Suzuki Vinson LT-A500F User manual

SUZUKI
LT-A500F
SERVICE MANUAL

FOREWORD
This manual contains an introductory description on
the SUZUKI LT-A500F and procedures for its
inspection, service, and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the vehicle and its mainte-
nance. Use this section as well as other sections as
aguide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of fast and reli-
able service.
* This manual has been prepared on the
basis of the latest specifications at the time
of publication. If modifications have been
made since then, differences may exist
between the content of this manual and the
actual vehicle.
*Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual vehicle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, includ-
ing special tools, for servicing SUZUKI vehi-
cles. If you do not have the proper
knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
A WARNING
Inexperiencedmechanicsormechanics
without thepropertoolsandequipment
maynotbeabletoproperly perform the
services describedinthismanual.
Improper repairmayresultininjurytothe
mechanicandmayrenderthevehicle
unsafefortherider.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
SHAFT DRIVE AND
DIFFERENTIAL GEARS
FUEL AND LUBRICATION
SYSTEM
COOLING SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
LT-A500FK1 ('01-MODEL)
SUZUKI MOTORCORPORATION
Motorcycle Service Department
© COPYRIGHT SUZUKI MOTOR CORPORATION 1999

HOWTOUSETHISMANUAL
TOLOCATE WHAT YOUARELOOKING
FOR:
1. The text of this manualisdividedintosections.
2. Thesection titles are listed inthe GROUP INDEX.
3.Holdingthemanualasshownattheright will allowyou
to findthe first pageofthesectioneasily.
4. Thecontentsare listed on the first page of eachsec-
tion tohelpyoufindtheitemandpageyouneed.
COMPONENTPARTSANDWORKTOBEDONE
Underthename of eachsystem or unitthere isan explodedviewwhichprovidesworkinstructions and
other serviceinformation(e.g.; tightening torque, lubricating points,andlockingagentpoints).
Example:Frontbrake
© Mastercylinderreservoircap
© Diaphragm
© Mastercylinderclamp
© Boot
© Piston/cupset
©Cup
® Spring
© Mastercylinder
© BrakehoseNo.1
® BrakehoseNo.2
® BrakehoseNo.3
© Brakepipejoint
© Brakepipe, RH
@ Brakepipe, LH
@ Piston
© Pistonseal
® Dust seal
© Brakecaliper
® Brakecaliperholder
© Brakepad
© PadSpring
® Mastercylinderclampbolt
® Brakehoseunionbolt
© Brakepipenut
© Airbleedervalve
© Brakecalipermountingbolt
© Brakepadmountingpin
H
ITEM Nm
kgf-m
Ib-ft
®
10 1.0 7.0
®
23 2.3 16.5
©
16 1.6 11.5
®
7.5 0.75 5.0
©
26 2.6 19.0
©
18 1.8 13.0

SYMBOL
Listed in thetablebelow are thesymbolsindicating instructions and otherinformationnecessary for servic-
ing. The meaning of eachsymbol is alsoincluded in thetable.
SYMBOL DEFINITION
SYMBOL DEFINITION
H
Torquecontrolrequired.
Databesideitindicatesspecified
torque.
Apply THREADLOCKSUPER "1305".
99000-32100
Indicates servicedata. Apply
THREADLOCKSUPER "1322".
99000-32110 (Except USA)
Apply oil. Use engineoilunless
otherwise specified. Apply
THREADLOCK "1342".
99000-32050
if
Applymolybdenumoilsolution,
(mixture of engineoil andSUZUKI
MOLYPASTEin a ratio of 1 : 1)
Apply or use brake fluid.
Apply SUZUKISUPERGREASE "A".
99000-25030 (For USA)
99000-25010 (For theothercountries)
Measure in voltagerange.
Apply SUZUKI SILICONEGREASE.
99000-25100
Measure in resistancerange.
Apply SUZUKIMOLYPASTE.
99000-25140
Measure in currentrange.
Apply WATERRESISTANCEGREASE
99000-25160
Measure in diode test range.
^12Q7B]
Apply SUZUKIBOND "1207B".
99104-31140 (For USA)
99000-31140 (For theothercountries)
II
Measure in continuity test range.
^1215]
Apply SUZUKIBOND "1215".
99000-31110 (Except USA)
Usespecial tool.
^1216]
Apply SUZUKIBOND "1216".
99104-31160 (For USA)
99000-31160 (For theothercountries)
Useenginecoolant.
99000-99032-11X (Except USA)
Apply THREADLOCKSUPER "1303".
99000-32030

