNECTIONS. <+-++++ss++ssessessesseeseeseeseesenes
AIR CLEANER: ELEMENT -2---2-<2--202-20<0s 0002s s0secnevnsesuse> bern ed sone
AUTOMATIC DE-COMPRESSION LEVER +++-+--0-0000000000
VALVE CLEARANCE 6 occa ek
‘SPARK PL UG Sissons eres aga sven sae duntnetnuges torueatodacn wwesensomessdaee
iby Lihie os eee ee ee
ENGINE OFL AND OIL FILTER <++-<s+<2065---+<05-c2y0nevzcovansacenaten
CARBURETOR
BALANCER CHAIN: srr cr reece cere ete ee eee eee e eee n eee e cece ee eeeeeeeeenene
STEERING
AAA
Penne
eee
n
eens
anaes
eneneneeeeserenesseesseessseeeenernsesasessessseese
FRONT
FORK
TERR
nee
eee
e
ener
eee eee
seen
a
eeae
sees
eee
esse
eeeeseseeesessssssesesses
CHASSIS
BOLTS
AND
NUTS
Seen
ene
cere
een
eseceneensenenscsenseesecs

PERIODIC
MAINTENANCE
SCHEDULE
2-1
PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
The
chart
below
lists
the
recommended
intervals
for
all
the
required
periodic
service
work
necessary
to
keep
the
motorcycle
operating
at
peak
performance
and
economy.
Mileages
are
expressed
in
terms
of
kilometers,
miles
and
time
for
your
convenience.
NOTE:
More
frequent
servicing
may
be
performed
on
motorcycles
that
are
used
under
severe
conditions.
PERIODIC
MAINTENANCE
CHART
INTERVAL:
THIS INTERVAL SHOULD BE JUDGED
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST
Battery (Specific gravity of electrolyte)
Cylinder head nuts, exhaust pipe bolts and muffler connections
Air cleaner element
Automatic de-compression lever
Valve clearance
Spark plugs
Fuel line
Fuel strainer
Replace every fou
—
Engine oil and oil filter
Carburetor idle rpm
Balancer chain
Clutch
Drive chain
Brakes
and lubricate every 1 000 km (600
miles).
nspect every 3 000 km (2 000 miles).
Brake hoses
aeenes.4
Replace every four years.
Brake fluid
Change every two years.
Tires
Steering
Front forks
Chassis bolts and nuts
NOTE: T = Tighten, | = Inspect, R= Replace, C= Clean

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
OILING POINTS
Proper
lubrication
is
important
for
smooth
operation
and
long
life
of
each
working
part.
Major
oiling
points
are
indicated
below.
G: Throttle grip
: Throttle cabl
3 ee M @: Brake lever holder
: Rear suspension bearing
A
and dust seal ‘ P vA
& J: Steering stem bearing
&:
Swingarm
pivot
bearing
i? .
and dust seal _o: Speedometer cable
G:
Brake
pedal pivot
&.
,.
;
ae
“ee:
@:
Kick
starterlever
pivot
@:
Spherical
ball
bearing
and
dust
seal
@: Clutch cable and
clutch lever holder | @: Manual De-comp. cable
)
@: Automatic De-comp. cable
We. Motor oil G: Side stand pivot
Grease @: Gearshift lever pivot
NOTE:
*
Lubricate
exposed
parts
which
are
subject
to
rust,
with
a
rust
preventative
spray
whenever
the
motorcycle
has
been
operated
under
wet
or
rainy
conditions.
If
the
spray
is
unavailable,
use
either
motor
oil
or
grease.
*
Before
lubricating
each
part,
clean
off
any
rusty
spots
and
wipe
off
any
grease,
oil,
dirt
or
grime.
L
[ WARNING: ral
Be
careful
not
to
apply
too
much
grease
to
the
brake
cam
shaft.
If
grease
gets
on
the
linings,
brake
ie
slippage
will
result.
=

2-3
PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
MAINTENANCE
AND
TUNE-UP
PROCEDURES
This
section
describes
the
servicing
procedures
for
each
item
of
the
Periodic
Maintenance
require-
ments.
BATTERY
Inspect Every 6 000 km (4 000 miles)
e@ Remove the frame covers and seat. (Refer to page
3-2)
e@ Check electrolyte for level and specific gravity.
Add distilled water, as necessary to keep the
surface of the electrolyte above the MIN. level
line but not above the MAX. level line.
e For checking specific gravity, use a hydrometer
to determine the charged condition.
cee weenie 1.28 at 20°C (68°F)
gravity
An S.G. reading of 1.22 (at 20°C) or under means
that the battery needs recharging. Remove the
battery from the motorcycle and charge it with a
battery charger.
| CauTioN:
* When removing the battery from the
motorcycle, be sure to disconnect the ©
lead wire first.
* Never charge a battery while still in the
motorcycle as damage may result to the
battery or regulator/rectifier.
* Be careful not to bend, obstruct, or change
the
routing
of
the
breather
pipe
from
the
battery, make certain that the breather
pipe
is
attached
to
the
battery
vent
fitting
and that the opposite end is always open.
*
When
installing
the
battery
lead
wires,
fix
the
@
lead
first
and
©
lead
last.
a
e@ Make sure that the breather pipe is tightly
secured and undamaged, and is routed as shown
in the figure.
Hydrometer
Battery breather pipe

