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Suzuki TS200R User manual

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FOREWORD
The
SUZUKI
TS200R
has
been developed
as
a
new
generation motorcycle to the TS-models.
It
is
packed
with
highly
advanced design concepts
including a
liquid
cooled engine, a crankcase reed
valve, a
Automatic
Exhaust Timing
Control
(A.
E.
T.C.) a Digital C.D. ignition system a
link
type
rear suspension. Combined
with
precise
control
and
easy
handling the TS200R provides excellentperfor-
mance andoutstanding riding comfort.
This service manual
has
been produced
primarily
for
experienced mechanics whose
job
is
to
inspect,
adjust, repair
and
service
SUZUKI
motorcycle.
Apprentice mechanics and
"do
it
yourself"
mechanics
will
also
find
this manual to be an
extremely usefulguide.
The TS200R, manufactured to standard specifica-
tions,
is
the main subject
matter
of
this manual.
However, the TS200R machines distributed
ih
your
country
might
differ
in
minor
respects from the
standard-specification and,
if
they do,
it
is
because
some
minor
modifications (which are
of
no
consequence
in
most
cases
as
far
as
servicing
is
concerned) had to be made to
comply
with
the
statutory
requirements
of
your
country.
This manual contains up-to-date
information
at
the
time
of
its
issue.
Later made modifications and
changes
will
be explained to
each
SUZUKI
distrib-
utor
in respective markets, to whom
you
are
kindly
requested
to
make query
about
updated
information,
if
any.
SUZUKI MOTOR CORPORATION
Motorcycle
Department
Overseas Service
Division
©COPYRIGHT SUZUKI MOTOR CORPORATION 1990
GROUP INDEX
GENERAL
INFORMATION
PERIODIC MAINTENANCE
AND
TUNE-UP PROCEDURE
IENGINE n
L___
_
__
g
Llc_o_o_L_IN
__
G_s_v_s_~_EM
__
·--~-------~
I
FUEL
AND
LUBRICATION SYSTEM
II
IELECTRICAL SYSTEM Ill
CHASSIS
IL
s_E_R_"'_Jc_I_N_G_IN_F_o_R_M_~_~_~_o_N
___
B
L..._T._S_2_o_o_R_N_f_'9_2_-M_O_D_E_L_J
___
___.q
TS200RP
('93-MODEL)
~
L_____
_
______jllliil
VIEW
OF
TS200R
For Conventional
front
fork
model
For
Inverted
front fork
model
GENERAL
INFORMATION
~----------------CONTENTS----------------~
VIN
AND
SERIAL NUMBER
LOCATIONS..............................
1-1
FUEL, OIL
AND
COOLING SOLUTION
RECOMMENDATIONS ....................................................... 1-1
BREAKING-IN PROCEDURES .............................................. 1-2
SPECIAL MATERIALS........................................................ 1-3
PRECAUTIONS
AND
GENERAL INSTRUCTIONS ................... 1-5
SPECIFICATIONS
..............................................................
1-j'
,:The
frame serial number or V.I.N. (Vehicle Identification
Number)
CD
is
stamped on the steering
head
pipe. The engine
serial number
®
is
located
on
the left side
of
the crankcase.
These
numbers
are
required especially
for
registering the
machine
and
ordering
spare
parts.
FUEL, OIL
AND
COOLING SOLUTION
RECOMMENDATIONS
FUEL
For
CANADA
model
Use
only
unleaded gasoline
of
at
least
87
pump
octane
( R
~M
method) or
91
octane
or higher rated by
the
Research
Method.
For
other
models
Gasoline used should be graded
85-95
octane or higher.
An
unleaded gasoline is recommended.
ENGINE OIL
Use SUZUKI
"CCI"
oil
or
SUZUKI CCI Super oil.
They
are
formulated
to
give
best
engine
performance
with
least
com-
bustion chamber deposits, least preignition,
maximum
spark
plug life and best lubrication.
If
they
are
not
available, a good
quality
TWO-STROKE OIL (non-diluent
type)
should be used.