GENERAL INFORMATION
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE 1- 2
GENERAL PRECAUTIONS 7-2
SUZUKI LT-A500FY (2000-MODEL) 1- 4
SERIAL NUMBER LOCATION 1- 4
FUEL, OIL, AND ENGINE COOLANT RECOMMENDATIONS 1- 4
FUEL 1- 4
ENGINE OIL 1- 5
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 1- 5
BRAKE FLUID 1- 5
ENGINE COOLANT 1-5
BREAK-IN PROCEDURES 1- 6
INFORMATION LABELS 1- 7
SPECIFICATIONS 1- 8
COUNTRY AND AREA CODES 1-10

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Pleasereadthismanualandfollowitsinstructionscarefully. To emphasizespecialinformation,thesymbol
andthewords WARNING, CAUTION and NOTE havespecialmeanings.Payspecialattentiontothemes-
sageshighlightedbythesesignalwords.
A WARNING
Indicatesa potentialhazard that couldresultindeathorinjury.
ACAUTIOINT
Indicatesa potentialhazard that couldresultinvehicledamage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Pleasenote,however,thatthewarningsandcautionscontained in thismanualcannotpossiblycoverall
potential hazardsrelatingtotheservicing, or lackofservicing,ofthevehicle.Inadditiontothe WARNINGS
and CAUTIONS stated,youmustusegoodjudgementandbasicmechanicalsafetyprinciples. If you are
unsureabouthowtoperform a particularserviceoperation,ask a moreexperiencedmechanicforadvice.
GENERAL PRECAUTIONS
A WARNING
*Properserviceandrepairproceduresare important forthesafetyoftheservicemechanic
andthesafetyandreliabilityofthevehicle.
*Whentwoormorepersonsworktogether,pay attention tothesafetyofeachother.
*Whenitisnecessarytoruntheengineindoors,makesure that exhaustgasisforcedout-
doors.
*Whenworking with toxicorflammablematerials,makesure that theareayouworkiniswell
ventilatedand that you follow allofthemanufacturer'sinstructions.
*Neverusegasolineasa cleaningsolvent.
*Toavoid getting burned,donottouchtheengine,engineoil,radiator,andexhaustsystem
until theyhavecooled.
* After servicingthefuel,oil,enginecoolant,exhaustorbrake systems, checkallofthelines,
and fittings relatedtothesystemforleaks.

GENERAL INFORMATION1-3
ACAUTION
*Ifpartsreplacementis necessary, replacethepartswithSUZUKIGenuinePartsortheir
equivalent.
*Whenremovingpartsthat aretobereused,keepthemarrangedinanorderlymannerso
that theymaybereinstalledintheproperorder.
*Besuretousespecialtoolswheninstructed.
*Makesurethat allpartsusedinreassemblyareclean.Lubricatethemwhenspecified.
*Usethespecifiedlubricants,bonds,or sealants.
*Whenremovingthebattery, disconnect the0 batteryleadwirefirst,thenthe0 batterylead
wire.
*Whenreconnectingthebattery,connectthe0 batteryleadwirefirst,thenthe0 battery
leadwire.Finally,coverthe© batteryterminalwiththeterminalcover.
*Whenperformingservicetoelectricalparts,disconnectthe0 batteryleadwire, unless the
service procedurerequiresthebatterypower.
*Whentighteningcylinderheadand crankcase nutsandbolts,tightenthelarger sizes first.
Always tightenthenutsandboltsfromtheinsideworkingout,diagonallyandtothe speci-
fiedtorque.
*Wheneveryouremoveoil seals, gaskets,packing,O-rings,self-lockingnuts,locking wash-
ers, cotterpins, circlips, andotherspecifiedparts,besuretoreplacethemwithnew ones.
Also, beforeinstallingthesenewparts,besuretoremoveany left overmaterialfromthe
mating surfaces.
*Neverreusea circlip.Wheninstallinga newcirclip,takecarenottoexpandtheendgap
largerthanrequiredtoslipthecirclipovertheshaft.Afterinstallinga circlip,alwaysensure
itiscompletelyseatedinitsgrooveandsecurelyfitted.
*Usea torquewrenchtotightenfastenerstothespecifiedtorque.Wipeoffgreaseandoilifa
threadissmearedwiththem.
*After reassembling, checkpartsfortightnessandproperoperation.
*Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,enginecoolant,all
otherfluids,batteries,andtires.
*Toprotecttheearth'snatural resources, properlydisposeofusedvehiclesandparts.

