Logical and straight forward organization - doesn't jump around. Comb Spiral Binding so the manual lays open nicely on your bench. Color Wiring Diagrams Included. Specifications section with detailed specs that include torque specifications.
Quality Paper - not cheap newspaper quality like so many other books. This professionally written Cyclepedia service manual is perfect for service, repairs, maintenance, and rebuild projects for your classic, no nonsense Suzuki TU bike.
Clear illustrations and photos show exploded views as well as component details to enhance the step-by-step service and repair procedures. Add to Cart. Item Description. Cyclepedia CPP The 'Ask a Question' function requires JavaScript. Didn't get a payment conformation? Was worried a little that I hadn't completed something? Was surprized when it arrived in a timely manner. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge.
If the clearance exceeds the service limit, replace crankshaft assembly or bring the deflection and side clearance into specifi- cation by replacing the worn parts. NOTE: Before installing the new oil filter and oil filter cap, make sure that the spring 4 and new O-rings 1, 2 are installed cor Replace the bearings if there is anything unusual. The clearance for each gearshift fork plays an important role in the smoothness and positiveness of the shifting action.
If any spring is not within the service limit, replace all of the spring. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling.
Page 2. NOTE: Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear. A Clutch driven plate NOTE: 1st ring and 2nd ring differ in shape. Before inserting each piston into the cylinder, check that the gaps are so located.
The static electricity from your body may damage this part. Otherwise, damage to ECM may result. If attempted, damage to ECM or sensors may result.
Locate abnormality, if any. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions. The user can only be notified by the FI indicator light. To check the function of the individual FI system devices, the dealer mode is provided. The memorized malfunction code is displayed by the flashing pattern of FI indicator light.
Malfunction means that the ECM does not receive normal signal from the devices. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis. Such disconnection may erase the memorized information in ECM memory. Therefore, it is possible to know engine and driving conditions e. Go to Step 2. Arrange 3 new 1. If OK, then check the ET sensor lead wire continuity. If OK, then check the TO sensor lead wire continuity.
Refer to the SDS operation manual for further details. At this time, if an operation sound is heard from the STVA, the function is normal. Connect the ET sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is placed on a stove.
If the resistance is not specified value, replace the HO2 sensor with a new one. The fuel in the fuel tank is pumped up by the fuel pump and pressurized fuel flows into the injector installed in the fuel delivery pipe. Keep heat, spark and flame away. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections and TO sensor.
If the TO sensor and fuel pump circuit connections are OK, the fuel pump may be faulty, replace the fuel pump with a new one. On the secondary throttle valve shaft 1, the fast idle cam 2 is installed. When this fast idle cam 2 is operated, the throttle valve is opened to control the fast idle speed.
With the secondary throttle valve 1 turned, the fast idle cam 2 pushes the throttle lever 3, causing the throttle valve to open slightly and increase the engine speed to the fast idle. Any service on the exhaust system should be performed when the system is cool. NOTE: Support the muffler to prevent it from falling. If any defect is found, replace the exhaust pipe or muffler with a new one. Check the exhaust pipe bolts, muffler connecting bolt and muffler mounting bolts are tightened to their spec- ified torque.
Do not use mix different types of fluid such as silicone-based or petroleum-based. Never reuse brake fluid left over from the last servicing or stored for long periods. If any damage is found, replace it with a new one. If any defects are found, replace it with a new one. Replace the disc if the thickness is less than the service limit, or if damage is found.
If any damage is found, replace the master cylinder with a new one. If any defects are found, replace the handlebars with a new one. Page Reassembly And Installation The stamped mark on the oil seal outside.
NOTE: Place a clean rag on the fuel tank to prevent the fuel tank scratched. If any abnormal points are found, replace the respective parts with new ones. Page Reassemble and install the rear brake in the reverse order of removal and disassembly.
If any defects are found, replace the shock absorber with a new one. It is unserviceable. NOTE: When removing the brake rod, depressing the brake pedal. If the runout exceeds the service limit, replace the rear axle with a new one. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. NOTE: The stamped mark on bearing should face outside.
If any damage is found, replace the swingarm with a new one. If the runout exceeds the service limit, replace the pivot shaft with a new one. When removing or installing the tire, be careful not to damage the tube. For operating procedures, refer to the instructions supplied by the tire changer manufacturer.
NOTE: When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the When installing the tire onto the wheel, observe the following points. The line must be equidistant from the wheel rim all around.
If the distance between the rim line and wheel rim Rim line varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides. Failure to follow the proper procedure can cause damage to these parts. Improper use can cause damage to the motorcycle and tester.
Are accessories being installed? Remove accessories. Step 2 1 Check the battery for current leaks. Go to Step 3. Go to Step 6. Go to Step 7. If the tester reads under the specified value, replace the gen- erator with a new one. Is a voltage OK?
Go to Step 4. If either carbon brush is defective, replace the brushes with new ones. Measure the length A of the carbon brushes using a vernier cal- ipers. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Grasp the clutch lever.
Step 1 1 Check the ignition system couplers for poor connections. If there is no continuity replace the respective parts. Measure the voltage between the terminals using the multi cir- cuit tester.
Refer to the following table. If the fuel level indicator light does not light up, check the lead wires, couplers, check relay and ignition switch. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection. If any abnormality is found, replace the respective switch assemblies withe new one. Never remove the container from the battery. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one.
If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper. Valve clearance out of adjustment Adjust. Poor seating of valves Replace or repair. Defective valve guides Replace. Worn rocker arms or cam surfaces Replace. Too large valve clearance Adjust.
Weakened or broken valve springs Replace. Worn and burnt camshaft journal bearings Replace. Weakened valve springs Replace.
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