WARNING - Serviceinfo MC cross/JR50/JR50K6P03.pdf · IMPORTANT WARNING/CAUTION/NOTE Please read...

99011-04493-03AJR

50

Part No. 99011-04493-03AJune, 2005 ENTKK6

JR50

Printed in Taiwan300 TAKATSUKA, HAMAMATSU, JAPAN

OWNER’S MANUALThis owner’s manual containsimportant safety information.Please read it carefully.

WARNINGFailure to follow these safetyprecautions may increase yourrisk of injury:• Wear a helmet, eye protec-

tion, and bright protectiveclothing.

• Off-road use only – do notuse on public roads or high-ways.

• Slow down on slippery sur-faces, unfamiliar terrain, orwhen visibility is reduced.

• Not recommended for chil-dren under age 7.

• Adult supervision required.• Single rider only – weight

limit 65 lbs (30 kg).• Do not touch any moving

parts or heated areas.• Read owner’s manual care-

fully.

No.1062 JR50 99011-04493-03A 2/1 DIC184(TDP006) 4 mm

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

California Proposition 65 Warning

WARNINGEngine exhaust, some of its constituents, and certain product com-ponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

This vehicle is not subject to the phased-in emission standards and related requirements for model year 2006 [off-highway motorcycles or all-terrain vehicles] applicable under 40 CFR 1051.

No.1062 JR50 99011-04493-03A 2/1 BLACK 4 mm

IMPORTANT

WARNING/CAUTION/NOTEPlease read this manual and fol-low its instructions carefully. Toemphasize special information,the symbol and the wordsWARNING, CAUTION and NOTEhave special meanings. Pay spe-cial attention to the messageshighlighted by these signal words:

NOTE: Indicates special informa-tion to make maintenance easieror instructions clearer.

WARNINGs and CAUTIONs arearranged like this:

WARNINGIndicates a potential hazardthat could result in death orinjury.

CAUTIONIndicates a potential hazardthat could result in motorcycledamage.

WARNING-or-CAUTIONThe first part will describe aPOTENTIAL HAZARD andWHAT CAN HAPPEN if youignore the WARNING or CAU-TION.

The second part will describeHOW TO AVOID THE HAZARD.

JR50_03A.book Page 1 Tuesday, April 12, 2005 5:06 PM

FOREWORD

Motorcycling is one of the mostexhilarating sports and to ensureyour youngster’s riding enjoy-ment. You and your youngstershould become thoroughly famil-iar with the information presentedin this Owner’s Manual beforeyour youngster rides the motorcy-cle.

The proper care and maintenancethat your motorcycle requires isoutlined in this manual. By follow-ing these instructions explicitlyyou will ensure a long trouble-freeoperating life for your motorcycle.Your authorized Suzuki dealerhas experienced technicians thatare trained to provide yourmachine with the best possibleservice with the right tools andequipment.

All information, illustrations, pho-tographs and specifications con-tained in this manual are basedon the latest product informationavailable at the time of publica-tion. Due to improvements orother changes, there may besome discrepancies in this man-ual. Suzuki reserves the right tomake production changes at anytime, without notice and withoutincurring any obligation to makethe same or similar changes tomotorcycles previously built orsold.

It is important that this manualremain with the motorcycle whenyou sell it. The next owner willneed this manual also. Store theowner’s manual with your motor-cycle.

Review the “Parents, Youngstersand Off-Highway Motorcycles”handbook supplied with thisowner’s manual (for owner’s inU.S.A.). This special handbookcontains a variety of safety tips,helpful hints, and practice exer-cise that can increase youryoungster’s riding enjoyment andsafety.

Suzuki Motor Corporationbelieves in conservation and pro-tection of Earth’s naturalresources. To that end, weencourage every vehicle owner torecycle, trade in, or properly dis-pose of, as appropriate, usedmotor oil, coolant, and other flu-ids: batteries, and tires.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2005


IMPORTANT ADVICE TO PARENTS

This motorcycle is designed foruse only as follows:• Read this owner’s manual

carefully.• Off-road use only – Not for use

on public roads.• Single rider only – Weight

limit 30 kg (65 pounds).• Not recommended for children

under age 7.• Parental supervision required

during operation.• Parent and rider to perform

daily inspection before riding –refer to applicable sections ofthis owner’s manual.

• Observe periodic maintenancerequirements outlined in thisowner’s manual.

• Do not touch any moving partsor heated areas such as theengine, the drive chain andexhaust system.

• Rider must always wear a hel-met, eye protection (gogglesor face shield) and protectiveclothing (gloves, leather orheavy cloth pants, long-sleeveshirt or jacket, boots that fitover the ankle).

• Rider must always ride safelyand be thoughtful of others.

• Drain the fuel tank and carbu-retor of fuel prior to transport-ing the motorcycle.

Your Suzuki JR50 was designedfor use by children, but thisowner’s manual is written for theadult who will be supervising thechildren. Suzuki strongly recom-mends, therefore, that you reviewthis entire manual with your child.Carefully explain the instructionsrequirements, and warnings thismanual contains so your child canunderstand them. Question yourchild as you go through the man-ual to make sure he or she under-stand what you are saying. It isyour responsibility to ensure thatthis motorcycle is properly andsafely ridden and maintained.

Children differ in skills, strengthand judgement, and some chil-dren may not be able to operateyouth-size motorcycles safely. Youshould always supervise yourchild’s use of the motorcycle. Per-mit continued use only if youdetermine that the child has theability to operate the motorcyclesafely. Note that children canbecome so excited and impatientthat they forget the importance ofsafety precautions.


Tips for supervising the young rider.

Your child’s safety depends onyour commitment to take the timenecessary to fully educate him orher on the proper operation of theJR50. Remember that properinstruction before your childbegins to ride is as important asproper instruction and supervisionduring riding.

Wear protective gear.A helmet is the most importantpiece of gear to wear off-highway,where visibility and trail conditionscan vary greatly from section tosection and season to season.These changes are sometimesunpredictable, and can causeeven an experienced rider to havean accident. Helmets do notreduce essential vision or hear-ing.

Generally, helmets do not causeor intensify injury if the ridercrashes. Helmets simply helpyour child’s skull protect his or herintelligence, memory, personality,and life.

Your child’s eyesight is equallyvaluable. Wearing eye protectioncan help keep his or her visionunblurred by the wind and helpshield his or her eyes frombranches and airborne matter likebugs, dirt, or pebbles kicked up bytires. Have your child wear a hel-met and eye protection every timehe or she rides.

WARNINGAllowing a child to operate thismotorcycle without adultsupervision can be hazardous.Without supervision, the childmay ride beyond his or her abil-ities and lose control of themotorcycle.

Never let your child ride amotorcycle without close adultsupervision. Take action if yourchild begins to ride beyond hisor her abilities. Introduce newriding areas slowly and makesure the riding area matchesyour child’s skill level.


Outfit your child in proper clothingwhen he or she rides. Avoid looseclothes or scarves, which couldget caught in moving parts. Abra-sion injuries can be minimized bywearing protective clothing includ-ing gloves, strong boots that fitover the ankle, long pants, andlong sleeve shirt or jacket. Experi-enced riders often wear a kidneybelt and chest or back protectorfor additional comfort and protec-tion.

Getting to know the JR50.Your child should become com-pletely familiar with the namesand functions of all controls. Letthe young rider sit on the bike,with the engine off, and ask him orher to operate specific controls.Demonstrate proper operation ofthe controls. Ask the child to applythe brakes, operate the enginestop switch, shift lever, etc. Prac-tice this exercise until the childcan operate all the controls with-out hesitation and without lookingat them.

SUZUKI recommends first use ofthe motorcycle in a safe, flat openarea so the rider can becomefamiliar with the controls, opera-tion, and handling characteristicsof the motorcycle.

Go over the INSPECTIONBEFORE RIDING section withyour child until he or she knows allthe items that should be checkedand how they should be checked.Give examples of things to lookfor. Before each use, an adultshould perform an inspection withthe rider.

Starting off and stopping.To help your child develop confi-dence, he or she should PRAC-TICE FIRST WITH THE ENGINEOFF, as follows:1. Have your child sit on the bike

while you balance and push hemotorcycle from behind.

2. As you push the bike, instructyour child to operate the con-trols, as described above. Thechild should be looking straightahead, not down at the con-trols.

Practice with the engine off untilyour child gets the feel of usingthe controls without hesitation andwithout looking at them. Thenstart the engine and have yourchild practice starting off, shiftinginto Drive, riding in a straight lineand coming to a complete stop.Walk alongside the motorcycle.Watch closely to make sure therider:1. Operates the throttle smoothly

to start moving gradually.2. Releases the throttle then

applies the front and rearbrakes evenly and shifts toneutral when stopping.


Practice this exercise until yourchild can start off, accelerate, andstop correctly and with confi-dence. Slowly introduce newmaneuvers into this routine as thechild becomes more comfortablewith the motorcycle, such as turn-ing and stopping quickly on yoursignal.

