Suzuki Intruder 1978 User manual
Foreword
This
manual
is designed
primarily
for
use by
snow-
mobile mechanics in a properly equipped shop.
However,
it
contains enough detail and basic
in-
formation
to make
it
useful to the snowmobile user
who
desires to perform his
own
basic
mainte-
nance and repair
work
. A basic knowledge
of
mechanics, the proper use
of
tools, and workshop
procedures
must
be understood in order to carry
out
maintenance and repair satisfactorily.
When-
ever the
owner
has
insufficient
experience
or
doubts his ability to do the work, the adjustments,
maintenance, and repair should be carried
out
only
by qualified mechanics.
In order to perform the
work
efficiently
and to
avoid costly mistakes, the mechanic should read
the
text, thoroughly familiarize
himself
with
the
procedures before starting work, and
then
do
the
work
carefully in a clean area.
Whenever
special
tools
or
equ ipment is specified, makeshift tools or
equipment
should
not
be used. Precision measure-
ments
can only
be
made
if
the proper
instruments
are used, and the use
of
substitute tools may
adversely affect safe operation
of
the
snowmobile.
Whenever
you see
the
symbols
shown
below, heed
their
instructionsI
Always
follow
safe operating
and maintenance practices.
IWARNINGI
This
warning
symbol
identifies
special
in-
structions
or
procedures
which
if
not
cor-
rectly
followed
,
could
result
in
personal
injury,
or
loss
of
life.
This
caution
symbol
identifies
special
in-
structions
or
procedures
which
if
not
strictly
observed,
could
result
in
damage to,
or
destruction
of
equipment
.
NOTE:
Indicates points
of
particular interest
for
more
efficient
and convenient operation.
This manual is divided
into
the
following
four
sections:
(1) Specifications
This section contains general and technical specifi-
cations, a complete torque chart and engine per-
formance
cu
rves.
(2)
Maintenance
and Theory
of
Operation
The procedures
for
inspection, adjustments and
minor
repair are described in
this
section.
An
explanation on the
structure
and
function
of each
of
the
major
components and assembly enables
the mechanic
to
better understand
what
he is
doing.
(3) Repair
This section shows the best method
for
removal,
disassembly, inspection, assembly, and installation
which
are necessary
for
proper
maintenance and
repair. Assembly and
installation
notes are pro-
vided to explain special points.
(4)
Appendix
The appendix in the back
of
the
manual
contains
miscellaneous
information,
including
metric
refer-
ence and conversion charts, special tools,
wiring
diagram, and an index.
This shop manual has been prepared to assist the
mechanic in servicing
the
KAWASAKI
snow-
mobiles.
All
procedures contained
within
should be
followed closely.
FOREWORD
,~
Quick Reference Guide
S
°fo
°
peci Icatlons .........................................................................
..
.
..
...
...............
Maintenance and Theory ...............................................................
..
...
..
......
Repair .......................................................
...
..
..........................................
..
..
..
.
Appendix
Using the
quick
reference
guide
will
assist
you in
quickly
locating a desired topic or
procedure
contained
within
this
shop manual. Bend the pages back
until
you
match
the
de-
sired section above
with
the
black tab on
the
right
hand side
of
the table of contents
for
that
section. Refer
to
the
table
of
contents for the exact pagels) to locate
the
specific
topic
or
procedure required.
SECTION
QUICK
REFERENCE
GUIDE
ii
I
"
Specifications
Table of Contents
Page
General Specifications . . . . . . . . . . . . . . . . . . . . . .
1-2
Se
rvice Specifications
.........
..
...........
1-6
Torque Chart .
..
...
..
...
.....
....
.
..
.....
1-8
Gear
Ra
tio Chart
.....
..
.
....
.
.....
..
....
1-12
Engine Performance Curv
es
.
..
...
.
..
.
...
..
. . 1-14
Port Dimensic-ns . . . . . . . . . . . . . . . . . . . . . . .
..
1-15
SPECIFICATIONS
1-1
General Specifications
GENERAL
Overall Length
..
. . .
..
. .
....
.. ..
...........
... ...
.
....
. .
....
...
..
. .
......
103 in. (2,616 mm)
Ov
erall Width . .
..
.
..
.......
.
..
.....
...
..
......
.
.. ..
.
...
..
. .
.....
....
...
. 40.5 in. (1,029 mm)
Ov
era
ll Height (With Windshield) . .
..
.....
..
.... ....
. .
....
..
......
.
...
....
..
.
...
35.5
in
. (902 mm)
Dry
Weight
(Approximate)
.
..
...
.
..
.
....
.
..
...
.....
. . .
.....
.
..
..
...
.
.....
. 365 pounds (165.5
kg)
ENG
I
NE
Model .
...
.
......
...
.. ..
.
....
..
......
.....
....
.
..
.
.........
. .
..
.
.. ..
..
.
..
.
Type
TA440C
Displacement
.........
. .
...
.....
.
...
....
.
..
...
..
........
....
.. ..
.....
..
.
..
26.6 C.I. (436cc)
Bore x Stroke
....
. . .
.........
.
......
...
. .
...
....
..
. .
....
. . . . 2.677 x 2.362 i
n.
(68 x 60 mm)
Number
of
Cylinde
rs
... ...
. . .
......
..
....
..
. . . .
..
....
.
..
....
.......
......
.
..
.
.....
....
2
Engine
RPM
at Full
Throttle
..........
.
.......
.
..
......
......
..
..
..
.
.....
.
....
7,100-7,300
RPM
Engine
RPM
at
Idle
Speed
....
.
..
.
..
. .
..
.......
...
...
.
....
.......
..
. .
...
.
..
.
......
2,500
RPM
Sta
rter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual rewind
IGNITION
Ign
it
ion System
..
....
. .
......
...
..
...
.
....
....
. .
...
. .
....
.......
....
Capa
cit
or Discharge
(C
.D.)
Spark Plug
.......
..
...
....
..
.
....
........
.........
. .
.....
.
..
.....
. . .
...
. .
..
