Suzuki RF 900 R - Final Inspection and Adjustment; Rebound;Compression Damping Force Adjustment

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Foreword3
Important3
Group Index3
How to Use this Manual4
To Locate What You Are Looking for4
Component Parts and Work to be Done4
Symbol5
General Information/Contents7
Warning/Caution/Note8
General Precautions8
Suzuki RF900RR (94-Model) Product View10
Serial Number Location10
Fuel, Oil and Engine Coolant Recommendation Fuel10
Break-In Procedures12
Cylinder Identification12
Information Labels13
Periodic Maintenance/Contents18
Periodic Maintenance Schedule/Chart19
Lubrication Points20
Maintenance and Tune-Up Procedures21
Exhaust Pipe Bolts21
Air Cleaner21
Tappet Clearance22
Tappet Clearance Adjustment23
Tappet Shim Selection Table (Intake)24
Tappet Shim Selection Table (Exhaust)25
Spark Plug26
Carbon Deposit26
Spark Plug Gap26
Electrode's Condition26
Engine Oil and Oil Filter27
Necessary Amount of Engine Oil27
Fuel Filter28
Carburetor28
Idling Adjustment28
Throttle Cable Play28
Clutch Fluid Level29
Bleeding Air from the Clutch Fluid Circuit29
Drive Chain Checking/Adjusting30
Drive Chain Cleaning and Lubricating31
Engine Coolant Level/Change31
Brake Fluid Level32
Brake Pads33
Brake Pedal Height33
Brake Light Switch33
Air Bleeding the Brake Fluid Circuit34
Tire Tread Condition35
Tire Pressure35
Steering36
Front Fork36
Rear Suspension36
Chassis Bolts and Nuts37
Compression Pressure Check/Specification39
Compression Test Procedure39
Oil Pressure Check/Specification40
Oil Pressure Test Procedure40
Low/High Oil Pressure40
Engine/Contents41
Engine Components Removable with Engine in Place42
Engine Removal43
Engine Reinstallation48
Engine Disassembly51
Cylinder Head Service63
Cylinder Head Distortion64
Valve Stem Runout/Deflection64
Valve Head Radial Runout64
Valve Face Wear64
Camshaft65
Cam Wear66
Camshaft Journal Wear66
Camshaft Runout67
Cam Sprocket67
Camshaft Reassembly68
Cam Chain Tensioner/Guide68
Cylinder Block Distortion68
Cylinder Bore69
Piston Diameter69
Piston-Cylinder Clearance69
Piston Ring-Groove Clearance69
Piston Ring Free End Gap and Piston Ring End Gap70
Piston Pin and Pin Bore71
Conrod Small End ID71
Conrod Big End Side Clearance71
Conrod-Crank Pin Bearing Selection72
Bearing Assembly73
Crankcase-Crankshaft Bearing Selection74
Bearing Selection Table75
Crankcase ID Specification75
Crankshaft Journal OD Specification75
Crankshaft Thrust Clearance76
Bearing Thickness Specification76
Crankshaft Runout77
Thrust Bearing Selection Table77
Clutch Diaphragm Spring78
Clutch Drive and Driven Plates78
Clutch Bearing78
Clutch Release Cylinder Disassembly/Inspection/Reassembly79
Oil Pump79
Transmission Disassembly80
Transmission Reassembly81
Gearshift Fork-Groove Clearance83
Starter Clutch Disassembly and Assembly84
Starter Clutch Reassembly85
Engine Reassembly86
Fuel and Lybrication System/Contents105
Fuel System106
Fuel Pump Description107
Fuel Pump Removal/Inspection108
Fuel Cock Mechanism109
Fuel Cock Removal109
Fuel Tank Removal110
Fuel Filter Removal/Inspection/Cleaning110
Carburetor Construction111
Specifications113
Diaphragm and Piston Operation114
Lower/Upper Position of Piston Valve114
Slow System115
Main System116
Starter/Float System117
Float System Removal/Disassembly118
Float System Inspection and Adjustment121
Needle Valve Inspection121
Float Height Adjustment/Reassembly/Remounting121
Balance of Carburetors122
Calibrating each Gauge122
Balancing Carburetors123
Oil Pressure/Filter124
Oil Sump Filter124
Engine Lubrication System Chart125
Engine Lubrication System126
Engine Oil Cooling System127
Cooling System/Contents129
Cooling System Description130
Cooling System Construction131
Engine Coolant133
Cooling System Removal and Disassembly134
Water Hoses and Thermostat Case134
Radiator134
Cooling Fan135
Engine Coolant Temperature Gauge and Cooling Fan Thermo-Switch135