Inspect the machine before riding.Review the instructions in the“INSPECTION BEFORE RIDING”section of this manual. Perform anentire pre-ride inspection withyour child before heading out onthe trail. Spending a few minutespreparing the machine for a ridecan help prevent accidents due tomechanical failure or costly,inconvenient breakdowns.

Specific additional safety items tobe considered include:

• Supervise operation of thismotorcycle AT ALL TIMES.

• Do not allow the rider to oper-ate the motorcycle beyond hisriding ability.

• Use of the motorcycle shouldbe controlled by the parents inrelation to the rider’s age (notrecommended for childrenunder 7 years old), physique,and operating intelligence andmaturity.

• Beware of hazardous situa-tions and instruct the rider tobeware of hazardous situa-tions.

• Before first use of the motorcy-cle, read this owner’s manualcarefully to become familiarwith the features, and safetyand maintenance require-ments of the motorcycle,instruct and review these itemswith rider.

Remember: With your help andsupervision, your child canbecome a skilled rider.


TABLE OF CONTENTS

1

2

3

4

5

6

7

8

9

10

INSTRUCTING THE YOUNG RIDER

FUEL AND OIL RECOMMENDATION

CONTROLS, EQUIPMENT AND ADJUSTMENTS

BREAK-IN AND INSPECTION BEFORE RIDING

RIDING TIPS

ACCESSORY USE AND MOTORCYCLE LOADING

INSPECTION AND MAINTENANCE

TROUBLESHOOTING

STORAGE PROCEDURE AND APPEARANCE CARE

CONSUMER INFORMATION

SPECIFICATIONS

INDEX



1-1

1


OPERATING SKILL ............................................................................................. 1-2CLOTHING ........................................................................................................... 1-4


1-2


Children are impatient; the sightof a new motorcycle excites theirimagination; and in their excite-ment they may forget the impor-tance of safety precautions.

Please go through this manualwith your youngster, page bypage, and help him or her under-stand not only the mechanismsbut also the rules of courtesy andsafety precautions. Here are sixrules to be impressed upon themind of the young rider before youbegin the training:

OPERATING SKILLKnow the mechanism.Memorize the name of each con-trol. The name suggests its func-tion. Know the path of power fromthe engine to the rear wheel.Learn the sequence of checkingthe items listed in the INSPEC-TION BEFORE RIDING section.

WARNINGAn incomplete understandingof motorcycle controls can behazardous. An improperly con-trolled motorcycle may causean accident.

Check to be sure the youngrider has perfectly learned: lethim or her demonstrate afteryou.


1-3

Rehearse before riding out for the first time.Let the young rider mount themachine and do a dry rehearsalwith the engine off. The ridershould be fully outfitted with hel-met, eye protection (goggles orface shield), and protective cloth-ing (gloves, leather or heavy clothpants, long sleeve shirt or jacket,boots that fit over the ankle).Watch the way he or she operatesthe controls (particularly throttleand brakes). Make sure the shift-ing sequence is perfectly memo-rized. Smooth simultaneousbraking (front and rear) is particu-larly important.

Learn the techniques of standing-start and stopping with both brakes.Practice makes perfect. Let theyoung rider repeat after you, asmany times as necessary, untilyou are sure he or she haslearned the technique.

WARNINGOperating this motorcycle with-out proper instruction can behazardous. The risk of havingan accident greatly increases ifyou do not train the youngsterhow to operate this motorcycleproperly in different situationsand on different types of ter-rain.

Train your young rider in alevel, open area free of any traf-fic so he or she can becomefamiliar with the operation ofcontrols and the handling char-acteristics of the motorcycle.


1-4

CLOTHING

As stated before, the minimumacceptable riding outfit includeshelmet, eye protection, and pro-tective clothing. Some guidelinesfor protective clothing are:

Wear simple clothes.Dangling belts and scarves, rib-bon-like trimmings, etc., are haz-ardous since they can get caughtin moving parts.

Wear full-coverage clothes.Do not ride with bare arms orlegs. Abrasion injuries can beminimized by wearing clothingthat fully covers the limbs. Off-road gloves and over-the ankleboots help protect hands and feet.Loss of body heat to wind cancontribute to riding fatigue. Properclothing can help keep the riderwarm and alert.

Wear flexible clothes.Make sure that riding clothesallow a full range of knee, elbow,and torso movement. Unrestrictedbody movements are essential forsafe riding.

WARNINGOperating this motorcycle with-out wearing an approvedmotorcycle helmet, eye protec-tion and protective clothingincreases your chances of asevere injury or death in theevent of an accident.

Always wear an approvedmotorcycle helmet that fitsproperly. Always wear eye pro-tection (goggles or faceshield). You should also weargloves, boots, long sleeve shirtor jacket, and long pants.


2-1

2


FUEL .................................................................................................................... 2-2ENGINE OIL ......................................................................................................... 2-3TRANSMISSION OIL ........................................................................................... 2-3


2-2


FUELYour motorcycle requires regularunleaded gasoline with a mini-mum pump octane rating of 87((R+M)/2 method). In someareas, the only fuels that areavailable are oxygenated fuels.Oxygenated fuels which meet theminimum octane requirement andthe requirements described belowmay be used in your motorcyclewithout jeopardizing the NewVehicle Limited Warranty.

NOTE: Oxygenated fuels arefuels which contain oxygen-carry-ing additives such as MTBE oralcohol.

Gasoline Containing MTBEUnleaded gasoline containingMTBE (Methyl Tertiary ButylEther) may be used in your motor-cycle if the MTBE content is notgreater than 15%. This oxygen-ated fuel does not contain alco-hol.

Gasoline/Ethanol BlendsBlends of unleaded gasoline andethanol (grain alcohol), alsoknown as GASOHOL, may beused in your vehicle if the ethanolcontent is not greater than 10%.

Gasoline/Methanol BlendsFuel containing 5% or less metha-nol (wood alcohol) may be suit-able for use in your motorcycle ifthey contain co-solvents and cor-rosion inhibitors. DO NOT USEfuels containing more than 5%methanol under any circum-stances. Fuel system damage ormotorcycle performance prob-lems resulting from the use ofsuch fuels are not the responsibil-ity of Suzuki and may not be cov-ered under the New VehicleLimited Warranty.

Fuel Pump LabelingIn some states, pumps that dis-pense oxygenated fuels arerequired to be labeled for the typeand percentage of oxygenate, andwhether important additives arepresent. Such labels may provideenough information for you todetermine if a particular blend offuel meets the requirements listedabove. In other states, pumpsmay not be clearly labeled as tothe content or type of oxygenateand additives. If you are not surethat the fuel you intend to usemeets these requirements, checkwith the service station operatoror the fuel suppliers.


2-3

NOTE: • To help clean the air, Suzuki

recommends you to use theoxygenated fuels.

• Be sure that any oxygenatedfuel you use has octane rat-ings of at least 87 pumpoctane ((R+M)/2 method).

• If you are not satisfied with thedriveability of your motorcyclewhen you are using an oxy-genated fuel, or if engine ping-ing is experienced, substituteanother brand as there are dif-ferences between brands.

ENGINE OIL

Use SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT oran equivalent good quality syn-thetic based 2-stroke engine oilrated FC under the JASO classifi-cation.

TRANSMISSION OILUse a good quality SAE 10W-40multi-grade motor oil.

CAUTIONSpilled gasoline containingalcohol can harm your motor-cycle. Alcohol can damagepainted surfaces.

Be careful not to spill any gas-oline when filling the fuel tank.Wipe spilled gasoline up imme-diately.



3-1

3


LOCATION OF PARTS ....................................................................................... 3-2LEFT HANDLEBAR ............................................................................................. 3-5RIGHT HANDLEBAR .......................................................................................... 3-5THROTTLE LIMITER ........................................................................................... 3-5FUEL TANK CAP ................................................................................................ 3-6FUEL VALVE ....................................................................................................... 3-7ENGINE OIL LEVEL ............................................................................................ 3-8CHOKE LEVER ................................................................................................... 3-9KICK STARTER LEVER ...................................................................................... 3-9GEARSHIFT LEVER .......................................................................................... 3-10REAR BRAKE PEDAL ...................................................................................... 3-10SIDE STAND ...................................................................................................... 3-10POWER REDUCTION PLATE ........................................................................... 3-11POWER REDUCTION PLATE REMOVAL INSTRUCTIONS ............................ 3-11SEAT HEIGHT ADJUSTMENT .......................................................................... 3-13


3-2


LOCATION OF PARTS

1Engine stop switch2Front brake lever3Throttle grip4Fuel tank cap


3-3

5Fuel valve6Spark plug7Gearshift lever8Footrest9Side stand0Drive chain


3-4

AKick starter leverBEngine oil inspection windowCTransmission oil filler capDAir cleanerEChoke leverFCarburetorGRear brake pedalHTransmission oil level screw


3-5

LEFT HANDLEBAR

Engine Stop Switch 1To stop the engine, push theengine stop switch.

RIGHT HANDLEBAR

Throttle Grip 1Engine speed is controlled by theposition of the throttle grip. Turn ittoward you to increase enginespeed. Turn it away from you todecrease engine speed.

