This service manual has been specially prepared to provide all the ... Suzuki
Motor Co., Ltd. reserves the right to make changes without notice at any time.
FOREWORD FASO.
FA50
This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the
The contents have been simplified so that
owners, as well as experienced mechanics, may fully utilize this manual.
The
FASO is a new type of motorcycle that has many special features such as: 2) Easy, smooth handling due to light weight and size 3) Simple to maintain and service 1)
4)
The
Easy to ride operation
Technical features such as PEI ignition and automatic clutch
FASO fits the needs of
a wide variety of motorcycle users.
Those who will be servicing this
motorcycle should carefully review this manual before performing any repairs or services.
II
SUZUKI MOTOR CO., LTD.
Service Department Overseas Operations Division
All specifications and construction details contained in this manual were correct at time of issue. Suzuki Motor Co., Ltd reserves the right to make changes without notice at any time.
Quoting, copying or otherwise using any part of this manual without explicit authorization from Suzuki Motor Co., Ltd. is not permitted as all rights to the publication are reserved under copyright law.
- ---
-------,
G ROUP IN DEX ---
..
[
--
-
------
� �
----�
aENERAi.�� FO M A IO N ._
IN_S_P_s _ c_Ti lO_ _ N_ AN_ D A_D �u _ _ s_ Ti_M_E _N_ T _
'----
. 1!11 __Iii
SERVICIN G P RO CEDU RE ____ _ ___ _
_ _ _ _
SER v1_ _c _1N_G _ l_NFO R M T 1_ _N _ _ ___ �_ o __
.___
_
_
_
.__ _
a I
_
_ __
ll
___
_
1-1
GENERAL INFORMAJ'TON
GENERAL INFO R M A TIO N - CONTENTS ..
------�
M O D E L I D ENTI FICATION ..................................................................... 1-2 SPECIFICAT I O N S
........................................ ............................................
1-3
FUEL A N D O I L RECOM M E N DATION ................................................ 1-5 G E N ERAL NOTES A N D PR ECAUTIONS ........................................... 1-6 TEC HNICAL FEATURES ........................................................................ 1-7 --
-----
•
II
..
1-2
GENEIUIL JNFOUMATION
MODEL IDENTIFICATION R I G HT SIDE VIEW
F RA M E N U MB E R The frame serial number is stamped o n the right side of the steering head pipe.
LEFT S I D E VIEW
ENG I N E NUMBER The engine serial number is located on the left side of the cran kcase.
, ... '7
These numbers are requ i red espec i a l l y for registering the machine and ordering the spare parts.
GENERAL fNFORAIATTON
SPECIFICATIONS DIM E N S I O N S A N D WEIGHT Overall length
1 585 mm (62.4 i n )
Overall width
670 m m (26.4 in)
Overa l l height
970 mm (38.2 i n ) 1 040 mm (40.2 i n )
Wheelbase
1 20 m m ( 4.7 i n )
Ground clearance D ry mass (weight)
45 kg
(99 lbs)
ENGINE Type
Two-stroke . a i r cooled
I ntake system
Reed valve
Number of cyl i nder Bore
4 1 .0 mm ( 1 .6 1 4 in)
Stroke
37.4 m m ( 1 .472 in)
Piston d i splacement
49 cm3 (3.0 cu. in)
Corrected compression ratio
6. 5 : 1
Carbu retor
M I K U N I V M 1 2SH, single
A i r cleaner
Polyurethane foam element
Starter system
Primary kick
Lubrication system
SUZU K I "CC I "
TRAN S M I SSION Clutch
Wet shoe, automatic, centrifugal type
Transmission
1-speed
Gearshift pattern
Automatic type
Primary reduction
1 .000
F inal reduction
D rive chain
5.564 (chain)
2.384 ( 3 1 / 1 3 )
(gear)
2.333 (56/24) D A I D O D . 1 .0. 270H, 64 l i n ks
1-3
1-4
GLiNER.-\L l./\'l'OR,\J:\'/'/Of\
CHASSIS Front suspension
Telescopic
Rear suspension
45° (right & left)
Swinging arm, oil dampened
Steering angle
65°00''
Caster Trail
70 mm (2.76 i n )
Turning radius
1 .4 m (4.6 ft)
Front brake
Internal expanding
Rear brake Front ti re size
I nternal expanding 2.25- 1 4 4 P R
Rear ti re size
2.25- 1 4 4 P R
Front ti re pressure Rear tire pressure
I
1 50 kPa ( 1 .50 kg/cm2, 2 1 psi) (Normal solo riding)
200 kPa (2.00 kg/cm 2 , 28 psi) (Normal solo ridi ng)
EL ECTRICAL Ignition type
SU Z U K I " P E I"
Ignition t i m i n g
25° B.T.D.C. at 4 000 rpm
Spark plug
NGK BP4HA or N I P PON D ENSO W 1 4 F P- U L
Battery
6V 7 . 2 k C (2 Ah)/1 0 H R
Generator
Flywheel magneto
Fuse
1 0A
Headlight
6V 20/20W
Tail/Brake l ight
6V 5.3/ 1 7W (3/2 1 cp)
H i gh beam indicator l i ght
6V 1 . 7W
Speedometer l ight
6V 1 . 5W
CAPAC I T I E S Fuel tank including reserve reserve
0.4 L (0.4 US qt)
2.5 L (0.66 U S gal)
Engine o i l tank
0.7 L (0.7 US qt)
Transmission oil
500 ml (0.5 US qt)
*
These specifications are subject to change without notice.