NGK
BR·9EV
CARBURETOR
LEFT
SIDE
RIGHT
SI
DE
Carburet
or
Make
..
.
.. ..
.....
...
.......
. .
..
...
. .
...
.
..
. .
Mikuni
Mikuni
Carburetor Model
...
..
....
.
.......
..
....
.
....
. .
...
....
. VM
32
Econo Jet VM 32 Econo Jet
Identification
Marki
ng
. . . .
.........
..
..
..
........
.
.....
. . L32/120 R32/
121
Type
of
Carburetor
...
..
. .
........
.
......
...
.
...
.
...
...
. Open Vent Open Vent
Ma
in Jet ...
...........
...
.....
. .
....
..
...
. . .
..
.....
. 170 170
Air
Je
t
......
.
............
. . . . .
.....
. . .
....
.
.......
.
Jet Needle . .
.....
.
.....
.
.....
...
....
...
..
..
....
..
...
. None None "
6DH7-3
6DH7·3
J
Needle Jet .
...
....
.
....
. . .
...
. . . .
....
.
...
.
...
....
. . . . 0 -0
0-0
Throttle
Slide (Cut Away) . .
..
.
....
.
..
.
..
...
..
.
..
.
...
..
..
. 0.098
in.
(2.5 mm) 0.098 in. (2.5 mm)
Pi
lot
Jet .
............
.....
..
. .
..
..
. . .
..
.
..
. .
..
.....
.
25
25
By
Pa
ss
.....
...
......
. .
..
.....
..
..
...
...
..
...
....
. . . 0.055 in. (1.4
mm)
0.055 in. (1.4 mm)
Pilot
Outlet
...
....
..
. .
...
. .
... ...
..
........
. . .
......
. 0.031 in. (0.8 mm) 0.
031
in. (0.8 mm)
Air Screw
.....
...
.
.....
...
..
.......
........
.
...
.
...
. 1.5 Tu
rns
1.5 Turns
Float
Va
l
ve
Seat
...
.
............
.
..
. . .
..
. .
....
..
..
....
. 0.059
in.
(1
.5 mm) 0.059 in. (1.5 mm)
Starter Jet . .
..
....
.......
.
....
...
...
.
.....
.
.........
. 0.059 in.
(1
.5 mm) 0.059
in
.
(2
.5 mm)
Type
of
Float
Chamber
..
.. ..
..
..
.
...
.
..
. . . .
..
. .
....
..
..
. Special Special
Starter System
..
.....
.
.....
.
..............
.
....
...
...
. Cable Cable
Econo (Power) Jet . . . .
..
...
..
. .
.....
.
.......
...
...
.
..
. . 150 130
1-2
GENERAL
SPECIFICATIONS
I
FUEL/OI
L
Gasoline
...
..
.......
..
.
..
....
.
..
...
.....
....
Regular leaded (minimum pump posted octane number 89)
Oil
............
...
. .
........
...
...
..
....
........
Kawa
sa
ki Snowmobile Oil
(B
.I.A. certified T.C.w
.)
Gasoline/Oil Ratio
..
..
...
. .
...
.
...
. . . . .
......
..
.. ..
......
..
. .
..
....
.......
.
..
. Oil Injection
Oil Tank Capacity
....
.
....
...........
..
.
........
. .
.....
...
.
...
.
..
..
....
2.5 Quarts (2.37 liters)
Fuel Tank Capacity
....
.
..........
.
..
...
..
..
...
.
......
.
....
...
. .
.......
8.5
gal
lons (32.
17
liters)
DR IVE CONVERTER
Engagement
Speed
(approximate rpm) . . .
...
..............
..
.. ..
.
.....
..
.
..........
....
...
.
..
.....
3700
Drive Converter rpm .
....
. .
...
.
......
.. ..
. .
.. ..
...
.
..
....
...
...
. . .
.. ..
......
.
..
.........
. . 7100·7300
Spring Part Number
and
Color (Standard)
....
. .
...
. . . . .
..
..
......
...
..
..
.....
.
..
...
. . 92031·3001 (Yellow)
Spring Part Number
and
Color (Optional) .
..........
.
....
. . .
..
.
..
. .
..
............
. .
...
. 92081-3004 (Pink)
92081 -3005
(R
ed)
92081·3006 (Blue)
92081·3002 (Black)
Spring
Length·
New
with
no load ± 0.25 in. (6.3 mm) .
..........
.
...
.
....
....
.
...
. 3.96 in. (Yellow) (100.5 mm)
/ 3.54 in. (Pink) (89.9 mm)
3.74 in.
(R
e
d)
(94.9 mm)
4.14 in. (Blue) (105.2 mm)
4.33 in. (Black) (110.1 mm)
Number
of
Spring Coils
(All
Colors) .
.............
........
.
..
.
......
.....
. . . .
..
..
....
....
......
.
..
5·1/2
Spring Wi
re
Diameter ± 0.
01
in. (0.2 mm) All Colors . .
........
...
...
.....
......
.
..
....
.
..
. 0.197 in. (5.0 mm)
Spring Rate ± 2.81b in. (0.05 kg·mm)
All
Colors
......
..
.
.......
.
..
. .
.....
. . . .
..
. . .
..
.
..
561b in.
(1
.0 kg·mm)
Spring Compression ± 5.5 Ib (2.5kg)
......
.
.........
....
.
..
. .
...
...
.........
.....
..
.....
77.2 Ib @2.54 in.
(35.6 kg @64.5 mm)
(Y
ellow)
55.1 Ib @2.54 in.
(25.4 kg @64.5 mm) (Pink)
66.1 Ib @2.
54
in.
(30.4
kg
@64.5 mm) (Red)
88.2 Ib @2.
54
in. '
(40
.7 kg
@64
.5 mm) (Blue)
99.2 Ib @2.54 in.
(45.6 kg @64.5 mm) (Black)
Spring Outside D
ia
meter ± 0.025 in. (0.63 mm)
All
Colors . . . .
....
......
..
.
....
. .
.........
. 2.28 in. (57.9 mm)
Weight Part Numbers (Standard)
....
.
.........