Front Brake Lever 2Apply the front brake by squeez-ing the front brake lever towardsthe grip.

THROTTLE LIMITER

Use the throttle limiter to restrictmaximum engine power by limit-ing throttle opening. Adjust thislimiter according to the rider’s skilland experience.

To adjust the throttle limiter:1. Loosen the lock nut 1.2. Turn the throttle limiter screw

2 clockwise to restrict maxi-mum engine power or counter-clockwise to increase themaximum engine power.

3. Tighten the lock nut 1.

When the maximum engine poweris required, remove the throttlelimiter screw and lock nut andinstall the throttle case plug.Throttle case plug: screw 5 × 5mm.


3-6

FUEL TANK CAP

To open the fuel tank cap, removethe end of vent tube from the han-dlebar cover and turn the capcounterclockwise. To close thecap, turn it clockwise and tightenit securely. Be sure that the venttube is connected securely androuted properly.

WARNINGOverfilling the fuel tank cancause the fuel to overflowwhen it expands due to heatfrom the engine or the sun.Spilled fuel can catch on fire.

Never fill the fuel above thebottom of the filler neck.

WARNINGFuel and fuel vapor are highlyflammable and toxic. You canbe burned or poisoned whenrefueling.

• Stop the engine and keepflames, sparks and heatsources away.

• Refuel only outdoors or in awell ventilated area.

• Do not smoke.• Wipe up spills immediately.• Avoid breathing fuel vapor.• Keep children and pets away.


3-7

FUEL VALVEThis motorcycle has a manuallyoperated fuel valve. There are twopositions: “ON” and “OFF.”

“ON” positionThe normal operating position forthe fuel valve is in the “ON” posi-tion. In this position, fuel will flowfrom the fuel valve to the carbure-tor whenever the fuel level in thecarburetor drops.

“OFF” positionTurn the fuel valve to the “OFF”position after stopping the engine.In this position, fuel will not flow tothe carburetor.

WARNINGLeaving the fuel valve in “ON”position when the engine is offcan be hazardous. The carbu-retor may overflow and fuelmay run into the engine. Thiscan cause a fire or causesevere damage when you startthe engine.

Always move the fuel valve tothe “OFF” position after turn-ing off the engine.


3-8

ENGINE OIL LEVEL

The engine oil tank is locatedbehind the right frame cover.Check the oil level through the oillevel inspection window 1 eachtime before starting the engine. Ifthe oil level is below the inspec-tion window, replenish the oil tankwith the specified oil. To replenishthe oil, unscrew the knob 2 toremove the frame cover and drawout the oil tank 3 from the frame.Fill up the tank with the specifiedoil. The oil tank holds 0.3 L (0.3US qt).

This motorcycle is equipped witha two-stroke engine. Two strokeengines consume oil along withgasoline in the combustion pro-cess. Therefore, it is important tocheck the engine oil level beforeeach ride.

CAUTIONRunning the engine without anadequate amount of engine oilcan cause severe engine dam-age such as overheating andpiston seizure.

Always check the amount ofengine oil before starting theengine.


3-9

CHOKE LEVER

This motorcycle has a choke sys-tem to provide easy starting whenthe engine is cold. The chokeworks by pushing the choke leverdown. The choke works bestwhen the throttle is in the closedposition. When the engine iswarm, you do not need to use thechoke for starting.

NOTE: Refer to the STARTINGTHE ENGINE section of the man-ual for the engine starting proce-dure.

KICK STARTER LEVER

Depressing the kick starter leverwith the transmission in neutralwill start the engine.

WARNINGAn improperly retracted kickstarter lever can interfere withrider control.

Be sure the kick starter lever isreturned to its home positionafter starting the engine.


3-10

GEARSHIFT LEVER

This motorcycle has a single-speed transmission which oper-ates as shown. To shift properly,close the throttle before you oper-ate the gearshift lever. Lift thegearshift lever to shift to the neu-tral position or depress the leverto shift to the drive position.

REAR BRAKE PEDAL

Pressing the rear brake pedal willapply the rear brake.

SIDE STAND

The motorcycle has a side stand.To place the motorcycle on theside stand, place your right footon the end of the side stand andpush down firmly until the standpivots fully through its arc andcomes to rest against its stop.

CAUTIONPark the motorcycle on firm,level ground to help prevent itfrom falling over.

If you must park on an incline,aim the front of the motorcycleuphill to reduce the possibilityof rolling off the side stand.

WARNINGRiding with the side standincompletely retracted canresult in an accident when youturn left.

Always retract the side standcompletely before starting off.


3-11

POWER REDUCTION PLATEThe power reduction plate reducethe power output of the engine.This enables the young rider todevelop his riding skills graduallywith reduced power output.Removal of these plate allows theengine to deliver full power.

POWER REDUCTION PLATE REMOVAL INSTRUCTIONS

1. Loosen the knob and removeright frame cover.

2. Remove the two bolts securingthe exhaust pipe with 5-mmhexagon L type wrench.

3. Move the oil tank out of theway.

WARNINGRemoving the power reductionplate before the rider hasdeveloped sufficient skills tooperate the motorcycle safelyis hazardous. Riding at exces-sive speeds increases chancesof losing control of the motor-cycle, which can result in anaccident.

Do not remove the powerreduction plate until the riderdevelops sufficient skills tooperate JR50 safely at the max-imum speed with the powerreduction system in place.

WARNINGA hot muffler can burn you. Themuffler will be hot enough toburn you for some time afterstopping the engine.

Wait until the muffler cools toavoid burns.


3-12

4. Remove the bolt securing themuffler at the center of themachine. This bolt needs a 12-mm T type wrench.

5. Using a 12-mm T type wrenchand a 12-mm wrench, removethe bolt securing second muf-fler.

6. Remove the muffler. Removethe power reduction plate fromexhaust pipe flange. This plateis positioned inside the flangedend.

7. Reinstall the muffler, makingsure that the exhaust pipe gas-ket is in good condition.(Replace the gasket as neces-sary.)


3-13

SEAT HEIGHT ADJUSTMENTThe seat height of this motorcycleis adjustable for the rider’s physi-cal size.

If higher seat height is required,carry out the following proce-dures.

1. Remove the fastener and takeoff the front number plate.

NOTE: To remove the fastener,push in the center pin as B andpull out the fastener. To install thefastener, pull the center pin as Cand fix the fastener by pushingthe center pin as A.

2. Loosen the front fork lowerclamp bolts.

3. Remove the two clamps andhandlebar cover. Remove theupper bracket bolts and pullboth forks downward.

4. Locate the right-side and left-side spacers as shown aboveand replace the bolts withlonger ones.

25 mm (1.0 in) higher

STANDARD SETTING 0 mm


3-14

NOTE: The spacers and longerbolts are provided in the tool bag.

5. Tighten the upper and lowerbolts securely in that order.

6. Reinstall the number plate.

7. Remove the frame cover andloosen the upper rear shockabsorber bolt. Do this on rightand left sides.

8. Remove the lower rear shockabsorber bolt. After taking offthe rubber cap from the higherboss, set the shock absorberon it. Tighten the upper andlower mounting bolts securely.Do this on both sides.

9. Reinstall the frame covers.

WARNINGFailure to cover the rear shockmounting boss with the capcan cause injury to the rider.

Fit the cap to the lower mount-ing boss of the rear shock.

Rubber cap and mounting boss


3-15

10.Adjust the side stand in orderto maintain the correct parkinglean angle. Remove screw 2and extend inner stand 1 sothat the higher clearance holeis visible through the outerstand screw hole. Reinstalland securely tighten screw 2.

Tightening torque:

WARNINGFailure to adjust the seatheight properly could lead toan accident.

Follow the following instruc-tions to avoid an accident:• Adjust the front fork and rear

shock absorbers at the sametime.

• Check the free travel of therear brake pedal after heightadjustment procedures arecomplete. Adjust rear brakepedal free travel if necessary.

• Adjust the side stand in orderto maintain the correct park-ing lean angle.

• Bolts and nuts must betorqued to the proper specifi-cations. We strongly recom-mend that this be done byyour authorized Suzukidealer or qualified mechanic.

Front fork upper bolts

25 N·m (2.5 kgf-m, 18.0 lb-ft)

Front fork lower clamp bolts

15 N·m (1.5 kgf-m, 11.0 lb-ft)

Rear shock absorber upper bolts

25 N·m (2.5 kgf-m, 18.0 lb-ft)

Rear shock absorber lower bolts

8 N·m (0.8 kgf-m, 5.5 lb-ft)



4-1

4


BREAK-IN ............................................................................................................ 4-2INSPECTION BEFORE RIDING .......................................................................... 4-3


4-2


BREAK-INThe first 20 hours is the mostimportant in the life of your motor-cycle. Proper operation duringthis break-in period will helpassure maximum life and perfor-mance from your new motorcycle.The following guidelines explainproper break-in procedures.

Maximum Throttle Operation RecommendationThe table below shows the maxi-mum throttle operation during thebreak-in period.

Vary the Engine SpeedVary the engine speed during thebreak-in period. This allows theparts to “load” (aiding the matingprocess) and then “unload”(allowing the parts to cool).Although it is essential to placesome stress on the engine com-ponents during break-in, you mustbe careful not to load the enginetoo much.

