FOREWORD

This service manual has been specially prepared to provide all the necessary information for the
proper maintenance and repair of the FZ50. The contents have been simplified so that FZ50
owners, as well as experienced mechanics, may fully utilize this nanual.

The FZ50 is a new type of motorcycle that has many special features such as:
1) Easy to ride operation
2) Easy, smooth handling due to light weight and size
3) Simple to maintain and service
4) Technical features such as PEI ignition, automatic transmission and clutch

The FZ50 fits the needs of a wide variety of motorcycle users. Those who will be servicing this
motorcycle should carefully review this manual before performing any repairs or services.

SUZUKI MOTOR CORPORATION

Motorcycle Technical
Service Department

All specifications and construction details contained in this manual were correct at time of issue.
Suzuki Motor Co. reserves the right to make changes without notice at any time.

Quoting, copying or otherwise using any part of this manual without explicit authorization
from Suzuki Motor Corporation is not permitted as all rights to the publication are reserved
under copyright law.
 GROUP INDEX
I GENERAL INFORMATION

I INSPECTION AND ADJUSTMENT B

I SERVICING PROCEDURE

I SERVICING INFORMATION

I FZ50"T" AND FZ50"X"

I FZ50"Z"

I FZ50"D"

I FZ50"G"

I FZ50"H"

~~-Z_5_0_'~-'-'~~~~--~~~m
~rF._Z5_0_'L'_'~~~~~-m
 GENERAL INFORMATION 1-1

GENERAL INFORMATION

MODEL IDENTI FICATl ON~~~~-~-~:.~-

...-... -....-...-...-...-...-...-...-...-...-...-...-.1--2---,
SPECIFICATIONS .......................................•............................................ 1-3
II
FUEL AND OIL RECOMMENDATION .........................•...................... 1-5
GENERAL NOTES AND PRECAUTIONS ........................................... 1-6
TECHNICAL FEATURES ........................................................................ 1-7
1-2 GENERAL INFORMATION

MODEL IDENTIFICATION
RIGHT SIDE VIEW

'

FRAME NUMBER
The frame serial number is stamped on the right
side of the steering head pipe.

LEFT SIDE VIEW

ENGINE NUMBER
The engine serial number is located on the left
side crankcase.

These numbers are required especially for registering the machine and ordering the spare parts.
 GENERAL INFORMATION 1-3

SPECIFICATIONS
DIMENSIONS AND WEIGHT

Overall length 1 650 mm (65.0 in)

Overall width 665 mm (26.2 in)
Overall height 990 mm (39.0 in)
Wheelbase 1 120 mm (44.1 in)
Ground clearance 120mm( 4.7in)
Dry mass ( weight) 59 kg ( 130 lbs)

ENGINE

Type Two-stroke, air cooled

Intake system Reed valve
Number of cylinder
Bore 41.0 mm (1.614 in)
Stroke 37.4 mm (1.472 in)
Piston displacement 49 cm 3 (3.0 cu.in)
Corrected compression ratio 6.1 : 1
Carburetor MIKUNI VM14SH, single
Air cleaner Polyurethane foam element
Starter system Primary kick
Lubrication system SUZUKI "CCI"

TRANSMISSION

Clutch Wet shoe, automatic, centrifugal type

Transmission 2-speed
Gearshift pattern Automatic type
Primary reduction 1.000
Final reduction 8.696
(chain) 2.384 (31/13)
(gear) 3.647 (62/17)
Gear ratios, Low 2.137 (62/29)
2nd 1.421 ( 54/38)
Drive chain DAI DO D.I.D. 270H, 64 links
1-4 GENERAL INFORMATION

CHASSIS

Front suspension Bottom link oil dampened

Rear suspension Swinging arm
Steering angle 45° ( right & left)
Caster 63°00"
Trail 81 mm (3.19 in)
Turning radius 1.7 m (5.6 ft)
Front brake Internal expanding
Rear brake Internal expanding
Front tire size 3.00-12-4PR
Rear tire size 3.00-12-4PR
Front tire pressure 125 kPa (1.25 kg/cm 2 , 18 psi) (Normal solo riding)
Rear tire pressure 150 kPa (1.50 kg/cm 2 , 21 psi) (Normal solo riding)

ELECTRICAL

Ignition type SUZUKI "PEI"

Ignition timing 20° B.T.D.C. at 4 000 r/min
Spark plug NGK BP4HA or NIPPON DENSO W14FP-UL
Battery 6V 14.4 kC (4 Ah)/10 HR
Generator Flywheel magneto
Fuse 10A
Headlight 6V 20/20W
Tail/Brake light 6V 5.3/17W (3/21 cp)
High beam indicator light 6V 1.7W

CAPACITIES

Fuel tank including reserve 4.5 L ( 1.2/1.0 US/I mp gal)

reserve 0.2 L (0.2/0.2 US/I mp qt)
Engine oil tank 1.2 L (1.27/1.06 US/Imp qt)
Transmission oil 800 ml (0.85/0.70 US/Imp qt)

* These specifications are subject to change without notice.

 GENERAL INFORMATION 1-5

FUEL AND OIL RECOMMENDATION

Be sure to use the specified fuel and oils. The following are the specifications:

FUEL
Gasoline used should be unleaded or low-
lead where they are available.

ENGINE OIL
For the SUZUKI CCI system, use of SUZUKI
CCI SUPER 2 OIL is highly recommended,
but if it is not available, a good quality two-
stroke oil (non-diluent type) should be used.

,_
~----------- -~
~

TRANSMISSION OIL
Use a good quality SAE 20W/40 multi-grade
motor oil.

Drain plug
1-6 GENERAL INFORMATION

GENERAL NOTES AND PRECAUTIONS

Observe the following items without fail when disassembling and reassembling motorcycles.

• Be sure to replace packings, gaskets, 0 rings, circlips and cotter pins with new ones.

• Tighten bolts and nuts from the ones of larger diameter to those of smaller diameter, and
from inside to out-side diagonally, with specified tightening torque.

• Use special tools where specified.

• Use specified genuine parts and oils.

• When 2 persons perform work in cooperation, pay attention to the safety of each other.

• After the reassembly, check parts for tightening condition and operation.

• Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never
use gasoline as cleaning solvent.

Warning, caution and note are included in this manual occasionally, describing the following
contents.

I WARNING .......... When personal safety of the rider is involved, disregard of the
information could result in his injury.

CAUTION I ........... For the protection of the motorcycle, the instruction or rule
must be strictly adhered to .

NOTE . . . . . . . . . . . . . . Advice calculated to facilitate the use of the motorcycle is given

under this heading.

SYMBOLS

The symbols used in this manual are as follows.

1~1 Tightening torque

I OIL I Oil

I GREASE I Grease
 GENERAL INFORMATION 1-7

TECHNICAL FEATURES
DESCRIPTION
The FZ50 has a 49 cm 3 (49 cc), 2-cycle engine with a reed valve. The simple construction
and rational design of the engine has minimized the number of inspection items, thus allowing
easy inspection and almost maintenance-free operation. This provides a unique motorcycle,
with a long enjoyable life, free from troubles.

Kick starter shaft

Counter shaft
1-8 GENERAL INFORMATION

REED VALVE
A reed valve is used in the intake system. The reed valve has thin, flexible steel pieces and are
fitted into the top of the crankcase. As the piston moves up and down, the pressure in the
crankcase alternately changes to negative and positive, thus causing the reed valve to open and
close. The reed valve timing and opening vary depending on the engine speed and throttle
opening. In other words, it can be said that the intake timing is ideally matched to the operating
condition of the engine.

ENGINE LUBRICATION
Engine oil is supplied by means of an oil pump which is driven by the crankshaft through the
oil pump driven shaft and oil pump drive gear mounted on the crankshaft. The supply of the
oil is controlled by the oil pump cable (interlocked with the throttle cable), and thus an optimum
amount of oil is discharged from the pump according to the engine speed.

Oil pump

Oil pump driven gear

 GENERAL INFORMATION 1-9

PISTON AND PISTON RING

Both 1st and 2nd piston rings are of keystone type, and an expander ring is with the 2nd ring.
The keystone ring is less sticking and has excellent durability. The expander ring absorbs the
noise generated by the piston sliding against the cylinder wall by means of its spring tension,
thus reducing overall noise.

2nd ring
Parkerized for better "wear-in" 1st ring
Chrome - plated for better durability

0
I 70

Sectional· form of piston ring

Both 1st and 2nd rings are sloped at
the top side.

CLUTCH

Automatic centrifugal shoe type clutches are secured to the crankshaft and counter shaft. These
clutches have simple construction. When the clutch drive shoes, which are thrown apart by cen-
trifugal force varying with the crankshaft speed, come in contact with the clutch driven wheel,
engine power is transmitted to the counter shaft. When the engine speed falls, the centrifugal force
decreases and the drive shoes comes close together, thus separating from the driven wheel. This
eliminates the flow of engine power.

Clutch driven wheel Clutch drive shoes

1-1 0 GENERAL INFORMATION

POWER TRANSMISSION

-Low
---- High

---~f--fl-
!

10 @

LOW HIGH
1. Crankshaft
2. 2nd drive gear - - - - - - - - - - 15. 2nd driven gear
3. Clutch drive shoes 16. Clutch No. 2
4. Clutch No. 1 17. Clutch drive shoes
5. 1st drive gear
6. 1st driven gear
7. Counter shaft _______________j
8. Drive sprocket
9. Drive chain
10. Driven sprocket
11. Final drive gear
12. Final driven gear
13. Drive axle shaft
14. Rear wheel

One way clutch

 GENERAL INFORMATION 1-11

The FZ50 is equipped with a fully automatic, 2-speed, transmission. Two, separate, centrifugal
clutches are used to select 1st and then 2nd gear. At lower engine RPM's, the low speed clutch
(Clutch No. 1) labeled © engages. The power from the crankshaft CD is directed through the low
speed clutch © into the 1st drive gear ® and then to the 1st driven gear ®. As the driven gear is
forced to rotate, small engagement dogs "lock" the gear to an inner shaft (Counter shaft) (J) which
is then forced to also rotate. Splined to the inner counter shaft (J) is the chain drive sprocket ®.
When the engine r/min increases clutch No. 2 @ engages for 2nd gear power transmission. As the
clutch begins to engage it forces the counter shaft (J) to turn faster than the r/min produced by the
drive of the 1st driven gear set ®. This is accomplished by the use of a one-way or free-wheeling
clutch inside of the 1st driven gear assembly. The one-way clutch is disengaged whenever the input
speed of the inner portion, which is driven by the counter shaft, is higher than the driven portion of
the outer gear. The power flow from the higher geared clutch No. 2 @ now is connected through
the counter shaft (J) to the chain drive sprocket ®.
1-12 GENERAL INFORMATION

DRIVE CHAIN
Power is transmitted from the counter shaft to the final drive shaft through a drive chain.
The drive chain is maintained at the proper tension by the chain tensioners provided for the
upper and lower parts of the chain and is immersed in transmission oil - oil bath type -
ensuring excellent durability.

FINAL DRIVE
Power transmitted to the final drive shaft through the drive chain. The driven sprocket and
final drive gear are press-fitted to the final drive shaft. The speed is reduced by the final drive
gear and the final driven gear mounted on the drive axle shaft.
The drive axle shaft is integrated with the final driven gear, and it rotates at a speed reduced
finally by the final drive gear. The shaft is installed in the rear part of the crankcase. Almost
half of the drive axle shaft projects outside and is splined to the rear wheel, thus causing it
to turn.
 GENERAL INFORMATION 1-13

KICK STARTER
When the brake lever is squeezed, the kick starter lifter lever is actuated, the kick starter lifter
shaft rotates and the kick starter lifter moves downward. By the movement of the kick starter
lifter, the kick starter guide is pushed and the guide end is raised. Keeping this condition,
when the kick lever is depressed, the kick starter is turned by the kick starter drive gear. As a
result, the kick starter moves to the left side of the kick idle gear while being turned by the
kick starter gear and meshes with the kick idle gear. The kick idle gear rotates and makes
the crankshaft turn.
1-14 GENERAL INFORM.ATION

"PEI" SYSTEM
In the FZ50 ignition system, the PEI system is used.
The PEI system uses a magneto as the power source, and the capacitor (condenser) momentarily
stores a charge up to hundreds of volts.
The charge is instantly discharged, at the specified ignition timing, to the ignition coil primary
winding, thus inducing a high surge of voltage in the secondary winding. As a result, a spark
occurs at the spark plug gap.
The PEI magneto has no breaker points and therefore it is free from mechanical trouble. This
ensures a stabler secondary high voltage and better spark performance.

Ignition coil

PEI
0

Magneto Spark plug

Features of "PEI" System

1. Spark plug deposits are minimized as high voltage spark is produced.
2. Disuse of contact points means no dust trouble. Contact points become worn by dust and
such as a spark occurs between them.
3. Original engine performance is kept as ignition timing is always correct.
4. Running cost is reduced as "PEI" system has no mechanical parts and therefore requires
no adjustment or replacement.
 GENERAL INFORMATION 1-15

Connecting Diagram

Engine stop switch

......&...-

~ Ignition coil
BIR B/Y

l
PEI
Unit Spark
R/B B/W
plug
Magneto

Wiring Circuit

R1
SCR

1 Spark

plug

R/B
Condenser
charging coil PEI Unit
Ignition coil

Description
1. As the magneto turns, the voltage generated by the condenser charging coil is charged
to the condenser through the following circuit:
Conderser charging coil -+ Diode 0 1 -+ Condenser C -+ Ignition coil primary winding
-+ Diode 0 3 -+ Conderser charging coil.
2. When the rotor turns 180°, the polarity of the red/black terminal becomes positive {+)
and the generated voltage, which is divided by R 1 , is applied through R2 to the SC R gate.
When this voltage arrives at the SCR gate, it makes SCR conduct {turned on).
3. When SCR conducts, the electrical charge stored in the condenser is rapidly discharged
through the following circuit:
Conderser C-+ SCR-+ Ignition coil primary winding-+ Conderser C.
4. In this way, a high surge of voltage quickly builds up in the secondary winding, thus
causing a good spark to jump across the spark plug gap.

NOTE:
In case of PEI, two sparks occur each crankshaft rotation.
1-16 GENERAL INFORMATION

STEERING
To make maintenance work more efficient, steering is now installed with a single bolt. As the
bolt is tightened, V shape of the end piece expands till it contacts the inside of the head pipe
and is fixed there.

Tighten bolt

\
FRONT FORK
Front suspension of leading link type assures soft and comfortable riding. Road sliocks are
transmitted to the arm by way of the front axle shaft and absorbed in the shock absorber.
On the contrary, when the shock absorber extends, the arm contacts the damper rubber and
thus shocks are dampened.

