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Love your site! Thank you. Remove the fuel valve. Replace the removed O-ring with a new one to pre- vent fuel leakage. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4.
The fuel in the float chamber 2 is metered by the main jet 3. The metered fuel enters the needle jet 4, mixes with the air admitted through the main air jet 5, and then forms an emulsion.
When the rider opens the throttle grip quickly, the intake air volume increases and air velocity at the bottom of the piston valve is slow and sucking volume of fuel is less. The starter jet 2 meters this fuel, which then flows into the fuel passage 3 and mixes with the air coming from the float chamber. Disconnect the throttle cables. Disconnect the coasting richer pump hose. Loosen the carburetor clamp screws, and then remove the carburetor assembly.
DR-Z Remove the throttle position sensor. Remove the accelerating pump assembly. Replace the removed O-ring with a new one to prevent fuel leakage. Remove the throttle valve. Remove the intake joint. Replace the removed O-ring with a new one to prevent air leakage.
Remove the float chamber. If any damages are found, replace the damaged parts with new ones. A high-capacity centrifugal pump is used for the water pump and a tube-and-fin type aluminum radiator, which is characterized by lightness in weight and good heat dissipation, is used. Check the cooling system for leaks with a radiator tester 1. Remove the radiator cap and connect the radiator tester to the filler.
Pressurize the cooling system with kPa 1. The engine must be cool before servicing the cool- ing system. Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation.
If ab- normal noise occurs or if rough movement is noted, replace the water pump bearing with a new one. Remove the front axle nut 1 and loosen the front axle pinch bolts 2. Support the motorcycle with a jack or wooden block and re- move the front axle 3 and front wheel 4. Do not operate the brake lever during or after front wheel removal. If any dam- age is found, replace the odometer gearbox with a new one.
If any damage is found, replace the wheel hub dust seal with a new one. Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment. Drive out the wheel bearing by striking the wedge bar. Page Reassembly And Remounting First, install the left wheel bearing, and then install the right wheel bearing.
Remove the front fork after loosening the front fork upper clamp bolts 3 and lower clamp bolts 4. NOTE: Hold the fork inverted for a few minutes to drain the oil. Remove the push rod 1, needle 2, and return spring 3. Slowly pull out the inner tube. NOTE: Be careful not to damage the inner tube. Remove the oil seal 2 , oil seal retainer 3 , outer tube antifriction metal 4 inner tube antifriction metal 5, and oil lock piece 6.
Pour the specified fork oil into the inner tube. Install the fork spring. NOTE: The end of the fork spring with the smaller inside diameter should be at the bottom of the front fork. Install a washer 1. Remove the odometer assembly. Remove the clamps 1 and engine stop switch 2. DR-Z Remove the front fender. Remove the handlebar 1 and ignition switch 2 DR-ZE. Remove the steering stem head nut. Remove the steering stem nut using the special tools.
NOTE: Hold the steering stem lower bracket to prevent it from falling. Remove the steering stem upper bearing. Page Forward specified torque. E, 28 Remove the rear axle nut. Replace the removed cotter pin with a new one. Support the motorcycle with a jack or wooden block and re- move the rear axle 1 and rear wheel. Do not operate the brake pedal during or after rear wheel removal. Page Inspection Reassemble and remount the rear wheel in the reverse order of removal and disassembly.
DR-ZE Remove the clamps. Disconnect the air cleaner breather hose and loosen the car- buretor clamp. If any damages are found, replace the spring or rear shock ab- sorber with a new one. Low gas pres- sure can result in oil leakage.
Abnormal gas pressure cannot provide normal performance of the rear shock absorber. Be sure to fill the rear shock absorber unit to the speci- fied pressure.
Disconnect the brake hose from the brake hose guide. Remove the cushion lever mounting bolt and nut. Inspect the spacers for any flaws or other damage. If any dam- ages are found, replace the spacers with new ones. If any damages are found, replace the swingarm with a new one. If there is excessive play, re- place the bearings with new ones.
Page Reassembly And Remounting Reassemble and remount the rear suspension in the reverse order of removal and disassembly. Remove the brake pads. Do not operate the brake lever during or after brake pad removal.
Replace the brake pads as a set, otherwise braking performance will be adversely affected. Install the new brake pads. Remove the master cylinder reservoir cap and diaphragm. Remove as much old brake fluid as possible. Fill the reservoir with new brake fluid. Specification and classification: DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle. Remove the spring. Place a rag over the brake caliper pistons to prevent them from popping out, and then force out the pistons using com- pressed air.
Do not use extremely high pressure air to remove the brake caliper pistons, otherwise damage to the pistons will result. Page Brake Caliper Reassembly And Remounting Apply brake fluid to all of the seals, brake caliper bores and pistons before reassembly. Remove the brake hose union bolt and disconnect the brake hose. Immediately wipe off any brake fluid contacting any part of the motorcycle.