..
.......
..
......
...
..
. .
...
.
.......
. .
........
. 92019·008
462F0500A
110G0620
Ramp Part Number
and
Identi-fication (Standard)
...
....
...
.
..
....
..
....
.
....
...
.
..
Production
Part·
No PIN C
Weight · Total gram weight (Standard) .
.......
.
..
... ...
....
...
.
...
. .
............
.
...
.
.......
....
...
61
.1
Part Number
92019·008
92001 ·3009
92001 ·3003
110G0620
462F0600A
39152·3004
Production
Part·
No PIN
We
ight Description
Nut, special, 6 mm
Bo
lt, aluminum, 6 x
15
mm
Bolt, aluminum, 6 x 20 mm
Bolt, steel, 6 x 20 mm
Washer,
6 mm
Ramp weight
C'
Ramp weight C
Gram Weight
2.3
1.8
2.1
6.0
1.1
50.7
51.7
GENERAL
SPECIFICATIONS 1·3
WEIGHT
51.7grams
55.8 grams
56
_1 grams
57.2 grams
WEIGHT
50.7 grams
54
.8 grams
55.1 grams
56
_2 gr
ams
57.3 grams
DRIVE
CONVERTER
RAMP
WEIGHT
COMBINATIONS
(USING RAMP
WEIGHT
IDE
NT
IF
IED
C)
COMB I
NAT
I
ON
PART
NO.
WE
IGHT
COMBIN
ATION
Weight Ramp Assy C No PI N 58.3 grams Weight Ramp Assy C
Bolt
-
Alum.
6 x 20 mm
Nut
-Special 6 mm
We
ight Ramp Assy C No PI N (2)
Washers
6 mm
Bolt
-
Alum
. 6 x 15 mm 92001-3009
60.0
grams Weight Ramp Assy C
Nut
-
Spe
ci
al
6 mm 92019-008
Bolt
-Steel 6 x 20 mm
Nut
-Special 6 mm
Weight Ramp Assy C No PI N 61.1 grams Weight Ramp Assy C
Bolt
-
Alum
. 6 x 20 mm 92001-3003
Bo
lt - Steel 6 x 20 mm
Nut
-Special 6 mm 92019-008
Nut
-Special 6
mm
(1) Washer 6
mm
Weight Ramp Assy C No PIN 62.2 grams Weight Ramp Assy C
Bo
lt
-
Alum
. 6 x 20 mm 92001-3003 Bolt -Steel 6 x 20 mm
Nut
-
Spe
c
ial
6 mm 92019-008 Nut -Special 6 mm
(1) Washer 6
mm
462F0600A
(2)
Washers
6 mm
DRIVE
CONVERTER
RAMP
WE
IGHT
COMBINATIONS
(USING RAMP
WEIGHT
IDENT
I
FIED
C')
COMBINATION
PART
NO.
WEIGHT
COMBINATION
Weight Ramp Assy
C'
39152-3004 59_0 grams Weight Ramp Assy
C'
Bolt
-Steel 6 x 20 mm
Weight Ramp Assy
C'
39152-3004
Nut
-Special 6 mm
Bolt
-
Alum.
6 x 15 mm 92001-3009
Nut
-Special 6 mm 92019-
008
60.1 grams Weight Ramp Assy
C'
Weight Ramp Assy
C'
Bolt
-Steel 6 x 20 mm
39152-3004
Nut
- Special 6 mm
Bolt
-
Alum
. 6 x 20 mm 92001-3003 (1) Washer 6 mm
Nut -
Spec
i
al
6 mm
920
19-008
Weight Ramp Assy
C'
61.2grams
Weight Ramp Assy
C'
39152-3004
Bolt
-St
ee
l 6 x 20 mm
Bolt
-
Alum
. 6 x 20 mm 92001-3003
Nut
-Special 6 mm
Nut
-Special 6 mm
92019
-
008
(2)
Washers
6 mm
(1) Washer 6 mm
462F0600A
Weight Ramp Assy
C'
39152-3004
Bo
lt
-
Alum.
6 x 20 mm 92001-3003
Nut
-Special 6 mm 92019-008
(2)
Washers
6
mm
462F0600A
1-4
GENERAL
SPECIFICATIONS
PART
NO.
No PIN
92001-3003
92019-008
462F0600A
No PIN
110G0620
92019-008
No PI N
110G0620
92019-008
462F0600A
No PIN
110G0620
92019-008
462F0600A
PART
NO.
39152-3004
110G0620
92019-008
39152-3004
110G0620
92019-008
462F0600A
39152-3004
110G0620
92019-008
462F0600A
DRIVEN
CONVERTER
Cam
Angle (Standard)
.. ..
.
......
..
. . .
..
.
..
...
..
....
..
.
..
. . .
....
..
..
.
.......
. . .
..
...
.
....
.
..
.
..
350
C
am
Ang
le
(O
pt
ion
al)
. . . . .
...
.
..
....
.....
..
...
..
. .
....
. .
...
..
. . . . . . .
..
...
. .
..
. . .
........
. .
...
. . 300
Spring Part
Numb
er
.
..
. .
..
....
...
..
....
.
...
..
....
.
...
.
..
..
. . . . .
..
.........
..
..
....
. .
..
. . 92081·3003
Spring
Color
..
.
..............
. . . . .
...
. .
..
.
......
.
..
.....
...
....
..........
...
. . . . . .
..
.
..
..
.
..
Bl
ack
Spri
ng
Length - New with no load
...
.
....
.
..
.
...
.
..
.
..
.. ..
. . .
..
..
...
..
. . . .
...
..
...
. . . 6.3 in. (160.0 mm)
Spring Wire Diamet
er
.
..
. . .
...
.. ..
....
..
. . .
........
.
....
...
..
.
...
...
..
.....
....
. .
..
0.177 in.
(4
.5 mm)
Numb
er
of
Spring
Co
ils
........
.
..
....
.
..
. .
......
..
...
..
. . . .
..
.....
..
. .
......
...
. . .
......
. . . 7 ± 1/4
Spring
Pr
eload -Counterclockwi
se
....