Shock absorber
 INSPECTION AND ADJUSTMENT 2-1

INSPECTION AND ADJUSTMENT

~~~~~~~CONTENTS~~~~~~~

PERIODIC MAINTENANCE SCHEDULE ........................................... 2-2

MAINTENANCE PROCEDURE ........................................................... 2-3
2-2 INSPECTION AND ADJUSTMENT

PERIODIC MAINTENANCE SCHEDULE

Vehicles should be inspected after a certain period of running for wear of parts, carbon deposits,
elongated cables, etc. Inspections should be made periodically and defects should be repaired or
adjusted beforehand to prevent trouble and prolong the motorcycle's service life.
Inspect and adjust the vehicle as indicated below.

NOTE:
More frequent maintenance may be performed on motorcycles that are used in an extreme
severe condition.

PERIODIC MAINTENANCE CHART

Interval Initial Every Every

Km I 1 000 3 000 6 000
Item Miles 600 2 000 ! 4 000
Month 2 6 12
Air cleaner element Wash and clean Wash and clean -

Battery Check specific gravity Check S.G. and service -

and service electrolyte electrolyte solution
solution
Brakes Adjust play Adjust play -

Brake shoes - Check wear -

Carburetor Adjust idle r/min Adjust idler/min Overhaul and clean
Cylinder head and cylinder Retorque head nuts and Retorque head nuts and Remove carbon
exhaust pipe bolts exhaust pipe bolts
Chassis bolts and nuts Retorque Retorque -

Fuel line Replace every 2 years

Fuel filter Clean - Clean
Oil pump Check operation and Check operation and -
adjust control lever adjust control lever
Spark plug Clean Clean and adjust gap Replace
Steering Check play Check play -
Throttle cable Adjust play Adjust play -
Tire Check tire pressure Check tire pressure -
and tread wear
Transmission oil Change Change -
 INSPECTION AND ADJUSTMENT 2-3

LUBRICATION CHART
Rotating and rubbing parts must be lubricated periodically. Insufficient lubrication will cause
rapid wear and severe damage may result.
Lubricate the following parts periodically.

Interval Every Every

Km 3 000 6 000
Item Mile 2 000 4 000
Month 6 12
Brake cables Motor oil -
Brake cam shaft - Grease
Choke cable Motor oil -
Front suspension arm shaft - Grease
Oil pump cable Motor oil -
Speedometer gear - Grease
Speedometer cable - Grease
Throttle cable Motor oil -

WARNING:
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings,
brake slippage will result.

Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions.

Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
2-4 INSPECTION AND ADJUSTMENT

MAINTENANCE PROCEDURE
AIR CLEANER CAUTION MISE EN GARDE

Clean at initial 1 000 km

and every 3 000 km - Battery
Batterie

/9-
O- Element

Non flammable
cleaning
solvent
'
','
0
~ .... _
8CC\
\.....__.,/
-~
~

oil '•
•,
6
Battery breather pipe
Reniflard de batterie

CAUTION: --uPPER--

* Before and during the cleaning oper- e__ LOWER__slz

ation, examine the element to see if

it is torn. A torn element must be
YUASA
6N4-2A
replaced. MADE IN JAPAN

* Be sure to position the element

snugly and correctly, so that no in-
coming air will bypass it. Remember,
rapid wear of piston rings and cylin-
der bore is often caused by a de-
fective or poorly fitted element. • If the electrolyte surface falls rapidly and
requires frequent addition of distilled
water, check the charging system for
proper charging rate.
• A S.G. reading of 1.220 {at 20° C, 68° F)
BATTERY
or under means that the battery needs
Check at initial 1 000 km recharging off the machine: take it off
and every 3 000 km and charge it from a recharger. Charging
the battery in place from the recharger
Electrolyte for can damage the rectifier and related
1.260 at 20°C (68° F) wiring.
specific gravity

• Check to be sure that the vent pipe is Charging current 0.4 A/10 hours
secure and routed properly.
S.G. Condition Measure
• Add distilled water, as necessary, to keep
over 1.250 Normal --
the surface of the electrolyte above the
1.220 - 1.250 Under charged Better to
LOWER level line but not above the recharge
UPPER level line. below 1.220 Run down Recharge
or replace
I

CAUTION:
Do not forget to remove three battery
caps to prevent possible battery damage
when recharging.
 INSPECTION AND ADJUSTMENT 2-5

BRAKES BRAKE SHOE WEAR

Adjust at initial 1 000 km Check every 3 000 km

and every 3 000 km
• When applying the front brake, if the ex-
• Adjust by turning the adjusting nut so tended line of the brake cam lever exceeds
that the clearance between grip and brake the range on the brake panel, replace the
lever is 20 - 30 mm (0.8 - 1.2 in) when brake shoes.
applying the front brake.

• As the rear brake wire is linked to the

• Remove inspection cap on the rear hub
kick starter lifter lever, first adjust with
panel and check the brake shoes. If they
the adjusting nut so that the lifter lever
are worn as much as the limit shown in
play is 1 mm (0.04 in).
the figure below, replace them.

• Adjust by turning the brake cable adjust-

ing nut so that the clearance between
lever and grip is 20 - 30 mm (0.8 - 1.2
in).

Adjusting nut
2-6 INSPECTION AND ADJUSTMENT

ENGINE IDLE R/MIN • Finally adjust the throttle cable play.

( Refer to page 2-12.)
Adjust at initial 1 000 km
and every 3 000 km 0.5 -1.0 mm
Throttle cable play
(0.02 - 0.04 in)
• Adjust the throttle cable play.
• Warm the engine up. CAUTION:
This adjustment will affect the oil
NOTE: pump lever adjustment. Therefore, re-
A warm engine means an engine has adjust the oil pump lever cable as
been run for 10 minutes. necessary.

• Turn the air screw back 1% turns from the CARBURETOR OVERHAUL AND
bottom. CLEANING
• Restart engine, and set the throttle valve
stop screw at lowest idle speed. [ Overhaul and clean every 6 000 km
• Turn the air screw in or out within % turn
from the original setting ( 1% turns). Find Wash the carburetor and component parts in
the position where the engine runs at the cleaning solvent after disassembly.
highest r/min. Turn the air screw in 1/8 Before reassembly, inspect the float level
turn. and needle valve. Adjust and replace parts
• Adjust the throttle stop screw to obtain when necessary. ( Refer to page 3-11.)
the idling r/min as follows. Then blow compressed air through all jets
and passages to make sure they are not
Idler/min 1 350 - 1 650 r/min clogged. Do not use wire, etc. to clean
them, as this can damage the parts.

CYLINDER HEAD NUTS

Retighten at initial 1 000 km

and every 3 000 km

• Cylinder head nuts, when they are not

tightened to the specified torque, may
result in leakage of the compressed
mixture and reduce output. Tighten the 4
nuts evenly one by one in stages until
each one is tightened to the specified
torque. Tighten the nuts in the order
indicated below.
 INSPECTION AND ADJUSTMENT 2-7

Cylinder head nut 0.8 - 1.2 kg-m

FUEL STRAINER
tightening torque (6.0 - 8.5 lb-ft)
Clean at initial 1 000 km
and every 6 000 km

CYLINDER HEAD AND CYLINDER If the fuel strainer cup is dirty with sediment
or water, gasoline will not flow smoothly
Remove carbon every 6 000 km and a loss in engine power may result. Clean
the strainer cup, leaving the cock lever in ON
Carbon deposits in the combustion chamber position.
and the cylinder head will raise the com-
pression ratio and may cause pre-ignition or
overheating. Carbon deposited at the ex-
haust port of the cylinder will prevent the
flow of exhaust, reducing the output. Re-
move carbon deposits periodically.

Cup
0
O - ring Filter
mesh

OIL PUMP

Adjust at initial 1 000 km

and every 3 000 km

Cable adjustment
The engine oil is fed by the oil pump to the
engine. The amount of oil fed to it is regu-
FUEL LINE lated by engine speed and the oil pump con-
trol lever which is controlled by the amount
I Replace every two years of throttle opening.
Check the oil pump in the following manner
Replace the fuel line every two years. to confirm correct operation for all throttle
valve opening positions.
• Turn the throttle grip until the dent mark
CD on the throttle valve comes to the
upper part of the hole.
2-8 INSPECTION AND ADJUSTMENT

• Check whether the mark on the oil pump Checking oil pump capacity
control lever is aligned with the index Use the special tool, check the pump for
mark when the throttle valve is positioned capacity by measuring the amount of oil the
as above. pump draws during the specified interval.

Engine oil discharge

amount measuring 09900-21602
tool

Mark
• Have the tool filled with SUZUKI CCI
SUPER 2 0 IL and connect it to the
suction side of the pump.

Index mark

• If the marks are not aligned, adjust by

means of the cable adjuster ® to align
them.

Air bleeding
Whenever evidence is noted of some air
having leaked into the oil line from the oil
tank in a machine brought in for servicing,
or if the oil pump has to be removed for
servicing, be sure to carry out an air bleeding
operation with the oil pump in place before
returning the machine to the user.
How to bleed the air: With the engine not
• Holding engine speed at the 2 000 r/min
running condition, loosen screw CD, to let
by turning the throttle stop screw, move
out the air; and, after making sure that the
the lever up to the fully open position and
trapped air has all been bled, tighten the
let the pump draw for 6 minutes. For this
screw good and hard.
operation, the reading taken on the
measuring cylinder should be from 1.02
to 1.26 ml.

Oil discharge 1.02-1.26 ml

amount at 2 000 r/min
(fully open position) for 6 minutes

~\
 INSPECTION AND ADJUSTMENT 2-9

SPARK PLUG • Check spark plug for burnt condition. If

abnormal, replace the plug as indicated
Check at initial 1 000 km below.
and every 3 000 km
Replace every 6 000 km Nippon
NGK Remarks
Denso
If the standard plug
Neglecting the spark plug eventually leads to
BP-2HA W9FP-UL is apt to get wet, re-
difficult starting and poor performance. If
I place with this plug.
the spark plug is used for a long period, the BP-4HA W14FP-UL Standard
electrode gradually burns away and carbon If the standard plug
builds up along the inside part. In ac- BP-5HA W16FP-UL is apt to overheat, re-
place with this plug.
cordance with the Periodic Inspection Chart,
the plug should be removed for inspection,
• Tighten the spark plug in the cylinder
cleaning and to reset the gap.
head with the specified torque.
• Carbon deposits on the spark plug will
prevent good sparking and cause misfiring.
Clean the deposits off periodically. Spark plug 2.5 - 3.0 kg-m
• If the center electrode is fairly worn tightening torque (18.0 - 21.5 lb-ft)
down, the plug should be replaced and the
plug gap set to the specified gap using a
thickness gauge.

Thickness gauge 09900-20803

STEERING STEM

Check at initial 1 000 km

and every 3 000 km

Steering should be adjusted properly for

smooth manipulation of handlebars and safe
running. Too stiff steering prevents smooth
manipulation of handlebars and too loose
steering will cause the handlebars to vibrate.
Check to see that there is no play in the
front fork fitting.
If any play can be found, adjust the steering
as follows:
• Support the motorcycle body and jack up
the front wheel.
• Remove the headlight housing.
• Loosen the steering stem nut securing nut
- - ~ - 0.6-0.7mm
----,--(0.024-0.028 in) CD, tighten the steering stem nut ® using
the special tool so that the front fork
moves smoothly.

1
1 0.6 - 0.7 mm Steering stem nut
Spark plug gap 09940-10122
(0.024 - 0.028 in) wrench
2-10 INSPECTION AND ADJUSTMENT

~Locknut THROTTLE CABLE

• Loosen the lock nut and adjust the cable
cg--Spacer slack by turning adjuster in or out to ob-
tain the following slack.
~Steering stem nut
After adjusting slack, tighten the lock nut.

~Dustcover
0.5-1.0 mm
Cable slack
(0.02 - 0.04 in)
~ 0

~
© 0

ll
0.5-1.0mm
__.l0.02-0.04in)

Lock nut

If any play is still found, inspect the follow-

ing items and replace the affected parts, if
necessary.
• Wear of the inner and outer races
• Wear or damage of steel balls
• Number of steel balls (upper 22 pcs lower
25 pcs)
• Distortion of steering stem CAUTION:
This adjustment will affect the oil
pump control lever adjustment. Re-
adjust the oil pump control cable ad-
justment.
 INSPECTION AND ADJUSTMENT 2-11

TIRE TRANSMISSION OIL

J Check every 3 000 km Change at initial 1 000 km
and every 3 000 km
Tire pressure
If the tire pressure is too high, the motor- After a long period of use, the transmission
cycle will tend to ride stiffly, have poor oil qualities will deteriorate and quicken the
traction. Conversely, if the tire pressure is wear of sliding and interlocking surfaces.
too low, stability will be adversely affected. Replace the transmission oil periodically
Therefore, maintain the correct tire pressure following the procedure below.
for good roadability and to prolong tire life. • Start the engine to warm up the oil, this
will facilitate draining of oil.
Cold inflation tire pressure • Unscrew the oil filler cap and drain plug,
Front Rear and drain the oil completely.
125 kfa 150 kpa • Tighten the drain plug.
(1.25 kg/cm , 18 psi) (1.50 kg/cm2, 21 psi) • Supply a good quality SAE 20W/40 multi-
grade motor oil.

CAUTION: 800ml
The standard tire fitted on this motor- Capacity
(0.85/0.70 US/Imp qt)
cycle is 3.00-12-4PR for front and rear.
The use of a tire other than the stan- • Check the oil level with the oil level
dard may cause handling instability. It screw.
is highly recommended to use a
SUZUKI Genuine Tire.

Filler cap
Level screw
Tire tread condition
Operating the motorcycle with the excessive-
ly worn tires will decrease riding stability
and consequently invite a dangerous situ-
ation. It is highly recommended to replace
the tire when the remaining depth of tire
Drain plug
tread reaches the following specifications.

FRONT and
1.6 mm (0.06 in)
REAR
2-12 INSPECTION AND ADJUSTMENT

CHASSIS BOLTS AND NUTS

Retighten at initial 1 000 km and every 6 000 km

These bolts and nuts listed below are important safety parts. They must be retightened, as neces-
sary, to the specified torque with a torque wrench.

No. Description Q'ty kg-m lb-ft

Front brake cam lever
CD nut
1 0.5-0.8 4.0- 5.5
Front shock absorber
® lower nut
2 1.0 - 1.5 7.5 - 10.5
Front suspension arm
@ rear nut
2 2.0-3.0 14.5 - 21.5
Front suspension arm
@) damper nut
2 1.0 - 1.5 7.5 - 10.5

® ' Front shock absorber 2 1.5 - 2.0 11.0 - 14.0

upper bolt
Rear shock absorber
® upper nut
1 2.0-3.0 14.5 - 21.5
Rear shock absorber
(j) lower nut
1 2.0- 3.0 14.5- 21.5
Rear brake cam lever
® nut
1 0.5-0.8 4.0- 5.5

(j) @

No. Description Q'ty kg-m lb-ft

® Rear axle nut 1 3.6- 5.2 26.5 - 37.5
@ Engine mounting nut 1 2.5-4.0 18.5 - 28.5
(fJ) Front footrest nut 2 1.0 - 1.5 7.5 - 10.5
Handlebar expander
(j]) 1 5.0- 6.5 36.5-47.0
bolt
@ Front axle nut 1 2.7 - 4.3 20.0 - 31.0
 SER VICING PROCEDURE 3-1

SERVICING PROCEDURE

~~~~~~~CONTENTS~~~~~~~

ENGINE REMOVAL/INSTALLATION ................................................... 3- 2

CYLINDER HEAD, CYLINDER, PISTON ............................................. 3- 3
KICK STARTER, LEFT COVER ............................................................ 3- 5
POWER TRANSMISSION ..................................................................... 3- 6
LEFT CRANKCASE ................................................................................. 3-1 O
CRANKSHAFT .......................................................................................... 3-11
CARBURETOR .......................................................................................... 3-13
FLYWHEEL MAGNETO ........................................................................ 3-14
CHASSIS ELECTRICAL ......................................................................... 3-16
SWITCHES ................................................................................................ 3-20
STEERING ................................................................................................ 3-22
FRONT SUSPENSION ........................................................................... 3-23
WHEELS AND BRAKES ........................................................................ 3-24
3-2 SER VICING PROCEDURE

ENGINE REMOVAL/INSTALLATION
\Right Side\ ] Left Side I

CD Remove the spark plug cap.

CD Remove the magneto lead wire. ® Remove the oil pump control cable.
® Remove the fuel line and the vacuum ® Remove the oil hose.
line with the fuel cock set to ON. @ Remove the rear brake cable.
® Remove the carburetor choke cable from @ Loosen and remove the rear shock ab-
the carburetor side. sorber lower bolt.
@ Remove the carburetor top cover. ® Remove the engine ground wire from the
@ Loosen the engine mounting nut. ignition coil side.
(J) Pull out the engine mounting bolt.
® Lift the body.

Right

®
2.5 - 4.0 kg-m
(18.5 - 28.5 lb-ft)

Left

®
2.0 - 3.0 kg-m
(14.5 - 21.5 lb-ft)
 SER VICING PROCEDURE 3-3

CYLINDER HEAD, CYLINDER, PISTON, PISTON RING

G)

I'.i)=e-_c" I: 0.8-1.2kg-m
(6.0 - 8.5 lb-ft)

® Remove carbon
G)--~
® ® Replace gasket

2.0 kg-m
(14.0 lb-ft)

Replace

@) Remove carbon of the exhaust port and

apply oil on the cylinder wall.

® Arrow mark on the piston crown faces

exhaust side.

(J), ® Remove carbon and apply oil.

Top mark "R" or "T" indicates up-
side on rings.
@----1,
® Replace with new circlips.

Apply thread

1
lock
"1342" r1.8mm

~~ Mark

A
®
~·6mm

Expander ring
3-4 SER VICING PROCEDURE

CYLINDER BORE
Cylinder gauge I 09900-20508

41.060 mm
Service Limit I (1.6165 in)

I
---- -- I
PISTON DIAMETER

Micrometer 09900-20202

0 ~
Service Limit
40.880 mm
(1.6094 in)

/
" 23 mm
(0.9 in)
~

'

RING END GAP

Thickness gauge 09900-20804

0.75 mm
Service Limit
(0.030 in)

RING FREE END GAP

Vernier caliper 09900-20101

!
R marked I
T marked
Service 3.6mm i 4.0mm
Limit (0.14 in) (0.16 in)
I

NOTE:
Replace the piston rings as a set.
 SER VICING PROCEDURE 3-5

KICK STARTER, LEFT COVER

Bearing remover 09921-20210

Sliding shaft 09930-30102

Sliding shaft

Oil seal,Spring

0.5 - 0.8 kg-m

(4.0 - 5.5 lb-ft)

• When installing the kick starter return

spring, install ® and then install ®.
• Apply Suzuki Super Grease A to the oil
seal lip and the kick starter spring.
• Replace the gasket.
• Install two dowel pins CD.
3-6 SERVICING PROCEDURE

POWER TRANSMISSION
CD
j Clutch holder 09920-30220

• Apply thread lock cement.

2.0 - 3.0 kg-m

(14.5 - 21.5 lb-ft)

To wheel

Adjust so that there is no clutch thrust play.

Circlip opener 09900-06107

• Replace all circlips.

