Suzuki A50 User Manual

Overview of the Suzuki A50 & AS50 as sport models with excellent performance.

Details the scope of the service guide, focusing on engine overhaul and limited inspection/adjustment details.

Specifications for motorcycle dimensions, weight, and tire sizes.

Technical details of the engine, including type, dimensions, displacement, and performance metrics.

Details on the fuel system components, including carburetor model and fuel tank capacity.

Specifications for the lubrication system, including oil types and capacities.

Details on the ignition system components, including type, timing, and spark plug.

Specifications for the transmission system, including clutch type, gearbox, and gear shifting mechanism.

Detailed gear ratios for all speeds and overall reduction ratios.

Specifications for the front and rear suspension systems.

Specifications related to the steering system, including angles and turning radius.

Specifications for the front and rear brake systems.

Details on the motorcycle's electrical components, including battery, fuse, and lighting specifications.

Comprehensive list of specialized tools required for servicing the motorcycle.

Guidance on the break-in period for new motorcycles, including speed limits.

Recommendations for fuel and oil types for the A50, including specific 2-stroke oil brands.

Advice on the importance of using genuine Suzuki parts for optimal performance and reliability.

Procedures for inspecting, adjusting, and repairing engine parts while the engine remains mounted in the frame.

Tasks that require the engine to be removed from the frame and the crankcase separated.

Step-by-step guide on how to safely remove the engine from the motorcycle frame.

Step-by-step procedures for dismantling the engine components.

Procedure for removing the cylinder head and cylinder from the engine.

Method for safely removing the piston pin and circlip from the piston.

Steps for removing the flywheel rotor, stator, and related components from the engine.

Procedure for removing the oil pump and its associated oil lines.

Instructions for removing the crankcase right cover.

Steps for disassembling and removing clutch components like springs, plates, and housing.

Procedures for removing the clutch release mechanism and kick starter components.

Steps for dismantling the gear shifting cam stopper, cam guide, and shaft.

Instructions for removing the gear shifting cam guide and the primary pinion.

Procedure for removing keys from the crankshaft to prevent loss.

Steps for removing the outer valve seat and primary pinion spacer.

Instructions for removing the valve plate and valve guide.

Information on removing the inner valve seat, noting it's often unnecessary.

Procedures for separating the crankcase halves and removing the crankshaft.

Techniques for safely removing oil seals from the crankcase.

Method for removing shrink-fitted bearings from the crankcase using heat.

Step-by-step procedures for reassembling the engine after inspection or repair.

Instructions for installing crankshaft bearings into the crankcase, including proper orientation.

Guidance on installing crankshaft and gearbox components into the crankcase right half.

Procedures for installing circlips and thrust washers on the counter shaft and driveshaft.

Steps for routing oil lines and applying oil to parts before joining crankcases.

Process for applying sealer to crankcase joining surfaces and securing the halves.

Guidance on installing oil seals with grease and checking shaft rotation.

Instructions for tightening crankcase screws in a criss-cross pattern to prevent warping.

Method for installing the inner valve seat, including screw tightening and thread lock use.

Procedure for installing the valve plate, ensuring correct alignment and smooth movement.

Instructions for installing the O-ring and outer valve seat, including the primary pinion spacer.

Method for installing the gear shifting shaft return spring.

Procedure for installing the kick starter shaft return spring.

Guidance on setting clutch springs on the clutch sleeve hub.

Instructions for assembling the clutch housing, sleeve hub, and thrust washers.

Method for installing clutch steel and cork plates in the correct sequence.

Ensuring correct alignment of the clutch pressure plate with the clutch sleeve hub.

Procedure for installing the engine sprocket spacer on the driveshaft, avoiding oil seal damage.

Instructions for installing the oil pump, ensuring the driving piece is correctly fitted.

Guidance on cleaning and installing piston rings, noting orientation and locating pins.

Procedure for installing the piston, emphasizing correct orientation based on the arrow mark.

Instructions for installing the cylinder head and tightening the nuts diagonally.

Explanation of the driving mechanism for the oil pump, including gear teeth counts and reduction ratios.

