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Summary of Contents for Suzuki RM85

• Page 1 RM85/L OWNER’S SERVICE MANUAL Part No. 99011-02B82-01A April, 2006...
• Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
• Page 3 Please read this manual and follow its instructions This manual is presented as a means whereby you carefully. To emphasize special information, the can maintain your RM85 in top working condition at symbol  and the words WARNING, CAUTION all times. Your riding skill and the maintenance and NOTE carry special meanings.
• Page 4 Of course, your friends will need their own motorcycles because motocross May all of your rides on your new Suzuki be winning models are not designed for passengers. If none rides! of your friends rides motocross, ask your Suzuki dealer how to go about joining a club.

• Page 5: Serial Number Location

  SERIAL NUMBER LOCATION The frame number 1 is stamped on the steering head. The engine serial number 2 is stamped on the right side of the crankcase assembly. Write down the serial numbers here for your future reference. Frame No. Engine No.
• Page 6 WARNINGS FOR SERVICING  WARNING  WARNING Never run the engine indoors or in a Fuel can catch on fire if you do not handle garage. Exhaust gas contains carbon mon- it properly. Gasoline vapors can catch fire oxide, a gas that is colorless and odorless easily.

• Page 7: Replacement Parts

  NOTE: Use of replacement parts which are not equivalent installing a circlip. • Use special tools where specified. in quality to genuine SUZUKI parts can lead to per- • Use genuine SUZUKI parts and recommended formance problems and damage. oil.
• Page 8 SYMBOL MARKS AND MATERIALS SYMBOL MARK MATERIALS Apply SUZUKI SUPER GREASE “A” 99000-25010 Apply SUZUKI SILICONE GREASE 99000-25100 Apply THREAD LOCK SUPER “1303” 99000-32030 Apply THREAD LOCK SUPER “1322” 99000-32110 Apply SUZUKI BOND “1207B” 99000-31140 Use or apply DOT 4 Brake fluid.
• Page 9 SYMBOL MARK MATERIALS Use SUZUKI FORK OIL SS-05 99000-99001-SS5 Use SUZUKI REAR SUSPENSION OIL SS-25 99000-99001-S25 Use engine coolant. SUZUKI COOLANT 99000-99032-11X Apply engine oil or transmission oil. Tighten a nut or bolt to the specified torque. Replace a part with a new one when...
• Page 10 – MEMO –...
• Page 11 GROUP INDEX GENERAL INSTRUCTIONS PERIODIC MAINTENANCE TROUBLESHOOTING MACHINE TUNING ENGINE REMOVAL AND INSTALLATION CYLINDER, PISTON AND EXHAUST VALVE CLUTCH KICK STARTER GEARSHIFTING TRANSMISSION AND CRANKSHAFT FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM FRONT AND REAR WHEELS FRONT AND REAR BRAKES FRONT FORK AND STEERING REAR SUSPENSION SERVICING INFORMATION...

• Page 12: Table Of Contents

  GENERAL INSTRUCTIONS GENERAL INSTRUCTIONS CONTENTS LOCATION OF PARTS ................1- 2 FUEL AND OIL RECOMMENDATION ............1- 3 INTRUCTING YOUNG RIDER ..............1- 4 THIS IS IMPORTANT ADVICE TO A PARENT ........1- 4 STARTING ENGINE ................1- 5 STARTING OFF ..................1- 7 BRAKING ....................

• Page 13: General Instructions

  GENERAL INSTRUCTIONS LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Front brake fluid reservoir 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Fuel valve 8 Carburetor starter knob 9 Gearshift lever 0 Rear brake fluid reservoir A Rear suspension compression damping adjuster B Kick starter lever...

• Page 14: Fuel And Oil Recommendation

  GENERAL INSTRUCTIONS FUEL AND OIL RECOMMENDATION Gasoline (ml) This motorcycle is of the two-stroke design, which requires a premixture of gasoline and oil. Gasoline: Use only unleaded gasoline of at least 90 pump 10.0 octane (R/2 + M/2 method)..For Canada 15.0 Use only unleaded gasoline of at least 95 octane.

• Page 15: Intructing Young Rider

  The RM85 requires the parent’s cooperation to actually enjoy the safety available.