• Adjust shim to reduce the final drive and
driven gear noise.
 SERVICING PROCEDURE 3-7

AUTOMATIC CLUTCH 2. CLUTCH "LOCK-UP" INSPECTION

INSPECTION (CLUTCH NO. 1)
Perform this inspection to determine if the
The FZ50 is equipped with an automatic clutch is engaging fully and not slipping.
clutch and automatic 2 speed transmission. • Warm the engine to normal operating
The engagement of the clutches are governed temperatures.
by engine RPMs and a centrifugal mecha- • Connect an electric tachometer to the
nism located in the two independant engine.
clutches. • Apply the rear brake as firm as possible.
To insure proper performance and longevity • Briefly open the throttle fully and note
of the clutch assemblies it is essential that the maximum engine RPMs sustained
the clutches enQage smoothly and gradually. during the test cycle.
Three inspection checks must be performed
to thoroughly check the operation of the CAUTION:
drivetrain. Follow the procedures listed. Do not apply full power for more than
10 seconds or damage to the clutch or
1. INITIAL ENGAGEMENT INSPECTION engine may occur.
(CLUTCH NO. 1)
• Warm the motorcycle up to normal
operating temperature. LOCK-UP R/MIN
• Connect an electric tachometer to the STD 3 800 r/min
engine.
Tolerance ±200 r/min
• Seated on the motorcycle with the motor-
cycle on level ground, increase the engine
RPMs slowly and note the RPM at which
the motorcycle begins to move forward.

ENGAGEMENT R/MIN

STD I
2 500 r/min
Tolerance ±200 r/min
I
3-8 SER VICING PROCEDURE

If the engine r/min does not coinside with

the specified r /min range then disassemble
the clutch.
• Clutch shoe - inspect the shoes visually
for chips, cracking, uneven wear, burning
and check the depth of the grooves on the
shoes. If there is no groove at any part of
the shoes, replace them as a set.
• Clutch springs - visually inspect the
clutch springs for stretched coils or
broken coils. Measure the free length of
the springs with vernier calipers.

Measuring clutch wheel.

NOTE:
Clutch shoes or springs must be
changed as a set and never individually.

• Clutch wheel - inspect visually the con-

dition of the inner clutch wheel surface
for scoring, cracks, or uneven wear.
Measure the inside diameter of the clutch
wheel with inside calipers. Measure the
diameter at several points to check for an
out-of-round condition as well as normal
wear.

Unit : mm (in) Inspecting clutch shoe groove.

Item Service limit

Clutch wheel I.D. 87 .40 (3.441)
Clutch shoe surface No groove
Clutch spring free
28.0 (1.06)
length

Measuring clutch spring.

 SER VICING PROCEDURE 3-9

3. SECOND GEAR SHIFT POINT CHAIN 20 PITCH LENGTH

(CLUTCH NO. 2)
Service limit 173.0 mm (6.83 in)
Ride the motor cycle in a normal manner
and note at what road speed the trans-
mission shifts to second gear.

2ND GEAR SHIFT POINT

1 2 3 • • • • • 19 20 21
STD 21 km/h (13 mph)
Tolerance ±2 km/h (± 1 mph)

The 2nd gear shift should be both quick and

smooth with no indications of slipping or
grabbing.

If the shift point does not coinside with the

standard MPH range then Clutch No. 2 com-
ponents should be inspected in the same
manner as was Clutch No. 1 in the following
areas:
• Clutch shoes
• Clutch springs
• Clutch wheel

Unit: mm (in)

Item Service limit

Clutch wheel I.D. 105.50 (4.154)
Clutch shoe surface No groove
Clutch spring free
33.0 (1.30)
length
3-10 SER VICING PROCEDURE

LEFT CRANK CASE

0.5 - 0.8 kg-m
(4.0 - 5.5 lb-ft)

(~eather
I kJ~~ver
)

Push out as shown in the figure.

Install the circlip in the outermost groove

and slide out the clutch and remove the
countershaft.

Circlip

NOTE:
Remove the rear brake shoe and slide
out the cam to the right. Be sure to
mark the cam lever position before re-
moval.

Pull out by using the bearing puller and

0.5 - 0.8 kg-m
sliding shaft.
(4.0 - 5.5 lb-ft)

'---.
I

0-ring Brake cam shaft

~i
I

Bearing remover
I
I

I /GREASE/
 SER VICING PROCEDURE 3-11

CRANKSHAFT

F~
@--Spacer

• Install the engine ground wire.

• Check for damage and bent reeds. Be
careful not to bend the reed valve stopper.

Ground w i r e ~
i
Oil pump control
cable guide

Oil pump
• Apply thread lock super "1303" to outer
surface of right oil seal.

Thread lock super

99000-32030
"1303" • Use a crankshaft remover to prevent
damage to the crankshaft bearing and
• Clean the inlet port mounting surface and crankshaft.
the case surface.
• When installing the crankshaft, apply the
liquid gasket to ®. Crankshaft remover 09920-13120

SUZUKI Bond
99104-31140
No. 12078

• Be sure to set the spacer when installing

the oil pump.
• Match the projecting part of oil pump and
the groove @.
• Check the oi I seal and the bearing for
damage or excessive clearance.
• Apply grease to the oil seal.
• Apply oil to the bearing.
3-12 SERVICING PROCEDURE

CRANKSHAFT DEFLECTION
Service limit 0.05 mm (0.002 in)

SMALL END DEFLECTION

Service limit 3.0 mm (0.12 in)

SMALL END BORE DIA.

Service limit 16.040 mm (0.6315 in)

PISTON PIN O.D.

Service limit 11.980 mm (0.4717 in)

 SERVICING PROCEDURE 3-13

CARBURETOR
Clean each passage of air and fuel with an air
gun.

Richer

3013-3

Check for damage and replace if any.

Be sure to clean it when

overhauling

l
22.4±0.1 mm
( 0.88± 0.02 in)
3-14 SER VICING PROCEDURE

FLYWHEEL MAGNETO
Flywheel holder 09930-40113

~"136r
Apply thread lock

[ '-H~

Sliding shaft 09930-30102

Fix the stator to align the scribed line with
Attachment C 09930-30161
the center of the screw hole so that correct
ignition timing is assured.

Wipe off oil on the taper thoroughly.

3.0 - 3.5 kg-m

Timing advance Timing retard (22.0 - 25.5 lb-ft)

Using a timing light, check whether the ig-

nition timing is correct by running the
engine at 4 000 RPM and noting that the
marks are aligned properly.

Timing advance Timing retard

 SER VICING PROCEDURE 3-15

Specifications
D Ignition method: 2 sparks per crankshaft rotation
D Light capacity: 5.2 V or more at 2 500 r/min
8.5 V or less at 8 000 r/min
D Charging capacity: 0.7 A or more at 4 000 r/min
3.0 A or less at 8 000 r/min
D Secondary voltage: 12 kV or more at 500 - 8 000 r/min
D Ignition coil resistance: Primary Approx. 0.5 n
Secondary Approx. 15 kn

30'--~--1-~~/'~--1-----............~~~~---+~~---t-~~-+~~--+--~~--+-~
>
::.::'.
a,
Cl
co
+-'
/
'v ------i---..
25 l-----A-----+--------l----+----=..._~----+----+----------:J:--
i---_r----_ J Secondary voltage
>
0 201---/--f-----+----f--------+-----,f-----t-----f-------==r------;t;::;t--~
2:'
co
-0 15.--------<IO----+~~~--+-~~--+-~~~~~~--+~~~-+-~~~-t-~~~t----
c
0
(.)
a,
C/l

v, !
a,
~ I
I
Cl
a,
251--~~----+~~~-+-~~~-+-~~~-1----~~--f~~~--+~~~---t-~~~-t-~
0 I Ignition timing
...
u
0
'
1::!~
2ot--~--t~~---t-=:::::::;~----r-~--i·~---1---;;;;::::=t=::::t
i--= ~i...----- I ,

f9. 151--~~----+~,.,£-~-+-~~~-+-~~~-1----~~--f~~~--+~~~-+-~~~-t-~
c
Cl
/v I
E 10~-/+.-l----~----+---~~1----~~~--1.~~--+--~--t~~---+--
·.;:::;
c
0 I
+-' 5
c . i
Cl
I .
I Battery capacity

9
i I
I
i
8
/
--
I Lighting capacity
i I
i i
1
I
I
i
!
/ !

I I

/ !
i
!
I
I
I
Charging capacity
I

!
I

1____.--1 I I

0 2 3 4 5 6 7 x 1000
r/min.
3-16 SER VICING PROCEDURE

STATOR Pocket tester 09900-25002

• Select the knob to RX "x 1".

• Make a following continuity test.

Unit: (.n)

R/B OFF OFF OFF

180-
220

CHASSIS ELECTRICAL

IGNITION COIL

• Using the pocket tester check the ignition

coil.
Knob
Resistance position
High tension cord Core - 8/Y o-1n x 1n
8/Y Core - High tension Approx. 15 kn x kn
8/Y - High tension Approx. 15 kn xkn
 SER VICING PROCEDURE 3-17

Main Electro-tester 09900-28106

switch

• Wire as shown in the figure and turn the

main switch to ON.
• If a bluish white spark occurs continuous-
ly for about ten minutes, it is in good
condition. When a red spark, a poor spark
or no spark is found, replace it.

Black

PEI UNIT
PE I test lead for FZ50 09900-28605

• Wire as shown in the figure and turn the

main switch to ON.
• It is in good condition if the indicator
light comes on and remains lit. If the light
stays off, replace it.
Indicator light
3-18 SER VICING PROCEDURE

PEI Inspection by Pocket Tester

Positive (+) pointer to touch:

Black/Red Red/Black Black/White Black/Yellow
.c Black/Red OFF OFF OFF
-u
I : : :,
-o
a, ..... Red/Black 2-7 kn O- 20 kn OFF
> ....
..........
·-
m
a,
c: Black/White 2-7 kn -------------
o-2on OFF
------------
c,,_
a, 0
z c.. Black/Yellow OFF OFF OFF
-----------
Test conditions
• The pocket tester's selector knob should be set at "X 1n" or "X 1 kn" range referring to the
chart.
• The two testing probes, (+) and (-), are to be placed on terminals of the PEI unit referring to
the chart.
• The (+) probe or pointer is to be placed on one of the terminals listed in the top horizontal row,
and the (-) probe or pointer on the corresponding terminal listed in the vertical column.

NOTE:
• Whether or not the PEI unit is in good condition can be determined easily by temporarily
replacing it with a new one.
 SERVICING PROCEDURE 3-19

RECTIFIER
• If continuity is found in n range when
connecting as shown in the figure and not
found when (+) (-) probes are reversed, it
is in good condition. If continuity is
found in both cases or no continuity in
either case, replace it.

HORN
• If the sound volume is insufficient, turn
the adjusting screw while connecting the
horn directly to the battery till the maxi-
mum volume is found and set it there.
• After turning the adjusting screw, if no

o/ I
Adjusting
screw
sound is heard or the sound volume is in-
sufficient, replace it.

• Connect the lead wire in the headlight

housing and the ground wire to the
pocket tester, set knob range to R and
press the horn button. If continuity is
Horn button found, it is in good condition.
3-20 SER VICING PROCEDURE

SWITCHES
IGNITION SWITCH
Pocket tester 09900-25002

• Turn the ignition switch to ON and OFF

as shown in the chart below. If continui-
ty is found, it is in good condition. If
not, replace it.

LEFT HANDLE SWITCH

• Set it to high beam pos1t1on and check
continuity between gray and yellow. If
continuity is found, it is in good con-
dition.
• Set it to low beam position and check
continuity between gray and white. If
Y(Hi)
continuity is found, it is in good con-
dition. If not, replace it.

ENGINE KILL SWITCH

~=
• Set the kill switch to OFF position, con-
nect B/R wire and ground wire to the
pocket tester and check continuity. If
Ell&IIIESTOP
continuity is found, it is in good con-
dition.
• When the kill switch is set to RUN posi-
B/R tion, if no continuity is found, it is in
good condition.
 SERVICING PROCEDURE 3-21

FRONT AND REAR BRAKE SWITCH

• Place the pocket tester between orange
lead wire and white lead wire with the red
Front Brake Rear Brake tube and squeeze the brake lever. If con-
tinuity is found, it is in good condition.
If not, replace it.

0
3-22 SER VICING PROCEDURE

STEERING

~
a
~
0~
1
\ ~
!GREASE! • Check inner or outer races for wear.
~Check inner or outer
·\ races for wear

· ~ iGREASEI
Vo

• Number of steel balls

Upper ............. 22 pcs
Lower ............. 25 pcs
 SER VICING PROCEDURE 3-23

FRONT SUSPENSION

1.5 - 2.0 kg-m

~ (11.0 - 14.0 lb-ft)

Check the shock absorber

for oil leakage

1.0 - 1.5 kg-m

~ (7.5 - 11.0 lb-ft)

Check the bushing for

wear or damage

2.0 - 3.0 kg-m

1.0 -1.5 kg-m ~ (14.5-21.5 lb-ft)
~ (7.5 - 11.0 lb-ft)
3-24 SER VICING PROCEDURE

WHEELS AND BRAKES

WHEELS
Tire pressure
FRONT
~ 2.7 - 4.3 kg-m
·-· (20.0-31.0lb-ft)
1.5 - 2.0 kg-m
(11.0 - 14.5 lb-ft)

CAUTION:
When applying grease, be sure to apply
it thin to avoid damaging the brake
shoe and braking effeciency.

REAR
Tire pressure
1.50kg/cm 2 (21psi)

~ 1.5-2.0 kg-m
~ (11.0 - 14.5 lb-ft)

~ 0.5 - 0.8 kg-m

·. ·=-· ', (4.0 - 5.5 lb-ft)
 SER VICING PROCEDURE 3-25

BEARING
Front wheel bearing is of grease sealed type
and one side of it is sealed. If noise or ex-
cessive clearance is found when rotating it
by hand, replace it.
As to the rear wheel bearing, both sides are
sealed. If noise or excessive clearance is
found between the inner race and the outer
race or rotation is not smooth, replace it.

FRONT AXLE SHAFT

Measure the front axle shaft deflection.

Service limit 0.25 mm (0.01 in)

BRAKE DRUM
Measure inner diameter of both front and
rear drums.

Service limit
100.7 mm (3.96 in)
(Front and Rear)

BRAKE LINING THICKNESS

Service limit 1 .5 mm (0.06 in)

NOTE:
As an indicator is attached to the rear
brake shoe, if it indicates the limit line,
replace it.
3-26 SER VICING PROCEDURE

WHEEL RUNOUT
Measure axial and radial wheel rim runout of
front and rear wheels.

Service limit
2.0 mm (0.08 in)
(Axial and Radial)

Radial

TIRE
Measure both front and rear tire tread depth.

Service limit
1.6 mm (0.063 in)
( Front and Rear)
 SER VICING INFORMATION 4-1

SERVICING INFORMATION

TROUBLESHOOTING ........................................................................... 4- 2
SPECIAL MATERIALS ........................................................................... 4- 5
SPECIAL TOOLS .................................................................................... 4- 6
WIRE AND CABLE ROUTING ............................................................... 4- 8
WIRING DIAGRAM ................................................................................. 4-10
TIGHTENING TORQUE ........................................................................... 4-11
SERVICE DATA ....................................................................................... 4-12
4-2 SER VICING INFORMATION

TROUBLESHOOTING
HARD ENGINE STARTING OR NO ENGINE STARTING

ENGINE
1. Compression leakage from crank chamber
• Leakage from crankcase mating surface
• Leakage due to defective crankshaft oil seal
• Leakage from cylinder base gasket
• Damaged or improperly tightened reed valve

2. Compression leakage from combustion chamber

• Loose spark plug mounting
• Worn or sticking piston ring
• Defective or warped cylinder head mating surface
• Loose cylinder head tightening nut
• Damaged cylinder head gasket
• Piston seizure, wear or holed piston

FUEL CIRCUIT
1. Fuel line
• Clogged fuel cock strainer
• Damaged fuel cock diaphram
• Clogged fuel hose

2. Air passage
• Clogged tank cap breather hole
• Air intake due to defective fuel cock vacuum hose
• Air intake due to damaged reed valve gasket
• Air intake due to loose carburetor inlet mounting

3. Carburetor
• Clogged needle valve
• Clogged air jet or pilot jet
• Poor return of choke plunger

ELECTRICAL CIRCUIT
1. No sparking at spark plug
• Bridged, carbon fouled or wet spark plug
• Broken or short circuited ignition coil
• Broken or improperly connected engine ground wire
• Defective engine kill switch
• Defective PEI unit
• Poor contact of ignition switch
• Defective wiring among stator, PEI unit and ignition coil
• Poor contact between spark plug cap and high tension cord

2. Sparking at spark plug

• Improperly timed ignition
• Loose mounting part of stator or rotor
• Check engine unit or fuel circuit
 SER VICING INFORMATION 4-3

ENGINE STALLING
1. Improper idling r/min.
2. Compression leakage from crankcase (oil seal, mating surface)
3. Fouled or worn spark plug
4. Lean fuel/air mixture
• Clogged fuel hose
• Clogged gasoline tank cap
• Clogged carburetor jet
• Incorrect carburetor fuel level
• Air screw out of adjustment

NOT ENOUGH ENGINE POWER

1. Worn cylinder, piston or piston rings
2. Sticking piston ring
3. Defective spark plug gap
4. Clogged carburetor jet
5. Incorrect carburetor fuel level
6. Clogged air cleaner
7. Clogged exhaust muffler
8. Slipping clutch (see clutch slippage)

POOR ENGINE PERFORMANCE AT LOW-SPEED

1. Carburetor adjustment
• Air screw adjustment
• Idling r/min out of adjustment
• Incorrect fuel level

2. Ignition system
• Improperly timed ignition (improper stator mounting position)
• Incorrect spark plug gap

3. Air cleaner element ripped or leaking

4. Air intake through inlet hose
5. Damaged reed valve

POOR ENGINE PERFORMANCE AT HIGH-SPEED

1. Clogged carburetor jet
2. Defective jet needle clip piston
3. Clogged air cleaner element
4. Improperly timed ignition (improper stator mounting position)
5. Defective ignition coil
6. Incorrect spark plug gap
4-4 SER VICING INFORMATION

ENGINE OVERHEAT
1. Carbon deposit
• Cylinder head, piston crown, exhaust port, spark plug

2. Ignition timing too advance

3. Oil pump adjustment, defective oil pump
4. Lean fuel/air mixture
• Carburetor float level
• Clogged carburetor jet

5. Dragging brake

DEFECTIVE CLUTCH
1. Slipping clutch
• Worn or burnt clutch shoe

2. Disengaged clutch
• Poor operation of clutch drive shoe

3. Incorrect clutch-engagement r/min

• Defective clutch spring
• Worn or burnt clutch drive shoe

4. Not smooth idling

• Defective clutch spring
• Too high idling r/min.
 SER VICING INFORMATION 4-5

SPECIAL MATERIALS
MATERIAL REQUIRED FOR o Screws (securing read valve)
MAINTENANCE o Crankshaft left end nut
The materials listed below are required for o Muffler clamp bolt
o Horn adjusting screw
maintenance works on the Model FZ50,
and should be kept on hand for ready use.
In addition, such standard materials as
--- o Cylinder stud bolts

cleaning fluids, lubricants, etc., should also

be available. Methods of use are discussed
in the text of this manual.