. . .
..
.
....
..
...
.
.. ..
......
. .
..
..
. .
..
.
.....
.
.. ..
....
. 1500
B2
or
C1
BELT
Part Number
..
...
... ...
.
..
.
....
..
..
..
.
....
.....
. . .
..
......
. . .
...
..
. .
...
. . .
.......
..
.
...
59011
-3
502
Outside
Ci
rcu
mference .
...
. . . .
.........
. .
..
. .
..
.....
..
.......
. . .
.. ..
...
46.62 ± 0.25 i
n.
(1,184 ±6.4 mm)
Width
of
Top
Su
r
fa
ces
.
......
..
. .
.....
...
.
.....
. .
....
. . .
.....
.
..
........
. 1.25 ± 0.03 in.
(31
.7 ± 0.8 mm)
Thickn
ess
- Top
of
be
lt
to
bottom
of
lug
..
...
. . . . .
......
.
...
....
. .
......
. .
...
0.53 ± 0.
03
in. (13.5 ± 0.8 mm)
Belt Taper Ang
le
......
..
.
....
.
...
.
...
..
.....
..
.
....
.
..
..
....
.
.......
.
...
...
..
......
.. ..
. .
..
...
30
0
BRAKE
Minimum
Br
ake
Pad
Thickne
ss
. .
......
...
..
. . . . . . .
...
.
...
.....
..
. .
...
.
..
.......
..
....
1/
16
in. (1.58 mm)
GEARING
Top
Sprocket . . .
...
...
.....
. . .
.....
.
.....
.
...
..
.
.. ..
. . .
..
.
....
..
.
.. ..
...
..
......
..
..
..
...
21
T
ee
th
Low
er Sprocket
.....
....
.
..
. .
..
.
..
. .
..
...
.
...
..
.
...
..
...
.
......
. .
....
..
...
...
....
...
...
. . 39
Te
eth
Sprocket
Ov
erall Ratio
...
.. ..
....
. .
..
.
..
.
...
...
...
.
..
. . .
.....
.......
....
. .
.......
.
.....
.
...
1.86
to
1
Chain
(S
ile
nt
Ty
pe)
....
. . .
....
..
....
.
....
..
....
..
.
..
.
....
.
..
.
...
....
. .
...
......
. .
...
.......
66 Pitch
Chain Tensioner Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
reen
Drive Chain Tension
...
.
.......
.
...
..
...
.
......
...
..
.....
. .
...
.
..
. .
..
...
.
........
.
.....
Se
lf
Adjusting
TRACK
AND
SUSPENSION
Track Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Rubber
(I
nternal Drive Lug)
Track Width
.....
.
..
..
.
....
.
...
..
. .
....
...
. .
...
. .
..
..
.
.. ..
....
..
.
..
...
.. ..
.
15
in. (381 mm)
Track Length
..
...
. . .
.....
..
....
..
.....
. . . . . . . .
.....
. .
.....
..
.
...
....
..
121
in. (3,073.4 mm)
Suspension
......
. .
..
.....
..
....
.
..
.
...
. .
.....
..
.
..
.
...
.
........
.. ..
...
.
...
..
.
Sl
i
de
Rail
GENERAL
SPECIFICATIONS
'-5
ELECTRI
CAL
COMPONENTS
Type
...
.........
.
...................
..
. . . .
..
.
..
...
.......
.. ..
. .
..
...
...
12
VAC,
120 W
Headlight Part . . .
...
..
.
...
..
. .
.....
. .
...
...
...
.
....
. . .
....
...
. . . . .
.....
..
.
...
92069·3501
12 V,
60/60
W
Tail/Brake Light
...
.. .. ..
....
.. ..
.
..
...
.
...
. .
... ... ...
.
...
....
.
..
.
....
. .
.......
G.E. 1157
Instrument
Light
..
.
..
. . .
..
..
...
.........
..
..
.....
.
....
..
...
.
..
....
.........
. .
..
. G.E.
53
12 V·3.4 W
FRAME
Frame . . . .
..
........
..
.
..
..
. .
..
..
.
...
.
....
.
....
.
.. ..
.
Aluminum
alloy
and
HSLA
steel
construction
Service Specifications
ENGINE
Effective Comp
res
sion Ratio .
...
..
...
. .
.......
.. ..
.
........
......
.
...
..
.
..
. .
......
......
..
.
..
7.3 to 1
Top
Ring/Groove Clearance
.. ..
..
.
....
..
...
.
..
.
..
...
....
..
.
......
.....
. .
..
....
0.009
in
. (max.) (0.22 mm)
B
otto
m Ring/Groove
Cl
earance .
....
. . . .
...
....
. . .
..
.
..
.
.....
...
..
. .
... ...
.
....
0.008 in. (max.) (0.19 mm)
Piston Ring End Gap (Top) .
....
..
. . . .
....
. .
..
.
....
. .
.......
. . . .
...
..
....
.
..
0.008·0.016 i
n.
(0.2·0.4 mm)
Piston Ring End Gap
(Bottom)
.
..
......
.....
..
. .
...
...
. .
..
.
....
.
......
..
.
...
. 0.008·0.016 in. (0.2·0.4 mm)
Piston Ski
rt
Cl
earance
...
.
...
. .
......
.
....
......
. . . .
..
....
. .
..
..
.
..
.
..
....
0.002·0.004 in. (0.05·0.10 mm)
Connecting Rod Radial Play
...
.
...
..
..
....
...........
.
...
..
...
. . . .
..
. .
..
..
0.0008·0.
001
in. (0.02·0.03 mm)
Connecting Rod Side
Cle
arance
.
.........
.
...
..
....
..
...
..
. . .
....
.
..
.
..
.
..
. . . 0.016·0.020 in. (0.4·0.5 mm)
Connecting Rod Small End Diameter
......
..
......
. . .
....
.
..
. .
...
.
.. ..
..
.
...
0.787·0.789 in.
(20.0·20
.5 mm)
Cranksha
ft
End Play (max.)
..
.
.....
..
...
..
. .
...