Allow the Engine Oil to Circulate before RidingAllow enough idling time afterwarm or cold engine start upbefore revving the engine or plac-ing the transmission in gear. Thisallows time for the lubricating oilto reach all critical engine compo-nents.

Observe Your Initial and Most Critical ServiceThe initial service (break-in main-tenance) is the most importantservice your motorcycle willreceive. During break-in opera-tion, all of the engine componentswill have mated together andseated. Maintenance required aspart of the initial service includescorrection of all adjustments,tightening of all fasteners andreplacement of dirty oil. Timelyperformance of this service willhelp make sure you get the bestservice life and performance fromthe engine.

Up to 20 hours

Below 4/5 throttle


4-3

INSPECTION BEFORE RIDING Check the condition of the motor-cycle to help make sure that youdo not have mechanical problemswhen your youngster rides.Before your youngster rides themotorcycle, be sure to check thefollowing items. Be sure yourmotorcycle is in good condition forthe personal safety of the riderand protection of the motorcycle.

WARNINGFailure to inspect and maintainyour motorcycle properlyincreases the chance of anaccident or equipment dam-age.

Always perform a pre-rideinspection before each ride.Refer to the table for checkitems. For further details, referto the INSPECTION AND MAIN-TENANCE section.

WARNINGUsing worn, improperlyinflated, or incorrect tires willreduce stability and can causean accident.

Follow all instructions in theTIRES section in this owner’smanual.

WARNINGChecking maintenance itemswhen the engine is running canbe hazardous. You could beseverely injured if your handsor clothing get caught in mov-ing parts.

Shut the engine off when per-forming maintenance checks,except when checking theengine stop switch and throt-tle.


4-4

WHAT TO CHECK CHECK FOR

Steering • Smoothness• No restriction of movement• No play or looseness

Brakes • Proper pedal and lever play

• No dragging• Brake shoe wear

Tires • Proper pressure• Enough tread depth• No cracks, rips or other

damage

Fuel tank • Enough fuel for the planned run

• Tank cap fastened securely

Engine stop switch

Proper operation

Engine oil Enough amount

Transmission oil

Correct level

Throttle • Proper play• Smooth response• Quick return to idle

position

Gearshift lever

• No damage• Smooth operation

Drive chain • Proper tension• Adequate lubrication• No excessive wear or

damage

General condition

• Bolts and nuts tightness• No rattle from any parts of

machine with the engine running

• No visible evidence of damage


5

5-1

RIDING TIPS

STARTING THE ENGINE .................................................................................... 5-2STARTING A COLD ENGINE ............................................................................. 5-2STARTING A WARM ENGINE ............................................................................ 5-3STARTING OFF AND SHIFTING ........................................................................ 5-5STOPPING AND PARKING ................................................................................ 5-6


5-2

RIDING TIPS

STARTING THE ENGINEBefore attempting to start theengine, make sure:

1. Turn the fuel valve lever fromOFF to ON.

2. Shift to NEUTRAL.

STARTING A COLD ENGINE

3. Push the choke lever down asfar as it will go.

4. Close the throttle grip com-pletely.


5-3

5. Kick the kick starter lever tostart the engine and, if thisfails to fire up, kick again. If 3rdor 4th kick fails, then pull backchoke lever to original position,open throttle wide (by turningthe grip all the way), and kickagain.

6. Upon firing up, run the enginefor 30 to 60 seconds.

7. This 30-to-60 seconds idlingwarms up the engine. Now pullthe choke lever up to its origi-nal position.

STARTING A WARM ENGINE

1. Do not use the choke lever ona warm engine.

2. Open throttle partially (1/8 – 1/4).

3. Kick the kick starter lever.(Engine will fire up).


5-4

WARNINGAn improperly retracted kickstarter lever can interfere withrider control.

Be sure the kick starter lever isreturned to its home positionafter starting the engine.

WARNINGRunning the engine indoors orin a garage can be hazardous.Exhaust gas contains carbonmonoxide, a gas that is color-less and odorless and cancause death or severe injury.

Only run the engine outdoorswhere there is fresh air.

WARNINGThis motorcycle can start mov-ing as soon as you start theengine with the transmission ingear. Unexpected movementcan cause you to lose controlof the motorcycle.

Shift into neutral before youstart the engine.

CAUTIONRunning the engine too longwithout riding may cause theengine to overheat. Overheat-ing can result in damage tointernal engine components.

Shut the engine off if you can-not begin your ride promptly.


5-5

STARTING OFF AND SHIFTING

1. Kick up side stand.2. Apply the front brake.

WARNINGCarrying a passenger cangreatly reduce your ability tobalance and steer this motor-cycle. If you carry a passenger,you can lose control and bothyou and the passenger can beseverely injured.

Never carry a passenger. Thismotorcycle has a long seat soyou can change position tomaneuver the motorcycle.

WARNINGOperating this motorcycle onpublic roads or highways canbe hazardous. This motorcycledoes not meet safety standardsfor use on public roads.

Never operate this motorcycleon any road or highway, even adirt or gravel one. It is illegal tooperate this motorcycle onpublic roads or highway inmany states.

WARNINGRiding this motorcycle atexcessive speed increasesyour chances of losing controlof the motorcycle. This mayresult in an accident.

Always ride within the limits ofyour skills, your motorcycle,and the riding conditions.

WARNINGRemoving your hands from thehandlebars or feet from thefootrests during operation canbe hazardous. If you removeeven one hand or foot from themotorcycle, you can reduceyour ability to control themotorcycle.

Always keep both hands on thehandlebars and both feet onthe footrests of your motorcy-cle during operation.


5-6

3. Push down to shift from NEU-TRAL to DRIVE position.

4. Release the front brake andopen throttle gently.

STOPPING AND PARKING

1. Turn the throttle grip away fromyourself to close the throttlecompletely.

2. Apply the front and rear brakesevenly and at the same time.

WARNINGRiding the motorcycle with theside stand in the down positioncan be hazardous. The sidestand in the down position mayinterfere with rider control dur-ing a left turn.

Check that the side stand isreturned to its full up positionbefore starting off.

WARNINGShifting into DRIVE at too highengine speed can be hazard-ous. The motorcycle may lurchforward, and this unexpectedmovement can cause you tolose control of the motorcycle.

Shut off the throttle completelyand apply the front brakebefore shifting into DRIVE.


5-7

3. Attempting to slow down byusing one brake alone is haz-ardous, particularly brakingthe front wheel alone. Thefront wheel may slide out (frontwheel braking) or the rearwheel might skid sidewise(rear wheel braking).

4. Shift into NEUTRAL justbefore the motorcycle stops.

WARNINGInexperienced riders tend tounderutilize the front brake.This can cause excessive stop-ping distance and lead to a col-lision. Using only the front orrear brake can cause skiddingand loss of control.

Apply both brakes evenly andat the same time.

WARNINGHard braking while turning maycause wheel skid and loss ofcontrol.

Brake before you begin to turn.

WARNINGHard braking on wet, loose,rough, or other slippery sur-faces can cause wheel skidand loss of control.

Brake lightly and with care onslippery or irregular surfaces.


5-8

5. Park the motorcycle on a firm,flat surface where it will not fallover by using the side stand.

6. Press and hold the enginestop switch until the enginestops.

7. Turn the fuel valve lever to the“OFF” position.

ADVICE TO THE PARENT:It takes some time for engine andmuffler to cool off after a long ride.Warn the young rider of the haz-ard: a number of adults haveburned their hands by touching ahot engine or muffler.

ON

OFF


Park the motorcycle wherepedestrians or children are notlikely to touch the muffler.

CAUTIONThe motorcycle can roll off theside stand if it is parked withthe front end facing down anincline.

Park the motorcycle on firm,level ground to help prevent itfrom falling over. If you mustpark on an incline, aim thefront of the motorcycle uphill toreduce the possibility of rollingoff the side stand.


6-1

6


MODIFICATION ................................................................................................... 6-3


6-2


There are a great variety ofaccessories available to Suzukiowners. Suzuki can not havedirect control over the quality orsuitability of accessories you maywish to purchase. The addition ofunsuitable accessories can leadto unsafe operating conditions. Itis not possible for Suzuki to testeach accessory on the market orcombinations of all the availableaccessories; however, your dealercan assist you in selecting qualityaccessories and installing themcorrectly.

Use extreme caution when select-ing and installing the accessoriesfor your Suzuki. We have devel-oped some general guidelineswhich will aid you when decidingwhether, and how to equip yourmotorcycle.

• Any time that additional weightor aerodynamic affectingaccessories are installed, theyshould be mounted as low aspossible, as close to themotorcycle and as near thecenter of gravity as is feasible.The mounting brackets andother attachment hardwareshould be carefully checked toensure that they provide for arigid mount. Weak mounts canallow the shifting of the weightand create a hazardous,unstable condition.

WARNINGImproper accessories or modi-fications can make your motor-cycle unsafe and can lead to anaccident.