GJ:NER.AL /,'\'f-'ORAli\ Tf()1\'
1-5
FUEL AND OIL RECOMMENDATION B e sure to use the specified fuel and oils. The fol lowing are the specifications:
FUEL Use only un leaded or l ow-lead type· gaso l i ne of at least 85 (
R
�
M
-
95 pump octane
Engine o i l tank cap
Fuel tank cap
method) or 89 octane or higher
rated by the Research method.
ENGINE OIL For the S U Z U KI CCI system, use of S U Z U KI CCI S U P E R 2-CY C L E MOTOR L U B RI CANT is highly recommended, but if it is
..
not available, a .good qua l ity synthetic based
2-cycle oil should be used.
TRANSMISSION OIL
Oil filler cap
Use a good quality SAE 2 0W/40 m u l ti-grade motor o i l .
Drain plug
1-6
Gb\/:'RAI.
1.1\'l:OR.\l:l'J IOS
GENERAL NOTES AND PRECAUTIONS Observe the following items without fail when d isassembling and reassembl i ng motorcycles. •
•
Be sure to replace packings, gaskets, 0 rings, circlips and cotter pins with new ones. T i ghten bolts and nuts from the ones of larger diameter to those of sma l ler d iameter, and from inside to out-side d iagonally, with specified tightening torque.
•
Use special tools where specified.
•
Use specified genuine parts and oils.
•
When 2 persons perform work i n cooperation, pay attention to the safety of each other. After the reassembly, check parts for tightening condition and operation.
• •
Treat gasoli ne, 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 occasional ly, describing the following contents.
WARNtN
Clutch drive shoes Primary drive gear Primary driven gear
, 6' Counter shaft 7 Drive sprocket 5
is transmitted to by
Power of the final drive shaft is transmitted to the drive axle shaft
and at the same time, the rear wheel
2,
If the engine revolution
is connected and the power of the crankshaft · 1
3
121 F inal driven gear Final drive gear
13) Drive axle shaft 141 Rear wheel
1- 1 1
GENERAL lNFORMA TION
D R I V E CHA I N Power is transmitted from the countershaft
to the final- drive shaft through a drive cha i n .
The drive chain is mai ntained a t the proper tension by the chain tensioners provided for the upper and lower parts of the chain and is i mmersed in transmission oil - oil bath type ensuring excel lent durability. Chain tensioner
I
l
Counter shaft
I
Chain tensioner
Final drive gear
•
F I N A L DRIVE
Power transmi tted to the final drive shaft through the drive chain. The driven sprocket and final drive gear a re press-fitted to the final drive shaft. The speed is reduced by the final drive gear and the final driven gear mounted on the drive axle shaft. The drive a x l e shaft is integrated with the fina l driven gear, and it rotates at a speed reduced finally by the final drive gear.
The shaft is installed i n the rear part of the crankcase. A l m ost
half of the drive axle shaft projects outside and is splined to the rear wheel, thus causing it to turn.
Tire
-
Axle shaft
....
1 12
(;/·:t\lilUL lvFOln/:l'fl(),\
KICK STARTER
I•, the kick starter l i fter
shaft rotates ' .2l and the kick starter lifter moves downward �). By the movement of the kick starter l i fter, the kick starter guide is pushed and the guide end is raised. Keeping this condition, when the kick lever is depressed 3_,, the kick starter is turned by the kick starter drive gear --- ------ ----! Remove carbon R etorque head nuts and 1 Retorque head nuts and
>---
Spark plug
I
Wash and clean
and service el ectrolyte solution
Brakes >----Brake shoes ,_. --Carburetor
t
3
--
- --
Check specific gravity
-+-- --
Every
--
Change
INSPECTION 1lND ,·ID}US"/'MJ::.NT
2-3
LUBRICATION C H A RT ...
Rotating and rubbing parts must be lubricated periodica l l y .
Insufficient lubrication w i l l cause
rapid wear and severe damage may resu l t . Lubricate the following parts periodica l l y .
-
Item
i
I nterval Km
Brake cables
Month -
-
--
Brake cam shaft
--
--
Choke cable ·-
Speedometer gear Speedometer cable
�·----
--
--
Mile
--
--
-
-
-
-
-
-
'------
-
Motor oil -
-
-- -
-
-
Motor oil
6 000 Every
4
000
12 -
I
---- -
-
Throttle cable
- -
�-·
--·-
000 -
Motor oil
- --
----
2
6
-
- -
Every 3 000
Grease -
'
Grease Grease
.
-
•
---------
WARNING: Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings, brake slippage will result.
Lubricate exposed parts which are subject to rust, with either motor o i l or grease whenever the motorcycle has been operated under wet
or
rainy conditions.
Before l ubricating each part, clean off any rusty spots and wipe off any grease, o i l , d i rt or grime.
L...
......
.....
.......
2-4
lNSPliC'JJ()N .·IND .-!Djl'STl\11:1\J"/'
MAINTENANCE PROCEDURE A I R CLEA N E R
f
Clean at initial
1 000
m
k
r
l
miles) · 1
(600
�every 3 00�� � (2 000 miles) _J _
_
''G') j",·0� �-�
/ \�
,. �'Ji/) if) '
I
.
r,n
I
Cle ane r case cover
Element
( I
.""
Battery
Slipper
�
...--...... _Element
'
...._;;;� ' .... �i� '� � _,._;._ r f � I •
'--UPPER--
Non flammable cleaning solvent
I
I
Motor o i l
CAUTION: Before and during the cleaning oper ation, examine the element to see if it is torn. torn element must be replaced. Be sure to position the element snugly and correctly, so that no in coming air will bypass it. Remember, rapid wear of piston rings and cylin der bore is often caused by a de�ctive � poorly f�t��d element. *
•
A
Check at initial and every Electrolyte for specific gravity
1 000-km (600;il;;-·
3 000 km
(2
000
miles)
--------
I
2 C
1.28 at 0°
(68° F)
• Check to be sure that the vent pipe is secure and routed properly. •
Add distilled water, as necessary, to keep
the surface of the electrolyte above the
LOW E R level line but not above the
l l
U P P E R eve line.