If any damages are found, replace the master cylinder with a new one. Do not operate the brake pedal during or after brake pad removal. Remove the reservoir cap and diaphragm. Replace the brake fluid. Remove the brake caliper. Do not use extremely high pressure air to remove the brake caliper piston, otherwise damage to the piston will result.
Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Pay special attention to the fol- lowing points: Wash the master cylinder components with new brake fluid before reassembly.
When connecting a connector, push it in so it is firmly attached. Inspect the connector for corrosion, contamination and any breakage in the cover.
The MF battery used in this motorcycle does not require main- tenance e. Improper use can cause damage to the motorcycle and tester. If the voltage and current values are not known, begin mea- suring in the highest range. When measuring the resistance, make sure that no voltage is applied. The regulator prevents overcharging of the battery by grounding the excessive AC current. Remove the battery cover. Measure the current between the - battery terminal and the - battery lead wire using the multi circuit tester.
If the reading ex- ceeds the specified value, leakage is evident. Measure the AC voltage between the lead wires of the genera- tor using the multi circuit tester. Pressing the starter button energizes the starter relay, causing the contact points to close, thus, completing the circuit from the starter motor to the battery.
The starter motor draws about 80 amperes to start the engine. If any damages are found, replace the brush assembly with a new one. Page Starter Motor Reassembly And Remounting Pay special attention to the follow- ing points: Replace the removed O-rings with new ones to pre- vent oil leakage and moisture. Remove the starter relay. Apply 12 V to the terminals and check for continuity between the positive and negative terminals using the multi circuit tester. This energy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
NOTE: The ignition coil peak voltage Correct inspection method is applicable only with the multi circuit tester and the peak volt adaptor. Connect a new spark plug to spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi circuit tester. If the resistance in both the primary and secondary windings is close to the speci- fied values, the windings are in sound condition.
Measure the resistance between the lead wires using the multi circuit tester. If the resistance is not within the specified value, the pickup coil and signal coil must be replaced. This en- ergy is released in a single surge at the specified ignition timing point and the current flows through the primary side of the ignition coil.
Correct Incorrect Correct Incorrect Incorrect Connect a new spark plug to the spark plug cap and ground it to the cylinder head. NOTE: Make sure that the spark plug cap and spark plug are connected properly and the battery is fully charged. Remove the left frame cover. Measure the pickup coil and signal coil peak voltage in the following procedure. Disconnect the headlight coupler and remove the headlight assembly.
Remove the bulb. Install the new bulb in the reverse order of removal. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy wa- ter to prevent premature bulb failure. If any abnormality is found, replace the re- spective switch assemblies with a new one. Remove the battery. NOTE: Disconnect the - battery lead wire, first. If the voltage reading is less than the When recharging the battery, remove the battery from the motorcycle.
Worn cylinder. Worn piston ring. Worn valve guide or improper valve seating. Repair or replace. Excessive valve chatter 1. Excessive tappet clearance. Weak or broken valve spring. Worn camshaft.
Worn or burnt camshaft journal. Noise seems to come from the piston 1. Worn gear. Worn or distorted gearshift fork. Weakened gearshift stopper spring. Worn gearshift pawl. Engine idles poorly. Tappet clearance out of adjustment.
Carbon buildup on piston crown. Insufficient amount of engine oil. Check level and add. Defective oil pump. Clogged oil circuit. Float chamber fuel level too low. Adjust float height. Overtightened steering stem nut. Broken bearing in steering stem. Distorted steering stem. Low tire pressure.
Handlebar wobbles. Loss of balance between right and left front forks. Adjust or replace. Leakage of brake fluid. Worn brake pad. Oil on brake pad surface. Clean brake disc and brake pads. Worn brake disc.
Defective ignition coil. Defective spark plug. Defective generator. Defective CDI unit. Spark plug is wet or 1. Adjust carburetor. Cracked battery case. Battery has been left in a run-down condition for a long Replace. Battery runs down 1. Incorrect charging method. Page Link type, coil spring, oil damped, spring preload fully ad- justable, rebound damping force way adjustable, com- pression damping force way adjustable Front fork stroke Slow air jet S.
Air jet A. Pilot screw P. Page Rear shock absorber gas kPa ——— pressure 9. Ignition coil resistance Terminal — An unleaded gasoline is recommended. Fuel tank including reserve If any abnormality is found, replace the respec- tive switch assemblies with a new one.
Green mark VIEW 1 After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Telescopic, coil spring, oil damped, rebound damping force way adjustable, compression damping force way adjustable Rear suspension Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force way adjustable, compression damping force way adjustable Front suspension stroke Link type, coil spring, oil damped, spring preload fully adjustable, rebound damping force way adjustable, compression damping force way adjustable Front fork stroke Never remove the container from the battery.
Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke Link type, coil spring, oil damped Front fork stroke Maintenance intervals are expressed in terms of kilometers, miles and months, and are dependent on whichever comes first.
Low gas pressure can result in oil leakage. Seat rail lower mounting bolt Page Prepared by 3rd Ed. February, 1st Ed.
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