. .
...
.
....
.. ..
..
.. ..
. .
..
.....
..
....
. 0.015 in.
(0
.38 mm)
Crankshaft Run
Out
(max
.)
. \ . . . .
.......
..
...
. .
....
. . .
..
.....
. .
...
..
...
....
..
0.002 in. (T.
I.R
.) (0.05 mm)
'·6
SERVICE
SPECIFICATIONS
IGNITION
Spark Plug Gap
...
. . . .
..
.
...
..
.
...
. .
...
.
..
.
..
....
. .
...
. .
..
. . . .
..
0.020-0.024 in. (0.5-0.6 m
m)
Igni
tion
Timi
ng
(D
y
nam
ic) . . .
..
...
..
..
..
....
..
...
......
. .
....
. .
..
.....
...
. 180 @
6,
500 R.P.M.
Igniti
on Timing (B.T.D.C.) . . . . . . . .
..
.
....
..
. .
..
........
..
...
.
..
. . .
...
..
. 0.073
in
. (1.86 m
m)
MAGNETO
RESISTANCE TESTS
It
em
Oh
mmet
er
Leads
Co
n
ne
cted
Be
t
ween
R
es
i
sta
n
ce
Lighting Coil Yellow-Yellow 0.18 ohm ± 20%
Exciter Coil
Red
-Grou
nd
128 ohms ± 20%
Pu
l
ser
Co
il
Red
-White 23 ohms ± 20%
IGNITION
COIL
RESISTANCE TESTS
Item Ohmmet
er
Leads
Con
nec
ted Betw
ee
n
Res
is
t
ance
Pr
imary windi
ng
Blu
e-
Grou
nd
0.37 ohm ± 20%
tSecondary winding High Tension-High Tension 10,
2000hms±20
%
+Spark Plug
Cap
T
er
min
als
at each
end
of
cap
5,000 ohms ± 20%
CARBURETOR
AirScr
ew Setti
ng
(Initia
l)
..
...
........
.
....
. . . .
....
.
..
.
..
...
..
.
....
...
.
...
...
.
....
..
. . . 1.5 TurnsOpen
Idle Screw Se
tti
ng
(Initial)
. .
..
. .
..
.
....
.. ..
.
..
. . .
.........
..
..
. .
..
. .
......
....
...
...
..
3 Turns
off
Seat
(Fi
na
l)
......
. . . .
.....
....
..
.
....
.....
...
.
........
.
..
. . .
....
. . .
..
. .
...
.
...
. .
...
.
..
...
2,500
R.P
.
M.
Float Arm Adj
us
tme
nt
...
..
. . . .
....
.
...
.
..
.
..
.
..
...
.....
. . .
..
. .
..
.
..
...
..
Parallel
to
Body G
aske
t Surface
CHASSIS
Converter Offset Distance
.....
.
...
.
..
.
.....
. . .
...
. .
..
. . .
....
..
..
...
..
.
....
. . 0.588 in. (14.9 mm)
Converter Center Distance .
.....
.
.....
..
.....
..
. .
..
. .
...
.
.......
. .
..
.
..
.
.. ..
...
12
in. (305 mm)
Drive Chain Tension . . . .
..•..
. . . .
.....
..
...
. . . .
......
.
...
..
.......
.
..
.
..
....
..
Self Adjusti
ng
Brake Lever Movement . .
....
..
.
.. ..
..
. .
...
.
...
.
..
. .
..
.
..
.
.. ..
....
..
. .
.. ..
.
..
. 3/4 in. (19 mm)
Track Tension .
...
..
...
..
.
...
.
....
.. ..
. .
...
. . . . . .
...
.
..
3/4 i
n.
m
ax
imum
de
fle
ct
i
on
(5
to
8 Ib pull)
Steering Alignment .
..
.
..
. .
..
..
..
. .
..
..
.
..
....
...
....
..
.
.......
.....Skis
pa
r
al
le
l or 1/8 in. toe
out
Tie
Rod End Adjustment Stud Jam
Nut
Dimension . . . . .
..
..
.......
.
..
. .
....
...
1-1/4 in. (32 mm) maximum
GENERAL
ENGINE TORQUE SPECIFICATIONS
Cylinder
Head
Bo
l
ts
. .
...
. .
......
.
..
..
....
. . . .
..
.....
..
....
....
. . .
...
. . . . . . 16
ft
Ib (2.2 k
g-
m)
Crankcase Bolts and Nuts .
........
.
...
. . .
.........
. . .
...
....
..
..
..
. .
..
..
..
. . . 16
ft
Ib
(2
.2 kg-m)
Flywheel
Nut
.
....
. . . .
...
..
.
......
...
.
... ...
..
....
..
. .
.•
.
..
..
.
..
...
..
. .
..
60
ft
Ib (8.3 k
g-m
)
Recoil
Bolt
. . . .
..
.
...
..
...
..
. .
.....
. . . . . . . . .
....
...
.......
..
..
. . . .
.....
50
in. Ib (0.6
kg-
m)
Spark Plug
..
. .
..
. . . . .
.......
.. ..
. . . . . . .
..
. .
...
..
. . .
...
...
..
. .
..
...
..
....
20
ft
Ib
(2
.7 kg-m)
Holder (Carb.) Bolts
..
.
..
. . .
..
...
.. ..
.
..
. . . . .
...
.
..
.
...
.
.....
.....
......
.
..
45 in. Ib (0.5 kg-m)
Dr
i
ven
Gear
Nut
.
..
......
. .
....
...
.
..
..
.
...
.
..
.
..•
. .
.......
..
.....
.....
.
..
12ftlb(1
.6 kg-m)
Gea
r
ca
se
Bolts (Socket He
ad)
....
......
..
.
....
. .
..
. .
..
.
..
.
..
. .
......
...
......
12
ft
Ib (1.6 k
g-
m)
t Remove spark pl
ug
caps.
NOTE: Defective coils
ca
nn
ot alw
ays
be det
ec
ted
usi
ng this te
st
alone. U
se
of a
co
il te
st
er
which simulat
es
op
er
ating
co
n-
ditions
isthe
re
comme
nd
ed te
st
method.