TRANSMISSION OIL
Use a
good
quality
SAE
20W/40
multi-grade
motor
oil.
FRONT FORK OIL
Use
fork
oil
#
1
0.
99000-99044-10G
:
SUZUKI FORK
OIL#
10
BRAKE FLUID
Specification
and
classification :
DOT
4
99000-2311
0 :
SUZUKI BRAKE FLUID
COOLING SOLUTION
Use an anti;.freeze
&
Summer coolant compatible:·
with
aluminum radiator, mixed
with
distilled
water
only,
at
ratio
of
50:
50.
WATER FOR MIXING
Use distilled
water
only.
Water
other than distilled
water
can
corrode and clog
the
aluminum radiator.
ANTI-FREEZE & SUMMER COOLANT
The
coolant
performs
as
corrosion and
rustinhibitor
as
well
as
anti-freeze. Therefore, the coolant should be used at all
times
even
though
the atmospheric temperature in
your
area
does
not
go
down
to
freezing point.
SUZUKI recommends
the
use
of
SUZUKI GOLDEN CRUISER
1200NA
anti-freeze
&
summer coolant.
If
this
is
not
availa-
ble, use an equivalent
which
is compatible
with
aluminum
radiator.
99000-99032-10X
:SUZUKI
GOLDEN CRUISER 1200NA
{Non-Amine type)
REQUIRED
AMOUNT
OF
WATER/COOLANT
Solution
capacity
{total) : 900 ml {0.95/0.79 US/Imp
qt)
CAUTION:
Mixing
of
anti-freeze &
summer
coolant
should be
limited
to
60%.
·Mixingbeyond
it
would
reduce
its
efficitmcy.
If
the anti-
freeze &
summer
coolant
mixing
ratio is
below
30%,
rust
inhibiting
performance is greatly reduced,
Be
sure
to
mix
it
above
30%
even
though
the
atmospheric temperature does
not
go
down
to
freezing point.
BREAKING-IN PROCEDURES
During manufacture only the best possible materials.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.
•
Keep
to
these
breaking-in engine
speed
limits.
Initial 800 km {500 miles) : Below 5 000
r/min
Up
to
1 600 km
{1
000 miles) : Below 7 000
r/min
Over 1 600 km
{1
000 miles) : Below 12 000
r/min
GENERAL
INFORMATION
1-2
1·3
GENERAL
INFORMATION
SPECIAL MATERIALS
The materials listed below
are
needed
for
maintenance
work
on the TS200R,
and
should
be
kept on
hand
for
ready
use.
They supplement
such
standard materials
as
cleaning fluids, lubrications, emery cloth
and the like. How
to
use
them
and
where
to
use
them
are
described in the
text
of
this manual.
Material
SUZUKI
SUPER
GREASE
"A"
99000-25010
SUZUKI
BOND No. 1207B
99000-31140
SUZUKI
BOND No. 1215
99000-31110
THREAD
LOCK
SUPER
"1322"
99000-32110
THREAD
LOCK SUPER
"1303"
99000-32030
THREAD
LOCK
SUPER
"1324"
99000-32120
Part
•
Throttle
grip
• Clutch lever
• Speedometer cable
and
tachometer cable
• Speedometer
gear
box
• Brake pedal shaft
• Side stand
• Kick starter lever
• Crankcase oil
seal
• Water
pump
mechanical
seal
• Crankcase mating surface
• Water thermo-gauge
• Engine sprocket
bolt
• Exhaust pulley
bolt
• Exhaust valve arm screw
• 2nd drive
gear
• Gearshift
arm·
stopper
• Magneto
rotor
nut
Page
Part
Page
2-
2 • Wheel bearings
2-
2
2-
2 7- 1
2- 2 7- 2
7-31
2-
2 • Steering stem bearing and
race
7-25
7- 1 7-29
7·
2 • Swingarm bearing and dust
seal
7-40
2-
2 7-47
2-
2 • Cushion lever and rod bearing 7-40
2-
2 7-47
3-27
4-
8
3-31
4-
9
3· 5 •
Kick
lever
bolt
3-40
3-
6
3-18
3-26
3-32
3-37
Material
~
THREAD
LOCK
SUPER
"1360"
99000-32020
&
THREAD
LOCK
"1342"
99000-32050
~
~
~
~········.A
-
SUZUKI SILICONE
GREASE 99000-25100
~
SUZUKI
BRAKE
FLUID
99000-23110 (0.5L)
~
~
~~~o.2.'-~
...