Never modify the motorcyclewith improper or poorlyinstalled accessories. Followall instructions in this owner’smanual regarding accessoriesand modifications. Use genu-ine SUZUKI accessories orequivalent designed and testedfor your motorcycle. Consultyour SUZUKI dealer if you haveany questions.


6-3

• Inspect for proper groundclearance and bank angle.Improperly mounted loadcould critically reduce thesetwo safety factors. Also deter-mine that the load does notinterfere with the operation ofthe suspension, steering orother control operations.

• Accessories fitted to the han-dlebars or the front fork areacan create serious stabilityproblems. This extra weightwill cause the motorcycle to beless responsive to your steer-ing control. The weight mayalso cause oscillations in thefront end and lead to instabilityproblems. Accessories addedto the handlebars or front forkof the machine should be aslight as possible and kept to aminimum.

• Certain accessories displacethe rider from his or her normalriding position. This limits thefreedom of movement of therider and may limit control abil-ity.

• Additional electrical accesso-ries may overload the existingelectrical system. Severe over-loads may damage the wiringharness or create a hazardoussituation due to the loss ofelectrical power during theoperation of the motorcycle.

If any load is to be carried on themotorcycle, mount it as low aspossible and as close as possibleto the machine. An improperlymounted load can create a highcenter of gravity which is veryhazardous and makes the motor-cycle difficult to handle. The sizeof the load can also affect theaerodynamics of the motorcycle.Balance the load between the leftand right sides of the motorcycleand fasten it securely.

MODIFICATIONModification of the motorcycle, orremoval of original equipmentmay render the motorcycle unsafeor illegal. Obey all applicableequipment regulations in yourarea.



7-1

7


MAINTENANCE SCHEDULE .............................................................................. 7-2GENERAL LUBRICATION .................................................................................. 7-4AIR CLEANER ..................................................................................................... 7-5SPARK PLUG ...................................................................................................... 7-8CARBURETOR .................................................................................................. 7-10FUEL HOSE ....................................................................................................... 7-11TRANSMISSION OIL ......................................................................................... 7-12DRIVE CHAIN .................................................................................................... 7-13BRAKES ............................................................................................................ 7-16TIRES ................................................................................................................. 7-18SPARK ARRESTER .......................................................................................... 7-20


7-2


MAINTENANCE SCHEDULEIt is very important to inspect andmaintain your motorcycle regu-larly. Follow the guidelines in thechart. The intervals between peri-odic services in months areshown. At the end of each inter-val, be sure to perform the main-tenance listed.

NOTE: The MAINTENANCECHART specifies the minimumrequirements for maintenance. Ifyou use your motorcycle undersevere conditions, perform main-tenance more often than shown inthe chart. If you have any ques-tions regarding maintenanceintervals, consult your SUZUKIdealer or qualified mechanic.

WARNINGImproper maintenance or fail-ure to perform recommendedmaintenance increases thechance of an accident ormotorcycle damage.

Always follow the inspectionand maintenance recommen-dations and schedules in thisowner’s manual. Ask yourSUZUKI dealer or qualifiedmechanic to do the mainte-nance items marked with anasterisk (*). You may performthe unmarked maintenanceitems by referring to theinstructions in this section, ifyou have mechanical experi-ence. If you are not sure how todo any of the jobs, have yourSUZUKI dealer or qualifiedmechanic do them.

WARNINGRunning the engine indoors orin a garage can be hazardous.Exhaust gas contains carbonmonoxide, a gas that is color-less and odorless and cancause death or severe injury.

Only run the engine outdoorswhere there is fresh air.

CAUTIONUsing poor quality replacementparts can cause your motorcy-cle to wear more quickly andmay shorten its useful life.

Use only genuine Suzukireplacement parts or theirequivalent.


7-3

MAINTENANCE CHART

NOTE: I= Inspect and clean, adjust, replace or lubricate if necessary,C= Clean, R= Replace, T= Tighten

IntervalInitial 1 month Every 3 months Every 6 months

Item

* Cylinder head and cylinder – – C

* Cylinder head nuts T – T

Spark plug – I R

Air cleaner element C C C

Carburetor I – I

Fuel lineI I I

*Replace every 4 years

Transmission oil R – R

Drive chain Clean, lubricate and inspect each time the motorcycle is ridden

* Steering I – I

* Brakes I I I

Tire I I I

Spark arrester – C C

* Chassis bolts and nuts T – T


7-4

GENERAL LUBRICATIONProper lubrication is important forsafe, smooth operation and a longlife for your motorcycle. Be surethat all lubrication is performedduring periodic maintenance onthe motorcycle. Increase fre-quency when your motorcycle isused in severe conditions.

1Throttle grip2Front brake lever holder3Front brake cable4Side stand pivot and spring

hook5Brake pedal arm pivot

...Motor oil ...Grease


7-5

AIR CLEANERThe air cleaner element must bekept clean to provide good enginepower and gas mileage. If youryoungster uses the motorcycleunder normal low-stress condi-tions, you should service the aircleaner at the intervals specified.If your youngster rides in dusty,wet, or muddy conditions, you willneed to inspect the air cleanerelement much more frequently.Use the following procedure toremove the element and inspectit.

WARNINGOperating the engine withoutthe air cleaner element in placecould allow a flame to spit backfrom the engine to the aircleaner, or could allow dirt toenter the engine. This couldcause a fire or severe enginedamage.

Never run the engine withoutthe air cleaner element prop-erly installed.

CAUTIONClean or replace the air cleanerelement frequently if the motor-cycle is used in dusty, wet ormuddy conditions. The aircleaner element will clog underthese conditions, and this maycause engine damage, poorperformance, and poor fueleconomy.

Clean the air cleaner case andelement immediately if watergets in the air cleaner box.


7-6

Air Cleaner Element Removal

1. Remove the cleaner cap.2. Take out the element.

Washing the ElementWash the element as follows:

1. Fill a wash pan larger than theelement with a non-flammablecleaning solvent A. Dip theelement in the solvent andwash it.

2. Squeeze the element bypressing it between the palmsof both hands to remove theexcess solvent. Do not twist orwring the element or it willdevelop cracks.

3. Dry the element.4. Fill a wash pan larger than the

element with motor oil B. Dipthe element in the oil.

5. Squeeze the element toremove excess oil.

CAUTIONA torn air cleaner element willallow dirt to enter the engineand can damage the engine.

Carefully examine the aircleaner element for tears dur-ing cleaning. Replace it with anew one if it is torn.


7-7

6. Clean any dirt or debris frominside the air cleaner case. Besure no dirt enters the carbure-tor.

7. Reinstall the cleaner elementin reverse order of removal. Besure that the element issecurely in position and isproperly sealed.

NOTE: Recycle or properly dis-pose of used oil and solvent.

WARNINGNew and used oil and solventcan be hazardous. Childrenand pets may be harmed byswallowing new or used oil orsolvent. Repeated, prolongedcontact with used engine oilmay cause skin cancer. Briefcontact with used oil or solventmay irritate skin.

• Keep new and used oil andsolvent away from childrenand pets.

• Wear a long-sleeve shirt andwaterproof gloves.

• Wash with soap if oil or sol-vent contacts your skin.

CAUTIONFailure to position the aircleaner element properly canallow dirt to bypass the aircleaner element. This willcause engine damage.

Be sure to properly install theair cleaner element.


7-8

SPARK PLUG

1. Extract the spark plug cap.2. Remove the spark plug with

the spark plug wrench pro-vided in the tool kit.

To maintain a hot, strong spark,keep the plug free from carbon.Remove carbon deposits from theplug, and adjust the gap to 0.6 –0.7 mm (0.024 – 0.028 in) forgood ignition. Use a thickness(feeler) gauge to check the gap.

Your motorcycle comes equippedwith NGK BPR4HS or DENSOW14FPR-UL spark plug. To deter-mine if the standard spark plug isright for your usage, check thecolor of the plug’s porcelain cen-ter electrode insulator after motor-cycle operation. A light browncolor indicates that the plug is cor-rect. If the plug tends to overheat(evidenced by whitening of its por-celain), replace it by the otherplug according to the chart below:

CAUTIONDirt can damage your engine ifit enters an open spark plughole.

Cover the spark plug holewhenever the spark plug isremoved.


7-9

Plug Replacement Guide InstallationTo install a spark plug, turn it in asfar as possible with your fingers,then tighten it with a wrench.

Carefully turn the spark plug byhand into the threads until it is fin-ger tight. If the spark plug is new,tighten it with a wrench about 1/2turn past finger tight. If you arereusing the old spark plug, tightenit with a wrench about 1/8 turnpast finger tight.

CAUTIONAn improper spark plug mayhave an incorrect fit or heatrange for your engine. Thismay cause severe engine dam-age which will not be coveredunder warranty.

Use one of the spark plugslisted below or equivalent.Consult your Suzuki dealer orqualified mechanic if you arenot sure which spark plug iscorrect for type of usage.

NGK DENSO REMARKS

BPR4HS W14FPR-UL Standard

BPR5HS W16FPR-UL

To replace standard plug tending to overheat.