1-4 GENERAL INFORMATION
SUZUKILT-A500FY(2000-MODEL)
RIGHT SIDE LEFT SIDE
* Differencebetweenphotographs andtheactualvehicles depends onthemarkets.
SERIAL NUMBERLOCATION
TheframeserialnumberorV.I.N.(VehicleIdentification Number) © isstampedontherightsideoftherear
framepipe. The engineserialnumber © is located on the left side of thecrankcase. These numbersare
requiredespeciallyforregisteringthemachineandorderingspareparts.
FUEL, OIL,ANDENGINECOOLANTRECOMMENDATION
FUEL (ForUSA)
• Useonlyunleadedgasoline ofat least 87 pump octane (R * M ) method or 91octane or higherrated
bytheResearchMethod.
• SUZUKI recommendsthatcustomersusealcohol-freeunleadedgasolinewheneverpossible.
• Use of blendedgasolinecontaining MTBE (MethylTertiaryButylEther)ispermitted.
• Use of blendedgasoline/alcoholfuelispermitted,providedthatthefuelcontainsnotmorethan10%eth-
anol. Gasoline/alcoholfuelmaycontainupto5%methanolifappropriatecosolventsandcorrosioninhib-
itors arepresentinit.
• Iftheperformance of thevehicle is unsatisfactorywhileusingblendedgasoline/alcohol fuel, youshould
switch toalcohol-freeunleadedgasoline.
• Failuretofollowtheseguidelinescouldpossiblyvoidapplicablewarrantycoverage.Check with yourfuel
suppliertomakesurethatthefuelyouintendtousemeetstherequirementslistedabove.

GENERAL INFORMATION 1-5
FUEL (ForCANADA)
Useonlyunleadedgasoline ofat least 87 pumpoctane (
R *^
) or 91octane or higherrated by the
ResearchMethod.
FUEL (Fortheothercountries)
Useunleadedgasolinethatisgraded91octaneorhigherbytheResearchMethod.
ENGINE OIL(ForUSA)
SUZUKI recommendstheuse of SUZUKI PERFORMANCE 4
MOTOR OILoroilsthatmeetAPIserviceclassifications SF or
SGandthathave a viscosityrating ofSAE 10W/40. If engine
oil with a ratingofSAE 10W/40 isnotavailable,selectanalter-
nativeaccordingtothechart.
ENGINE OIL(Fortheothercountries)
Use a premiumquality4-strokemotoroiltoensurelongerser-
vice life of yourvehicle. Use onlyoilsthatmeetAPIservice
classifications SForSGand thathave a viscosityrating of
SAE 10W/40. If engineoil with a rating ofSAE 10W/40 is not
available,selectanalternativeaccordingtothechart.
DIFFERENTIAL GEAR ANDFINAL BEVEL GEAR OIL
UsehypoidgearoilthatmeetstheAPIserviceclassificationGL-5andisratedSAE#90.Use a hypoidgear
oil with a rating of SAE#80ifthevehicleisoperatedwheretheambienttemperatureisbelow 0°C (32°F).
BRAKE FLUID
Specification and classification: DOT4
AWARNING
This vehicle uses a glycol-basedbrakefluid.Donotuseormixdifferenttypes of brakefluid
such as silicone-based andpetroleum-basedfluidsforrefillingthe system, otherwiseserious
damagewillresulttothebrake system.
Neveruseanybrakefluidtakenfromold, used, orunsealedcontainers.
Neverreusebrakefluid left overfromthelastservicingorwhichhasbeenstoredfor a long
periodoftime.
ENGINE COOLANT
Sinceantifreezealsohascorrosion-andrust-inhibitingproperties,alwaysuseenginecoolantcontaining
antifreeze,eveniftheatmospherictemperaturedoesnotgobelowthefreezingpoint.
Useanantifreezedesignedforaluminumradiators. SUZUKI recommendstheuse of SUZUKI COOLANT
antifreeze.Ifthisisnotavailable,useanequivalentantifreezeforaluminumradiators.
Mix onlydistilledwater with theantifreeze.Othertypesofwatercancorrodeandclogthealuminumradia-
tor.
Mixdistilledwaterandantifreezeata ratioof50:50 - 40:60.
Formoreinformation,refertopage6-5intheCoolingSystemsection.
MULTIGRADE
Mt.wgi.mr.iva^
°C
TEMP •
-30 -20-10 0 10203040
°F -22
-41432506886 104