'···'<~
SUZUKI GOLDEN
CRUISER 1200NA
(Non-Amine type)
99000-99032-1
ox
~
•
OIL
..
~
SUZUKI FORK
OIL#
10
99000-99044-1
OG
Part
• Disc
bolt
Page
7- 1
7- 2
7-31
• Gearshift retainer screw
and
bolt
3-32
• Pawellifter
nut
and
cam
guide screw 3-33
•
Cam
driven
gear
bolt
3-33
• Front
fork
damper rod
bolt
7-13
• Caliper axle
• Brakes
• Cooling solution
•
Front
fork
7-16
7- 5
7-34
1-
1
2-10
1-
2
1-
1
7-17
7-22
GENERAL
INFORMATION
1-4
Part
Page
1-5
GENERAL
INFORMATION
PRECAUTIONS
AND
GENERAL INSTRUCTIONS
Observe
the
following
items
without
fail
when
disassembling and reassembling
motorcycles.
o Do
not
run engine indoors
with
little
or no
ventilation.
o
Be
sure
to
replace packings, gaskets, circlips,
0-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
is
completely
seated in
its
groove and securely
fitted.
o Tighten cylinder head and case bolts and
nuts
beginning
with
larger diameter and ending
with
smaller
diameter, and
from
inside
to
outside diagonally,
to
the
specified
tightening
torque.
o Use special
tools
where
specified.
o Use genuine parts and recommended oils.
o
When
more
than
2 persons perform
work
together,
pay
attention
to
the
safety
of
each other.
o
After
the
reassembly, check parts
for
tightness
and operation.
o Treat gasoline,
which
is
extremely
flammable and
highly
explosive,
with
greatest care. Never use
gasoline as cleaning solvent.
Warning, Caution and
Note
are included in
this
manual occasionally, describing
the
following
contents.
WARNING
.................
The personal
safety
ofthe
rider
or
bystanders
may
be involved. Disregarding
this
information
could result in personal injury.
CAUTION..................
These instructions point
out
special service procedures
or
precautions
that
must
be
followed
to
avoid damaging
the
machine.
NOTE
...
;...................
This
provides
special
information
to
make
maintenance
easier
or
important
instructions
clearer.
REPLACEMENT PARTS
When
you
replace
any
parts, use
only
genuine SUZUKI
replacement parts, or their equivalent. Genuine SUZUKI parts
are high
quality
parts
which
are designed and
built
specifi-
cally
for
SUZUKI vehicles.
CAUTION:
Use
of
replacement parts
which
are
not
equivalent in
quality
to
genuine SUZUKI parts can lead
to
performance problems
and damage.
ASBESTOS INFORMATION
Note
the
following
when
handling a
supply
part
with
the
above WARNING LABEL or
any
part
in
the
parts
list
in
this
section
which
contains
asbestos.
• Operate
if
possible
out
of
doors in a
well
ventilated
place.
• Preferably use hand
tools
or
low
speed
tools
equipped,
if
necessary,
with
an
appropriate
dust
extractor
facility.
If
· high speed
tools
are used,
they
should
always
be so
equipped.
•
If
possible, dampen before
cutting
or
drilling.
• Dampen
dust
and place
it
in a properly closed receptacle
and dispose
of
it
safely.
Any
domestic
asbestos
product
to
which
the
above does
not
apply,
but
which
is likely
to
release fibres during use should
be replaced
by
new
one
when
worn.
Exhaust pipe gasket
GENERAL
INFORMATION
1-6
WARNING
CONTAINS
ASBESTOS
Breathing
ubeatoa
duet
Ia
dang8f'OUI
tohnhh
Follow
safety
Instruction•