• Page 16: Starting Engine

  GENERAL INSTRUCTIONS NOTE: HELMET For practice, choose a level ground free of traffic and spacious GOGGLES enough to permit driving several yards with the engine powered. In short, break-in the young rider gradually. GLOVES CLOTHING Rule 4. Wear simple clothes Loose fitting clothes are unsafe for riding.
• Page 17 GENERAL INSTRUCTIONS • Pull the starter knob out. • Close the throttle. Kick the kick starter lever to start the engine. If the engine fails to fire up, kick again. If third or fourth attempt fails, then push back starter knob to original position, and open the throttle wider by turning the throttle grip fully.

• Page 18: Starting Off

  GENERAL INSTRUCTIONS STARTING OFF • Pull in the clutch lever fully and push the gearshift lever down to change the gear from neutral to low position. • Release the clutch lever gently while twisting the throttle grip slowly.  WARNING Twisting the throttle grip fully in standing start can jump the machine and it can throw you off the seat.

• Page 19: Stopping Engine

  GENERAL INSTRUCTIONS • An attempt to slow down by braking alone is dangerous, par- ticularly braking of the front wheel alone. The front wheel may slide out (front wheel braking) or rear wheel might skid side- wise (rear wheel braking). ...

• Page 20: Periodic Maintenance

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE ................ 2- 2 SPARK PLUG ....................2- 4 AIR CLEANER ..................... 2- 5 TRANSMISSION OIL ................... 2- 6 ENGINE COOLANT ..................2- 8 CLUTCH CABLE ..................2- 9 THROTTLE CABLE ..................2-10 FUEL HOSE ....................2-10 FUEL VALVE ....................

• Page 21: Periodic Maintenance

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE INSPECTION BEFORE PRACTICE WHAT TO CHECK CHECK FOR Spark plug • Heat range, fouled electrode, tightness • Loose high-tension cord Air cleaner element Lubrication Transmission oil Oil level Engine coolant Engine coolant level Cooling system • Radiator hose damage •...

• Page 22: Periodic Maintenance Chart

  PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART It is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe conditions.

• Page 23: Spark Plug

  PERIODIC MAINTENANCE SPARK PLUG • Inspect the spark plug condition, electrode color, carbon deposits, spark plug gap, and washer damage, after removing the spark plug. NOTE: Remove the dirt around the spark plug before removing the spark plug to prevent dirt from entering the combustion cham- ber.

• Page 24: Air Cleaner

  PERIODIC MAINTENANCE AIR CLEANER AIR CLEANER ELEMENT REMOVAL • Remove the seat. • Remove the air cleaner cap 1. • Remove the wing nut 2. • Remove the element from the element holder. WASHING • Fill a washing pan large enough to hold the element with a non-flammable cleaning solvent A.

• Page 25: Transmission Oil

  PERIODIC MAINTENANCE • Install the element in the air cleaner box. CAUTION Improper element installation allows dust and dirt to enter the combustion chamber. It can result in piston and cylinder wear. Be sure to check the element seals properly after installing the elements.

• Page 26: Transmission Oil Level Inspection/replenishment

  PERIODIC MAINTENANCE TRANSMISSION OIL LEVEL INSPECTION AND REPLENISHMENT • Run the engine for a few minutes and stop it. Wait 5 minutes. • Place the motorcycle on level ground and hold the motorcycle vertically. • Remove the oil level screw 1. Check that oil comes out of the hole.

• Page 27: Engine Coolant

  PERIODIC MAINTENANCE ENGINE COOLANT ENGINE COOLANT LEVEL CHECK WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.

• Page 28: Engine Coolant Replenishment

  PERIODIC MAINTENANCE ENGINE COOLANT REPLENISHMENT • Drain engine coolant. (12-3) • Pour engine coolant. (12-3) • Use an anti-freeze and Summer engine coolant which is com- patible with aluminum radiator, mixed with distilled water at the ratio of 50 : 50. NOTE: The radiator, cylinder and cylinder head are made of aluminum alloy.

• Page 29: Throttle Cable

  2-10 PERIODIC MAINTENANCE MINOR ADJUSTMENT • Loosen lock-nut 3. 10 – 15 mm (0.4 – 0.6 in) • Turn adjuster 4 so the clutch lever has 10 – 15 mm (0.4 – 0.6 in) play at the clutch lever end before pressure is felt. •...