1-6 GENERAL INFORMATION
ACAUTION
The percentageofantifreezeinthecoolantshouldbebetween50to60%.Ifthepercentageof
antifreezeisaboveorbelowthisrangethecoolant'sfrostprotectionandrust-inhibiting capa-
bilities will bereduced.Alwayskeeptheantifreezecontentabove50%eveniftheatmospheric
temperaturedoesnotgobelowthefreezingpoint.
BREAK-IN PROCEDURES
Duringmanufacturingonlythebestpossiblematerialsareusedandallmachinedpartsarefinishedto a
veryhighstandard. Itis still necessary to allowthemovingparts to "BREAK-IN" beforesubjecting the
enginetomaximumstresses.Thefutureperformanceand reliability oftheenginedependsonthecareand
restraint exercisedduringitsearly life. Refertothefollowingbreak-inenginespeedrecommendations.
• Keeptothesebrake-inenginespeed limits.
Break-in engine speeds
Initial 500km(300miles): Less than12 throttle
• Upon reaching an odometerreading of 500km(300miles)youcansubjectthevehicleto full throttle
operation, forshortperiodsof time.

GENERAL INFORMATION 1-7
INFORMATION LABELS
NO
LABEL orPLATENAME APPLIEDSPECIFICATION
NO
LABEL orPLATENAME E-03 E-24 E-28 E-33
©
Certification plate o o
—
o
©
Compliancelabel
—
o o
—
©
Informationlabel
— — —
o
©
Tire air pressurelabel ©
o o o o
©
Tire air pressurelabel and warningno-passengerlabel © — —
o
—
©
Generalwarninglabel ©
o o o o
©
Generalwarninglabel © — —
o
—
©
Warningno-passengerlabel ©
o o o o
©
Age, 16 label© o o o o
®
Age, 16 label and gearshiftlabel © — —
o
—
®
Manualnoticelabel o
— —
o
Max AMP cautionlabel ©
o o o o
®
Max AMP cautionlabel ©,© — —
o
—
©
Fuelcautionlabel
—
o
— —
Gearshiftlabel ©
o o o o
©
Frontcarrierwarninglabel ©
o o
—
o
©
Frontcarrierwarninglabel ©,© — —
o
—
©
Rear carrierwarninglabel ©
o o
—
o
©
Rear carrierwarninglabel ©,© — —
o
—
©
Trailertowarninglabel ©
o o o o
®
Trailertowarninglabel © — —
o
—
© ICESCanada
label
— —
o
—
©: English ©: French