Material Use
Thread lock cement
o Oil seals 99000-32040
o Cable (speedometer) o Crankshaft RH oil seal
! o Brake cam shaft (to outer surface of oil seal)
! o Speedometer gears o Magneto rotor nut
o Front shock absorber arm
and arm shaft

I
i
I
Suzuki super grease I

"A" 99000·25030 i Thread lock

i o Crankcase mating super "1303"
I
surface 99000-32030

USE OF GENUINE SUZUKI

PARTS
To replace any part of the machine, use a
genuine SUZUKI replacement part. Imi-
tation parts or parts supplied from any
other source than SUZUKI, if used to re-
Suzuki bond p Iace parts of SUZUKI origin in the ma-
No. 12078 chine, will lower the inherent capacity of the
99104-31140
machine and, even worse, could induce
o Muffler fitting bolt costly mechanical trouble.

Thread lock
"1342"
99000-32050
4-6 SER VICING INFORMATION

SPECIAL TOOLS

PEI Test lead Clutch holder Bearing remover (ID 12mm)

09900-28605 09920-30220 09921-20210

Snap ring pliers Impact driver set Thickness gauge

09900-06107 09900-09003 09900-20803

Torque wrench O - 450 kg-m CCI oil measuring tool Pocket tester
09900-21101 09900-21602 09900-25002

Electro tester (SS-I I) 6mm stud bolt installer Con rod stopper
09900-28106 09910-10110 09910-20115
 SER VICING INFORMATION 4- 7

Piston pin puller Bearing installer Crankshaft remover

0991 0-3451 0 09913-75820 09920-13120

Spark plug wrench Rotor remover (shaft) Attachment C (Screw 27mm)

09930-10111 09930-30102 09930-30161

Flywheel holder Steering stem lock nut wrench Steering race installer
09930-40113 09940-1 0122 09940-53111

Steering race installer

09941-34513
4-8 SER VICING INFORMATION

WIRE AND CABLE ROUTING

WIRING ROUTING
 0
l>
OJ
j"'
m
Speedometer cable
:::c
Choke cable 0
Front brake cable Rear brake cable c
---i
Front brake cable Throttle cable z
G)
Front fork

Throttle cable

~
~
:s
(j
~
(;

~
Horn clamp Speedometer cable 25
~

~
::j
0
<
-IS.
'C
 f"-
.....
0

r
FRONT BRAKE PEI UNIT MAGNETO Vl

!hi
LIGHT SWITCH t.~TION COIL h1
REAR BRAKE LIGHT SWITCH~

0 3:
1{
o~
3:>-
[W
mm mum,,0:: ~ ~'->-~ l5PARK PLUG
:>;:"J
:::;
Q
~

~5EoR TUBEt~.--- '.2:

'11
0
:>;:"J

~
::j
~ ~ >- ~ 0
CD CD
<
-=e
(5.3/17W)
TAIL/BRAKE LIGHT

t=~~-----j~~~~~~~~~~~+--+~~~~-1---1-===,i~i~ :0
~ T IIIII I T 1 1 ck Jr-
-
zG')

l i Jl
HEADLIGHT
(20/20W)
Q

~~
3:

;~f
c
-
~;~J ~W'-b~ U 1 ~
Fci',fE )>
G')

~?mf" ..
HIGH BEAM INDICATOR
(UW)
3: RECTIFIER :0
Q I '- 0::
)>
~ mm<Osoe
~
BATTERY
(6V 4Ah)
s
DIMME R SWITCH/ HORN
SWITCH
ENGINE KILL SWITCH OFF
WIRE COLOR
ON
SWITCH
W ...... White B/W .... Black with White tracer
Y ...... Yellow W/R .... White with Red tracer
R ...... Red B/Y .... Black with Yellow tracer
0 ...... Orange BIR .... Black with Red tracer
G ...... Green R/B .... Red with Black tracer
Gr ..... Gray
 SER VICING INFORMATION 4-11

TIGHTENING TORQUE
ITEM Q'TY kg-m lb-ft

ENGINE

Cylinder head nut 4 0.8 - 1.2 6.0 - 8.5

Exhaust pipe bolt 2 1.5 - 2.0 11.0-14.0
Muffler bolt 1 1.5 - 2.0 11.0-14.0
Clutch nut 1 2.0 - 3.0 14.5-21.5
Kick starter lifter lever nut 1 0.5 - 0.8 4.0 - 5.5
Kick starter lever bolt 1 0.5 - 0.8 4.0 - 5.5
Flywheel magneto nut 1 3.0 - 3.5 22.0 - 25.5

CHASSIS

Front brake cam lever nut 1 0.5 - 0.8 4.0 - 5.5

Front suspension arm lower nut 2 1.0-1.5 7.5 - 10.5
Front suspension arm rear nut 2 2.0 - 3.0 14.5 - 21.5
Front suspension arm damper nut 2 1.0 - 1.5 7.5 - 10.5
Front shock absorber upper bolt 2 1.5 - 2.0 11.0 - 14.0
Rearshockabsorberuppernut 1 2.0 - 3.0 14.5 - 21.5
Rear shock absorber lower bolt 1 2.0 - 3.0 14.5 - 21.5
Rear brake cam lever nut 1 0.5 - 0.8 4.0 - 5.5
Rear axle nut 1 3.6 - 5.2 26.5 - 37.5
Engine mounting nut 1 2.5 - 4.0 18.5 - 28.5
Front footrest nut 2 1.0-1.5 7.5 - 10.5
Handlebar expander bolt 1 5.0 - 6.5 36.5 - 47.0
Front axle nut 1 2.7 - 4.3 20.0 - 31.0
4-12 SER VICING INFORMATION

SERVICE DATA
PISTON + RING + CYLINDER Unit : mm (in)

ITEM STANDARD LIMIT

Piston - Cylinder clearance 0.070 - 0.080 (0.0028 - 0.0031) 0.120 (0.0047)

Cylinder bore 41.000 - 41.015 (1.6142 - 1.6148) 41.060 (1.6165)

Measuring point: 15 (0.60)
from the cylinder top
surface

Piston dia./Measurement point 40.925 - 40.940 (1.6112 - 1.6118) 40.880 (1.6094)

Measuring point: at a piston height of 23
(0.90)

Cylinder warpage - 0.05 (0.002)

Cylinder head warpage - 0.05 (0.002)

Piston ring free end gap AIKEN (Rl TEIKOKU (Tl RIKEN TEI KO KU
TYPE
(Rl (Tl

1st Keystone 4.5 (0.181 5.0 (0.20)

3.6 4.0
(0.14) (0.16)
2nd Keystone 4.5 (0.181 5.0 (0.20)

Piston ring end gap RIKEN (R) TEIKOKU (T)

0.10 - 0.25 0.10 - 0.25
1st&2nd
(0.004 - 0.010) (0.004 - 0.010) 0. 75 (0.030)

Piston ring width 1. 7 - 1 .9 (0.067 - 0.075)

1st

2nd 1.5 - 1. 7 (0.059 - 0.067)

Piston pin - Pin bore clearance 0.002 (tight) - 0.010 (0.0001 - 0.0004) 0.08 (0.0031)
Piston pin bore I.D. 11.998 - 12.006 (0.4724 - 0.4727) -
Piston pin O.D. 11.996 - 12.000 (0.4723 - 0.4724) 11.980 (0.4717)

CRANKSHAFT Unit : mm (in)

ITEM STANDARD LIMIT

Con-rod small end bore 16.003 - 16.011 (0.6300 - 0.6304) 16.040 (0.6315)
Con-rod deflection (small end) - 3.0 (0.12)
Con-rod big end wear - 0.08 (0.003)
Crankshaft runout - 0.05 (0.002)

OIL PUMP
ITEM SPECIFICATION

Oil pump reduction ratio 7.000 (14/2)

CCI pump discharge rate (Full open) 1.02 - 1.26 ml (cc) 6 minutes at 2 000 r/min
 SERVICING INFORMATION 4-13

CLUTCH Unit : mm (in)

ITEM STANDARD LIMIT

87.00 - 87.15 87.40
Low
(3.425 - 3.431) (3.441)
Clutch wheel I.D.
105.00 - 105.15 105.50
2nd
(4.134 - 4.140) (4.154)

Low - No groove at any part

Clutch shoe surface
2nd - No groove at any part

Low - Over 28.0 (1.06)

Clutch spring free length
2nd - Over 33.0 (1.30)

Clutch No. 1

Engagement r/min 2 500 ±200 r/min -

Lock up r/min 3 800 ±200 r/min -
Clutch No. 2 21 ±2 km/h -
Gear shift point (13 ±1 mph) -
0 - 0.03 0.1
Pri. drive - driven gear backlash
(0 - 0.0012) (0.004)

TRANSMISSION Unit : mm (in)

ITEM STANDARD LIMIT

Primary reduction 1.000

Final reduction 8.696 (31/13 x 62/17)

Gear ratios, Low 2.137 (62/29)

2nd 1.421 (54/38)

Gear backlash 0.05 - 0.10 (0.002 - 0.004) 0.15 (0.006)

Drive chain size D.I.D. "270 H" 64 links

20 pitch length 170.0 (6.69) 173.0 (6.83)

4-14 SER VICING INFORMATION

CARBURETOR Unit : mm (in)

ITEM SPECIFICATION

Idler/min 1 500 ±150 r/min

Carburetor type MIKUNI VM14SH

I.D. No. 02420

Bore size 14 mm (0.6 in)

Float height 22.4 ±1.0 (0.88 ±0.04)

Air screw 1% turns back

Throttle valve cut-away 2.0

Jet needle 3013-3

Pilot jet #15

Pilot outlet 0.9

Needle jet E-2

Main jet #57.5

ELECTRICAL Unit : mm (in)

ITEM SPECIFICATION

Ignition timing 20° B.T.D.C. at 4 000 r/min.

Spark plug NGK BP-4HA or ND W14FP-UL

Spark plug gap 0.6 - 0.8 (0.024 - 0.031)

Ignition coil resistance (primary) Approx. 0.5 .Q

Ignition coil resistance (secondary) Approx. 15 k.Q

Magneto coil resistance (charge) Y/R - W/R: Approx. 0.4 .Q

Magneto coil resistance (lighting) Y/R - Ground: Approx. 0.2 .Q

Magneto coil resistance (primary) B/R - R/B: Approx. 200 .Q
Battery capacity YUASA or FURUKAWA make "6N4-2A" 6V 14.4kC (4Ah)/10HR

Specific gravity 1.26 at 20°C (68°F)

Fuse size 10A

Lighting coil output Above 5.2V at 2 500 r/min, Below 8.5V at 8 000 r/min
 SERVICING INFORMATION 4-15

BRAKE + WHEEL Unit : mm (in)

ITEM STANDARD LIMIT

Axle runout ( Front & Rear) - 0.25 (0.010)

Brake drum I. D. Front: 100 (3.94) 100. 7 (3.96)

Rear: 100 (3.94) 100. 7 (3.96)

Brake lining thickness (Front & Rear) - 1.5 (0.06)

-,-------~·
Wheel rim runout ( Radial & Axial) - 2.0 (0.08)

Ti re size Front: 3.00 - 12 - 4PR

Rear: 3.00 - 12 - 4PR

Ti re Tread depth Front: - 1.6 (0.06)

Rear: - 1.6 (0.06)

TIRE AIR PRESSURE

FRONT REAR

125 kPa 150 kPa

(1.25 kg/cm2, 18 psi) (1.50 kg/cm2, 21 psi)

SUSPENSION Unit : mm (in)

ITEM STANDARD LIMIT

I I
Front wheel travel 78 (3.1)
I
Rear wheel travel 82 (3.2)
I

Engine mounting pivot shaft runout j - 0.6 (0.024)

I

CAPACITY Unit : mm (in)

ITEM SPECIFICATION

Fuel tank including reserve 4.5 L (1.2/1.0 US/Imp gal)

reserve 0.9 L (0.24/0.20 US/Imp gal)

Engine oil tank 1.2 L ( 1.27 /1.06 US/I mp qt)

Transmission oil Change: 800 ml (800 cc, 0.85/0.70 US/Imp qt)

Overhaul: 850 ml (850 cc, 0.90/0. 75 US/I mp qt)

Fuel type Unleaded or low-leaded gasoline

SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or

Engine oil type
equivalent good synthetic based 2-cycle oil

Transmission oil type Good quality SAE 20W/40 multi-grade motor oil
 FZSO"T" AND FZ50"X" 5-1

FZ50''T'' AND FZ50''X''

FOREWORD

The FZ50 "T" model was introduced as a new model in 1980. Many innovative refinements were
incorporated in the new model. The 1981 FZ50 "X" model utilizes the same technical innova-
tions that were introduced on the "T" model. This supplementary service manual has been
produced to aid Suzuki mechanics in properly maintaining and repairing both the 1980 'T" and
1981 "X" models.
This manual has been written primarily for the experienced Suzuki mechanic but will also be very
useful even for the amateur, do-it-yourself mechanic. The entire manual should be thoroughly
reviewed before any servicing is performed.

Please also refer to the FZ50 "N" MODEL (1979 MODEL) Service Manual for all other areas of
information not covered in this publication.