If
6N2-2A-4
YUASA 6ATTlRY (0 .LTD MAOE IN JAPAN
•
1
the electrolyte surface falls rapidly and
requires
water,
frequent
check
addition
of distilled
the charging system for
proper charging rate.
*
BATTERY
§2___ LOWER-�
! YuAsA
I
• An S.G. reading
of
1.22 (at 20°c, 68°F)
or under means that the battery needs
recharging off the machine:
take it off
and charge it from a recharger.
Charging
the battery in place from the recharger damage
can
1,
j
wiring.
the
.Charging current ---
S.G.
over
-·
1.250
1.220 - 1.250
below
,----
1.220 -
-
rectifier
and
related
0.2 A/10 hours
Condition Normal I Under charged Run down
Measure Better rechargeto orRecharge replace
CAUTION: Do not forget to remove three battery caps to prevent possible battery damage when recharging.
JNSPEC"/'ION AND 11DjUSTMl:iNT
BRAKES
BRAKE S H O E WEAR
Adjust a t initial 1
and
..
every 000 3
000 km (600 000
km (2
Check every 000
miles)
miles)
-- - ------'
Adjust by turning the adjusting nut so
•
2-5
3
L__
•
k m (2
000
miles)
When applying the front brake, if the ex tended line of the brake cam lever exceeds
the range on the brake panel, replace the
that the clearance between grip and brake
brake shoes.
lever is 20 - 30 mm (0.8 - 1 .2 in) when
applying the front brake.
20 - 30 mm (0.8 - ·1.2 1n.)
Adjusting nut
......
•
As the rear brake wire is linked to the
kick starter lifter lever, first adjust with the adjusting nut so that the lifter lever
play is 1 mm (0.04 in).
�·1£ ; L l0 c
� -- -
Adjusting nut
Kick starter lifter lever
,
'
.
-
-
'
� �
Rear brake camlever
1 mm
(0.04 in.I
•
Adjust by turning the brake cable adjust
ing nut so that the clearance between
lever and grip is 20 - 30 mm (0.8
in).
r------ ---------
...... ......
"' -
0
-�-
-
-
When applying the rear index
mark
is
located
brake,
1 .2
if• the
forward
indicator, replace the brake shoes.
·OIP ;
•
the
4Vjl 'STMl:'N'f
l.\"SPEC'r!ON .-11\iD
2-6
E N G I N E I DLE RPM
L
1
Adjust at initial 000 km (600 and every 000 km 000 3
_
...
• •
[
I
--- - - -,
miles) miles)
(2
Adjust the throttle cable play .
Warm the engine up.
-
NOTE:
warm engine means an been run for 10 minutes. A
• •
Finally adjust the throttle cable play.
-1.0 mm Throttle cable play II 0.5 (0.02 0_04 in) _
THROTTLE CABLE
engine
1
has I
J
Turn the air screw back 1 � turns from the ___
•
•
bottom.
•
Loosen the lock nut and adjust the cable
slack by turning adjuster in or out to ob
tain the following slack.
After adjusting slack, tighten the lock nut.
0.5 -1.0 mm (0.02 - 0.04 in)
Cable slack
Restart engine, and set the throttle valve
stop screw at lowest idle speed.
Turn the air screw in or out within 11.s turn
from the original setting ( 1 % turns). Find
the position where the engine runs at the
highest rpm. turn.
•
Turn the air screw in 1 /8
Adjust the throttle stop screw to obtain the idling rpm as follows.
Idle rpm
1
500 150 ±
rpm
0.5-1.0mm (0.02 - 0.04 in.)
I
Lock nut
'
Adjuster
CARB U R ETOR OVERHA U L A N D CLEA N I N G
Overhaul and clean every 6 000 km (4 000
-·-----
-
miles)
J
-
Wash the carburetor and component parts in cleaning solvent after disassembly.
Before reassembly, inspect the float level
and needle valve.
Adjust and replace parts
when necessary. (Refer to page 3-12.)
Then blow compressed air through all
jets
and passages to make sure they are not Throttle stop screw
clogged.
Do not use wire, etc. to clean
them, as this can damage the parts.
INSPEC/10N l'lND ADJUS"fMENT
CYLI N D E R H E A D NUTS
FUEL LI N E
Retighten at initial 1 000 (600 and 000 (2 000 miles) km
every 3
2-7
miles)
km
• Cy l i nder head nuts, when they are not
l �eplace every _
two years
Replace the fuel l i n e every two years.
tightened to the specified torque, may result
in
leakage
of
the
compressed
mixture and reduce output. Tighten the 4 nuts evenly one by one i n stages until each one is tightened to the specified Tighten the nuts in the order torque. i n dicated below.
OIL PUM P
·�pect at initial 1 000 km (600 � a�� :_ 000 (2 000 ile� I bleeding m
eve
3
km
m
•
Cylinder head tightening torque
nut
Air Whenever evidence is noted of some a i r
0.8 - 1.2 kg·m (6.0 -
having leaked i n t o t h e o i l l i ne from t h e oil
8.5 lb-ft)
tank i n
--J
CYLI N D E R HEAD AND CYLIN DER
Remove carbon every 6 000 km (4 000 miles) -
-
- -
Carbon deposits i n the combustion chamber and the cylinder head will raise the com
pression ratio and may cause pre-ignition or overheating.
Carbon deposited at the ex
haust port of the cylinder wi l l prevent the flow of exhaust, reducing the output. move carbon deposits periodical l y .