1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONSANDDRYMASS
Overalllength 2 005mm(79.0 in)
2 050mm(80.7in) E-17
Overallwidth 1 170mm(46.1 in)
Overallheight 1 185mm(46.7 in)
Wheelbase 1 230mm(48.4 in)
Fronttrack880mm(34.6 in)
885mm(34.8in) E-17
Reartrack850mm(33.5 in)
Groundclearance235mm ( 9.3in)
Seatheight850mm(33.5 in)
Drymass275kg(606lbs)
286kg(630lbs) E-17
ENGINE
Type Four-stroke,liquid-cooled, OHC
Number of cylinders 1
Bore87.5mm(3.445 in)
Stroke82.0mm(3.228 in)
Pistondisplacement493cm3(30.1cu.in)
Compressionratio 8.5: 1
CarburetorMIKUNI BST34SS
Air cleanerPolyurethanefoamelement
Starter systemElectricandrecoilstarter
Lubrication systemWetsump
Idle speed 1 500 ± 100r/min
TRANSMISSION
Clutch Wetshoe,automatic,centrifugaltype
TransmissionAutomatic,variableratio with reverseand2-speed
transmission
Gearshiftpattern,ForwardHandleveroperated
ReverseHandleveroperated
ReductionratioVariablechange(2.555 - 0.706)
Secondaryreductionratio 1.133 (17/15)
Finalreductionratio,Front3.600(36/10)
Rear3.600(36/10)
Transmissionreduction ratio, Low6.406(40/16 x 41/16)
High3.523(33/24 x 41/16)
Reverse5.125(28/16 x 32/28 x 41/16)
DrivesystemShaftdrive

GENERAL INFORMATION 1-9
CHASSIS
Frontsuspension
Rear suspension
Steeringangle
Trail
Turningradius
Frontbrake
Rear brake
Front tire size
Rear tire size
Frontwheeltravel
Rear wheeltravel
ELECTRICAL
Ignition type
Ignition timing
Sparkplug
Battery
Generator
Mainfuse
Headlight
Taillight
Brakelight/Taillight
Back-uplight
Speedometerlight
Reverseindicatorlight
Neutral indicatorlight
Highbeamindicatorlight
Enginecoolanttemp,indicatorlight
CAPACITIES
Fueltank,includingreserve
reserve
Engineoil, oil change
oil and filter change
engineoverhaul
Differential gear oil
Finalbevelgear oil
Enginecoolant
Independent,doublewishbone, coil spring, oil
damped,springpreload5-wayadjustable
4-link rigidaxle, coil spring, oil damped,spring
preload5-wayadjustable
Inside 38°
Outside 26°
17 mm(0.67in)
3.0 m (9.8ft)
Discbrake
Internal expanding,mechanicallyoperated
AT25 x 8-12^<r
AT25 x 10-12<r <r
150 mm(5.9in)
150 mm(5.9in)
Electronic ignition (CDI)
10° BTDCat 1 500 r/min
NGK: CR6E
DENSO:U20ESR-N
12 V 50.4kC(14 Ah)/10 HR
Three-phase A.C. generator
30 A
12 V 30/30 W
12 V 35/36.5 W E-17
12V5W
12 V 7/3.4W E-17
12V21 W E-17
12V 1.7W
12V3.4W
12V3.4W
12V 1.7W
12V3.4W
12.5 L (3.3US gal, 2.7Impgal)
3.8 L (1.0US gal, 0.8Impgal)
2 300ml(2.4US qt, 2.0Impqt)
2 500ml(2.6US qt, 2.2Impqt)
3 000ml(3.2US qt, 2.6Impqt)
150 ml (5.1 USoz,5.3Impoz)
300 ml(9.5USoz,10.6Impoz)
2 000ml(1.9US qt, 2.3Impqt)
NOTE:
*These specifications are subject to change without notice.

1-10 GENERAL INFORMATION
COUNTRY AND AREACODES
Thefollowingcodesstand for theapplicablecountries and areas.
CODE
COUNTRY OR AREA
E-03 USA
E-17 Sweden
E-24
Australia
E-28 Canada
E-33 California (USA)

PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE 2-2
PERIODIC MAINTENANCE CHART. 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES 2- 3
AIR CLEANER 2- 3
EXHAUST PIPE NUTS AND MUFFLER BOLTS 2- 4
VALVE CLEARANCE 2- 5
SPARKPLUG 2- 6
FUEL HOSE 2-7
THROTTLE CABLE PLAY 2- 7
ENGINE IDLE SPEED 2- 8
ENGINE OIL AND OIL FILTER 2- 8
DIFFERENTIAL GEAR AND FINAL BEVEL GEAR OIL 2-10
ENGINE COOLANT 2-11
RADIATOR HOSES 2-72
DRIVE BELT 2-72
SPARK ARRESTER 2-74
BRAKES 2-75
BRAKE FLUID 2-16
BRAKE HOSES 2-77
TIRES 2-78
STEERING 2-73
SUSPENSIONS 2-19
CHASSIS NUTS AND BOLTS 2-20
GENERAL LUBRICATION 2-22
COMPRESSION PRESSURE CHECK 2-23
COMPRESSION TEST PROCEDURE 2-23
OIL PRESSURE CHECK 2-24
OIL PRESSURE TEST PROCEDURE 2-24
INITIAL ENGAGEMENT AND CLUTCH LOCK-UP INSPECTION 2-25
INITIAL ENGAGEMENT INSPECTION 2-25
CLUTCH LOCK-UP INSPECTION 2-26

2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCESCHEDULE
Thechartbelow lists therecommendedintervals for alltherequiredperiodicserviceworknecessary to
keepthevehicleoperating at peakperformance and economy.Maintenanceintervals are expressed in
terms of kilometers,milesandmonths,andaredependentonwhichevercomes first.
NOTE:
More frequent servicing may be performed on vehicles that are used under severe conditions.
PERIODIC MAINTENANCECHART
Interval
Item ^^^-^
km
200
1 000
2 000
Interval
Item ^^^-^
miles 100 600
1 200
Interval
Item ^^^-^
months 1
3
6
Air cleaner
—
C C
Exhaustpipenutsandmufflerbolts T T T
Valveclearance I
— I
Sparkplug
— —
I
Sparkplug Replaceevery
6 000km (4 000miles).
Fuel hose
—
I I
Fuel hose Replaceeveryfouryears.
Throttle cable
I I I
Engine idlespeed I I I
Engine oilandoil filter
R
— R
Differential gearandfinalbevelgearoil
— —
I
Differential gearandfinalbevelgearoil Replaceeverytwoyears.
Engine coolant Replaceeverytwoyears.
Radiatorhoses — — I
Drivebelt —
I R
Sparkarrester
— —
C
Brakes
I I I
Brakefluid
— I I
Brakefluid Replaceeverytwoyears.
Brakehoses
— — I
Brakehoses Replaceeveryfouryears.
Tires
— — I
Steering I I I
Suspensions
— —
I
Chassis nutsandbolts T T T
General lubrications
— L L
/= Inspect and adjust, clean, lubricate, or replace as necessary.
R = Replace
T = Tighten
C = Clean
L = Lubricate

MAINTENANCEANDTUNE-UP
PROCEDURES
Thissectiondescribestheservicingproceduresforeachitem
mentionedinthePeriodicMaintenancechart.
AIR CLEANER
Clean every1 000km(600miles,3 months).
If theaircleaner is clogged with dust,intakeresistance will be
increased, with a resultantdecrease in poweroutput andan
increaseinfuelconsumption.Checkandcleantheaircleaner
elementinthefollowing manner.
• Remove theseat. 7-4)
• Remove theaircleanercasecover ©.
NOTE:
Be careful not to drop the O-ring into the air cleaner box that is
attached to the air cleaner case cover.
• Remove theaircleanerelement ®.
• Separate the polyurethanefoamelement ® and element
frame(4).
• Fill a washpan ofa propersize with a non-flammableclean-
ingsolvent.Immersetheaircleanerelementinthecleaning
solventandwashit.
• Press theair cleanerelementbetween the palms of both
hands toremovetheexcesssolvent:donot twist orwringthe
elementorit will tear.
• Immersetheelementinmotoroil,andthen squeeze outthe
excessoilleavingtheelement slightly wet.
® Non-flammablecleaningsolvent
® MotoroilSAE#30orSAE 10W/40
ACAUTIONT
*Inspecttheaircleanerelementfortears.A torn ele-
mentmustbereplaced.
*Ifdrivingunderdustyconditions,cleantheaircleaner
elementmorefrequently.Thesurestwaytoacceler-
ateenginewearistooperatetheenginewithoutthe
elementor with one that istorn. Make sure that theair
cleaner elementisingoodconditionatalltimes.Life
oftheenginedependslargelyonthiscomponent!
• Remove thedrainplug © fromtheaircleanerdrainhoseto
allow anywatertodrainout.