~ - - - - - - CONTENTS------~
VIEW OF SUZUKI FZSO"T" ............................................................... 5- 2
SPECIFICATIONS ................................................................................. 5- 3
TRANSMISSION OIL ........................................................................... 5- 5
''PEI" SYSTEM .................................................................................... 5- 6
FLYWHEEL MAGNETO ..................................................................... 5- 7
CHASSIS ELECTRICAL ..................................................................... 5- 8
SPECIAL MATERIALS ........................................................................ 5-11
SPECIAL TOOLS ................................................................................. 5-1 2
WIRE AND CABLE ROUTING ............................................................ 5-14
WIRING DIAGRAM .............................................................................. 5-16
SERVICE DATA .................................................................................... 5-17
VIEW OF SUZUKI FZSO''X'' ............................................................... 5-23
IGNITION COIL .................................................................................... 5-24
TURN SIGNAL LIGHT SWITCH ......................................................... 5-24
WIRING DIAGRAM .............................................................................. 5-25
SERVICE DATA .................................................................................... 5-26

Quoting, copying or otherwise using any ,i,art of this manual without explicit authorization from Suzuki Motor Co., Ltd. is not
permitted as all rights to the publication are reserved under copyright law.
5-2 FZ50"T" AND FZ50"X"

VIEW OF SUZUKI FZSO"T"

RIGHT SIDE VIEW

'I

LEFT SIDE VIEW

(.:,
I
 FZ50"T" AND FZ50"X" 5-3

SPECIFICATIONS
DIMENSIONS AND WEIGHT

Overal I length 1 650 mm (65.0 in)

Overall width 665 mm (26.2 in)
Overall height 990 mm (39.0 in)
Wheelbase 1 120 mm (44.1 in)
Ground clearance 120mm( 4.7in)
Dry mass (weight) 59 kg ( 130 lbs)

ENGINE

Type Two-stroke, air cooled

Intake system Reed valve
Number of cylinder
Bore 41.0 mm (1.614 in)
Stroke 37.4 mm ( 1.472 in)
Piston displacement 49 cm 3 (3.0 cu.in)
Corrected compression ratio 6.1 : 1
Carburetor MIKUNI VM14SH, single
Air cleaner Polyurethane foam element
Starter system Primary kick
Lubrication system SUZUKI "CCI"

TRANSMISSION

Clutch Wet shoe, automatic, centrifugal type

Transmission 2-speed
Gearshift pattern Automatic type
Primary reduction 1.000
Final reduction 8.696
(chain) 2.384 (31/13)
(gear) 3.647 (62/17)
Gear ratios, Low 2.137 (62/29)
2nd 1.421 (54/38)
Drive chain DAIDO D.I.D. 270H, 64 links
5-4 FZ50"T" AND FZ50"X"

CHASSIS

F rant suspension Bottom link oil dampened

Rear suspension Swinging arm
Steering angle 45° ( right & left)
Caster 63°00"
Trail 81 mm (3.19 in)
Turning radius 1.7 m (5.6 ft)
Front brake Internal expanding
Rear brake I nterna I expanding
Front tire size 3.00-12 4PR
Rear tire size 3.00-12 4PR
Front tire pressure 125 kPa (1.25 kg/cm 2 , 18 psi) (Normal solo riding)
Rear tire pressure 150 kPa (1.50 kg/cm 2 , 21 psi) (Normal solo riding)

ELECTRICAL

Ignition type SUZUKI "PEI"

Ignition timing 25° B.T.D.C. at 4 000 r/min
Spark plug NGK BP4HA or NIPPON DENSO W14FP-UL
Battery 6V 14.4kC (4Ah)/10 HR
Generator Flywheel magneto
Fuse 10A

CAPACITIES

Fuel tank including reserve 4.5 L (1.2 US gal)

reserve 0.2 L (0.2 US qt)
Engine oil tank 1.2 L ( 1.27 US qt)
Transmission oil 800 ml (0.85 US qt)

* These specifications are subject to change without notice.

 FZ50"T" AND FZ50"X" 5-5

TRANSMISSION OIL
Use a good quality SAE 20W/40 multi-grade .
motor oil.
5-6 FZ50T" AND FZ50"X"

"PEI" SYSTEM
In the FZ50 ignition system, the PEI system is used.
The PEI system uses a magneto as the power source, and the capacitor (condenser) momentarily
stores a charge up to hundreds of volts.
The charge is instantly discharged, at the specified ignition timing, to the ignition coil primary
winding, thus inducing a high surge of voltage in the secondary winding. As a result, a spark
occurs at the spark plug gap.
The PEI magneto has no breaker points and therefore it is free from mechanical trouble. This
ensures a stabler secondary high voltage and better spark performance.

Ignition coil

D
Spark plug

Magneto

CONNECTING DIAGRAM

Ignition switch
....L..

~
Magneto
Ignition
Coil
8/Y B/R-0-8/R

Spark

Plug l ..,.._..__ _..RIB -0-,

--
CD
a:

PEI Unit
 FZ50"T" AND FZSO"X" 5-7

FLYWHEEL MAGNETO
SPECIFICATIONS
O Ignition method: 2 sparks per crankshaft rotation
D Light capacity: 5.5 V or more at 2 500 r/min
8.5 V or less at 8 000 r/min
O Charging capacity:

0.7 A or more at 4 000 r/min

D Secondary voltage: 3.0 A or less at 8 000 r/min
O Ignition coil resistance: 12 kV or more at 500 - 8 000 r/min
Primary Approx. 0 - 1 n
Secondary Approx. 15 - 17 kn

35
>
~ 30
~ .......
Q)
Cl
....
Ctl
25
I ............ r-,-......___
,--............ ...____
0
>
>
ro
20
I
I r--- __ ;
Secondary voltage

"'O
c
0
(.)
Q)
CJ)
15

10
-
Ignition timing

- v
/
25
~
en
Q) ~ ~/
20
Cl~
c Cl
Q)
I/ r---.~
·-
Eo
Q)
15 /
·.;:::;
cU
0 .
I
.....
·- 0 10
·c I-
Cl .
- en 5

Night time Battery capacity (V)

/

--
9

8
> / __,,,. i..--"" \
- <t:
<t: -
u
u
Q)
7

6
- /
,.,,,, Lighting capacity (V)
O gi
- 0....
Q)
ro > 5
~v
a. ....
E
Ctl
~ ~ 4
/
....c (.):i
~
~
Cl
c 3
/
::J
(.)
·- ....
cCtl

-----
....
(.) ~
2
~
l....---"""'" -----
Q) Q)
.:: ~

--
0 <t:
" Night time Charging capacity (A)
0
2 3 4 5 6 7 8 9 10
x1 ,000 r/min
5-8 FZ50"T" AND FZ50"X"

STATOR Pocket tester 09900-25002

• Select the knob to RX "x 1".

• Make a following continuity test.

Unit: Approx. (n)

COLOR CODE APPROX. (n)

B/W-Y 0.4
B/W-W/R 0.75
B/R - R/B 230

CHASSIS ELECTRICAL

IGNITION COIL

• Using the pocket tester check the ignition

coil.
Knob
Resistance
position
Core - B/Y 0- 1.Q x 1n
Core - High tension Approx. 15-17 k.Q x k.Q
B/Y - High tension Approx. 15-17 k.Q x k.Q

High tension cord

Core
 FZ50"T" AND FZ50"X" 5-9

"PEI" UNIT
PEI test lead (coupler type) 09900-28607

• Wire as shown in the figure and turn the

main switch to ON.
/ ' • It is in good condition if the indicator
light comes on and remains lit. If the light
stays off, replace it.
09900- 28607

Indicator light

Main switch
ON
 5-10 FZ50"T" AND FZ50"X"

PEI Inspection by Pocket Tester

Positive (+) pointer to touch:

Black/White Black/Yellow Black/Red Red/Black
..c:
(J Black/White OFF 5- 7 S1 4-6 S1
:::, ' I
-o
I .,
-o
Cl) +-'
Black/Yellow OFF ~ OFF OFF

~
> ...
·+-'
- +-'
Cl) Black/Red 4-6S1 OFF OFF
en,_
"' c:
Cl) 0 Red/Black OFF OFF 15 - 17 S1
z Q.

Test conditions
• The pocket tester's selector knob should be set at "X 1S1" or "X 1 kS1" range referring to the
chart.
• The two testing probes,(+) and (-), are to be placed on terminals of the PEI unit referring to
the chart.
• The (+) probe or pointer is to be placed on one of the terminals listed in the top horizontal row,
and the (-) probe or pointer on the corresponding terminal listed in the vertical column.

NOTE:
• Whether or not the PE I unit is in good condition can be determined easily by temporarily
replacing it with a new one.
 FZ50"T" AND FZ50"X" 5-11

SPECIAL MATERIALS
MATERIAL REQUIRED FOR o Screws (securing read valve)
MAINTENANCE o Crankshaft left end nut
The materials listed below are required for o Muffler clamp bolt
o Horn adjusting screw
maintenance works on the Model FZ50,
and should be kept on hand for ready use.
In addition, such standard materials as
--- o Cylinder stud bolts

cleaning fluids, lubricants, etc., should also --- i

be available. Methods of use are discussed
in the text of this manual.

Material Use
Thread lock cement
o Oil seals 99000-32040
o Cable (speedometer)
o Crankshaft RH oi I seal
o Brake cam shaft
(to outer surface of oil seal)
o Speedometer gears
o Magneto rotor nut
o Front shock absorber arm
and arm shaft

Suzuki super grease

"A" 99000-25030 Thread lock
o Crankcase mating super "1303"
surface 99000-32030

Suzuki bond
No. 12078
99104-31140
o Muffler fitting bolt

Thread lock
"1342"
99000-32050
5-12 FZ50"T" AND FZ50"X"

SPECIAL TOOLS

Snap ring pliers (opening type)

09900-06107

Micrometer
Dial gauge
09900-20205 (O- 25 mm)
09900-20202 (25 - 50 mm)
Cylinder gauge set
09900-20508 6
09900-20606 (0 - 10 mm, 1 0 mm)

Torque wrench
Thickness gauge 09009-21102 (0 - 120 kg-cm) CCI oil gauge
09900-20803 09900-21103 (100 - 900 kg-cm) 09900-21602
II
1,
I,
11
,, i
I,
Ii---------

Pocket tester Electro-tester Hydrometer

09900-25002 09900-28106 09900-28403

PE I test lead Stud bolt installer Piston pin puller

09900-28607 099 10- 10110 09910-34510

Bearing installer Crankshaft remover Clutch holder

09913-75820 09920-13120 09920-30220
 FZ50"T" AND FZ50"X" 5-13

Bearing remover Spark plug wrench Rotor remover slide shaft

09921-20210 09930-10111 09930-30102

Attachment C (27 mm screw) Rotor holder Steering stem nut wrench

09930-30161 09930-40113 09940-101 22

Steering race and swing arm

Spoke nipple wrench Steering race installer baring installer
09940-60113 09940-53111 09941-34513

Tire pressure gauge

96200-41330
 Turn signal relay
:e- ';'i
......
-Is.
Meter/Handlebar switch lead wires
lJ
m
lJ ~
...,..
0 c::,
c -4
-t
~
PEI Unit z
c, @
~
< C?
<
from the left side
-
lJ
><

(ignition lead) Tail/Brake light m

l>
z
c
(')
l>
OJ
r-
m
lJ
0
c:
Horn -z
~

c,
 0
)>
O'J
r-
m
::0
0
Front brake cable Rear brake cable c
Front brake cable ::!
Rear brake cable
z
G')
Front fork

Clamp them with wiring harness Speedometer

Front
f

Rear brake cable

Throttle cable

pivot

~
Cable guide plate "'
0

i
::is
§
Speedometer cable
~
"'
0

Rear brake cable

·---Elf-- y,
......
"'
 \'......>
°'
~
~
c
i
Im
FRONT BRAKE PEI UNIT
WIRE COLOR ~ MAGNETO ::i.
}r ~
LIGHT SWITCH
~
tr
G ....................... Green REAR BRAKE LIGHT SWITCH ~GNITION COIL
Gr ...................... Gray
II ~~

ff .m. . >
a: ~ ai
O ....................... Orange 03: 03: 3:> a:m
maimer ~a: 3:
1SPARK PLUG

RJ ri ~~ ,I,~~:~~~
R ....................... Red
><
W ...................... White
Y ....................... Yellow
B/R .................... Black with Red tracer
,---- TUB B/R~ ~ TUBE
B/Y
B/W ................... Black with White tracer
B/Y .................... Black with Yellow tracer
R/B .................... Red with Black tracer
~
m aia: .
a:a::~
:e-
W/R ................... White with Red tracer
Y/R .................... Yellow with Red tracer
'
>'3: '
m
TAIL/BRAKE LIGHT -z
:D
C)
.------+----~ r II I lI I ! I : 1 111'C~:~ -l>c
l.~f It ~
HEADLIGHT

n ~~~.l~H
.
C)

HIGH BEAM INDICATOR

• •~ ~ ]
1
11 l Fci',SE
:D
l>
s:
_____w_ li:" Q I ' a:
RECTIFIER

~l' ~
h
;,;,~>o•
BATTERY
DIMMER SWITCH / HORN
SWITCH
ENGINE KILL SWITCH OFF
ON
 FZ50"T" AND FZ50"X" 5-17

SERVICE DATA
CYLINDER+ PISTON+ PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.070 - 0.080 0.120
( 0.0028 - 0.0031 ) I ( 0.0047 )
Cylinder bore 4 1.000 - 4 1.015
41.060
( 1.6142 - 1.6148 )
( 1.6165 )
Measure at the 15 ( 0.6 ) from top surface.

Piston diam. 40.925 - 40.940

I
40.880
( 1.6112 - 1.6118 ) I
( 1.6094 )
Measure at the 23 ( 0.9 ) from skirt end.[
I

Cylinder distortion ' 0.05

i
( 0.002 )
I
Cylinder head distortion I 0.05
I ( 0.002 )
I

Piston ring free end gap 4.5 3.6

R Approx. ( 0.14 )
( 0.18 ) I
1st !
5.0 4.0
T Approx. ( ) )
0.20 I ( 0.16
4.5 3.6
R i Approx. ( 0.18 ) ( 0.14 )
2nd
5.0 4.0
T Approx.
( 0.20 ) ( 0.16 )

Piston ring end gap 0.10- 0. 25 0.75

( 0.004 - 0.010 ) I ( 0.030 )
I

Piston ring to groove clearance 0.020 - 0.060

1st I
( 0.0008 - 0.0024 ) I

0.020 - 0.060 I
2nd
( 0.0008 - 0.0024 ) I

Piston pin bore 11.998 - 12.006 12.030

I
( 0.4724 - 0.4727 ) ' ( 0.4736 )
'
Piston pin 0. D. 11.996 - 12.000 11.980
( 0.4723 - 0.4724 ) ( 0.4717)
5-18 FZ50"T" AND FZ50"X"

CONROD+ CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003 - 16.011 16.040
( 0.6300 - 0.6304 ) ( 0.6315 )
Conrod deflection 3.0
( 0.12 )
Crank web to web width 40.0 ± 0.1
( 1.57 ± 0.004 )

Crankshaft runout 0.05

( 0.002 )

OIL PUMP
ITEM SPECIFICATION

Oil pump reduction ratio 7.000 ( 14 I 2 )

CCI pump discharge rate ml

1.02 - 1.26
(Full open) (0.034/0.036- 0.043/0.044US/lmp oz)
for 6 minutes at 2000 r/min.

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I. D. 87.00 - 87.15 87.40
Low )
( 3.425 - 3.431 ( 3.441 )
105.00 - 105.15 105.50
High ( 4.134 - 4.140 ) ( 4.154 )
Clutch shoe 0. D. 86.9 - 87.0 No groore at any
Low
( 3.42 - 3.43 ) part
104.7 - 104.8 No groore at any
High
( 4.12 - 4.13 ) part
Clutch engagement
2500 ± 200 r/min.

Clutch lock-up 3700 ± 300 r/min.

Clutch spring free length Low 28

( 1.10 )
33
High
( 1.30 )
 FZSO"T" AND FZSO"X" 5-19

TRANSMISSION Unit: mm (in)

ITEM STANDARD LIMIT

Primary reduction ratio 1.000

Final reduction ratio 8.696 (31 / 13 X 62 / 17)

Gear ratios Low 2.137 ( 62 / 29 )

2nd 1.421 ( 54 / 38 )

Shih fork thickness 0.05 - 0.10 0.15

( 0.002 - 0.004 ) ( 0.006 )

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain
Type D.I.D.: 270 H

Links 64

! 170.0 173.0
20 pitch length I
I
I ( 6.69 ) ( 6.83 )
CARBURETOR Unit: mm (in)
SPECI FICA Tl ON
ITEM

Carburetor type MIKUNI VM 14SH

Bore size 14 (0.6)

I. D. No. 02420

Idler/min. 1500 ± 150 r/min.

FI oat height 22.4 ± 1.0

( 0.88 ± 0.04 )

Mai_n jet (M. J.) ff 57.5

Air jet (A. J.) 2.5

Jet needle (J. N.) 3013-3

Needle jet (N. J.) E-2

Cut-away (C. A.) 2.0

Pilot jet (P. J.) # 15

Pilot outlet (P. 0.) 0.9

Air screw (A. S.) 1%

Valve seat (V. S.) 1.2

Starter jet (G. S.) 35

Throttle cable play 0.5 - 1.0

( 0.02 - 0.04 )
5-20 FZ50"T" AND FZ50"X"

ELECTRICAL Unit· mm (in)

ITEM SPECI FICA Tl ON NOTE

Ignition timing
25° ± 20 B.T.D.C. at 4000 r/min.

Spark plug NGK BP4HA or NIPPON

Type
DENSO W14FP-UL
0.6 - 0.8
Gap ( 0.024 - 0.031 )
B/Y - Ground
Ignition coil resistance Primary Approx. 0-1 S2
Plug cap -Ground
Secondary 15 - 17
Approx. kS2

Magneto coil resistance Y/R - Ground

Lighting
Approx. 0-1 .Q
W/R - Ground
Charge
Approx. 0- 1 .Q
B/R - R/B
Primary
Approx. 180 - 220 .Q

Charging rate Above 0. 7 A at 4000 r/min.