Re
a
machine brought i n for servicing, · or if the oil pump has to be removed for servicing, be sure to carry out an a i r bleeding operation with the oil pump i n place before returning the machine to the user. running condition; loosen screw CD, to let out the air; and, after making sure that the How to bleed the air: With the engine not
trapped a i r has a l l been bled, tighten the screw good and hard.
2-8
INST'ECHO.Y ,l./\'D
. ID]l 'STM/il\'T
Checking oil pump capacity
SPARK PLUG
Use the special tool , check the pump for
Check at initial 1 000 km (600 miles) and every 3 000 km (2 000 miles) Replace every 6 000 km (4 000 miles)
capacity by measuring the amount of oil the pump draws during the specified interva l .
Engine oil discharge • 1 09900-21602 amount measuring tool
..
1
•
1
J
- - -- _J
Neglecting the spark plug eventual l y leads to difficult starting and poor performance. I f the spark plug i s used for a long period, the
Have the tool f i l led with SUZ U K I CCI S U P E R 2-CYCLE MOTOR L U B R I CANT and connect it to the suction side of the pump.
electrode gradual l y burns away and carbon In ac builds up along the inside part. cordance with the Periodic Inspection Chart, the plug should be removed for inspection, cleaning and to reset the gap. •
Carbon deposits on the spark plug w i l l prevent good sparking a n d cause misfiring. Clean the deposits off periodica l l y .
•
I f the center electrode is fairly worn down, the plug should be replaced and the plug gap set to the specified gap using a thickness gauge.
Thickness gauge
09900-20803
Oil pump
r •
Holding engine speed at the 2 000 rpm by turning the throttle stop screw and let the pump draw for 6 minutes.
For
this operation, the reading taken on the measuring cylinder should be from 0.97 to 1 . 1 4 ml (0.033 - 0.039 US oz).
r -Oil j discharge amount
0.97 - 1.14 ml (0.033 - 0.039 2 000 rpm for 6 minutes
US oz)
at
l
f (0.024 - 0.031 in)
____ 0.6
Spark plug gap
- 0.8 mm
0.6- 0.8 mm (0.024 - 0.031 in)
l/\'SPT'.CTION /IND ADJUSTAII:.N'f
•
Check spark p l ug for burnt condition.
If
abnormal, replace the plug as indicated below. N i ppon Denso
NGK
..
B P-2 H A
BP-4HA BP·5HA
•
2-9
@ ©J
R emarks
/&>::;)
�
If the standard plug W9FP-UL
l I
·
W14FP-UL W16FP-UL
I
I I I
is apt to get wet, re place with this plug. Standard
(;J
·• ....
---
2.5
torque
Spacer
[GREAS Ej
Steering stem nut Check inner o r · outer races for wear Steel balls
If the standard plug is apt to overheat, re· p l ace with this plug.
Tighten the spark plug in the cyli nder head with the specified tQrque.
Spark plug tightening
Lock nut
- 3.0
O
kg-m
(18.0 - 21.5 lb-ft)
L�£l EAS�J Steel balls
I
I_ STE E R I N G STEM
nit al
km
miles)
�d every 3 000 km (=- 000 mi � Check at i
i
1 000
(600
_]
Steering should be adjusted properly for
smooth manipu lation of hand lebars and safe run n ing. Too stiff steering prevents smooth manipu lation of handlebars and too loose steering w i l l cause the handlebars to vibrate. Check to see that there is no play in the front fork fitting. I f any play can be found, adjust the steering as fol lows: • •
Support the motorcycle body and jack u p the front wheel. (!), tighten the steering stem nut CV using the special tool so that the front fork moves smoothly. Loosen the steering stem nut securing nut
Steering stem nut wr n h I I
e c
......
09940-10122
If any play is sti l l found, inspect the follow i n g items and replace the affected parts, if necessary .
•
• • •
Wear of the inner and outer races . Wear or damage of steel balls N u m ber of steel bal ls (upper 25' pcs lower 25 pcs) Distortion of steering stem
JNSPL:CTJON AND .1VjUSTJ\lliN'J'
2-10
TRANSMISSION OIL
TIRE
Check at initial 1 000 (600 000 km (2 000 miles) and Tire pressure km
Change at initial 1 000 km (600 miles) and every 000 km (2 000 miles) L.
---·-----
m iles)
every 3
...
3
If the tire pressure is too high, the motor cycle w i l l tend to ride stiffly, have poor traction.
Conversely, if the tire pressure is
too low, stabi l ity w i l l be adversely affected. Therefore, maintain the correct tire pressure for good roadab i l ity and to prolong tire life.
--
-
150 kpa ( 1.50 kg/cm2, 21 psi)
After a long period of use, the transmission oil qualities wi l l deteriorate and quicken the wear of sliding and interlocking su rfaces. Replace the transmission oil periodically following the procedure below. • •
Cold inflation tire pressure Front Rear
�-- -
•
200 kpa (2.00 kg/cm', 28 psi)
•
CAUTION: The standard tire fitted on this motor cycle is 2.25-14 4PR for front and rear. The use of a tire other than the stan dard cause handling instability. It is highly recommended to use a SUZUKI Genuine Tire. Tire tread condition ly a
----�
Start the engine to warm up the oil, this w i l l facil itate draining of o i l . U nscrew the oil f i ller cap a n d drain plug, and drain the oil completely. Tighten the drain plug. Supply a good quality grade motor oi I.
500 ml (0.50 US qt)
Capacity •
may
SAE 20W/40 multi
level with the o i l level
Check the o i l
"
screw.
Oil filler cap
I
Operating the motorcycle with the excessive worn tires w i l l decrease riding stab i l ity
and consequently invite
dangerous situ
ation. It is highly recommended to replace the t i re when the rema i n ing depth of tire tread reaches the following specifications.