Detailed description of the oil pump's internal workings, including plunger movement and port operation.

Explanation of how throttle opening controls the oil pump's discharge rate.

Graph illustrating the relationship between control lever angle and the amount of oil pumped.

Detailed specifications for the carburetor fitted to the AS50 model.

Detailed specifications for the carburetor fitted to the A50 model, including regional variations.

A numbered list of components within the transmission system with their specifications.

Explanation of how pinions and gears engage for each speed (Neutral, Low, Second, Third).

Explanation of gear engagement for Fourth and Top speeds.

Overview of the gear shifting mechanism and its operation.

Guidance on operating the gear shifting lever for different gear changes.

Description of the gear shifting cam and its grooves for five-speed transmission.

Specifications for inspecting the cylinder head for warpage on the joining surface.

Specifications for cylinder wear and piston-to-cylinder clearances.

Specification for measuring wear on the piston pin.

Specifications for piston ring width, wear, and open end gap.

Specification for measuring piston diameter above the bottom.

Specifications for checking crankshaft and con-rod small end shake.

Specification for measuring the outside diameter of the clutch housing spacer.

Specification for checking and adjusting axial play in the clutch housing.

Specification for measuring backlash between the primary pinion and gear.

Specifications for clutch plate thickness and warp.

Specification for checking warpage of the intake valve plate.

Specification for measuring the free length of the clutch spring.

Specification for measuring the free length of the gear shifting pawl return spring.

Specification for measuring the free length of the gear shifting cam stopper spring.

Specification for measuring the inside diameter of the drive shaft bushing.

Specifications for flywheel magneto primary coil and lighting coil resistance.

Specifications for lighting and charging capacity under various conditions.

Specifications for ignition performance, adjustable spark timing, and contact point gap.

Procedure to measure the resistance of the ignition coil's primary coil.

Method for measuring and adjusting the spark plug gap.

Procedure to check the conductivity of the rectifier in both directions.

Procedure for adjusting the oil pump control cable for proper operation.

Steps for adjusting the carburetor's idle circuit, including throttle valve and pilot air screws.

Guidance on adjusting carburetor part-throttle circuits to correct rich or lean mixture symptoms.

Procedure for adjusting the fuel level in the carburetor by modifying the float height.

Method for adjusting ignition timing using aligning marks on the flywheel rotor and crankcase.

Procedure for adjusting the volume of the horn using an adjusting screw.

Method for adjusting the brake lamp switch to ensure proper activation timing.

Procedure for adjusting the drive chain tension, specifying deflection limits.

Instructions for adjusting front and rear brakes, including cable and rod travel.

Methods for adjusting the clutch using both the cable adjuster and release adjusting screw.

Specifications for recommended tire pressures for front and rear tires under different riding conditions.

Table listing specified tightening torque values for various bolts, nuts, and screws.

Troubleshooting steps for engine starting issues related to fuel supply to the carburetor.

Troubleshooting steps for engine starting issues related to spark plug and ignition system.

Troubleshooting steps for engine starting issues related to compression.

Diagnosis and causes for abnormal noises originating from the engine.

Common causes and checks for engine overheating, including oiling system and cooling fins.

Further checks for engine overheating related to compression, carbon deposits, and piston rings.

Troubleshooting engine overheating related to clutch operation, ignition timing, and fuel mixture.

Troubleshooting steps for clutch slippage and dragging issues.

Diagnosis and solutions for problems with gear engagement and gear shifting.

Troubleshooting for the gear shifting lever not returning to its normal position.

Diagnosis for gears disengaging while the motorcycle is running.

Troubleshooting for stiff handlebars and instability issues.

Troubleshooting for wheel trueness, hub bearings, spokes, and frame alignment.

Chart listing recommended intervals for engine maintenance tasks like inspecting the battery and spark plug.

Chart listing recommended intervals for chassis maintenance tasks like drive chain and brake inspection.

Chart detailing lubrication intervals for various components like cables, gearboxes, and bearings.

Schematic diagram illustrating the electrical connections of the motorcycle's components.

Key explaining the color coding used for wires in the wiring diagram.