Night
Below 3.0 A at 8000 r/min.
Lighting coil output Above 5.5 Vat 2500 r/min.
Below 8.5 Vat 8000 r/min.
Battery Type designation 6N4-2A

Capacity 6V 14.4kC(4Ah)/1 OHR

Standard
1.26 at 20°C (68°F)
electrolyte S. G.
Fuse size 10 A
 FZ50"T" AND FZ50"X" 5-21

BRAKE+ WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake lever distance 20- 30
( 0.8 - 1.2 )

Rear brake lever distance 20 - 30

( 0.8 - 1.2 )

Brake drum I. D. 100.7

Front
( 3.96 )
Rear
100.7
( 3.96 )
Brake lining thickness 1.5
( 0.06 )
Wheel rim runout 2.0
Axial
( 0.08 )
2.0
Radial
( 0.08 )
Wheel axle runout 0.25
Front ( 0.010 )
Tire size 3.00 - 12 4PR
Front

Rear 3.00- 12 4PR

Tire tread depth 1.6

Front
( 0.06 )
1.6
Rear
( 0.06 )

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Engine mounting pivot shaft runout 82
( 3.1 )

Swing arm pivot shaft runout 0.6

( 0.02 )
5-22 FZ50"T" AND FZ50"X"

FUEL+OIL
ITEM SPECIFICATION NOTE

Fuel type Use only unleaded or low-lead type gasoline of at

least 83 - 95 pump octane ( R; M method) or
89 octane or higher rated by the Research method.

Fuel tank including reserve 4.5 L

( 1.2 I 1.0 US/Imp gal)
reserve 0.2 L
( 0.21 I 0.18 US/Imp qt)
Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality
synthetic based 2-cycle oil.

Engine oil tank capacity 1.2 L

( 1.3 I 1. 1 US/Imp qt)

Transmission oil type SAE 20W/40

Transmission oil capacity 800 ml

Change
( 0.85 I 0.70 US/Imp qt)
850 ml
Overhaul
( 0.90 I 0.75 US/Imp qt)

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE

kPa kg/cm 2 psi

FRONT 125 1.25 18

REAR 150 1.50 21

WATTAGE W (CP)
I ITEM SPECIFICATION

Headlight HI 20

LO 20

Tail/Brake light 5.3/17(3/21)

High beam indicator light 1.7

 FZSO"T" AND FZSO"X" 5-23

VIEW OF SUZUKI FZSO"X"

RIGHT SIDE VIEW

LEFT SIDE VIEW

5-24 FZ50"T" AND FZ50"X"

IGNITION COIL

• Using the pocket tester check the ignition

coil.
Knob
Resistance
position
Core - B/Y 0 -1D x 1D
Core - High tension Approx. 4-6kD x kD
B/Y - High tension Approx. 4-6kD x kD

High tension cord

Core

TURN SIGNAL LIGHT SWITCH

Check the conductivity between the lead
terminals on the left handle switch box
when the turn signal indicator knob is
operated.
If there is conductivity where no connection
is shown in the table or no conductivity
where a connection is indicated, replace
I~[ the switch.

~
c..:2:..=io
_1) +
B Lbl Lg
Left ~ l-o
Right 0 -0
 :e-
z-
:D
WIRE COLOR RIGHT HANDLEBAR SWITCH

B ....................... Black ENGINE KILL ;:~T~~ BRAKE LIGHT MAGNETO IGNITION COi L C)

~ W,t
G ....................... Green

-l>c
TURN SIGNAL

Gr ...................... Gray B/R .................... Black with Red tracer

Lbl ..................... Light blue B/W ................... Black with White tracer
Lg ...................... Light green B/Y .................... Black with Yellow tracer
>-
C)
0 ....................... Orange R/B .................... Red with Black tracer a5
R ....................... Red W /B ................... White with Black tracer :c; ij 6 :D
...J O
l>
W ...................... White
Y ....................... Yellow
W/R ................... White with Red tracer
Y/R .................... Yellow with Red tracer coa:
~
s
-co
0:
-~
0:
-:s:: s:
®:i
FRONT TURN SIGNAL LIGHT IR)
O S:
REAR TURN SIGNAL LIGHT
IR)

Lg ~
TURN SIGNAL INDICATOR f2>r-- Lg Lg-C31--- Lg
LIGHT ~B

W/B-c:31--~
t-~~~+-+-~~~~~~~+---1~~~~~~~~~~-+-~~~+-~0----------c3t--O ~

HEADLIGHT

~ l!ITlll I~
TAIL/BRAKE LIGHT

> >I "s: o c:, "'--'"'

111111 =11£0
~ m<:J"> o a:
1
!
I
::: a:~ FUSE
B----C?:1-----B~

REAR TURN SIGNAL LIGHT

~
> <:J --' ; 0: IL)

l'Xo
0:
a, l10AI
i
FRONT TURN SIGNAL LIGHT I FRAME EARTH ~a:
IL) l?r-B/W _J Q
~y ~~
HIGH BEAM INDICATOR
LIGHT Ll a:
J...J
-f4- N
v,

HI
LO
OFF
ON
LJ
BATTERY
RECTIFIER
0

--:i
;,,.
§
HORN BUTTON

LE FT HANDLEBAR SWITCH
~
0

v,
~
v,
5-26 FZ50"T" AND FZ50"X"

SERVICE DATA
CYLINDER+ PISTON+ PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.070 - 0.080 0.120
( 0.0028 - 0.0031 ) ( 0.0047)
Cylinder bore 41.000-41.015 41.060
( 1.6142 - 1.6148 )
( 1.6165 )
Measure at the 15 ( 0.6 ) from top surface.

Piston diam. 40.925 - 40.940 40.880

( 1.6112 - 1.6118 ) ( 1.6094 )
Measure at the 23 ( 0.9 ) from skirt end.

Cylinder distortion 0.05

( 0.002 )

Cylinder head distortion 0.05

( 0.002 )

Piston ring free end gap 4.5 3.6

R Approx. ( ) ( 0.14 )
0.18
1st
5.0 4.0
T Approx. ( ) )
0.20 ( 0.16
4.5 3.6
R Approx.
( 0.18 ) ( 0.14 )
2nd
5.0 4.0
T Approx.
( 0.20 ) ( 0.16 )
Piston ring end gap 0.10- 0. 25 0.75
( 0.004 - 0.010 ) ( 0.030 )

Piston ring to groove clearance 0.020 - 0.060

1st
( 0.0008 - 0.0024 )

2nd 0.020 - 0.060

( 0.0008 - 0.0024 )
Piston pin bore 11.998 - 12.006 12.030
( 0.4724 - 0.4727 ) ( 0.4736 )
Piston pin 0. D. 11.996 - 12.000 11.980
( 0.4 723 - 0.4 724 ) ( 0.4717)

CONROD+ CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003 - 16.011 16.040
( 0.6300 - 0.6304 ) ( 0.6315 )
Conrod deflection 3.0
( 0.12 )
Crank web to web width 40.0 ± 0.1
( 1.57 ± 0.004 )

Crankshaft runout 0.05

( 0.002 )
 FZ50"T" AND FZ50"X" 5-27

OIL PUMP
ITEM SPECIFICATION

Oil pump reduction ratio 7.000 ( 14 I 2 )

CCI pump discharge rate 1.02 - 1.26 ml

(Full open) (0.034/0.036 - 0.043/0.044 US/Imp oz)
for 6 minutes at 2000 r/min.

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I.D. 87.00- 87.15 87.40
Low
( 3.425 - 3.431 ) ( 3.441 )
105.00 - 105.15 105.50
High ( 4. 134 - 4. 140 ) ( 4.154 )
Clutch shoe 0.0. 86.9 - 87.0 No groore at any
Low
( 3.42 - 3.43 ) part
104.7 - 104.8 No groore at any
High
( 4.12- 4.13 ) part
Clutch engagement
2500 ± 200 r/min.

Clutch lock-up 3700 ± 300 r/min.

Clutch spring free length Low 28

( 1.10 )
33
High
( 1.30 )

TRANSMISSION Unit: mm (in)

ITEM STANDARD LIMIT

Primary reduction ratio 1.000

Final reduction ratio 8.696 (31 I 13 X 62 I 17)

Gear ratios Low 2.137 ( 62 I 29 )

2nd 1.421 ( 54/ 38 )

Shift fork thickness 0.05 - 0.10 0.15

( 0.002 - 0.004 ) ( 0.006 )

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270 H

Links 64
170.0 173.0
20 pitch length
I ( 6.69 ) ( 6.83 )
5-28 FZ50"T" AND FZ50"X"

CARBURETOR Unit: mm (in)

ITEM SPECI FICATl ON
Carburetor type MIKUNI VM 14SH

Bore size 14 (0.6)

1.D. No. 02421

Idler/min. 1500 ± 150 r/min.

Float height 22.4 ± 1.0

( 0.88 ± 0.04 )

Main jet (M. J.) # 57.5

Air jet (A. J.) 2.5

Jet needle (J. N.) 3013-3

Needle jet (N. J.) E-2

Cut-away (C. A.) 2.0

Pilot jet (P. J.) =t= 15

Pilot outlet (P. 0.) 0.9

Air screw (A. S.) 1%

Valve seat (V. S.) 1.5

Starter jet (G. S.) 35

Throttle cable play 0.5- 1.0
( 0.02 -0.04 )
 FZ50"T" AND FZ50"X" 5-29

ELECTRICAL Unit· mm (in)

ITEM SPECI FICATl ON NOTE

Ignition timing
25° ± 20 B.T.D.C. at 4000 r/min.

Spark plug NGK BP4HA or NIPPON

Type
DENSO W14FP-UL
0.6 - 0.8
Gap ( 0.024 - 0.031 )
8/Y - Ground
Ignition coil resistance Primary Approx. 0-1 Q
Plug cap - Ground
Secondary
Approx. 4-6 kn
Magneto coil resistance BIW-Y
Lighting
Approx. 0.4 n
8/W-W/R
Charge
Approx. o.75n
8/R - R/8
Primary
Approx. 23on
Charging rate Above 0. 7 A at 4000 r/min.
Night
Below 3.0 A at 8000 r/min.
Lighting coil output Above 5.5 Vat 2500 r/min.
Below 8.5 Vat 8000 r/min.
Battery Type designation 6N4-2A

Capacity 6V 14.4kC(4Ah)/1 OHR

Standard
1.26 at20°C (68°F)
electrolyte S. G.
Fuse size 10 A
5-30 FZ50"T" AND FZ50"X"

BRAKE+ WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake lever distance 20-30
( 0.8- 1.2 )

Rear brake lever distance 20-30

( 0.8 - 1.2 )

Brake drum I. D. 100.7

Front
( 3.96 )

Rear
100.7
( 3.96 )

Brake lining thickness 1.5

( 0.06 )

Wheel rim runout 2.0

Axial )
( 0.08
2.0
Radial ( )
0.08
Wheel axle runout 0.25
Front ( )
0.010
Tire size 3.00 - 12 4PR
Front

Rear 3.00- 12 4PR

Ti re tread depth 1.6

Front ( )
0.06
1.6
Rear
( 0.06 )

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Engine mounting pivot shaft runout 82
( 3.1 )
Swing arm pivot shaft runout 0.6
( 0.02 )
 FZ50"T" AND FZ50"X" 5-31

FUEL+OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline of at
least 83 - 95 pump octane ( R; M method) or
89 octane or higher rated by the Research method.

Fuel tank including reserve 4.5 L

{ 1.2 I 1.0 US/Imp gal)
reserve 0.2 L
{ 0.21/0.18 US/Imp qt)
Engine oil type Use SUZUKI CCI SUPER 2-CYCLE MOTOR
LUBRICANT or an equivalent good quality
synthetic based 2-cycle oil.

Engine oil tank capacity 1.2 L

{ 1.3 I 1.1 US/Imp qt)

Transmission oil type SAE 20W/40

Transmission oil capacity 800 ml
Change
{ 0.85 I 0.70 US/Imp qt)
850 ml
Overhaul
{ 0.90 I 0.75 US/Imp qt)

TIRE PRESSURE
NORMAL RIDING
i
COLD INFLATION
I SOLO RIDING
TIRE PRESSURE
!
I I
I
kPa I kg/cm 2 1 psi
!
FRONT I
125 i 1.25 18

REAR 150 I 1.50 21

WATTAGE W (CP)
ITEM SPECIFICATION
Headlight HI 20
I
LO 20
I

Tail/Brake light 5.3/17(3/21)

i

Turn signa I I ight 17

I
Turn signal indicator light I
3
I
High beam indicator light 1.7
I
 FZ50"Z" 6-1

FZ50''Z''

SERVICE DATA .................................................................................... 6- 1

6-2 FZ50"Z"

SERVICE DATA

CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065-0.075 0.120
Cylinder bore 41.000-41.015
41.060
Measure at the 1 5 from top surface
Piston diam. 40.930-40.945
40.880
Measure at the 23 from skirt end
Cylinder distortion -- 0.05
Cylinder head distortion -- 0.05
Piston ring free end gap R Approx. 4.5 3.6
1st
T Approx. 5.0 4.0
R Approx. 4.5 3.6
2nd
T Approx. 5.0 4.0
Piston ring end gap 0.10-0.25 0.75
Piston ring to groove clearance 1st 0.020-0.060 --
2nd 0.020-0.060 --
Piston pin bore 11.998-12.006 12.030
Piston pin O.D. 11.995-12.000 11.980

CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003-16.011 16.040
Conrod deflection -- 3.0
Crank web to web width 40.0 ± 0.1 --
Crankshaft runout -- 0.05

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 7.000 ( 14/2 )
CCI pump discharge rate (Full open) 1.02-1.26 ml
for 6 minutes at 2 000 r/min.
 FZ50"Z" 6-3

CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch wheel I.D. Low 87.00-87.15 87.40
High 105.00-105.1 5 105.50
Clutch shoe O.D. No groove at any
Low 86.9-87.0
part

High No groove at any

104.7-104.8
part
Clutch engagement 2 500 ± 200 r/min. --
Clutch lock-up 3 700 ± 300 r/min. --
Clutch spring free length -- 28
-- 33

TRANSMISSION Unit: mm
ITEM STANDARD LIMIT
Primary reduction ratio 1.000 --
Final reduction ratio 8.696 ( 31/13x62/17 ) --
Gear ratios Low 2.137 ( 62/29 ) --
2nd 1.421 ( 54/38 ) --

DRIVE CHAIN Unit: mm

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270H --
Links 64 --
20 pitch length I 170.0 173.0
6-4 FZ50"Z"

CARBURETOR Unit: mm
ITEM SPECIFICATION
Carburetor type MIKUNI VM 14SH
Bore size 14
I.D. No. 02421
Idle r/min. 1 500± 150 r/min.
Float height 22.4 ± 1.0
Main jet (M.J.) 57.5
Air jet (A.J.) 2.5
Jet needle (J.N.) 3013-3rd
Needle jet (N.J.) E-2
Cut-away (C.A.) 2.0
Pilot jet (P.J.) #15
Pilot outlet (P.O.) 0.9
Air screw (A.S.) 1 3/4 turn out
Valve seat (V.S.) 1.5
Starter jet (G.S.) #35
Throttle cable play 0.5-1.0
 FZ50"Z" 6-5

ELECTRICAL Unit: mm
ITEM SPECIFICATION NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4 000 r/min.
Spark plug NGK BP4HA or NIPPON
Type
DENSO W1 4EP-UL
Gap 0.6-0.8
Ignition coil resistance Primary B/Y-Ground
Approx. 2-4 n

Secondary Plug cap-Ground

Approx. 5- 7 kn
Magneto coil resistance B/W-Y/W
Lighting
Approx. 0.24 n
Charge B/W-W/R
Approx. 0.32 n

Primary B/R-R/B
Approx. 205 n
Charging rate Night Above O.BA at 4 000 r/min.
Below 2.5 A at 8 000 r/min.
Lighting coil output Above 6.2 V at 2 500 r/min.
Below 9.4 V at 8 000 r/min.
Battery Type designation 6N4-2A
Capacity 6V14.4kC(4Ah)/1 OHR
Standard
electrolyte S.G. 1.26 at 20°C (68°F)

Fuse size Main 10 A

6-6 FZ50"Z"

WATTAGE (W)

ITEM SPECIFICATION
Headlight HI 20
LO 20
Tail/Brake light 5.3/17
Turn signal light 17
Turn signal indicator light 3
High beam indicator light 1.7

BRAKE + WHEEL Unit: mm

ITEM STANDARD LIMIT
Front brake lever distance 20-30 --
Rear brake pedal free travel 20-30 --
Brake drum I.D. Front -- 100.7
Rear -- 100.7
Brake lining thickness -- 1.5
Wheel rim runout Axial -- 2.0
Radial -- 2.0
Wheel axle runout Front -- 0.25
Tire size Front 3.00-12 4PR --
Rear 3.00-12 4PR --
Tire tread depth Front -- 1.6
Rear -- 1.6

SUSPENSION Unit: mm
ITEM STANDARD LIMIT NOTE
Pivot shaft runout -- 0.6
 FZ50"Z" 6-7

TIRE PRESSURE
COLD INFLATION
kPa kg/cm 2 psi
TIRE PRESSURE
FRONT 125 1.25 18
REAR 150 1.50 22

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline
of at least 85-95 pump octane (R;M method)
or 89 octane or higher rated by the Research
method.
Fuel tank including reserve 4.5 L
reserve 0.2 L
Engine oil type Use SUZUKI CCI SUPER 2-CYCLE
MOTOR LUBRICANT or an equivalent
good quality synthetic based 2-cycle oil.
Engine oil tank capacity 1.2 L
Transmission oil type SAE 20W/40
Transmission oil capacity Change 800 ml
Overhaul 850 ml
 FZ50"D" 7-1

FZ50''D''

r--~~~~~~coNTENTs~~~~~~--,
SERVICE DATA .................................................................................... 7- 1
7-2 FZ50"D"

SERVICE DATA

CYLINDER+ PISTON+ PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065 - 0.075 0.120
( 0.0026 - 0.0030 ) ( 0.0047 )
Cylinder bore 41.000 - 41.015
41.065
( 1.6142 - 1.6148 ) ( 1.6167)
Measure at 15 ( 0.6 ) from the top surface.