Thermostat135
Water Pump135
Radiator Inspection/Removal/Installation137
Engine Coolant Temperature Gauge Removal/Inspection138
Engine Coolant Temperature Gauge Reassembly139
Cooling Fan Removal/Inspection139
Cooling Fan Thermo-Switch139
Cooling Fan Thermo-Switch Removal/Inspection/Reassembly140
Thermostat Removal/Inspection/Reassembly141
Thermostat Valve Opening Temperature141
Thermostat Valve Lift141
Water Pump Removal/Disassembly/Inspection/Reassembly142
Water Pump Bearing142
Mechanical Seal142
Chassis/Contents144
Chassis Exterior Parts145
Chassis Removal146
Cowling and Cowling Brace146
Seat148
Chassis Remounting149
Frame Cover149
Front Wheel Removal150
Front Wheel Inspection and Disassembly151
Speedometer Gearbox Dust Seal151
Tire and Front Wheel151
Wheel Bearing151
Front Wheel Reassembly and Remounting152
Front Axle152
Brake Disc152
Speedometer Gearbox153
Brake Caliper153
Tire Removal155
Inspection Wheel157
Valve Inspection157
Tire/Valve Installation158
Brake Pad/Fluid Replacement160
Caliper Removal and Disassembly161
Front Brake162
Caliper Inspection163
Caliper Reassembly and Remounting163
Brake Disc Inspection164
Master Cylinder Removal and Disassembly165
Master Cylinder Inspection/Reassembly/Remounting166
Front Fork Removal and Disassembly168
Front Fork Inspection/Reassembly/Remounting171
Fork Spring171
Inner and Outer Tube171
Damper Rod171
Damper Rod Bolt172
Fork Oil172
Inner Rod and Lock Nut173
Suspension Setting174
Spring Pre-Load Adjustment174
Front Suspension Setting174
Steering Removal and Disassembly175
Steering Inspection and Disassembly177
Steering Reassembly and Remounting178
Outer Races178
Stem Nut178
Steering Tension Adjustment179
Ignition Switch Removal and Remounting180
Rear Wheel Removal181
Rear Wheel Inspection/Disassembly/Reassembly/Remounting183
Rear Axle183
Cushion/Sprocket183
Mounting Drum Bearing184
Rear Sprocket/Axle185
Rear Brake Exploded View186
Caliper Inspection/Reassembly/Remounting189
Master Cylinder Bolts191
Rear Suspension Exploded View192
Rear Suspension Removal193
Rear Suspension Inspection and Disassembly195
Swingarm195
Cushion Lever196
Shock Absorber196
Swingarm Pivot Shaft196
Chain Buffer196
Rear Suspension Reassembly and Remounting197
Swingarm Bearing197
Final Inspection and Adjustment199
Rebound/Compression Damping Force Adjustment199
Clutch Master Cylinder Removal/Disassembly/Reassembly200
Electrical System/Contents201
Cautions in Servicing202
Connector202
Coupler202
Clamp202
Battery203
Connecting Battery203
Wiring Procedure203
Using Pocket Tester203
Location of Electrical Components204
Charging System Description (Generator with IC Regulator)205
Battery Leak Current Inspection207
Charging Output Inspection207
Charging System Removal and Disassembly208
Charging System Inspection210
Rotor Bearing210
Stator Coil Continuity Check210
Rotor Coil Continuity Check210
Carbon Brush211
Rectifier211
IC Regulator212
Charging System Reassembly and Remounting213
Reassembly Information215
Starter System Description216
Side-Stand/Ignition Interlock System Description216
Starter Motor Removal/Disassembly/Inspection219
Starter Motor Reassembly220
Commutator220
Armature Coil Inspection220
Oil Seal Inspection220
Starter Relay Inspection221
Side-Stand/Ignition Interlock System Part Inspection222
Diode222
Starter Relay Wiring Diagram222
Neutral/Side-Stand Switch223
Side-Stand/Ignition Interlock Relay223
Ignition System Description224
Ignition System Inspection226
Ignition Coil (Checking with Electro/Pocket Tester)226
Signal Generator226
Ignition Coil Resistance226
Heat Range227
Ignition Unit (Checking with Digital Ignitor Checker)228
Combination Meter Removal/Disassembly/Inspection230
Engine Coolant Temperature Meter Inspection232
Fuel Level Indicator Inspection233
Headlight Bulb Replacement235
Tail/Brake Light236
Turn Signal Light236
Switches237