2-4 PERIODIC MAINTENANCE
EXHAUST PIPE NUTS AND MUFFLER
BOLTS
Tighteninitially at200 km(100 miles, 1 month) and
every 1 000 km(600 miles, 3 months)thereafter.
• Remove therearfender.(CU37-7)
•Tightentheexhaustpipenuts ©, mufflerconnectionbolt(2),
andmufflermountingbolts ® tothespecifiedtorque.
H Exhaust pipe nut:23Nm(2.3 kgf-m, 16.5Ib-ft)
Muffler connectionbolt: 23N m (2.3 kgf-m, 16.5Ib-ft)
Muffler mountingbolt: 23N m (2.3 kgf-m, 16.5Ib-ft)

VALVE CLEARANCE
Inspect initiallyat200 km(100miles,1 month)and
every2 000 km(1200miles,6 months)thereafter.
Excessivevalveclearanceresults in valvenoise and insuffi-
cient valveclearanceresults in valve damage and reduced
power.
Check the intake and exhaustvalveclearances atthe dis-
tances indicated above and adjust the valveclearances to
specification, if necessary.
• Remove thefueltank. (CU3 5-2and5-3)
• Remove thesparkplug © andvalveinspectioncaps ©.
• Remove the TDC plug ©.
• Remove therecoilstarter. ({^ZT 3-11)
EHSJ Valveclearance(whencold)
IN: 0.05-0.10 mm (0.002-0.004 in)
EX: 0.17-0.22 mm (0.007-0.009 in)
NOTE:
Valve clearance is to be checked when the engine is cold.
The intake and exhaust valves must be checked and adjusted
when the piston is at Top-Dead-Center (TDC) of the compres-
sion stroke.
• Turn the generatorrotoruntil the piston isatTDConthe
compressionstrokebyturningthestartercup.Turntherotor
until theline @ on therotor is aligned with themark © on
the crankcase.
• Insertthethickness gauge to checktheclearancebetween
the valvestem endand theadjustingscrew on therocker
arm.
09900-20803: Thickness gauge
• Iftheclearanceisout of specification, bringitintothespeci-
fied rangeusingthespecial tool.
09917-14920:Valveadjusterdriver
[5Valveclearanceadjusterlocknut:
10N m (1.0kgf-m,7.0 Ib-ft)
ACAUTION
Securely tightenthelocknutaftercompletingadjust-
ment.
• Installthesparkplug,valveinspectioncaps, TDC plug, and
recoil starter.
HTDCplug:23N m (2.3kgf-m,16.5 Ib-ft)

2-6PERIODICMAINTENANCE
SPARK PLUG
Inspect every2 000km(1200miles,6 months).
Replace every6 000km(4000miles).
• Remove the left frontfendersidecover. (CU37-5)
• Disconnect the sparkplug capand remove the spark
plug ©.
Standard
Cold type
NGK
CR6E CR7E
DENSO
U20ESR-N U22ESR-N
CARBON DEPOSITS
Check tosee if therearecarbondeposits on thesparkplug. If
carbon is deposited,remove it using a sparkplugcleaner
machineorcarefullyuse a tool with a pointedend.
SPARK PLUG GAP
Measure thesparkplug gap using a thickness gauge. Ifthe
sparkpluggapisoutof specification, adjustthegap.
mm Standard
Spark pluggap: 0.7-0.8 mm (0.028-0.031 in)
IT55L1 09900-20803:Thicknessgauge
ELECTRODE
Check theconditionoftheelectrode.
If theelectrode is extremelyworn or burnt,replacethespark
plug with a newone.
Also,replacethesparkplug ifit has a brokeninsulator,dam-
aged threads,etc.
ACAUTION
Check thethreadsizeandreachwhenreplacingthe
spark plug.Ifthereachistooshort,carbonwillbe
depositedonthescrewportionofthesparkplughole
andenginedamagemayresult.
i 0.7-0.8 mm
T
(0.028-0.031 in)