FRONT and REAR
[_
1.6 mm (0.06 in)
I _J
Level screw
Drain plug
-·-----------�
INSl'FC'J'JON AND .-l DJ USTMEN'J'
2-11
CHASSIS BOLTS A N D N UTS Retighten at initial 1
000 (600 km
miles) and every 3
000
km (2
000
miles)
These bolts and nuts l i sted below are important safety parts. They must be retightened, as neces sary, to the specified torque with a torque wrench . .. Description
No.
,,
,I
3• 4'
0.ty
nut Rear shock upper nut
absorber
Rear shock
absorber
lower nut
1
Rear brake cam lever nut
lb-ft
kg·m
Front brake cam lever
J
0.3 -0.6
2.0- 4.5
2.0-3.0
14.5-21.5
2.0-3.o
14.5 -21.5
0.3-0.6
4.5
2.0-
2
•
(11 No.
5 6
......
Description
O'ty
kg-m 3.6-
Rear axle nut
lb-ft 5.2
26.5-37.5 18.5 -28.5
Engine mouting nut
1
2.5 - 4.0
7
Footrest nut
6
0.4
B 9
Handlebar set nut
9.5- 12.0
68.5-86.5
Front axle nut
2.7 -
20.0-31.0
-
0.7
4.3
3.0-
5.0
SL:R !'ICING PROCEDURc
3-1
SERVICIN G P RO CEDU RE CONTENTS ..
E N G I N E R E M OVAL/INSTALLATION
POWER TRANSM ISSION LEFT CRANKCASE CRAN KSHAFT
...............................
CHASSIS E LECTRICAL
........................
................ .....
............... . ..............................
...................... .........................
. ......................................................
........
. ................ ......... .............. ..................
.................................... ............................
.... ...................................................................
..
................................................................................................
. .................... ..........
.................................................................
FRONT SUS P E N S ION
..................................
WHEELS A N D BRAKES
.....
............................
......... ..................... ............................................
FLYW HEEL M A G N ETO
STE E R I N G
......................
--- --�
................
CARBURETOR .
SWITCHES
..............
..........................
--
.......................
CYL I N D E R HEAD, CYLIN DER, PISTON K I C K STARTER, LEFT COVER
-
. ............... ......................... .......................
.................................................
3- 2
3- 3 3- 5
3- 6
3- 9
3-10
3-12
3-13
3-16 3-20
3-22
3-23 3-24
3-2
Sl:'R. I 'ICING PROCEDL'RI:
ENGINE REMOVAL/INSTALLATION CD Remove the support bracket.
Left side
@ Remove the frame upper cover.
• © Remove the oil p u m p cover a n d oil
Upper side
® Remove the engine oil tank cap, fuel
..
tank cap and battery .
7,
Remove the fuel line and the vacuum line with the fuel cock set to O N .
@ Remove the magneto lead wire.
® Remove the carbu retor top cover.
@ Remove the spark plug cap.
1J)
hose.
110>
Remove the carburetor choke cable from
the carburetor side.
Right side
1J! Loosen and remove the rear shock ab
® Loosen the engine mounting nut.
Remove the rear brake cable.
\1� Pull out the engine mounting bolt. sorber lower bolt.
11]) Lift the body. \ ,..
3
•
� ��·--
/
--�
--
2.5 kg-m (18.5 - 28.5 lb-ft) - 4.0
-
2.0 kg-m (14.5 - 21.5 lb-ft) -
3.0
SER VICING PROCEDURE
3-3
CYLINDER HEAD, CYLINDER, PISTON, PISTON RING Q)
I
..
·
,,__...._....,..
'
r �, I
0.8 - 1 .2 kg-m 16.0 - a.5 1b-111
® Remove carbon
@, Replace gasket
1.5 - 2.0 kg-m ( 1 1 .0 - 1 4. 0 lb-ft)
© Remove carbon of the exhaust port and apply oil on the cylinder wall.
® Arrow mark on the piston crown faces exhaust side.
:]J, ®
Remove carbon and apply oil.
Top mark "R" or "T" indicates up
side on rings.
(9,. Replace with new circlips.
......
�:\l;
cement
Apply thread lock
{ff)_ "#1363C" @
�
r-1.Smm
J
... --0) 1111111
fi�--@�16mm n
Expander ri g
....
�
Mark
3--t
SJ.OR I "JC/NG J>ROCl'.Vl .RE
CYL I N D E R BORE 09900-20508
Cylinder gauge ..
(0.6in)
15mm
.L
/
0
(1.6167 in)
PISTON D I A M ETER
-
----
41.065 mm
Service Limit
09900-20202
M icrometer
I
Service Limit
'\
-
'
40.880 mm (1.6094 in)
23 mm
(0. 9 in)
1---L
-
'-
l
R I N G E N D GAP Thickness gauge
09900-20803 0.75 m m
Service Limit
(0.030 in)
RING F R E E E N D GAP
�e
rnier caliper
Service i it Lm
I
R
09900-20101
marked
3.6mm (0.14 in)
Tmarked 4.0mm (0.16 in)
- -- --- �
� �
NOTE:
R pl ce the � iston rings as _
: set. _
_
SHR VJCl NC PROCEDURE
3-5
KICK STARTER, LEFT COVER Bearing remover Sliding shaft
09921-20210 r-·I
09930-30102
..
Sliding shaft
•
11
0.5 - 0.8 kg-m (4.0 - 5.5 lb-ft)
• • • •
spring, insta l l ® and then insta l l @. Apply Suzuki Super Grease A to the o i l seal lip a n d t h e kick starter spring. When
insta l l i n g the kick starter return
Replace the gasket. Insta l l two dowel pins(!).