SERVICE SPECIFICATIONS 1-7
Torque Chart and Loctite Table
Description Quanti
ty
Torque Loctite
ENGINE
MOUNT
AND
EXHAUST
Engine
mount
to
damper -nuts 6 105 in. Ib (1.21 kg'm)
Muffler
mounting
-nuts 4 95 in.
lb
(1.09 kg'm)
Engine
mount
to
chassis
-nuts 2
31
ft
Ib (4.28
kg'm)
PTO
mount
to
chassis
-screw 5 80-90 in. Ib (0.92-1.04
kg
'm)
ELECTRICAL
SYSTEM
Ignition
switch -
nut
1 30 in. Ib (0.35 kg'm)
Voltage regulator
mounting
-
nut
1 105 in. Ib (1.21
kg
'm)
Brake and
throttle
lever -lockscrew 1 20-25 in. Ib (0.23-0.29 kg'm)
Tail lamp lens
mounting
-screws 2 50 in.
Ib
(0.058 kg'm)
Tail lamp
to
bracket -
nut
2 32 in. Ib (0.37
kg
'
m)
DRIVE
CONVERTER
Drive converter
to
crankshaft -bo
lt
1 60-70
ft
Ib (8.30
-1
0 kg'm)
Cover
to
movable
sheave
-
bolt
6 8
-1
0ft
Ib
(1.1-1.4kg
·m)
Roller and
pin
assembly in movable
sheave
-
bolt
6 8-10
ft
Ib (1.1-1.4 kg'm)
Weight ramp and pin
assy
to
spider -
bolt
6
6-8ft
Ib (0.
8-1
.
1kg
·m)
Weight ramp -
nut
3 4-5
ft
Ib (0.5-0.7
kg
'm)
DRIVEN
CONVERTER
AND
BRAKE
Dr
iven converter
to
i,ackshaft -
bolt
1 40-50
ft
Ib (5.53-6.92
kg
'm)
Coupling
to
fixed
sheave
-
bolt
6
8-10ft
Ib
(1.1 -1.4 kg'm)
Brake disc
to
hub
mounting
-screw 6 55-60 in. Ib (0.6-0.7
kg
'm)
Clevis retainer
to
cam mounting -
nut
1 40-50 in. Ib (0.46-0.57 kg'm)
Caliper
to
chaincase -
nut
2 35
ft
Ib
(4.84 kg'm)
CHAINCASE
AND
JACKSHAFT
Chainc
ase
mounting
-nuts 4 18
ft
Ib
(2.5
kg
'm)
Chain
case
cover
mounting
-
screVl(s
6 70 in. Ib (0.
81
kg'm)
Jackshaft bearing retainer
to
chassis
-rear bolt 1
31
ft
Ib (4.28 kg 'm)
Jackshaft bearing retainer
to
chassis
-
front
bolt
1
19ft
Ib (2.63 kg'm)
Top
sprocket
mounting
-screw 1 40-50
ft
Ib (5.53-6.92
kg
'm)
Jackshaft -bearing retainer adjusting
bolt
-
jamnut
1
10-20ft
Ib
(1
.38-2.77
kg
'm)
Tensioner
arm
-
bolt
2
70
in. Ib (0.
81
kg'm)
Lower sprocket
mounting
-
nut
1 35
ft
Ib (4.84 kg 'm)
Bearing flange -
bolt
3 105 in. Ib
(1
.
21
kg'm)
Bearing
locking
collar -
set
screw 1 36 in. Ib (0.41 kg'm) 222
Bearing
lock
collar (locking
torqu
e)
1 36 in. Ib (0.41 kg'm)
NOTE:
Loctit
e formulas
are
selected on the
basis
of
the diameter
of
the fastener, and the strength
of
the bond
req
uired.
General
ly,
No.
222
is
used
on fasteners up
to
5/16 in. (8 mm) diameter.
If
a
particularly
strong bond
is
required, or the
fastener diameter
is
greater than
5/16
in. (8
mm),
No
. 242
is
specified.
Loctite
may significantly increase
the
torque
nec-
essary
to
remove a fastene
r.
Be
careful when applying extra
forc
e
as
this risks damaging the parts.
Use
only
the specified
formula
on
eac
h fastener requiring
Loctite.
Loctite
No
. 222 and No. 242
are
industrial designations. The consumer equiva-
lent
which
may
be
substituted
is
Loctite
"Lock 'n Seal,"
product
number 21, blue.
'-8
TORQUE
CHART
>
Description
Quantity
Torque
Loctite
SUSPENSION
Rear
pivot
l
ink
-bolts 2
11
ft
Ib (1.52
kg'm)
Rear suspension arm -
bolt
2 30
ft
Ib
(4
.15
kg
'm)
Rear axle -bolts 2 25
ft
Ib (3.46
kg
'
ml
Limiter
shaft -bolts 2 25
ft
Ib (3.46
kg'm)
Idl
er shaft -bolts 2 25 ft Ib (3.46
kg
'm)
Shock absorber
mounting
-nuts 2 35 ft Ib (4.84
kg'm)
Eyebolts
to
suspension brackets -nuts 2
Adjust
Swing arm -bolts 2 25
ft
Ib (3.46 kg'm)
Wear
strip
attaching -nuts 2 25 in. Ib (0.29
kg'm)
Cross shaft
mounting
-screws 4 30
ft
Ib (4.15
kg'm)
Front
pivot
shaft
to
chassis
-bolts 2 25
ft
Ib (3.46 kg '
ml
Suspension brace -
front
and rear -bolts 4 25
ft
Ib (3.46
kg'm)
Limiter
damper -
nut
1 35
ft
Ib (4.84 kg'm)
DRIVESHAFT
Bearing flange
mounting
-bolts 3 18
ft
Ib (2.5
kg
'm)
Speedometer drive adapter -
nut
1 8-
10ft
Ib (1.1-1.4 kg'm)
Bearing locking collar -set screw 1 72 in. Ib (0.83
kg'm)
222
Bearing lock collar (locking torque) 1 72 in. Ib (0.83
kg
'm)
SKI
AND
SPINDLE
Ski attaching -
nut
and
skeg
(wear runner) 6 18
ft
Ib (2.5
kg'm)
Front
spring
mount
-
bolt
2 25 in. Ib (0.29
kg'm)
Shock absorber
to
ski and spindle -
nut
4
31
ft
Ib (4.28
kg
'm)
Saddle
to
spring -screw 4 46
ft
Ib
(6.36
kg'm)
Spindle
to
ski saddle -
nut
2 35
ft
Ib (4.84
kg'm)
Rear spring
mount
-
bolt
2
31
ft
lb
. (4.28
kg'm)
STEERING
Handle holder -
bolt
1 35
ft
Ib
(4.84
kg'm)
Steering arm
to
spindle -
bolt
2
30
ft
Ib (4.15
kg
'm)
Steering column
to
tie rod -
nut
1
30
ft
Ib
(4.15
kg'm)
Steering arms
to
tie rods -nuts 2 30
ft
Ib
(4.15kg·ml
Upper steering post
mounting
-nuts 2 18
ft
Ib
(2.5
kg
'm)
Lower steering post
mounting
-nuts 2 20
ft
Ib (2.77
kg'm)
Tie
rod jam -
nut
(LH)
2 100-120 in.