CAUTIONA crossthreaded or overtight-ened spark plug will damagethe aluminum threads of thecylinder head.

Follow the procedure below toavoid damage.


7-10

CARBURETORThe carburetor is factoryset forthe best performance. Do notattempt to alter its setting. Thereare two items of adjustment, how-ever, under your care: idle speedand throttle cable play.

Idle Speed AdjustmentThe engine idle speed may beadjusted by turning the throttlevalve adjusting screw 1 and thepilot air adjusting screw 2 in thefollowing procedures.

1. Start the engine and allow it towarm up.

2. After the engine warms up,stop it momentarily. Turn thepilot air adjusting screw 2 allthe way in and then back it out1-1/4 turns.

3. Start the engine again andadjust the throttle valve adjust-ing screw 1 so that the engineruns at the lowest steadyspeed.

4. Turn the pilot air adjustingscrew 2 in or out within 1/4turn from the standard setting(1-1/4 turns) to find the opti-mum position where theengine runs most smoothly.

5. When the idling mixture hasbeen adjusted by turning theair adjusting screw 2, theproper engine idle speed maybe obtained by adjusting thethrottle valve adjusting screw1.

NOTE: In the event that carbure-tor adjustment is required due todifferent altitude or climate condi-tions, take your motorcycle toauthorized SUZUKI dealer.Mechanical malfunctions resultingfrom the owner tampering withcarburetion adjustment will not becovered by the warranty.


7-11

Throttle Cable AdjustmentMeasure the throttle cable play byturning the throttle grip. The throt-tle grip should have 2.0 – 4.0 mm(0.08 – 0.16 in) play.

To adjust the throttle cable play:1. Loosen the lock nut 1.2. Turn the adjuster 2 in or out to

obtain the proper amount ofthrottle grip free play.

3. Tighten the lock nut 1.4. Recheck the throttle cable

play. Readjust it if it is notwithin the correct limits.

FUEL HOSE

Inspect the fuel hose for damageand fuel leakage. If any defectsare found, the fuel hose must bereplaced.

WARNINGInadequate throttle cable playcan cause engine speed to risesuddenly when you turn thehandlebars. This can lead toloss of rider control.

Adjust the throttle cable playso that engine idle speed doesnot rise due to handlebarmovement.


7-12

TRANSMISSION OILThe transmission oil shouldalways be changed when theengine is warm so the oil will draineasily.

To change transmission oil:

1. Place the motorcycle on levelground on its side stand.

2. Remove the oil filler cap 1.3. Remove the drain plug 3 from

the bottom of the engine. Drainthe oil into a drain pan whileholding the motorcycle verti-cally.

4. Reinstall the drain plug 3.5. Remove the oil level screw 2.

6. Pour fresh oil of the specifiedtype through the oil filler holeuntil the oil reaches the oillevel hole. Be sure to checkthe oil level with the motorcy-cle held vertically.

NOTE: Approximately 450 ml (0.5US qt) of oil will be required.

7. Refit the oil level screw and theoil filler cap.

NOTE: Recycle or properly dis-pose of used oil and solvent.

WARNINGNew and used oil and solventcan be hazardous. Childrenand pets may be harmed byswallowing new or used oil orsolvent. Repeated, prolongedcontact with used engine oilmay cause skin cancer. Briefcontact with used oil or solventmay irritate skin.

• Keep new and used oil andsolvent away from childrenand pets.

• Wear a long-sleeve shirt andwaterproof gloves.

• Wash with soap if oil or sol-vent contacts your skin.


7-13

DRIVE CHAINThe condition and adjustment ofthe drive chain should be checkedbefore each use of the motorcy-cle. Always follow the guidelinesbelow for inspecting and servicingthe chain.

Inspecting the Drive ChainWhen inspecting the chain, lookfor the following:• Loose pins• Damaged rollers• Dry or rusted links• Kinked or binding links• Excessive wear• Improper chain adjustment

If you find anything wrong with thedrive chain condition or adjust-ment, correct the problem if youknow how. If necessary, consultyour authorized Suzuki dealer.

Damage to the drive chain meansthat the sprockets may also bedamaged. Inspect the sprocketsfor the following:• Excessively worn teeth• Broken or damaged teeth• Loose sprocket mounting nuts

If you find any of these problemswith your sprocket, consult yourSuzuki dealer.

WARNINGRiding with the chain in poorcondition or improperlyadjusted can lead to an acci-dent.

Inspect, adjust, and maintainthe chain properly before eachride, according to this section.

WARNINGImproperly attached chain jointclip may drop from the chainand cause the chain to comeoff the sprockets or to becaught in the engine. This maycause an accident or severeengine damage.

Be sure to inspect and main-tain the chain before each ride,according to these guidelines.


7-14

Drive Chain Cleaning and OilingClean and oil the chain as follows:1. Wash the chain with kerosene.

Kerosene will lubricate andclean the chain.

2. Allow the chain to dry, thenlubricate the links with Suzukichain lube or an equivalent.

Drive Chain Adjustment

Inspect the drive chain slackbefore each use of the motorcy-cle. The drive chain should beadjusted for 20 – 25 mm (0.8 – 1.0in) of slack, as shown.

WARNINGKerosene can be hazardous.Kerosene is flammable. Chil-dren or pets may be harmedfrom contact with kerosene.

Keep flames and smokingmaterials away from kerosene.Keep children and pets awayfrom kerosene. If swallowed,do not induce vomiting. Call aphysician immediately. Dis-pose of used kerosene prop-erly.

WARNINGToo much chain slack cancause the chain to come off thesprockets, resulting in an acci-dent or serious damage to themotorcycle.

Inspect and adjust the drivechain slack before each use.


7-15

To adjust the drive chain, followthe procedure below:

1. Remove the cotter pin 1 andloosen the axle nut 2.

2. Turn the right and left adjusternuts 3 until the chain has 20 –25 mm (0.8 – 1.0 in) of slackhalfway between the enginesprocket and rear sprocket.

3. At the same time that thechain is being adjusted, therear sprocket must be kept inperfect alignment with the frontsprocket. To assist you in per-forming this procedure, thereare reference marks 4 on theswing arm and each chainadjuster which are to bealigned with each other and tobe used as a reference fromone side to the other.

4. Tighten the axle nut 2securely. Replace the cotterpin with a new one.

5. Recheck the chain slack aftertightening and readjust if nec-essary.

6. Tighten adjusting nuts.7. Check and, as necessary,

readjust the brake pedal playas outlined in page 50. This isbecause adjusting the drivechain as above could alter thepedal play.

Rear axle nut tightening torque:35 N·m (3.5 kgf-m, 25.3 lb-ft)


7-16

BRAKESThis motorcycle is equipped withfront and rear drum brakes.

NOTE: Operating in mud, water,sand, or other extreme conditionscan cause accelerated brakewear. If your youngster operatesthe motorcycle under these condi-tions, the brake must beinspected more often than recom-mend in the MAINTENANCESCHEDULE.

Front Brake AdjustmentThe front brake lever play shouldbe 15 – 25 mm (0.6 – 1.0 in) mea-sured at the brake lever end whenthe lever is lightly pulled intowards the throttle grip. Checkthe play every time before ridingand adjust it if necessary, as fol-lows:

WARNINGFailure to inspect and properlymaintain the brakes increasesyour chance of having an acci-dent.

Inspect the brake systembefore each use according tothe INSPECTION BEFORERIDING section. Follow theMAINTENANCE SCHEDULEsection to maintain your brakesystem.

WARNINGFailure to adjust the front brakelever and rear brake pedal playproperly can lead to an acci-dent or damage your motorcy-cle. If there is too much play,the brakes may not stop themotorcycle when you usethem. This could lead to anaccident. If there is too littleplay, the brake shoes may rubagainst the drums when thebrakes are not applied, causingdamage to the shoes anddrums.

Follow the procedure below toadjust the front brake lever andrear brake pedal.

15 – 25 mm(0.6 – 1.0 in)


7-17

1. Turn the front brake adjuster1 clockwise or counterclock-wise to obtain the specifiedplay. Turning the adjusterclockwise will decrease theplay.

2. After adjusting the play, checkthat there is no dragging whenturning the front wheel with thewheel off the ground and thatthere is enough clearancebetween the front brake leverand throttle grip when the leveris tightly squeezed.

Rear Brake Pedal Adjustment

Adjust the rear brake pedal sothat there is approximately 20 –30 mm (0.8 – 1.2 in) of pedal playas shown in the illustration. Toadjust the rear brake pedal play,turn the adjusting nut 2. Turningthe adjusting nut clockwise willdecrease the amount of travel.

WARNINGRiding with worn brake shoeswill reduce braking perfor-mance and will increase yourchance of having an accident.

Inspect brake shoe wear beforeeach use. Ask your SUZUKIdealer or qualified mechanic toreplace brake shoes if theshoes are worn to the limit.


7-18

TIRES Tire Pressure and LoadingTire pressure and tire loading areimportant factors. Overloadingyour tires can lead to tire failureand loss of motorcycle control.