J-6
SER l'ICINC PROCL:D l 'RJ;
POWER TRANSMISSION CD
/
09920-30220
Clutch holder
•
Apply thread lock cement.
I
'
2.0
-
J.o kg·m
( 1 4.5 - 2 1 .5 lb-ft)
J
Q) o��·O ®� @ � rnITJ @ @� Look !-_'- Key
I
w"h" W"h"
,. ' One way clutch
W"h"
W"h"
0
W"h"
oj"� � .
ij
�
Wave washer ,
•
J
Circlip opener
09900-06 1 07
• Replace a l l circlips . . • Adjust sh i m to reduce th!;! final drive and driven gear noise.
Sl-.'U. VICI NG
AUTOMATIC C L U TCH I NSPECTION
2. C LUTCH " LOCK-UP" INSPECTION
The F A50 i s equ ipped with an automatic
clutch i s engaging fu lly and not slipping.
clutch.
The engagement of the clutch is
mechanism located in the clutch. To insure proper performance and longevity of the clutch assemblies it · is essential that the cl utch engage smoothly and gradually. Two inspection checks must be performed to thoroughly check the operation of the drivetrain. Follow the procedures l i sted. 1 . I N ITIAL ENGAGEIVIENT I NSPECTION • Warm the motorcylce up to normal operating temperature. •
Connect an electric tachometer to the
•
Seated on the motorcycle with the motor
engine. cycle on level ground, increase the engine RPMs slowly ?nd note the RPM at which the motorcycl e !:>egins to move forward.
ENGAG EMENT RPM STD
2 400 rpm
Tolerance
±200 rpm
3- 7
Perform this inspection to determine if the the engine to normal operating
•
Warm
•
Connect an electric tachometer to the
•
Apply the rear brake as firm as possible.
governed by engine RPMs and a centrifugal
....
PROCEDURE
•
temperatures. engine. Briefly open the throttle f u l l y and note the
maximum
engine
RPMs sustained
during the test cycle. CAUTION: Do not apply full power for more than 10 seconds or damage to the clutch or engine may occur.
LOCK-UP RPM STD
-
3 500 rpm
-
Tolerance
±300 rpm
.i-8
Sl-'R 1 ·1c1sc t>1!.
>
30
"'
en
e 0
25
C'O " c 0 u cu (/)
20
>
�
15
I
I
� J
.
,�
-
-'-
-
...... �
\\-......
-- -
Secondary voltage
10 • .,, cu
30
en � 2 5 c en ·cu
. 20
E O
·;::;
c� oo
2'f9.
:;;:: ....,: 15 . c
i..--
v
/ _,
9
L...-
8
� c: ....
>
5
E "'
... ::J c u
C'O t
4
i3 ·:;;
3
� �
2
....
c
... u
c ....
� en
Ci u 7 � -
�
c;::,
t-
SPEEDOMETER llGHl •UCU BEAM INOICAlOR LIGHT
FRO!\ T BRA)(I LICH f SWITCH
'""""' �"'"
�"' ' � �
�I « .,
uE•DttGHT
@; ,...----1 1
HI Alt HUl\Kl l llill I C-,WI U,;tt
!
�I
!
Ii
I • !
1; [ --' -'-'-v -S-- v ----
•w;:&1" : Ij
mill nmr d
v, � ;;:; �
;
li
Q
I ff P ' " "' H �r I I 1
!i I
l
-
f
:
� ,.:.; .....
;:;:;
0
j
,
� � ''"' """"' l av.��
•
�L���� t
L•o•r
�
t.�AC"ETO
W I R E COLOR IGNITIO".I SWITCH
..
-
-
l
ON
:e :c z G> c )> G> :c )> s:
-
I�I� I
!!�I
Off
;: ; I i;
% (;
G .
. Green
B/R
Gr
. Gray
B(W
Black with White tracer
0 .
. Orange
B/Y
Black with Yellow tracer
Black with Red tracer
R .
. Red
R/B
Red with Black tracer
w .
. Whit e
W/B
. Yellow
W/R
White with Black tracer White with Red tracer
Y/R
Yellow with Red tracer
Y .
-..: """' '"' :,... /
SER l 'TCTNG
INFORMA TJON
TIGHTENING TORQUE ITEM
kg-m
O'TY
lb-ft
..
ENGINE Cylinder head n u t
4
Exhaust pipe bolt
2
I I
Muffler bolt Clutch nut Kick starter lifter lever nut Kick starter lever bolt Flywheel magneto nut
0.8 - 1 . 2
I
6.0 - 8.5
1 . 5 - 2.0
1 1 .0 - 14.0
1 . 5 - 2.0
1 1 .0 - 1 4 . 0
4.0 - 6.0
29.0 - 43.5
0.5 - 0.8 0.5 - 0.8 3 . 0 - 4.0
4.0 -
5.5
4.0 -
5.5
22.0 - 28.5
.......
CHASSIS Front brake cam lever n u t
1
0.3
1
2.0
Rear brake cam lever nut
1
0.3
Rear axle nut
1
3.6
Rear shock absorber upper nut Rear shock absorber lower bolt
2.0
-
-
-
0.6 3.0 3.0 0.6
I
2.0 -
4.5
14.5 - 2 1 .5 14.5 - 2 1 . 5 2.0 -
4.5
5.2
26.5 - 37.5
4.0
18.5 - 28.5
0.7
Engine mounting nut
1
2.5
-
Footrest bolt
6
0.4
-
Handlebar set nut
1
9.5
- 1 2. 0
68.5 - 86.5
Front axle nut
1
2.7
-
20.0 - 3 1 .0
Spoke nipple ( F ront and rear tires)
'---
1
-
-
56
0.25 -
4.3
0.3
3.0 -
1.8 -
5.0
2.1
4- 1 1
4-12
SER 1 7CJN(; INFOR/11.l T]().\'
S E R V I C E DATA C Y LIND E R + PISTON + PISTON RING STANDARD
L I M IT
0.055 - 0.085 ( 0.0022 - 0.0033 )
0. 1 20 ( 0.0047 )
4 1 .000 - 4 1 . 0 1 5 ( 1 .6 1 42 - 1 .6 1 48 ) Measure at the 1 5 ( 0.6 ) from top surface.
