Suzuki AY50 - Carburetor AY50 W and AY50 WR

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Foreword2
Group Index2
Component Parts and Work to be Done3
How to Use this Manual3
To Locate What You Are Looking for3
Symbol4
Contents5
General Information5
General Precautions6
Warning/Caution/Note6
Fuel, Oil and Engine Coolant Recommendations8
Serial Number Location8
Suzuki AY50V/50WV ('97-Model) View8
Anti-Freeze and Distilled Water9
Break-In Procedures9
Coolant Mixture Ratio9
Information Labels10
Specifications AY5011
Specifications AY50W12
Country or Area13
Periodic Maintenance14
Periodic Maintenance Chart15
Periodic Maintenance Schedule15
Lubrication Points16
Battery17
Maintenance and Tune-Up Procedures17
Air Cleaner18
Cylinder Head and Cylinder19
Spark Plug19
Fuel Line20
Throttle Cable Play20
Cooling System (for AY50W)21
Engine Coolant Change21
Engine Coolant Level Check21
Final Gear Oil22
Front Brake Fluid Level23
Front Brake Pads23
Air Bleeding the Brake Fluid Circuit24
Brake Shoe Wear25
Front Fork25
Rear Brake Lever Play25
Steering25
Rear Suspension26
Tire Tread Condition26
Chassis Bolts and Nuts27
Cylinder Head Nuts and Exhaust Pipe Bolt and Nut27
Automatic Clutch Inspection29
Clutch "Lock-Up" Inspection29
Initial Engagement Inspection29
Engine30
Engine Center31
Engine Components Removable with the Engine in Place31
Engine Left Side31
Engine Right Side31
Engine Removal32
Engine Reinstallation34
Engine Disassembly35
Engine Components Inspection and Service43
Rear Axle Shaft Bearing43
Right Driveshaft Bearing and Idle Shaft Bearing43
Left Driveshaft Bearing44
Right Crankshaft Bearing44
Left Crankshaft Bearing45
Oil Seals45
Crankshaft Oil Seals46
Drive Shaft Oil Seal46
Rear Axle Shaft Oil Seal46
Engine Mounting Bushings47
Clutch Shoe/Movable Driven Face49
Disassembly49
Clutch Shoes51
Driven Face Spring51
Driven Face Pins and Oil Seals52
Reassembly52
Movable Drive Face53
Roller and Sliding Surface53
Cylinder Head54
Drive Belt54
Carbon Removal55
Piston Diameter55
Piston-Cylinder Clearance55
Piston Pin Bore56
Piston Pin O.D.56
Piston Rings56
Condition of the Big End Bearing57
Conrod Small End I.D.57
Crankshaft Runout57
Reed Valve58
Crankshaft59
Engine Reassembly59
Crankcase60
Rear Axle Shaft and Transmission61
Starter Pinion and Starter Gear64
Movable Drive65
Kick Starter67
Piston68
Magneto69
Oil Pump Driven Gear69
Fuel and Lubrication System70
Fuel Valve71
Fuel Tank and Oil Tank72
Fuel Tank and Oil Tank Cushions73
Remounting73
Carburetor74
Needle Valve Inspection77
Float Height Adjustment78
Reassembly and Remouting78
Air Bleeding79
Checking Oil Pump79
Oil Pump79
Cooling System (AY50W)80
Cooling System81
Description81
Engine Coolant82
Radiator and Engine Coolant Reservoir83
Radiator Removal83
Engine Coolant Reservoir Removal84
Installation84
Radiator Hoses Inspection84
Radiator Inspection84
Engine Coolant Temperature85
Inspection85
Removal and Disassembly86
Water Pump86
Chassis90
Leg Shield and Frame Covers91
Leg Shield Removal92
Frame Cover Removal93
Leg Shield and Frame Cover Remounting93
Front Wheel94
Inspection and Disassembly95
Speedometer Gearbox Dust Seal95
Wheel Bearings95
Front Axle96
Reassembly and Remounting96
Wheel96
Brake Disc97
Speedometer Gearbox97
Front Brake98
Brake Fluid Replacement99
Brake Pads Replacement99
Brake Caliper Removal and Disassembly100
Brake Caliper Inspection101
Brake Caliper Reassembly and Remounting102
Brake Disc Inspection103
Master Cylinder Removal and Disassembly103
Master Cylinder Inspection104
Master Cylinder Reassembly and Remounting105
Front Suspension106
Bushings108
Damper and Spring108
Fork Spring108
Bushing109
Circlip109
Stopper Ring109
Handlebar Covers/Speedometer Cover110
Steering Stem112
Steel Ball115
Steering Stem Nut115
Rear Wheel and Brake117
Brake Drum118
Rear Shock Absorber118
Brake Shoe119
Tire and Wheel120