Piston diam. 40.930 - 40.945

40.880
( 1.6114 - 1.6120 ) ( 1.6094 )
Measure at 23 ( 0.9 ) from the skirt end.
Cylinder distortion 0.05
( 0.002 )
Cylinder head distortion 0.05
( 0.002 )

Piston ring free end gap 4.5 3.6

1st R Approx. ( 0.18 ) ( 0.14 )

T Approx. 5.0 4.0

( 0.20 ) ( 0.16 )

R Approx. 4.5 3.6

2nd ( 0.18 ) ( 0.14 )

T Approx. 5.0 4.0

( 0.20 ) ( 0.16 )
Piston ring end gap 0.10- 0.25 0.75
( 0.004 - 0.010 ) ( 0.030 )

Piston ring to groove clearance 1st 0.020 - 0.060

( 0.0080 - 0.0024 )
2nd 0.020 - 0.060
( 0.0080 - 0.0024 )
Piston pin bore 11.998 - 12.006 12.030
( 0.4 724 - 0.4 727 ) ( 0.4736 )
Piston pin 0. D. 11.996 - 12.000 11.980
( 0.4 723 - 0.4 724 ) ( 0.4717 )
 FZ50"D" 7-3

CONROD+ CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003 - 16.011 16.040
( 0.6300 - 0.6304 ) ( 0.6315)
Conrod deflection 3.0
( 0.12 )
Crank web to web width 40.0 ± 0.1
( 1.57 ± 0.004 )

Crankshaft runout 0.05

( 0.02 )

OIL PUMP
ITEM SPECIFICATION

Oil pump reduction ratio 7.000 ( 14/2 )

CCI pump discharge rate 1.01 - 1.24 ml
(Full open) ( 0.037 /0.036 - 0.042/0.044 US/I mp oz )
for 5 minutes at 2000 r/min.
7-4 FZ50"D"

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I. D. 87.00 - 87.15 87.40
No 1 ( 3.441 )
( 3.425 - 3.431 )
105.00 - 105.15 105.40
No 2
( 4.134 - 4.140) ( 4.154 )
Clutch shoe 0. D. 86.90 - 87.00 No groove
No 1 at any part
( 3.421 - 3.425 )
104. 70 - 104.80 No groove
No 2 ( 4. 122 - 4.126 ) at any part
Clutch engagement
Low 2600 ± 200 r/min.

Clutch lock-up Low 3650 ± 250 r/min.

Gear shifting point Low to

top 18 - 22 km/h

Clutch spring free length 35.7

No 1
( 1.41 )
40.4
No 2 ( 1.59 )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT

Final reduction ratio 3.647 ( 62/17 )

Gear ratios Low 18.593 (62/29 x 31/13 x 62/17)

Top 12.358 (54/38 x 31/13 x 62/17)

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270H
~

Links 64
'
173.4
20 pitch length ( 6.83 )
I
 FZSO"D" 7-5

CARBURETOR
ITEM SPECIF !CATION

Carburetor type MIKUNI VM 14 SH

Bore size 14

I.D. No. 02421

Idler/min. 1500 ± 150 r/min.

Float height 22.4 ± 1.0 mm

( 0.88 ± 0.004 in )
I
i
Main jet (M. J.) # 57.5
-

Air jet (A. J.) 2.5

Jet needle (J. N.) 3013 - 3rd

Needle jet (N. J.) E-2

Cut-away (C. A.) 2.0

Pilot jet (P. J.) # 15

Pilot outlet (P. 0.) 0.9 mm ( 0.04 in )

Air screw (A. S.) 1% turn out

Valve seat (V. S.) 1.5 mm ( 0.06 in )

Starter jet (G. S.) # 35

Throttle cable play 0.5 - 1.0 mm
( 0.02 - 0.04 in )
7-6 FZ50"D"

ELECTRICAL Unit· mm (in)

ITEM SPECI FICATl ON NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4000 r/min.
Spark plug I I

Type N.G.K BP4HA i

N.D. W14FP-UL I
I
0.6 -0.8
Gap ( )
I 0.02 - 0.03
Spark performance Over 8 (0.3) at 1 atm

Magneto coi I resistance B/R - B/W

Primary Approx. Q
160 - 250 -~
I Y/R - B/W
I Lighting Approx. 0-1 Q
I i ~~~-
--~
W/R - B/W
Charging
Approx. 0-1 Q
I

Charging rate Above 0.7 A at 4000 r/min. I

Below 3 A at 8000 r/min

Lighting coil output Above 5.5 Vat 2500 r/min.
Below 8.5 Vat 8000 r/min.
Battery Type designation 6N4-2A

Capacity 6V14.4 kC(4Ah)/10HR

Standard
1.26 at 20° C (68° F)
electrolyte S. G.
I

Fuse size Main 10 A

I
 FZ50"D" 7-7

BRAKE+ WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front and rear brake lever distance 20-30
( 0.8 - 1.2 )

Brake drum I.D. Front 100.7

( 3.96 )

Rear 100.7
( 3.96 )
Brake lining thickness 1.5
( 0.06 )
Wheel rim runout Axial 2.0
( 0.08 )
2.0
Radial ( )
0.08
Wheel axle runout 0.25
Front ( 0.010 )

0.25
Rear ( 0.010 )

Tire size Front 3.00 - 12 4PR

Rear 3.00-12 4PR

Tire tread depth 1.6

Front ( )
0.06

Rear 1.6
( 0.06 )

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Rear wheel travel 82
( 3.2 )

Swing arm pivot shaft runout 0.6

( 0.024 )
7-8 .FZ50"D"

FUEL+ OIL
ITEM SPECIFICATION NOTE
Fuel type
Use only unleaded or low-lead type gaso-
line of at least 85 - 95 pump octane ( R;M)
Method or 89 octane or higher rated by the
Research method.

Fuel tank including reserve 4.5 L

( 1.2/1.0 US/Imp gal)
reserve 0.2 L
( 1.2/0.18 US/Imp qt)
Engine oil type
Use SUZUKI CCI SUPER 2-CYCLE
MOTOR LUBRICANT or an equivalent
good quality syntletic based 2-cycle oil.

Engine oil tank capacity 1.2 L

( 1.27/1.06 US/Imp qt)
Transmission oil type SAE 20W/40
Transmission oil capacity 800 ml
Change
( 0.85/0.70 US/Imp qt)
850 ml
Overhaul
( 0.90/0.75 US/Imp qt)

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE
kPa kg/cm 2 psi

FRONT 125 1.25 18

REAR 150 1.50 22
 FZ50"D" 7-9

WATTAGE Unit. W

ITEM SPECIFICATION

Headlight HI 20
LO 20
Tail/Brake light 5.3/17 ( 3/21 CP )
Turn signal light 17 ( 21 CP )
Turn signal indicator light 3
High beam indicator light 1.7
 FZ50"G" 8-1

