GENERAL INFORMATION
2.
Repairs go much faster and easier
if
the bike
is clean before
yo
u begin work. There are special
cleaners. such
as
Gunk or Bel-Ray Degreaser
for
washing the engine and related parts. Ju
SI
spray
or brush on the cleaning solution, let
it
stand. then
rinse
it
away
with
a garden hose. Clean all
oi
ly
or
greasy parts with cleaning sol
ven!
as
you
remove
them.
II
t-tRN
ING
Neve
r
use
gasoline as a clean
in
g
agent. It presents an extreme
fi
re
hazard. Be s
ur
e to work in a weff-
verllilate(I
ar
ea when
/I
sing cleaning
solve
lll
. K
eep
afire
ex
tin
gu
isher,
rat
ed
for gasoline fires. Itmldy in tiny case.
3.
Special tools arc required
fo
r so
me
repair
procedures. These m
ay
be purchased from a
Suzuki dealer or motorcycle sho
p.
femed from a
tool rental dealer or fabricated
by
a mechanic or
machinist (often at a considerable savings).
4. Much
of
the labor charged
by
mechanics is to
remove a
nd
disassemble other
pans
10
r
eac
h the
defective
un
it.
It
is usually possible to perfonn the
preliminary operations yourse
lf
and then take the
defective unit
in
to the dealer for repair.
5.
Once you have decided to tackle the
jo
b
yo
ur
se
lf. read the entire sect
io
n completely while
looking at the actual
pans
before starting the job.
Making sure
yo
u have identified the pr
oper
one.
Study the illustrations and text until
yo
u have a
good idea of what is involved
in
completing
Ih
ejo
b
sa
ti
sfactoril
y.
If special tools or replaceme
nl
pa
ns
arc required, make arrangements to get them before
I.,.
3
yo
u start.
It
is frust rating a
nd
time-consuming to
get
panl
y into
ajob
and then
be
unable to complete
it.
6.
Simple wiring checks
ca
n be easily made at
home, but
kn
owledge
of
electronics
is
almost a ne-
cessity for performing tests with complicated
electronic testing gear.
7.
Whenever servicing
th
e engine or transmission,
or when removing a suspension
co
mponent. the
bike should be secured
in
a safe manner. If
th
e bike
is to
be
parked on the sidesta
nd
or ee
nl
er
stand,
check the stand to make sure
it is sec
ur
e and not
damaged.
Bl
ock the frO
nl
and rear wheels
if
th
ey
remain on
th
e ground. A small hydraul
ic
jack
and
a block
of
wood can be used to raise the chassis.
If
the transmission is not going to be worked on
and
th
e drive chain is
co
nn
ected to the rear wheel.
s
hi
ft the trans
mi
ssion into first gear.
8.
Di
sco
nnect the nega
ti
ve battery ca
bl
e when
working on or near
th
e electrical. cl
ut
ch or starter
systems and before disconnecting any electrical
wires.
On most batte
ri
es.
th
e negative terminal wi
ll
be marked with a minus
(-)
sign a
nd
the positive
terminal with a plus
(+)
sign.
9.
During disassembly
of
parts, keep a few gen-
eral cautions
in
mind. For
ce
is
rar
ely needed to
get things apart. If
partS are a
ti
ght fit . such as a
bearing in a case. there
is
usually a tool designed
to separate th
em.
Never u
se
a screwd
ri
ver to pry
parts with machined surfaces such as crankcase
halves.
You
will
mar
the surfaces and end up with
leaks.
10.
Make diagrams (or take a Polaroid picture)
wherever similar-appearing parts
are
found. For
instance, cra
nk
case bolts arc often not the
sa
me
length.
You
may think you can remember where
everything c
ame
from, but
mi
stakes
ar
e cos
tl
y.
There
is
also the possibility
yo
u m
ay
be sidetrac
ked
and not return to work
fo
r days or even weeks.
in
which interv
al
carefully laid out pa
rt
s may have
become disturbed.
11.
Tag all similar internal parts for location and
mark all mating parts for position (A.
Figur
e 3).
Record number and thickness
of
any shims as they
are removed.
Sma
ll
parts such as bolts can
be
identified
by
placing them
in
plastic
sa
ndw
ic
h bags
(B,
Figur
e 3). Seal and label them with masking
tape.
12.
Pl
ace parts from a specific area of the en
gi
ne
(e.g. cylinder head. cylinder. clutch. shift mecha-
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