lb
(1
.15-1.38
kg
'
ml
Tie
rod jam -
nut
(RH) 2 100-120
in.lb
(1
.15-1.38
kg'ml
RH tie rod
to
steering arm -
nut
1 30
ft
Ib (4.15
kg
'm)
Handlebar
to
steering column
mounting
-screws 4 105 in.
Ib
(1.21 kg'm)
Tie
rod adjusting -nuts (R H) 2 100-120 in. Ib (1.15-1.38 kg'm)
Tie
rod adjusting -nuts
(LH)
2 100-120 in.lb
(1
.15-1.38
kg
'm)
NOTE:
Loctite
formulas
are
selected on the
basis
of
the diameter
of
the fastener,
and
the strength
of
the bond required.
Generally, No. 222
is
used
on fasteners
up
to
5/16
in. (8
mm)
diameter.
If
a
particularly
strong bond
is
required, or the
fastener diameter
is
greater than
5/16
in. (8
mm),
No. 242
is
specified.
Loctite
may
significantly
increase the torque
nec-
essary
to
remove a fastener.
Be
careful when applying extra force
as
this risks damaging
the
parts.
Use
only
the specified
formula
on
each
fastener requiring
Loctite
.
Loctite
No
. 222 and
No
. 242
are
industrial designations. The consumer
eq
u
iva-
lent
which may
be
substituted
is
Loctite
"Lock
'n Seal,"
product
number 21, blue.
TORQUE
CHART
'-9
Description
Quantity
Torq
ue Loctite
CHASSIS
Snow
flap
to
bu
lk
head
-
nut
2 50 in. Ib (0.57 kg'm)
Hood guide
and
trim
mounting -screws 8 20 in. Ib (0.23
kg
'm)
Hood guide,
front
bumper
and
hood hinge attachi
ng
-nuts 18 95 in. Ib (1.09
kg
'm)
Passenge
r handle attaching -
nu
ts 4 18
ft
Ib (2.5
kg
'm)
Pan
brace attachi
ng
-screws 2 70 in. Ib (0.81 kg'm)
Rear stay attaching -bolts 2 19
ft
Ib (2.63
kg
'm)
Trim
attachi
ng
-screws 2 20 in.
Ib
(0.23 kg'm)
Seat attachi
ng
-bolts 4 35 in. Ib (0.40 kg'm)
FUEL
SYSTEM
Fuel
pump
assy
mounting
-nuts 2 70 in. Ib (0.81
kg
'm)
Primer
pump
-
nut
1 30 in. Ib (0.35 kg'm)
CABLES
Brake
ca
ble jam -nuts 2 95 in. Ib (1.09 kg'm)
Enrichener cable
assy
-nuts 2 15-20 in. Ib (0.17-0.23 kg'm)
Enrichener
assy
pal
-
nut
1 Hand Tighten
Speedometer cable - nuts 1 Hand Tight
en
Thrott
le cable
assy
-nuts 2 15-20 in. Ib (0.17-0.23
kg'm)
FA
N
C,L"SE
AND
AIR
SHROUD
Air
shroud
mounting
screws 10
Use
impact
dr
iver 222
Fan
case
to
crankcase
mounting
nuts 4 10-12
ft
Ib
(1.4-1.7 kg·m)
HOOD
Windshield
mounting
screws 10 15 i
n.
Ib
(0.
17
kg
·
m)
Hood hinge -nuts 6 25 i
n.
Ib (0.29 kg'm)
Hood latch band -
screws
4 Compress rubber
0.06 i
n.
(1
.55 mm)
INSTRUMENT
PANEL
&
INSTRUMENTS
Ins
trument
pane
l bracket -
nut
3 95 in.
Ib
(1.09 kg'm)
Gauges
to
panel -nu
ts
6
11
in. Ib (0.13 kg'm)
Instrument panel -
screws
12 32 in. Ib (0.37
kg
'm)
Ig
nition
panel - screws 2 32 in. Ib (0.37 kg'm)
CRANKSHAFT
Flywhe
el -
nut
1 60
ft
Ib (8.
30
kg'm)
CRANKCASE
AND
CYLINDER
Cylinder head -nuts 16 16
ft
Ib (2.2 kg'm)
Spark plug 2 20
ft
Ib (2.77
kg
'm)
Crankcase -bolts 8 16
ft
Ib (2.2 kg'
m)
1-10
TORQUE
CHART
Description Quantity Torque Loctite
EXHAUST
Exhaust manifold -nuts 4 8-
10ft
Ib
(1
.