Tire Removal120
Valve Inspection122
Tire Installation123
Valve Installation123
Electrical System125
Cautions in Servicing126
Connector126
Coupler126
Semi-Conductor Equipped Part126
Connecting the Battery127
Using the Pocket Tester128
Location of Electrical Components129
Charging and Lighting System130
Charging Output Check131
Regulator/Rectifier132
Stator Coil132
Starter System133
Armature Coil135
Carbon Brush135
Commutator135
Starter Motor Inspection135
Starter Relay Inspection136
Ignition System137
CDI/Ignition Coil Inspection138
Checking with the Suzuki Pocket Tester138
Pick-Up Coil139
Speedometer139
Fuel Level Gauge Inspection140
Fuel Meter Inspection140
Oil Level Indicator Switch141
Thermoelement and Carburetor Heater141
Carburetor Heater Inspection (P-02 Only)142
Carburetor Thermo-Switch Inspection (P-02 Only)142
Wire Color143
Battery (for P-53)144
Filling Electrolyte144
Initial Charging144
Recharging Operation145
Servicing145
Service Life146
Battery (for the Others)147
Servicing Information150
Troubleshooting151
Radiator (AY50W)152
Brakes154
Electrical155
Battery (for Conventional Battery for P-53)156
Battery (MF Battery)157
For P-02158
Wiring Diagram AY50158
For the Others159
Wiring Diagram AY0W160
Wire Routing162
Wire, Cable and Hose Routing162
Cable Routing164
Fuel Hose Routing165
Battery Breather Hose (for P-53)167
Oil Hose Routing167
Front Brake Hose Routing168
Center Stand Set-Up169
Special Tools170
Tightening Torque172
Tightening Torque Chart173
Cylinder + Piston + Piston Ring174
Service Data174
Clutch175
Conrod + Crankshaft175
Radiator + Engine Coolant Temp. Switch AY50W175
Carburetor AY50176
Transmission176
Carburetor AY50W177
Brake + Wheel178
Wattage178
Suspension179
Tire Pressure P-26, 34, 53179
Fuel + Oil + Coolant180
AY50W/WW/WRW ('98-Model)181
Specifications AY50WW183
Specifications AY50WRW184
Radiator + Engine Coolant Temp. Switch AY50W and AY50WR186
Carburetor AY50W and AY50WR188
AY50X/WX/WRX ('99-Model)192
AY50Y/WY/WRY ('00-Model)192
Specifications AY50X/Y193
Specifications AY50WX/WY194
Specifications AY50WRX/WRY195
Service Data AY50X/Y196
Fuel + Oil199
Tire Pressure P-26, 34199
Specifications AY50WX/WRX/WY/WRY200
Radiator + Engine Coolant Temp. Switch + Engine Coolant201
Rear Wheel (for AY50WX/WRX/WY/WRY)205
Rear Brake206
Caliper209
Brake Disc Inspection and Replacement211
Brake Disc Removal211
Rear Brake Hose Routing213
Table of Contents214
AY50K1/WRK1 (’01-Model)214
AY50K2/WRK2 (’02-Model)214
Specifications AY50K1215
Specifications AY50WRK1216
Service Data AY50K1217
Ay50K1219
- Service Data AY50WRK1221
- Thermostat + Radiator + Engine Coolant Temp. Switch + Engine Coolant222
Thermostat (for AY50WRK1)226
Engine Coolant Temp. Switch (for AY50WRK1)227
CDI/Ignition Coil229
Regulator/Rectifier229
- Wiring Diagram AY50K230
- For P-39231
- Wiring Diagram AY50WRK1233
- For P-18234
- AY50K3/SK3/WK3/WSK3 (’03-Model)236
- Specifications AY50 and AY50S237
- Specifications AY50W and AY50WS239
- Service Data AY50 and AY50S241
- Headlight243
- High Beam Indicator Light243
- Oil Level Indicator Light243
- Speedometer Light243
- Trunk Light243
- Turn Signal Indicator Light243
- Turn Signal Light243
- Fuel Tank244
  - Tire Pressure AY50S & AY50244
  - Service Data AY50W and AY50WS245
- Battery247
- Fuse247
- Headlight247
- High Beam Indicator Light247
- Oil Level Indicator Light247
- Speedometer Light247
- Turn Signal Indicator Light247
- Turn Signal Light247
  - Tire Pressure AY50WS & AY50W248
  - Wiring Diagram AY50 and AY50S250
  - Wiring Diagram AY50W and AY50WS252
  - AY50K4/WK4 (’04-Model)255
- Capacities257
- Coolant Temperature Check Light257
- Engine Oil Tank257
- Final Gear Oil, Oil Change257
- Trunk Light257
- Service Data AY50258
- Service Data AY50W262

Suzuki AY50 - Carburetor AY50 W and AY50 WR

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