4 1 .065 ( 1 .6 1 67 )
40.930 - 40.945 ( 1 .6 1 1 4 - 1 .6 1 20 ) Measure at the 23 ( 0.9 ) from skirt end .
40.880 ( 1 .6095 )
I TEM Piston to cylinder clearance ----
Cylinder bore
U n i t : mm ( i n )
Piston dia.
-·
.
0.05 ( 0.002 )
Cylinder distortion
0.05 ( 0.002
Cylinder head d i stortion Piston ring free end gap
R
Approx.
T
Approx.
1 St
R
Approx.
T
Approx.
2nd
0. 1 0
Piston ring end gap
( 0.004 Piston ring to groove clearance
4.5 (
0. 1 8
)
5.0 (
0.20
)
2nd
-
4.0 0. 1 6
) ) )
4.5 {
0. 1 8
)
(
5.0 (
0.20
)
(
4.0 0.16
0.25 - 0.0 1 0
-
) - 0.060
0.75 ( 0.030 )
{ 0.0008 - 0.0024 ) 0.020 - 0.060 ( 0.0008 - 0.0024 )
Piston pin bore
1 1.998 - 1 2.006
Piston pin 0. D .
( 0.4 724 - 0.4 727 ) 1 1 .996 - 1 2.000
�
(
)
3.6 0. 1 4
0.020
1 st
(
)
3.6 0. 1 4
( 0.4723 - 0.4724 )
1 2 .030 ( 0.4736 ) 1 1 .980 ( 0.47 1 7 )
.'i/:R l '/C/NG INl'ORM:ITION
CON ROD + C RAN K S H A F T
I!
STAN D A R D
ITEM
1 6 .003 - 1 6.01 1
Conrod s m a l l e n d l . D . -
Con rod d e f l ect ion Crank well to w eh width
-
-
-
---
I
( 0.6300 - 0.6304 )
-
-
40 . 0 ( 1 . 57 ---
Crankshaft r u n o u t
I
.
. .
t
0. 1 0 . 004
I
I
)
I
I
4-13
Unit: mm (in) L I M IT
1 6.040 ( 0.63 1 5 ) )
3.0 0. 1 2
(
0.05 0 . 002 ) (
OIL PUMP ITEM O i l p u m p reduction ratio �
CC I pump d i scharge rate
SP E C I F I CAT I O N --�-- -
( F u l l open)
7.00 ( 1 4 -
-
I
2
)
( 0.033 I 0.034 - 0.039 I 0.040 U S / I m p o z ) 0.97
1 .14
ml
f o r 6 m i n utes at 2000 rpm
•
CLUTCH + PRIMARY GEAR
Unit: mm (in)
ITEM
Clutch wheel I . D.
STANDARD 87.00 - 87. 1 5
C l u tch shoe O . D .
( 3.425 - 3.43 1 86.9 - 87.0
C l utch engagement
r-
---
· --- ··-
( 3.42
-
3.43
2400
±
200
3500
±
300
C l u tch sp r i n g free length
Below
P r i mary drive to driven gear
0.02
28 ( 1 . 06 ) - 0.07
LIMIT
)
backlash
( 0 . 00 1
-
0 . 003
3.441
)
any part
No groove at
rpm
rpm
---
Clutch lock u p
87.40
)
28
Over
( 1 .06 ) )
0. 1 0 ( 0.004
)
4- 1 4
SJ:R l'ICJNG INl'OR.M/ITION
TRANSM I SS I O N
Unit: m m ( i n ) LIMIT
STAN DAR D
ITEM
1 .000
Primary reduction ratio -
F i nal reduction ratio
5.564
2.384 (
--
Gear ratios
Chain
2.333 (
Gear
31 56
I
I
13
)
24
)
DRIVE CHAIN
Unit: mm (in)
ITEM
LIMIT
STANDARD
Drive chain
Type >-
0 . 1 . D . : 270H
Links 2 0 p i tch length
64
I
1 73 . 7
1 70.0 ( 6.69
)
( 6.84
) •
:) lo R. l 'ICING 11\'FORMATION
C A R B U R ETOR
SPEC I F ICATION -
ITEM Carburetor type ..
1 . D. No.
-
12 02340
-----
1 500
I d l e r/min.
--
Main jet
(M. J.)
Air jet
(A. J . )
Jet need le
(J . N . )
Needle jet
(N. J.)
Cut-away
(C. A. ) --
(P. J . )
P i lot outlet
(P. 0 . )
A i r screw
(A. S . )
Valve seat
(V. S.)
Starter jet
(G. S . )
Throttle cable play
-
-
-
rpm
1 50
±
22 . 4 ( 0.88
Float height
P i lot jet
Unit: mm (in)
M I K U M I V M 1 2SH
Bore size
1 .0
±
0.04
---
±
:rt 7 7 . 5
--
)
25
-
3 F 1 3-3 -
-
--�
-- -
-
.