11
-1.3
8kg
·
m)
COl
MAGNETO
Stator plate mounting -
screws
2 5-6
ft
Ib (0.69-0.83 kg'm)
Wire clamps
to
stator plate -
screws
2
Use
impact
dr
i
ver
Exciter coil
and
pulser coil mounting -
screws
2
Use
impact driver
Lighting coil mounting -
screws
2
Use
impact driver
ELECTRICAL
COl igniter mounting -
screws
2 60 in. Ib (0.69
kg
'm)
Igni
tion
coil mounting -screw 1 5-6 ft Ib (0.69-0.
83
kg
'
m)
RECOI L STARTER
Drive plate mounting -
nut
1 8-
10ft
Ib (1.11-1 .
38kg
·m)
Starter pulley mounting -bol
ts
3 16-18
ft
Ib
(2
.2
-2.
5 kg'm)
Starter
mount
i
ng
-bolts 4
5-6
ft
Ib
(0
.69-0.83
kg
'm)
TORQUE
CHART
1-11
.....
N
G')
m
»
:Il
:Il
l>
-i
o
(")
:::c
l>
:Il
-i
:::c
f-
w
w
f-
LL
0
a:
w
co
~
::::>
z
I
f-
w
~
u
0
a:
0.-
(/)
z
w
>
a:
a
36
37
38
39
40
Gear Ratio Chart
Drive Sprocket -Number
of
Teeth
17
18 19 20
Gear Ratio 1.90 1.80
Speed
*75
MPH
*80
MPH
Chain Pitch 64 64
Tensioner Spring
Red
Pink
Gear Ratio 2.18 2.06 1.95
Speed
*66
MPH
*69
MPH
*73
MPH
Chain Pitch 64
64
64
Tensioner Spring
Red
Pink Green
Gear Ratio 2.24
2.11
1.90
Speed
*64
MPH
*68
MPH
*75
MPH
Chain Pitch 64 64 66
Tensioner Spring Pink Green
Red
Gear Ratio 2.05 1.95
Speed
*70
MPH
*73
MPH
Chain Pitch 66 66
Tensioner Spring
Red
Pink
Gear Ratio 2.35 2.22
2.11
2.00
Speed *61 MPH
*64
MPH
*68
MPH
*72
MPH
Chain Pitch 66 66
66
66
Tensioner SprinQ Pink Pink Green Green
*Theoretical
MPH
at
7,200
RPM
NOTE:
All
top
speeds based
on
0.96
overdrive
in
converter
and
engine
RPM
at
7,200.
..
\'
'"
21
22
1.76 1.68
*81 MPH
*85
MPH
66 66
Red
Pink
1.81
1.
73
*79
MPH
*83
MPH
66 66
Pink Green
1.86
*77
MPH
66
Green
G)
m
l>
JJ
JJ
l>
-I
o
(')
::I:
l>
JJ
-I
...
w
Color
Black
White
Red
Orange
Pink
Yellow
Green
Blue
Chain Tensioner Springs
Length
2.50 in. (63.50 mm)
2.50 in. (63.50 mm)
3.00 in. (76.20 mm)
3.00 in. (76.20 mm)
3.38 in. (85.85 mm)
3.38 in. (85.85
mm)
3.75 in. (95.25
mm)
3.75 in. (95.25 mm)
Wire Dia.
0.049 in. (1.245 mm)
0.055 in. (1.397 mm)
0.049 in. (1.245 mm)
0.055 in. (1.397 mm)
0.049 in. (1.245 mm)
0.049 in. (1.245
mm)
0.049 in. (1.245 mm)
0.055 in. (1.397 mm)
0:
LLJ
S
o
a..
llJ
(f)
0:
o
:r:
Engine Performance Curves
I
~
V
~
HORSEP~WER
I
t,
...
~
/TORQUE
~
~
....
/ /
""'"
'\
LV
'~
L
)(
V""""
...........
~
./
FUEL
CONSUMPTION
/
a
a
a
")
a
a
a
'<1"-
a
a
a
LCl
ENG
INE R.P.M.
a
a
LCl
CD-
a
a
a
r--
a
a
LCl
r--
1-14 ENGINE PERFORMANCE CURVES
40
U)
a:l
30
....J
--
I-
u.
w
~
20 d
0:
0
I-
10
1.60
0:
:r:
1.40
ri...
:r:
--
1.20
U)
a:l
....J
1.00
....J
W
~
0.80 u.
MODEL
ST440-A1
A = 1
.575
in
(40
B = 1.272 in· .0 mm)
C = 1 1 . . (32.3 mm)
.
50
In
(292
D = 1.890 in· . mm)
E = 1.189 in· (48.0 mm)
F = 3.807 in· (30.2 mm)
G = 0.516 in· (96.7 mm)
H =
19
..
(13.1mm)
. 061n
(484
I = 1.906 in· . mm)
J = 0.516 i
n·
(48.4 mm)
K =
0787
. . (13.1 mm)
L = .
In.
(20.0 mm
0.787 in (20 )
. .Omm)
Port
0-
Imensions
---~
PORT DIMENSIONS 1-15
Table of contents
Other Suzuki Motorcycle manuals
Suzuki
Suzuki SV650 Manual
Suzuki
Suzuki DL1000 User manual
Suzuki
Suzuki VZR1800 2007 User manual
Suzuki
Suzuki GSX-R1000 User manual
Suzuki
Suzuki GSX 600F 2000 User manual
Suzuki
Suzuki GV1200GLG User manual
Suzuki
Suzuki GSX-R600 User manual
Suzuki
Suzuki PE400 User manual
Suzuki
Suzuki GSX1300BKA Manual
Suzuki
Suzuki GS1100E User manual
Suzuki
Suzuki MT50 Guide
Suzuki
Suzuki RM-Z250L9 User guide
Suzuki
Suzuki EN125-2A User manual
Suzuki
Suzuki Intruder VL1500B User manual
Suzuki
Suzuki Raider 150 FU150SC User manual
Suzuki
Suzuki GSX-R750 User manual
Suzuki
Suzuki sv1000S User manual
Suzuki
Suzuki Intruder VZ800 User manual
Suzuki
Suzuki GSX1300BK B-King User manual
Suzuki
Suzuki 1999 SV650 User manual