Check tire pressure each timebefore you ride, according to thetable below. Tire pressure shouldonly be checked and adjustedbefore riding since riding will heatup the tires and lead to higherinflation pressure readings.Under-inflated tires make smoothcornering difficult and can resultin rapid wear. Over-inflated tireshave a smaller amount of tire incontact with the ground, whichcan contribute to skidding andloss of control.

WARNINGFailure to follow these warn-ings may result in an accidentdue to tire failure. The tires onyour motorcycle form the cru-cial link between your motorcy-cle and the road.

Follow these instructions:• Check tire condition and

pressure, and adjust pres-sure before each ride.

• Avoid overloading yourmotorcycle.

• Replace a tire when worn tothe specified limit, or if youfind damage such as cuts orcracks.

• Always use the size and typeof tires specified in thisowner’s manual.

• Balance the wheel after tireinstallation.

• Read this section of owner’smanual carefully.

Front & Rear 150 kPa(1.5 kgf/cm2, 22 psi)


7-19

Tire Condition and TypeTire condition and tire type affectmotorcycle performance. Cuts orcracks in the tires can lead to tirefailure and loss of motorcycle con-trol. Worn tires are susceptible topuncture failures and subsequentloss of motorcycle control. Tirewear also affects the tire profile,changing motorcycle handlingcharacteristics.

Check tire condition each timebefore you ride. Replace tires iftires show visual evidence ofdamage such as cracks or cuts, orif tread depth is less than 4.0 mm(0.16 in).

Whenever you replace a tire, usea tire of the size and type listedbelow. If you use a different sizeor type of tire, motorcycle han-dling may be adversely affected,possibly resulting in loss of motor-cycle control.

Front & Rear

Always balance the wheel afterrepairing a puncture or replacingthe tire. Proper wheel balance isimportant to avoid variable wheel-to-ground contact and to avoiduneven tire wear.

Type CHENG SHIN C-183A

Size 2.50-10 2PR

WARNINGAn improperly repaired,installed, or balanced tire cancause loss of control orshorten tire life.

Ask your SUZUKI dealer orqualified mechanic to performtire repair, replacement, andbalancing because propertools and experience arerequired.


7-20

SPARK ARRESTERThe muffler has a spark arresterwhich must be periodicallycleaned to maintain good effi-ciency. At the intervals shown inthe maintenance chart, clean thespark arrester as follows.

1. Remove the bolts 1.

2. Remove the spark arrester.

3. Use a brush to remove carbondeposits from the sparkarrester screen. Be careful notto damage the spark arresterscreen. Check that the screenhas no holes and breaks.Replace the screen if neces-sary.


Wait until the muffler cools toavoid burns.


8-1

8

TROUBLESHOOTING

FUEL SYSTEM CHECK ...................................................................................... 8-2IGNITION SYSTEM CHECK ................................................................................ 8-3


8-2

TROUBLESHOOTING

This troubleshooting guide is pro-vided to help you find the cause ofsome common complaints.

COMPLAINT: Engine is hard tostart or does not start at all.

Something is probably wrong withthe fuel system or ignition system.

FUEL SYSTEM CHECK1. Make sure there is enough fuel

in the fuel tank.2. Check that the fuel valve is in

the “ON” position.3. Make sure there is enough fuel

reaching the carburetor fromthe fuel valve.a. Turn the fuel valve to the

“OFF” position.b. Loosen the drain screw

located under the carbure-tor. Drain the fuel from thecarburetor into a container.

c. Tighten the drain screw.d. Turn the fuel valve to the

“ON” position for a few sec-onds and then turn it to the“OFF” position.

e. Loosen the drain screw andcheck that the carburetor isfilled back up with fuel.

f. If fuel is reaching the carbu-retor, ignition systemshould be checked next.

CAUTIONFailure to troubleshoot a prob-lem correctly can damage yourmotorcycle. Improper repairsor adjustments may damagethe motorcycle instead of fixingit. Such damage may not becovered under warranty.

If you are not sure about theproper action, consult yourSuzuki dealer about the prob-lem.

WARNINGFuel and fuel vapor are highlyflammable and toxic. You canbe burned or poisoned whenhandling fuel.

When draining the carburetor:• Stop the engine and keep

flames, sparks, and heatsources away.

• Drain fuel only outdoors or ina well-ventilated area.

• Do not smoke.• Wipe up spills immediately.• Avoid breathing fuel vapor.• Keep children and pets away.• Dispose of drained fuel prop-

erly.


8-3

IGNITION SYSTEM CHECK

1. Remove the spark plug andreattach it to the spark pluglead.

2. While holding a spark plugwith its base firmly against theengine, depress the kickstarter lever. If the ignition sys-tem is operating properly, ablue spark should jump acrossthe spark plug gap. If there isno spark, take your machine toyour authorized Suzuki dealer.

COMPLAINT: Engine Stalls1. Make sure there is enough fuel

in the fuel tank.2. Check to see that the spark

plug is not fouled. Remove theplug and clean it. Replace it, ifnecessary.

3. Make sure the fuel valve is notclogged. Also check that theair vent hose connected to thefuel tank is not clogged.

4. Check the idle speed. If neces-sary, adjust it using a tachom-eter. The correct idle speed is1400 – 1600 r/min.

WARNINGPerforming the spark testimproperly can cause a highvoltage electrical shock or anexplosion.

Avoid performing this check ifyou are not familiar with thisprocedure, or if you have aheart condition or wear a pace-maker. Keep the spark plugaway from the spark plug holeduring this test.



9-1

9


PROCEDURE FOR RETURNING TO SERVICE ................................................. 9-3CORROSION PREVENTION ............................................................................... 9-3MOTORCYCLE CLEANING ................................................................................ 9-4INSPECTION AFTER CLEANING ....................................................................... 9-5


9-2


If your motorcycle is to be leftunused for an extended period oftime, it needs special servicingrequiring appropriate materials,equipment and skill. For this rea-son, Suzuki recommends that youtrust this maintenance work toyour Suzuki dealer. If you wish toservice the machine for storageyourself, follow the general guide-lines below:

MOTORCYCLEClean the entire motorcycle.Place the motorcycle on the sidestand on a firm, flat surface whereit will not fall over.

FUELDrain the fuel from the fuel tankusing a commercially availablehand pump or siphon. Drain thefuel from the carburetor using thecarburetor drain screw.

ENGINEDrain the transmission oil com-pletely and refill the transmissionoil all the way up to the filler hole.Cover the air cleaner intake andthe muffler outlet with oily rags toprevent humidity from entering.

TIRESInflate tires to the normal pres-sure.

WARNINGFuel and fuel vapor are highlyflammable and toxic. You canbe burned or poisoned whenhandling fuel.

When draining the fuel:• Stop the engine and keep

flames, sparks, and heatsources away.

• Drain fuel only outdoors or ina well-ventilated area.

• Do not smoke.• Wipe up spills immediately.• Avoid breathing fuel vapor.• Keep children and pets away.• Dispose of drained fuel prop-

erly.


9-3

EXTERNAL1. Spray all vinyl and rubber

parts with rubber protectant.2. Spray unpainted surface with

rust preventative.3. Coat painted surfaces with car

wax.

PROCEDURE FOR RETURNING TO SERVICE1. Clean the entire motorcycle.2. Remove the oily rags from the

air cleaner intake and muffleroutlet.

3. Drain all the transmission oil.Fill the transmission with freshoil as outlined in this manual.

4. Remove the spark plug. Turnthe engine a few times bydepressing the kick starterlever. Reinstall the spark plug.

5. Lubricate all places asinstructed in this manual.

6. Perform the INSPECTIONBEFORE RIDING as listed inthis manual.

7. Start the motorcycle as out-lined in this manual.

CORROSION PREVENTIONIt is important to take good care ofyour motorcycle to protect it fromcorrosion and keep it looking newfor years to come.

Important Information About CorrosionCommon causes of corrosion1. Accumulation of salt, dirt mois-

ture, or chemicals in hard-to-reach areas.

2. Chipping, scratches, and anydamage to treated or paintedmetal surfaces resulting fromminor accidents or impactsfrom stones and gravel.

Salt, sea air, industrial pollution,and high humidity will all contrib-ute to, corrosion.

How to Help Prevent Corrosion1. Wash your motorcycle fre-

quently, at least once a month.Keep your motorcycle as cleanand dry as possible.

2. Remove foreign materialdeposits. Foreign materialsuch as chemicals, tar, treesap, bird droppings and indus-trial fall-out may damage yourmotorcycle’s finish. Removethese types of deposits asquickly as possible. If thesedeposits are difficult to washoff, an additional cleaner maybe required. Follow the manu-facturer’s directions whenusing these special cleaners.


9-4

3. Repair finish damage as soonas possible Carefully examine your motor-cycle for damage to thepainted surfaces. Should youfind any chips or scratches inthe paint, touch them upimmediately to prevent corro-sion from starting. If the chipsor scratches have gonethrough to the bare metal,have a Suzuki dealer make therepair.

4. Store your motorcycle in a dry,well-ventilated area If you often wash your motor-cycle in the garage or if youfrequently park it inside whenwet, your garage may bedamp. The high humidity maycause or accelerate corrosion.A wet motorcycle may corrodeeven in a heated garage if theventilation is poor.