E-6
-
2.0
-
#
----
15
0. 7
-
1 :y.,
---------- ---- ---
1.5
---- - - -
30 0.5
( 0.02
-
-
1.0 0.04
)
4- 1 5
"
4- 1 6
SER I 'TC/NG INJ'ORAll\ 'J'ION
E L ECTR I CA L Ignition timing
ITEM
Unit· mm (in) NOTE
SPE C I F ICATION
1_
25° ± 2° B.T.D.C. at 4000 rpm
Spark plug
-
-,-L
� �
--
Ty e
I
Spark performance Ignition coil resistance
Gap
1
---' -
- - -II
1
_
n mary
� ---
-
DENS 0� 1 4 � P-U L _� 0.6 0.8 ( 0.02 - 0.03 l
I J I r-
Over 8 (0.3) at 1 atm P .
�-
_ N PP O N G K BP4-HA or N-1 _
-
Ground ...J ___ n 1 - Ground - 1 8 kn 1 W/R
B/Y- =
-
Approx .
0
-
--
- - Plug cap Sec ond ary Approx. 1 ·6 ,----+--' - ------� --_ _ _ _ _ _ n_ - _ 1 MY/R ag eto coil resistanc e Appr �_ o_ :: _ _ 1 _ __ n_ · _ _ B/W W/R I Approx. 0 1 n I - -- y/R -+------1 -
1
L
l
1-'-------1
I
I
�I I _ I _ 1. = .�=-i -=i
Approx.
----
-
Charging r ;e
Battery
·
-
-----
Below
Above
1----- ---- ------
-
90
5.5 V at -
B/W
n
--+------
__}JQ_ 9_
-
B/R
1 1O
•
--------l
n
�.5A � 8000 �-m-�----- -· -
Below - --8. 7 V at I ---i- Type designation -
1
-
_
-.!- Approx.
-
2300
8000
--
-
rpm
rpm
-
6N2-2A-4
- - ----- - --------' Capacity 6V 7.2kC (2 Ah)/1 0 H R
-
Standard
i-----
Fuse size
-
0
R/B
-1 App:_o��-R/B -
_ -- -- - -
Lighting coil output
-
.::-Sii/
-
-
-
1 .280 at 20°C (68° F) electrolyte S. G. -! � - - - - - --10 A -
SER VJCLNG INFORJ\lfA TJON
BRAKE + W H E E L
Unit: mm (in) LIMIT
STANDARD
ITEM
-
20
Front brake lever distance --
4- 1 7
--
- ·
(
0.8
(
0.8
..
Brake drum I. D .
Front
1.2
-
20
Rear brake lever distance
30
-
30
-
1 .2
)
)
80.5
( 3. 1 7 ) 80.5
-
Rear
( 3. 1 7 1 .5
Brake l i n i ng thick ness Wheel rim runout
---
Axial
Tire tread depth
( 0.06 2.0
)
( 0.08
)
2.0
Radial Tire size
)
( 0.08
Front
2.25- 1 4 4 P R
Rear
2.25- 1 4 4 P R
)
1 .6
Front
( 0.06 - )
---
1 .6 ( 0.06
Rear
SUSP E N S I ON
)
Unit : mm ( i n ) STANDARD
ITEM
40
F rant fork stroke
(
1 .57 80.2
F rant fork spring free length -
Rear wheel travel Engine mounting pivot shaft runout
( 3.16 60
( 2.36
---
NOTE
L IM I T
) ) )
0.6
( 0.02
)
4- 1 8
Sl: R l "/Cl ."l.'G l.\TORM-'. 'f'ION
FUEL + OIL ITEM
SPEC I F ICATION Use only unleaded or low-lead type gasoline of at R+M least 85 - 95 pump octane ( - method) or 2 method. . 89 octane or higher rated by the R esearch - I 2.5 L
Fuel type
( 0.66 I 0.55 U S / I m p gal )
1
Fuel tank including reserve
- t Use
Engine o i l type
SUZU K I
L U B R ICANT
-r-----· -
--
--
-
( 0.42 I 0.35 US/Imp qt) 0.4
reserve
CCI or
L
SUPER an
2·CYCL E
equivalent
l
IL _ __ _J
Transmission oil type Transmission oil capacity
'-·�-
------+
quality
I
--
I 1
good
-
-
500 m l ( 0.53 I 0.44 U S/ I m p qt) 5 50 ml /_ S_ (_ /l_ l 0_ 0 .4 8_ 8 U .5 _ _ _ _ m _ _ p _ q t_ _
I
---· --
1
._ I
_ _ _
__.
_ _ _ _ _
•
T I R E P R ESSU R E NORMAL C O L D I N F LATION T I R E P R ESSU R E
L
- --
FRONT -
REAR
I
I
SOLO R I D I N G '
kPa
kg/cm2
psi
1 50
1.5
21
200
2.0
28
-
---·-
L
SAE 20W/40
_ _ _ _
i
_l MOTOR
( 0.74 I 0.62 US/ Imp qt) 0.7
NOTE
-
synthetic based 2-cycle oil.
Engine o i l tank capacity
I
SER l 'IC!NC INJ:-'OR.MA TION
4- 1 9
(Wl
WATTAGE SPEC I F ICATION
ITEM
-
I
Headlight
I i
..
I
,._
---
HI
-
-
20 -
-
LO
20 -
-
- -
Tail/Brake l ight
5 . 3/ 1 7
�
- -·
-
Turn signal l ight ,_
-
-··
-
Tachometer light
-
-
-
�
-
Speedometer light
,_
---
-
-- --
-
1.5 -
-
Turn signal indicator light
-
--�-
---
-
- ----
High beam ind icator light
---
-
1 .7
-
-
Neutral ind icator light ,__
.. -
-
O i l level warning light -
-
--
-
-
-
-
----
---
-
-
-
-
Charging ind icator l ight r--
Parking or city light
--
-
- ---
•
......