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 24
CYLINDER HEAD NUTS, EXHAUST
PIPE BOLTS AND MUFFLER
CONNECTIONS
Tighten Initial 1 000 km (600 miles) and
Every 6 000 km (4 000 miles)
CYLINDER HEAD
e Remove the frame covers, seat and fuel tank.
(Refer to page 3-2)
e
Remove
the
cylinder
head
cover.
(Refer
to
page
3-11)
e Disconnect the de-comp. cables, automatic and
manual. (Refer to page 3-4)
e
First
loosen
and
retighten
the
four
10-mm
@
and
two
8-mm
@)
nuts
to
the
specified
torque
with
a
torque
wrench
sequentially
in
diagonally
with
the
engine
cold.
35 —40N-.m
( 3.5 — 4.0 kg-m )
25.5 — 29.0 Ib-ft
torque 23 —27N-m
( 2.3 — 2.7 kg-m )
16.5 — 19.5 Ib-ft
Tightening
e
After
firmly
tightening
the
six
nuts,
tighten
the
two
6-mm
nuts
(indicated
as
@))
to
the
torque
value
below:
7-—11N-m
Tightening torque @) ee —11 a
5.0 — 8.0 Ib-ft
e@ When installing the cylinder head cover, apply
SUZUKI Bond No. 12078 to the mating surface.
(Refer to page 3-64)
EXHAUST PIPE AND MUFFLER
© Tighten the exhaust pipe bolts, muffler connec-
tion bolt and muffler mounting bolts to the
specified torque with a torque wrench.
Tightening torque
9-—12N-m
Exhaust pipe bolts @) is — 1.2 kg-m
6.5-—8.5 ay
Muffler connection and 18 — 28 N.m
muffler
mounting
bolts
(
1.8
—
2.8
kg-m
)
® 13.0 — 20.0 Ib-ft

2-5
PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
AIR CLEANER ELEMENT
Clean Every 3 000 km (2 000 miles)
lf the air cleaner is clogged with dust, intake
resistance will be increased with a resultant decrease
in power output and an increase in fuel consump-
tion.
Check and clean the element in the following
manner.
Remove the frame covers and seat. (Refer to
page 3-2)
Remove the air cleaner case cover by loosening
screw (1).
Remove the wing nut (2) and take off the air
cleaner element.
Remove the polyurethane foam element (3)
from the element frame @).
Fill a washing pan of a proper size with non-
flammable cleaning solvent. Immerse the ele-
ment in the cleaning solvent and wash it clean.
Squeeze the cleaning solvent out of the washed
element by pressing it between the palms of
both hands.
Immerse the element in motor oil, and squeeze
the oil out of the element leaving it slightly wet
with oil.
NOTE:
Do not twist or wring the element because it
will tear or the individual cells of the element
will be damaged.
CAUTION:
Inspect the element carefully for rips, torn
seams, etc. If any damage is noted, replace
the element.
Non-flammable ges
cleaning solvent
=>
ae ae a
“
«
| SAE 10W/40 OIL
=:

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 246
AUTOMATIC DE-COMPRESSION LEVER
Inspect Initial 1 000 km (600 miles) and
Every 6 000 km (4 000 miles)
Incorrect adjustment of the lever free play may
result in starting difficulties or engine damage.
Check the lever free play and if necessary, adjust
as follows:
e
Remove
the
spark
plug
and
valve
timing
inspec-
tion
plug.
e Remove the magneto cover cap and turn the
crankshaft counterclockwise with the box
wrench to set the piston at T.D.C. on the com-
pression stroke. (Refer to page 2-7)
e Loosen both lock nuts (1) on the cable adjuster
2).
e Locate the adjuster (2) to provide the specified
play.
@ Tighten the both lock nuts (1).
VALVE CLEARANCE
Inspect Initial 1 000 km (600 miles) and |
Every 6 000 km (4 000 miles)
Excessive
valve
clearance
results
in
valve
noise
and
insufficient
valve
clearance
results
in
valve
damage
and
reduced
power.
At
the
distances
indicated
above,
check
and
adjust
the
clearance
to
the
specification.
The
procedure
for
adjusting
the
valve
clearance
is
as
follows:
When
the
de-compression
cable
play
is
properly
adjusted,
the
de-compression
lever
should
have
1
—
2
mm
of
free
play
with
the
piston
at
T.D.C.
on
the
compression
stroke.
1—2mm
(0.04 — 0.08 in)
De-compression
lever play @
NOTE:
Valve clearance is to be checked when the
engine is cold.
Both the intake and exhaust valves must be
checked and adjusted when the piston is at
Top—Dead—Center (TDC) on the compression
stroke.
Remove the seat, frame covers and fuel tank.
(Refer to page 3-2)
Remove the spark plug and valve inspection
caps, intake and exhaust. (Refer to page 3-11)
CAUTION:
Before adjusting the valve clearance, check or
adjust the automatic decompression lever
play.
Valve clearance specifications
IN. and EX. 0.08 — 0.13 mm
(0.003 — 0.005 in)

2-7
PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
e@
Remove
the
valve
timing
inspection
plug
and
magneto
cover
cap.
e
Turn
the
crankshaft
counterclockwise
with
the
box
wrench
to
set
the
piston
at
T.D.C.
on
the
compression
stroke.
(Turn
the
crankshaft
until
the
“T”
line
on
the
magneto
rotor
is
aligned
with
the
center
of
hole
on
the
magneto
cover.)
@
Insert
the
thickness
gauge
into
the
clearance
between
the
valve
stem
end
and
the
adjusting
screw
on
the
rocker
arm.
e If clearance is off the specification, bring it into
the specified range by using the screw driver.
Securely tighten the lock nut after adjustment is
completed.
CAUTION:
Both the right and left valve clearances,
should be as closely set as possible.
—t
NOTE:
Make sure to recheck the automatic de-
compression lever play, after valve clearance
adjustment is made.
e Reinstall the spark plug, valve inspection caps,
valve timing inspection plug and magneto cover
cap.
MANUAL DE-COMPRESSION LEVER
e After adjusting the valve clearance, adjust the
de-compression cable.
@
With
the
de-compression
lever
squeezed,
loosen
and
adjust
the
two
adjuster
lock
nuts
so
that
the
clearance
between
the
lever
on
the
engine
and
upper
cylinder
head
cover
becomes
zero
as
indicated
in
Fig.
at
right.
©
After
adjusting
the
cable
correctly,
tighten
the
two
lock
nuts.
S
wii
Lock
nut
Lock nut
Cylinder
head cover

PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
2-8
SPARK PLUGS
Clean Every 6 000 km (4 000 miles) and
Replace Every 12 000 km (7 500 miles)
The plug gap is adjusted to 0.8 — 0.9 mm (0.03 —
0.04 in). The gap is correctly adjusted by using a
thickness gauge. When carbon is deposited on the
spark plug, remove the carbon with a tool with a
pointed end. If the electrodes are extremely worn
or burnt, replace the plug. Also replace the plug if
it has a broken insulator, damaged thread, etc.
NGK DP9EA-9 or NIPPON DENSO X27EP-U9 as
listed in the table should be used as the standard
plug. However, the heat range of the plug should
be selected to meet the requirements of speed,
actual load, fuel, etc. If the plugs need to be
replaced, it is recommended that the standard
plugs listed in the table be selected. Remove the
plugs and inspect the insulators. Proper heat range
would be indicated if all insulators were light
brown in color. If they are blackened by carbon,
they should be replaced by a hot type NGK
DP8EA-9 or NIPPON DENSO X24EP-U9.
NOTE:
To check the spark plugs, first make sure that
the fuel tank contains unleaded gasoline, and
after a test ride if the plugs are either sooty
with carbon or burnt white, replace them.
_——
NOTE:
Confirm the thread size and reach when
replacing the plug. If the reach is too short,
carbon will be deposited on the screw portion
of the plug hole and engine damage may
result.
Gap 0.8 — 0.9mm
(0.03 — 0.04 in)
NIPPON
DENSO REMARKS
NGK
If the standard plug is
apt to get wet, replace it |
with this hot type plug.
DP8EA-9
X24EP-U9
DP9EA-9 X27EP-U9
“R”’ type spark plug
NIPPON
DENSO
NGK REMARKS
If the standard plug is
apt to get wet, replace it
with this hot type plug.
NOTE:
“R” type spark plug is installed for some
specifications. “‘R’” type spark plug has a
resister located at the center electrode to
prevent radio noise.
DPR8EA-9 X24EPR-U9