5. Cover your motorcycle Exposure to mid-day sun cancause the colors in paint andplastic parts to fade. Coveringyour motorcycle with a high-quality, “breathable” motorcy-cle cover can help protect thefinish from the harmful UV raysin sunlight, and can reduce theamount of dust and air pollu-tion reaching the surface. YourSuzuki dealer can help youselect the right cover for yourmotorcycle.

MOTORCYCLE CLEANINGWashing the MotorcycleWhen washing the motorcycle,follow the instructions below:1. Remove dirt and mud from the

motorcycle with running water.You may use a soft sponge orbrush. Do not use hard materi-als which can scratch thepaint.

2. Wash the entire motorcyclewith a mild detergent or carwash soap using a sponge orsoft cloth. The sponge or clothshould be frequently soaked inthe soap solution.

NOTE: Avoid spraying or allowingwater to flow over the followingplaces:• Ignition switch• Spark plug• Fuel tank cap• Carburetor

3. Once the dirt has been com-pletely removed, rinse off thedetergent with running water.

4. After rinsing, wipe off themotorcycle with a wet chamoisor cloth and allow it to dry inthe shade.

5. Check carefully for damage topainted surfaces. If there isany damage, obtain “touch-up”paint and “touch-up” the dam-age.


9-5

Waxing the MotorcycleAfter washing the motorcycle,waxing is recommended to furtherprotect and beautify the paint.Observe the precautions speci-fied by the wax manufacturer.

INSPECTION AFTER CLEANINGFor extended life of your motorcy-cle, lubricate according to “GEN-ERAL LUBRICATION” section.

Follow the procedures in the“INSPECTION BEFORE RIDING”section to check your motorcyclefor any problems that may havearisen during your last ride.

WARNINGWet brakes can cause poorbraking performance and maylead to an accident.

Avoid a possible accident byexpecting longer stopping dis-tances after washing yourmotorcycle. Apply brakes sev-eral times to let heat dry thebrake pads or shoes.



10

10-1


TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...................... 10-2SERIAL NUMBER LOCATION .......................................................................... 10-3LOCATION OF LABELS ................................................................................... 10-3


10-2


TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITEDFederal law prohibits the followingacts or the causing thereof;1. The removal or rendering in-

operative by any person otherthan for purposes of mainte-nance, repair, or replacement,of any device or element ofdesign incorporated into anynew vehicle for the purpose ofnoise control prior to its sale ordelivery to the ultimate pur-chaser or while it is in use, or

2. The use of the vehicle aftersuch device or element ofdesign has been removed orrendered inoperative by anyperson.

Among those acts presumed toconstitute tampering are the actslisted below:• Removing or puncturing the

muffler, baffles, header pipes,screen type spark arrester (ifequipped) or any other compo-nent which conducts exhaustgases.

• Replacing the exhaust systemor muffler with a system ormuffler not marked with thesame model specific code asthe code listed on the Motorcy-cle Noise Emission ControlInformation label, and certifiedto appropriate EPA noise stan-dards.

• Removing or puncturing the aircleaner case, air cleanercover, baffles, or any othercomponent which conductsintake air.

Whenever replacing parts on yourmotorcycle, Suzuki recommendsthat you use genuine Suzukireplacement parts or their equiva-lent.


10-3

SERIAL NUMBER LOCATIONYou need to know the frame andengine serial numbers to get titledocuments for your motorcycle.You also need these numbers tohelp your dealer when you orderparts.

The frame number 1 is stampedon the steering head tube. Theengine serial number 2 isstamped on the left side of thecrankcase assembly.

Write down the serial numbershere for your future reference.

LOCATION OF LABELSRead and follow all of the warn-ings labeled on your motorcycle.Make sure you and your childunderstand all of the labels. Keepthe labels on your motorcycle. Donot remove them for any reason.

Frame No.:

Engine No.:


10-4

1

2

3









fully.

WARNINGDo not touch hot muffler.



SPECIFICATIONS

DIMENSIONS AND DRY MASSOverall length ..................................................1245 mm (49.0 in)Overall width.................................................... 595 mm (23.4 in)Overall height .................................................. 730 mm (28.7 in)Wheelbase ...................................................... 860 mm (33.9 in)Ground clearance............................................ 115 mm (4.5 in)Dry mass ......................................................... 38 kg (84 lbs)

ENGINEType.................................................................Two-stroke, Air-cooledIntake system ..................................................Piston valveNumber of cylinder ..........................................1Bore Stroke .....................................................41.0 mm (1.614 in) × 37.8 mm (1.488 in)Displacement...................................................49 cm3 (3.0 cu. in)Corrected compression ratio ...........................5.6 : 1Carburetor .......................................................MIKUNI VM12, singleAir cleaner .......................................................Polyurethane foam elementStarter system .................................................KickLubrication system ..........................................SUZUKI CCI

TRANSMISSIONClutch ..............................................................Wet multi-plate, Automatic, Centrifugal typeGearshift pattern .............................................1-down, 1-up Transmission ...................................................Single-speed constant meshPrimary reduction ratio ....................................2.650 (53/20)Final reduction ratio.........................................2.153 (28/13)Gear ratio ........................................................2.230 (29/13)Drive chain ......................................................DID 420, 78 links

CHASSISFront suspension .............................................Telescopic, coil springRear suspension .............................................Swingarm, coil springSteering angle .................................................45° (right & left)Caster..............................................................25° 00’Trail ..................................................................37 mm (1.46 in)Turning radius..................................................1.3 m (4.3 ft)Front brake ......................................................Drum brakeRear brake.......................................................Drum brakeFront tire size...................................................2.50-10 2PRRear tire size ...................................................2.50-10 2PR

ELECTRICALIgnition type .....................................................Electronic ignition (CDI)Spark plug .......................................................NGK BPR4HS or DENSO W14FPR-UL

CAPACITIESFuel tank.......................................................... 2.0 L (0.5 US gal)Engine oil tank................................................. 0.3 L (0.3 US qt)Transmission oil ...............................................450 ml (0.5 US qt)



INDEX

AAIR CLEANER ....................... 7-5

BBRAKES............................... 7-16BREAK-IN .............................. 4-2

CCARBURETOR .................... 7-10CHOKE LEVER...................... 3-9CLOTHING............................. 1-4CORROSION PREVENTION........................ 9-3

DDRIVE CHAIN ...................... 7-13

EENGINE OIL........................... 2-3ENGINE OIL LEVEL............... 3-8

FFUEL ...................................... 2-2FUEL HOSE......................... 7-11FUEL SYSTEM CHECK......... 8-2FUEL TANK CAP ................... 3-6FUEL VALVE.......................... 3-7

GGEARSHIFT LEVER............ 3-10GENERAL LUBRICATION..... 7-4

IIGNITION SYSTEM CHECK ...................................8-3INSPECTION AFTER CLEANING .............................9-5INSPECTION BEFORE RIDING ...................................4-3

KKICK STARTER LEVER.........3-9

LLEFT HANDLEBAR................3-5LOCATION OF LABELS.......10-3LOCATION OF PARTS ..........3-2

MMAINTENANCE SCHEDULE ............................7-2MODIFICATION .....................6-3MOTORCYCLE CLEANING .............................9-4

OOPERATING SKILL................1-2

PPOWER REDUCTION PLATE ..................................3-11POWER REDUCTION PLATE REMOVAL INSTRUCTIONS...................3-11PROCEDURE FOR RETURNING TO SERVICE..........................9-3


RREAR BRAKE PEDAL ......... 3-10RIGHT HANDLEBAR ............. 3-5

SSEAT HEIGHT ADJUSTMENT ..................... 3-13SERIAL NUMBER LOCATION........................... 10-3SIDE STAND........................ 3-10SPARK ARRESTER............. 7-20SPARK PLUG ........................ 7-8STARTING A COLD ENGINE.................................. 5-2STARTING A WARM ENGINE.................................. 5-3STARTING OFF AND SHIFTING............................... 5-5STARTING THE ENGINE ...... 5-2STOPPING AND PARKING... 5-6

TTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ....................... 10-2THROTTLE LIMITER ............. 3-5TIRES................................... 7-18TRANSMISSION OIL .....2-3,7-12

Total page:88



This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

California Proposition 65 Warning

WARNINGEngine exhaust, some of its constituents, and certain product com-ponents contain or emit chemicals known to the State of Californiato cause cancer and birth defects or other reproductive harm.

This vehicle is not subject to the phased-in emission standards and related requirements for model year 2006 [off-highway motorcycles or all-terrain vehicles] applicable under 40 CFR 1051.

No.1062 JR50 99011-04493-03A 2/1 BLACK 4 mm

99011-04493-03AJR

50

Part No. 99011-04493-03AJune, 2005 ENTKK6

JR50

Printed in Taiwan300 TAKATSUKA, HAMAMATSU, JAPAN

OWNER’S MANUALThis owner’s manual containsimportant safety information.Please read it carefully.









fully.

No.1062 JR50 99011-04493-03A 2/1 DIC184(TDP006) 4 mm

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