Suzuki TS200R User manual

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•