Battery Specifications238
Initial Charging238
Filling Electrolyte238
Battery Servicing239
Recharging Operation240
Servicing Information/Contents241
Troubleshooting/Engine242
Troubleshooting/Radiator and Carburetor245
Troubleshooting/Chassis246
Troubleshooting/Brakes247
Troubleshooting/Electrical248
Troubleshooting/Battery249
Wiring Diagram (for Canada and USA)250
Wiring Diagram (for Australia)257
Wiring Diagram (for the Others)258
Wire Harness Routing259
High-Tension Cord Routing261
Cable Routing262
Fuel System Hose Routing263
Oil Hose Routing264
Cooling System Hose Routing265
Front Brake Hose Routing267
Rear Brake Hose Routing268
Clutch Hose Routing269
Pair (Air Supply) System Hose Routing (for Austria, Switzerland and USA (California Only))270
Cowling Set up271
Frame Cover Set up273
Special Tools274
Tightening Torque/Engine277
Tightening Torque/Chassis278
Tightening Torque Chart279
Service Data Valve and Guide280
Service Data Camshaft and Cylinder Head281
Service Data Cylinder, Piston and Piston Ring281
Service Data Conrod and Crankshaft282
Service Data Oil Pump282
Service Data Clutch283
Service Data Thermostat, Radiator and Fan283
Service Data Transmission and Drive Chain283
Service Data Carburetor284
Service Data Electrical285
Service Data Wattage286
Service Data Brake and Wheel287
Service Data Suspension288
Service Data Fuel, Oil and Engine Coolant288
Service Data Tire Pressure289
Emission Control Information/Contents290
Emission Control Carburetor Components291
Evaporative Emission Control System (California Model Only)292
Canister Hose Routing (California Model Only)293
Pair (Air Supply) System Diagram (California Model Only)294
Pair (Air Supply) System Hose Routing (California Model Only)295
RF900RS (95-Model)/Contents296
RF900RS (95-Model)/Specifications297
RF900RS (95-Model)/Service Data299
RF900RS (95-Model)/Service Information309
RF900RS (95-Model)/Disassembly310
RF900RS (95-Model)/Inspection312
RF900RS (95-Model)/Reassembly313
RF900RS (95-Model)/Cable Routing315
RF900RS (95-Model)/Carburetor318
RF900RT (96-Model)/Contents344
RF900RT (96-Model)/Specifications345
RF900RT (96-Model)/Service Data347
RF900RT (96-Model)/Service Information357
RF900RT (96-Model) Disassembly and Inspection358
RF900RT (96-Model) Reassembly359
RF900RT (96-Model) Ignitor Unit Inspection360
RF900RT (96-Model) Rear Brake and Torque Link Rod361
RF900RT (96-Model) Front Suspension362
Suspension Setting Setting362
RF900RT (96-Model) Wire Harness Routing363
RF900RV (97-Model)/Contents364
RF900RV (97-Model)/Specifications365
RF900RV (97-Model)/Service Data367
How to Use Microfich Parts Catalogue378
Composition of the Micro Catalogues378
Indexing System379
Dimensions/Abbreviations380
Inner Parts of Assembly380
Modification Notice380
Serial Frame Number380
Color Chart382
Millimeter-Inch Conversion Chart383
Crankshaft385
Starter Clutch386
Cam Shaft - Valve387
Cam Chain389
Cylinder Head Cover390
Cylinder Head391
Cylinder392
Crankcase393
Crankcase Cover395
Oil Pan/Pump396
Carburetor Fittings403
Muffler405
Fuel Pump406
Oil Cooler/Filter407
Gear Shifting409
Radiator Hose412
Clutch (Model R)414
Clutch (Model S/T/V)416
Transmission417
Headlamp420
Turnsignal Lamp421
Tail Lamp422
Wiring Harness423
Handle Switch424
Starting Motor425
Alternator426
Electrical430
Speedometer431
Under Cowling Body432
Front Damper (Model R/S)434
Front Damper (Model T/V)435
Steering Stem436
Front Wheel437
Front Calipers438
Front Brake Hose439
Front Master Cylinder440
Clutch Cylinder441
Optional443
Rear Swinging Arm (Model R/S)444
Rear Swinging Arm (Model T/V)445
Rear Cushion Lever446
Rear Wheel (Model R/S)447
Rear Wheel (Model T/V)448
Rear Caliper (Model R/S)449
Rear Caliper (Model T/V)450
Rear Master Cylinder451

Suzuki RF 900 R - Final Inspection and Adjustment; Rebound;Compression Damping Force Adjustment

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