FZ50''G''
~~~~~~~CONTENTS~~~~~~--.

SERVICE DATA ..........................................................................................8- 1

8-2 FZ50"G"

SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065-0.075 0.120
( 0.0026-0.0030 ) ( 0.0047 )
Cylinder bore 41.000-41.015
41.065
1.6142-1.6148 )
(
( 1.6167 )
Measure at 1 5 ( 0.6 ) from the top surface
Piston diam. 40.930-40.945
40.880
1.6114-1.6120 )
(
( 1.6094 )
Measure at 23 ( 0.9 ) from the skirt end
Cylinder distortion -- 0.05
( 0.002 )
Cylinder head distortion -- 0.05
( 0.002 )

Piston ring free end gap 4.5 3.6

R Approx. ( 0.18 ) ( 0.14 )
1st
5.0 4.0
T Approx. ( 0.20 ) ( 0.16 )

4.5 3.6
R Approx. ( 0.18 ) ( 0.14 )
2nd
5.0 4.0
T Approx. ( 0.20 ) ( 0.16 )

Piston ring end gap 0.10-0.25 0.75

( 0.004-0.010 ) ( 0.30 )

Piston ring to groove clearance 0.020-0.060 --

1st ( 0.0008-0.0024 )
0.020-0.060 --
2nd ( 0.0008-0.0024 )
Piston pin bore 11.998-12.006 12.030
( 0.4724-0.4727 ) ( 0.4736 )

Piston pin 0.0. 11.996-12.000 11.980

( 0.4723-0.4724 ) ( 0.4717 )

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I. D. 16.003-16.011 16.040
( 0.6300-0.6304 ) ( 0.6315 )

Conrod deflection -- 3.0

( 0.12 )
Crank web to web width 40.1 ± 0.1 --
( 1.57 ± 0.004 )

Crankshaft runout -- 0.05

( 0.02 )

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 7.000 ( 14/ 2 )

CCI pump discharge rate 1.01 -1 .24 ml

(Full open) for 5 minutes at 2 000 r/min.
 FZ50"G" 8-3

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I.D. 87.00-87.15 87.40
No.1 ( 3.425-3.431 ) ( 3.441 )
105.00-105.1 5 105.40
No.2 4.134-4.140 )
( ( 4.154 )
Clutch shoe O.D. 86.90-87.00 No groove
No.1 ( 3.421-3.425 ) at any part
104. 70-104.80 No groove
No.2 ( 4.122-4.126 ) at any part
Clutch engagement Low 2 600 ± 200 r/min. --
Clutch lock-up Low 3 650 ± 250 r/min. --
Gear shifting point Low to --
18-22 km/h
top
Clutch spring free length -- 35.7
No.1 ( 1.41 )

-- 40.4
No.2 ( 1.59 )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Final reduction ratio 3.647 ( 62/17 ) --
Gear ratios Low 18.593 ( 62/29 x 31 /13 x 62/17 ) --
Top 12.358 ( 54/38 x 31 /13 x 62/17 ) --

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270H --
Links 64 --

-- 173.4
20-pitch length
I ( 6.83 )

CARBURETOR
ITEM SPECIFICATION
Carburetor type MIKUNI VM 14SH
Bore size 14 mm ( 0.55 in )

I.D. No. 02421

Idle r/min. ± 150 r/min.
1 500
Float height 22.4 ± 1.0 mm ( 0.08 ± 0.04 in )

Main jet (M.J.) #57.5

Air jet (A.J.) 2.5 mm ( 0.10 in )

Jet needle (J.N.) 3013-3rd

Needle jet (N.J.) E-2
Cut-away (C.A.) 2.0
Pilot jet (P.J.) #15
Pilot outlet (P.O.) 0.9 mm ( 0.04 in )

Air screw (A.S.) 1 3/4 turn out

8-4 FZ50"G"

ITEM SPECIFICATION
Valve seat (V.S.) 1.5 mm ( 0.06 in )
Starter jet (G.S.) #35
Throttle cable play 0.5-1.0 mm ( 0.02-0.04 in )

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4 000 r/min.
Spark plug NGK: BP4HA
Type N.D.: W14FP-UL
0.6-0.8
Gap ( 0.02-0.03 )
Spark performance Over 8 (0.3) at 1 atm.
Magneto coil resistance B/R-B/W
Primary
Approx. 160- 250 Q
Y/R-B/W
Lighting
Approx. 0-1 Q
W/R-B/W
Charging
Approx. 0-1 Q
Charging rate Above 0.7 A at 4 000 r/min.
Below 3 A at 8 000 r/min.
-
Lighting coil output Above 5.5 Vat 2 500 r/min.
Below 8.5 Vat 8 000 r/min.
Battery Type designation 6N4-2A
Capacity 6V 14.4kC (4Ah)/10 HR
Standard
1.26 at 20°C (68°F)
electrolyte S.G.
Fuse size Main 10 A

WATTAGE Unit:W
ITEM SPECIFICATION
Headlight HI 20
LO 20
Tail/Brake light 5.3/17
Turn signal light 17
Turn signal indicator light 3
High beam indicator light 1.7

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake cable play 3-7 --
( 0.12-0.28 )
Rear brake pedal free travel 20-30 --
( 0.8-1.2 )

Brake drum I.D. -- 100.7

Front ( 3.96 )

-- 100.7
Rear ( 3.96 )
 FZ50"G" 8-5

ITEM STANDARD LIMIT

Brake lining thickness -- 1.5
( 0.06 )
Wheel rim runout -- 2.0
Axial ( 0.08 )

-- 2.0
Radial ( )
0.08
Wheel axle runout -- 0.25
Front ( 0.010 )

-- 0.25
Rear ( 0.010 )
Tire size Front 3.00-12 4PR --
Rear 3.00-12 4PR --
Tire tread depth -- 1.6
Front ( 0.06 )

-- 1.6
Rear ( )
0.06

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Rear wheel travel 82 --
( 3.2 )
Swingarm pivot shaft runout -- 0.6
( 0.024 )

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE
kPa kg/cm 2 psi
FRONT 125 1.25 18
REAR 150 1.50 21

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline
of at least 85-95 pump octane (R+M method)
or 89 octane or higher rated by tht Research
Method.
Fuel tank including reserve 4.5 L
( 1 .2/1 .0 US/Imp gal )

reserve 0.2 L
( 1.2/0.18 US/Imp qt )
Engine oil type SUZUKICClorSUZUKICCI SUPER
Engine oil tank capacity · 1.2 L
( 1.27/1.06 US/Imp qt )
Transmission oil type SAE 20W/40
Transmission oil capacity 800 ml
Change ( 0.85/0. 70 US/Imp qt )
850ml
Overhaul ( )
0.90/0. 75 US/Imp qt
 FZ50"H" 9-1

FZ50''H''

SERVICE DATA ..........................................................................................9- 1

9-2 FZ50"G"

SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065-0.075 0.120
( 0.0026-0.0030 ) ( 0.0047 )
Cylinder bore 41.000-41.015
1.6142-1.6148 )
( 41.065
( 1.6167 )
Measure at 1 5 ( 0.6 ) from the top surface
Piston diam. 40.930-40.945
40.880
1.6114-1.6120 )
(
( 1.6094 )
Measure at 23 ( 0.9 ) from the skirt end.
Cylinder distortion -- 0.05
( 0.002 )
Cylinder head distortion -- 0.05
( 0.002 )
Piston ring free end gap 4.5 3.6
R Approx.
( 0.18 ) ( 0.14 )
1st
5.0 4.0
T Approx.
( 0.20 ) ( 0.16 )
4.5 3.6
R Approx.
( 0.18 ) ( 0.14 )
2nd
Approx. 5.0 4.0
T
( 0.20 ) ( 0.16 )
Piston ring end gap 0.10-0.25 0.75
( 0.004-0.010 ) ( 0.30 )
Piston ring to groove clearance 0.020-0.060 --
1st
( 0.0008-0.0024 )
0.020-0.060 --
2nd
( 0.0008-0.0024 )
Piston pin bore 11.998-12.006 12.030
( 0.4724-0.4727 ) ( 0.4736 )
Piston pin O.D. 11.996-12.000 11.980
( 0.4723-0.4724 ) ( 0.4717 )

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003-16.011 16.040
( 0.6300-0.6304 ) ( 0.6315 )
Conrod deflection -- 3.0
( 0.12 )
Crank web to web width 40.0 ± 0.1 --
( 1.57 ± 0.004 )
Crankshaft runout -- 0.05
( 0.02 )

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 7.000 ( 14/2 )

CCI pump discharge rate 1.01-1.24 ml

(Full open) for 5 minutes at 2 000 r/min.
 FZ50"G" 9-3

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I.D. 87.00-87.15 87.40
No.1
( 3.425-3.431 ) ( 3.441 )
105.00-105.15 105.40
No.2
( 4. 1 34-4. 140 ) ( 4.154 )
Clutch shoe O.D. 86.90-87.00 No groove
No.1
( 3.421-3.425 ) at any part
104. 70-104.80 No groove
No.2
( 4.122-4.126 ) at any part
Clutch engagement Low 2 600 ± 200 r/min. --
Clutch lock-up Low 3 650 ± 250 r/min. --
Gear sifting point Low to --
18-22 km/h
top
Clutch spring free length -- 35.7
No.1
( 1.41 )

-- 40.4
No.2
( 1.59 )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Final reduction ratio 3.647 ( 62/17 ) --
Gear ratios Low 18.593 ( 62/29 x 31 /13 x 62/17 ) --
Top 12.358 ( 54/38 x 31/13 x 62/17 ) --

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270H --
Links 64 --
-- 173.4
20-pitch length
I ( 6.83 )

CARBURETOR
ITEM SPECIFICATION
Carburetor type MIKUNI VM 14SH
Bore size 14 mm ( 0.55 in )
I.D. No. 02421
Idler/min. 1 500 ± 1 50 r/min.
Float height 22.4 ± 1 .0 mm ( 0.08 ± 0.04 in )
Main jet (M.J.) #57.5
Air jet (M.A.J.) 2.5 mm ( 0.10 in )
Jet needle (J.N.) 3D13-3rd
Needle jet (N.J.) E-2
Cut-away (C.A.) 2.0
Pilot jet (P.J.) #15
Pilot outlet (P.O.) 0.9 mm ( 0.04 in )
Air screw (A.S.) 1 % turns out
9-4 FZ50"G"

ITEM SPECIFICATION
Valve seat (V.S.) 1.5 mm ( 0.06 in )

Starter jet (G.S.) #35

Throttle cable play 0.5-1.0 mm ( 0.02-0.04 in )

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4 000 r/min.
Spark plug NGK: BP4HA
Type
N.D.: W14FP-UL
0.6-0.8
Gap
( 0.02-0.03 )
Spark performance Over 8 (0.3) at 1 atm.
Magneto coil resistance B/R-B/W
Primary
Approx. 160-250 Q
Y/R-B/W
Lighting
Approx. 0-1 Q
W/R-B/W
Charging
Approx. 0-1 Q
Charging rate Above 0. 7 A at 4 000 r/min.
Below 3 A at 8 000 r/min.
Lighting coil output Above 5.5 Vat 2 500 r/min.
Below 8.5 Vat 8 000 r/min.
Battery Type designation 6N4-2A
Capacity 6V 14.4 kC (4Ah)/10 HR
Standard
1.26 at 20°C (68°F)
electrolyte S.G.
Fuse size Main 10 A

WATTAGE Unit:W
ITEM SPECIFICATION
Headlight HI 20
LO 20
Tail/Brake light 5.3/17
Turn signal light 17
Turn signal indicator light 3
High beam indicator light 1.7

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake cable play 3-7 --
( 0.12-0.28 )
Rear brake pedal free travel 20-30 --
( 0.8-1.2 )
Brake drum I.D. -- 100.7
Front
( 3.96 )

Rear -- 100.7
( 3.96 )
 FZ50"G" 9-5

ITEM STANDARD LIMIT

Brake lining thickness -- 1.5
( 0.06 )
Wheel rim runout -- 2.0
Axial
( 0.08 )

-- 2.0
Radial
( 0.08 )
Wheel axle runout -- 0.25
Front
( 0.010 )

-- 0.25
Rear
( 0.010 )
Tire size Front 3.00-12 4PR --
Rear 3.00-12 4PR --
Tire tread depth -- 1.6
Front ( 0.06 )

-- 1.6
Rear
( 0.06 )

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Rear wheel travel 82 --
( 3.2 )

Swingarm pivot shaft runout -- 0.6

( 0.024 )

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE
kPa kg/cm 2 psi
FRONT 125 1.25 18
REAR 150 1.50 21

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline
of at least 85-95 pump octane (R+M method)
or 89 octane or higher rated by th~ Research
Method.
Fuel tank including reserve 4.5 L
( 1.2/1.0 US/Imp gal )
reserve 0.2 L
( 1 .2/0. 18 US/Imp qt )

Engine oil type SUZUKICClorSUZUKICCISUPER

Engine oil tank capacity 1.2 L
( 1.27/1.06 US/Imp qt )

Transmission oil type SAE 20W/40

Transmission oil capacity 800 ml
Change
( 0.85/0. 70 US/Imp qt )

Overhaul 850 ml
( 0.90/0. 75 US/Imp qt )
 FZ50"K" 10-1

FZ50''K''

SERVICE DATA .......................................................................................... 10-1

10-2 FZ50"K"

SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065-0.075 0.120
( 0.0026-0.0030 ) ( 0.0047 )
Cylinder bore 41 .000-41.01 5
1.6142-1.6148 )
( 41.065
( 1.6167 )
Measure at 1 5 ( 0.6 ) from the top surface
Piston diam. 40.930-40.945
1.6114-1.6120 )
( 40.880
Measure at 23 ( 0.9 ) from the skirt end.
( 1.6094 )

Cylinder distortion -- 0.05

( 0.002 )
Cylinder head distortion -- 0.05
( 0.002 )

Piston ring free end gap Approx. 4.5 3.6

R
( 0.18 ) ( 0.14 )
1st
Approx. 5.0 4.0
T ( 0.20 ) ( 0.16 )

Approx. 4.5 3.6

R
( 0.18 ) ( 0.14 )
2nd
T Approx. 5.0 4.0
( 0.20 ) ( 0.16 )
Piston ring end gap 0.10-0.25 0.75
( 0.004-0.010 ) ( 0.30 )
Piston ring to groove clearance 1st 0.020-0.060 --
( 0.0008-0.0024 )

2nd 0.020-0.060 --
( 0.0008-0.0024 )

Piston pin bore 11.998-12.006 12.030

( 0.4724-0.4727 ) ( 0.4736 )
Piston pin O.D. 11.996-12.000 11.980
( 0.4723-0.4724 ) ( 0.4717 )

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003-16.011 16.040
( 0.6300-0.6304 ) ( 0.6315 )

Conrod deflection -- 3.0

( 0.12 )

Crank web to web width 40.0 ± 0.1 --

( 1.57 ± 0.004 )

Crankshaft runout -- 0.05

( 0.02 )

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 7.000 ( 14/2 )

CCI pump discharge rate 1.01-1.24ml

(Full open) for 5 minutes at 2 000 r/min.
 FZ50"K" 10-3

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel 1.0. 87.00-87.15 87.40
No.1
( 3.425-3.431 ) ( 3.441 )
105.00-105. 1 5 105.40
No.2
( 4.134-4.140 ) ( 4.154 )
Clutch shoe 0.0. 86.90-87.00 No groove
No.1
( 3.421-3.425 ) at any part
104. 70-104.80 No groove
No.2
( 4.122-4.126 ) at any part
Clutch engagement Low 2 600 ± 200 r/min. --
Clutch lock-up Low 3 650 ± 250 r/min. --
Gear sifting point Low to --
18-22 km/h
top
Clutch spring free length -- 35.7
No.1
( 1.41 )

-- 40.4
No.2
( 1.59 )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Final reduction ratio 3.647 ( 62/17 ) --
Gear ratios Low 18.593 ( 62/29 x 31 /13 x 62/1 7 ) --
Top 12.358 ( 54/38 x 31/13 x 62/17 ) --

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type 0.1.D.: 270H --
Links 64 --

-- 173.4
20-pitch length
I ( 6.83 )

CARBURETOR
ITEM SPECIFICATION
Carburetor type MIKUNI VM 14SH
Bore size 14 mm ( 0.55 in )
1.0. No. 02421
Idler/min. 1 500 ± 1 50 r/min.
Float height 22.4 ± 1.0 mm ( 0.08 ± 0.04 in )
Main jet (M.J.) #57.5
Air jet (M.A.J.) 2.5 mm ( 0.10 in )
Jet needle (J.N.) 3013-3rd
Needle jet (N.J.) E-2
Cut-away (C.A.) 2.0
Pilot jet (P.J.) #15
Pilot outlet (P.O.) 0.9 mm ( 0.04 in )
Air screw (A.S.) 1 3/4 turn out
10-4 FZ50"K"

ITEM SPECIFICATION
Valve seat (V.S.) 1.5 mm ( 0.06 in )
Starter jet (G.S.) #35
Throttle cable play 0.5-1.0 mm ( 0.02-0.04 in )

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4 000 r/min.
Spark plug NGK: BP4HA
Type
N.D.: W14FP-UL
0.6-0.8
Gap
( 0.02-0.03 )
Spark performance Over 8 (0.3) at 1 atm.
Magneto coil resistance B/R-B/W
Primary
Approx. 160-250 Q
Y/R-B/W
Lighting
Approx. 0-1 Q
W/R-B/W
Charging
Approx. 0-1 Q
Charging rate Above 0. 7 A at 4 000 r/min.
Below 3 A at 8 000 r/min.
Lighting coil output Above 5.5 Vat 25 000 r/min.
Below 8.5 Vat 8 000 r/min.
Battery Type designation 6N4-2A
Capacity 6V 14.4 kC (4Ah)/10 HR
Standard
1.26 at 20°C (68°F)
electrolyte S.G.
Fuse size Main 10 A

WATTAGE Unit:W
ITEM SPECIFICATION
Headlight HI 20
LO 20
Tail/Brake light 5.3/17
Turn signal light 17
Turn signal indicator light 3
High beam indicator light 1.7

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake cable play 3-7 --
( 0.12-0.28 )
Rear brake pedal free travel 20-30 --
( 0.8-1.2 )
Brake drum I.D. -- 100.7
Front
( 3.96 )

Rear -- 100.7
( 3.96 )
 FZ50"K" 10-5

ITEM STANDARD LIMIT

Brake lining thickness -- 1.5
( 0.06 )

Wheel rim runout Axial -- 2.0

( 0.08 )

-- 2.0
Radial
( 0.08 )

Wheel axle runout Front -- 0.25

( 0.010 )

Rear -- 0.25
( 0.010 )
Tire size Front 3.00-12 4PR --
Rear 3.00-12 4PR --
Tire tread depth -- 1.6
Front ( 0.06 )

Rear -- 1.6
( 0.06 )

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Rear wheel travel 82 --
( 3.2 )

Swingarm pivot shaft runout -- 0.6

( 0.024 )

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE
kPa kg/cm 2 psi
FRONT 125 1.25 18
REAR 150 1.50 21

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline
of at least 85-95 pump octane (R+M method)
or 89 octane or higher rated by th~ Research
Method.
Fuel tank including reserve 4.5 L
( 1.2/1.0 US/Imp gal )

reserve 0.2 L
( 1 .2/0. 18 US/Imp qt )

Engine oil type SUZUKICClorSUZUKICCISUPER

Engine oil tank capacity 1.2 L
( 1.27/1.06 US/Imp qt )
Trans.mission oil type SAE 20W/40
Transmission oil capacity 800ml
Change
( 0.85/0. 70 US/Imp qt )

Overhaul 850ml
( 0.90/0. 75 US/Imp qt )
 FZ50"L" 11-1

FZ50''L''

SERVICE DATA ..........................................................................................11-1

m
11-2 FZ50"L"

SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.065-0.075 0.120
( 0.0026-0.0030 ) ( 0.0047 )

Cylinder bore 41.000-41.015

1.6142-1.6148 )
( 41.065
Measure at 1 5 ( 0.6 ) from the top surface
( 1.6167 )

Piston diam. 40.930-40.945

1.6114-1.6120 )
(
40.880
Measure at 23 ( 0.9 ) from the skirt end.
( 1.6094 )

Cylinder distortion -- 0.05

( 0.002 )
Cylinder head distortion -- 0.05
( 0.002 )
Piston ring free end gap Approx. 4.5 3.6
R
( 0.18 ) ( 0.14 )
1st
T Approx. 5.0 4.0
( 0.20 ) ( 0.16 )

R Approx. 4.5 3.6

( 0.18 ) ( 0.14 )
2nd
T Approx. 5.0 4.0
( 0.20 ) ( 0.16 )
Piston ring end gap 0.10-0.25 0.75
( 0.004-0.010 ) ( 0.30 )
Piston ring to groove clearance 1st 0.020-0.060 --
( 0.0008-0.0024 )

2nd 0.020-0.060 --
( 0.0008-0.0024 )
Piston pin bore 11.998-12.006 12.030
( 0.4724-0.4727 ) ( 0.4736 )

Piston pin O.D. 11 .996-12.000 11.980

( 0.4723-0.4724 ) ( 0.4717 )

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 16.003-16.011 16.040
( 0.6300-0.6304 ) ( 0.6315 )
Conrod deflection -- 3.0
( 0.12 )
Crank web to web width 40.0 ± 0.1 --
( 1.57 ± 0.004 )

Crankshaft runout -- 0.05

( 0.02 )

OIL PUMP
ITEM SPECIFICATION
Oil pump reduction ratio 7.000 ( 14/2 )

CCI pump discharge rate 1.01 -1.24 ml

(Full open) for 5 minutes at 2 000 r/min.
 FZ50"L" 11-3

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel I.D. 87.00-87.15 87.40
No.1
( 3.425-3.431 ) ( 3.441 )
105.00-105.15 105.40
No.2
( 4.134-4.140 ) ( 4.154 )
Clutch shoe O.D. 86.90-87.00 No groove
No.1
( 3.421-3.425 ) at any part
104. 70-104.80 No groove
No.2
( 4.122-4.126 ) at any part
Clutch engagement Low 2 600 ± 200 r/min. --
Clutch lock-up Low 3 650 ± 250 r/min. --
Gear sifting point Low to --
18-22 km/h
top
Clutch spring free length -- 35.7
No.1
( 1.41 )

-- 40.4
No.2
( 1.59 )

TRANSMISSION Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Final reduction ratio 3.647 ( 62/17 ) --
Gear ratios Low 18.593 ( 62/29 x 31 /13 x 62/17 ) --
Top 12.358 ( 54/38 x 31/13 x 62/17 ) --

DRIVE CHAIN Unit: mm (in)

ITEM STANDARD LIMIT
Drive chain Type D.I.D.: 270H --
Links 64 --

-- 173.4
20-pitch length
I ( 6.83 )

CARBURETOR
ITEM SPECIFICATION
Carburetor type MIKUNI VM 14SH
Bore size 14 mm ( 0.55 in )
I.D. No. 02421
Idler/min. 1 500 ± 1 50 r/min.
Float height 22.4 ± 1 .0 mm ( 0.08 ± 0.04 in )
Main jet (M.J.) #57.5
Air jet (M.A.J.) 2.5 mm ( 0.10 in )
Jet needle (J.N.) 3013-3rd
Needle jet (N.J.) E-2
Cut-away (C.A.) 2.0
Pilot jet (P.J.) #15
Pilot outlet (P.O.) 0.9 mm ( 0.04 in )
Air screw (A.S.) 1 3/4 turn out
11-4 FZ50"L"

ITEM SPECIFICATION
Valve seat (V.S.) 1.5 mm ( 0.06 in )
Starter jet (G.S.) #35
Throttle cable play 0.5-1.0 mm ( 0.02-0.04 in )

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 25° ± 2° B.T.D.C. at 4 000 r/min.
Spark plug NGK: BP4HA
Type
N.D.: W14FP-UL
0.6-0.8
Gap
( 0.02-0.03 )

Spark performance Over 8 (0.3) at 1 atm.

Magneto coil resistance B/R-B/W
Primary
Approx. 160-250 Q

Y/R-8/W
Lighting
Approx. 0-1 Q

W/R-B/W
Charging
Approx. 0-1 Q

Charging rate Above 0. 7 A at 4 000 r/min.

Below 3 A at 8 000 r/min.
Lighting coil output Above 5.5 Vat 25 000 r/min.
Below 8.5 Vat 8 000 r/min.
Battery Type designation 6N4-2A
Capacity 6V 14.4 kC (4Ah)/10 HR
Standard
1.26 at 20°C (68°F)
electrolyte S.G.
Fuse size Main 10 A

WATTAGE Unit: W
ITEM SPECIFICATION
Headlight HI 20
LO 20
Tail/Brake light 5.3/17
Turn signal light 17
Turn signal indicator light 3
High beam indicator light 1.7

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Front brake cable play 3-7 --
( 0.12-0.28 )

Rear brake pedal free travel 20-30 --

( 0.8-1.2 )
Brake drum I.D. -- 100.7
Front
( 3.96 )

-- 100.7
Rear
( 3.96 )
 FZ50"L" 11-5

ITEM STANDARD LIMIT

Brake lining thickness -- 1.5
{ 0.06 )
Wheel rim runout -- 2.0
Axial
( 0.08 )

-- 2.0
Radial
{ 0.08 )
Wheel axle runout -- 0.25
Front
{ 0.010 )

-- 0.25
Rear
{ 0.010 )
Tire size Front 3.00-12 4PR --
Rear 3.00-12 4PR --
Tire tread depth -- 1.6
Front { 0.06 )

-- 1.6
Rear
{ 0.06 )

SUSPENSION Unit: mm {in)

ITEM STANDARD LIMIT NOTE
Rear wheel travel 82 --
{ 3.2 )

Swingarm pivot shaft runout -- 0.6

{ 0.024 )

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE
kPa kg/cm 2 psi
FRONT 125 1.25 18
REAR 150 1.50 21

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded or low-lead type gasoline
of at least 85-95 pump octane (R+M method)
or 89 octane or higher rated by th'e Research
Method.
Fuel tank including reserve 4.5 L
{ 1.2/1.0 US/Imp gal )
reserve 0.2 L
{ 1.2/0.18 US/Imp qt )
Engine oil type SUZUKICClorSUZUKICCISUPER
Engine oil tank capacity 1.2 L
{ 1.27/1.06 US/Imp qt )
Transmission oil type SAE 20W/40
Transmission oil capacity 800ml
Change
{ 0.85/0. 70 US/Imp qt )
850 ml
Overhaul
{ 0.90/0. 75 US/Imp qt )
 Prepared by

SUZUKI MOTOR CORPORATION

Motorcycle Technical Service Department
6th Ed. October, 1990
1st Ed. April, 1979
Manual No. 99500-10054-03E

Printed in Japan

148
SUZUKI MOTOR CORPORATION