• Page 30: Fuel Valve

  PERIODIC MAINTENANCE 2-11 FUEL VALVE • Drain the fuel. • Disconnect the fuel hose 1 and remove the fuel valve 2. WARNING Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. • Clean the fuel filter with compressed air. CAUTION The O-ring 3 must be replaced with a new one to pre- vent fuel leakage.

• Page 31: Cylinder Head, Cylinder And Piston

  2-12 PERIODIC MAINTENANCE CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD • Remove the cylinder head. (6-3) • Remove carbon deposits from the combustion chamber sur- face. • Inspect for pinholes, cracks and other damage. CYLINDER • Remove the cylinder. (6-3) •...

• Page 32: Exhaust Silencer

  • Tighten three bolts. NOTE: To seal between the black frontal pipe flange and the aluminum case, apply SUZUKI BOND “1207B” to the contact area of the flange.  99000-31140: SUZUKI BOND “1207B” DRIVE CHAIN AND SPROCKETS DRIVE CHAIN SLACK •...

• Page 33: Drive Chain Adjustment

  • Clean the drive chain with non-flammable cleaning solvent. • Do not use gasoline to clean the drive chain. • Dry the drive chain. • Apply Suzuki Chain Lube or an equivalent to the link plates and rollers. • Reassemble the drive chain.

• Page 34: Drive Chain Guide, Buffer, Tensioner Roller

  PERIODIC MAINTENANCE 2-15 SPROCKET INSPECTION • Inspect the engine sprocket and rear sprocket for wear and cracks. Replace the sprockets if necessary. NOTE: When replacing a worn sprocket, it is likely that the drive chain will need to be replaced as well. Normal wear Excessive wear DRIVE CHAIN GUIDE, BUFFER, TENSIONER ROLLER...

• Page 35: Brakes

  2-16 PERIODIC MAINTENANCE BRAKES BRAKE FLUID LEVEL • Inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than LOWER (LWR) mark, replenish the reservoir with the specified brake fluid to the UPPER level.

• Page 36: Front Fork

  PERIODIC MAINTENANCE 2-17 NOTE: Wear limit * Pump the brake lever/pedal several times to restore the brake pads after replacing the brake pads. * Replace both right and left pads together when replacing the brake pads. FRONT BRAKE LEVER ADJUSTMENT Adjust the brake lever play as follows: •...

• Page 37: Rear Suspension

  2-18 PERIODIC MAINTENANCE REAR SUSPENSION • Move the rear suspension up and down several times and inspect for smooth movement. • Inspect for damage and oil leaks. • Inspect the bolts and nuts for tightness. WHEELS AND TIRES WHEEL RIM •...

• Page 38: Steering

  PERIODIC MAINTENANCE 2-19 STEERING • Inspect the steering by moving the front forward and back- ward, and right and left. If the steering has play or binds, inspect steering stem head nut tightness and steering bear- ings. (16-13)

• Page 39: Lubrication

  The following materials are necessary: A. Lightweight oil such as WD-40 or penetrating oil. B. Suzuki chain lube or an equivalent C. Water-proof wheel bearing grease. Follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance.

• Page 40: Tightening Torque

  PERIODIC MAINTENANCE 2-21 TIGHTENING TORQUE PART N·m kgf-m lb-ft Cylinder head nut 20.5 Magneto rotor nut 25.5 Cylinder nut 18.0 Crankcase bolt Clutch sleeve hub nut 50.5 Primary drive gear nut 50.5 Spark plug 20.5 Transmission oil drain plug 16.5 Transmission oil level screw 0.55 Water pump drain plug...
• Page 41 2-22 PERIODIC MAINTENANCE For other bolts and nuts not listed in the table, refer to this chart. Conventional or “4” marked bolt “7” marked or crown headed bolt Bolt Diameter (mm) N·m kgf-m lb-ft N·m kgf-m lb-ft 10.0 13.0 23.0 16.5 29.0 21.0...

• Page 42: Troubleshooting

  TROUBLESHOOTING TROUBLESHOOTING CONTENTS TROUBLESHOOTING ................. 3- 2 ENGINE ....................3- 2 CHASSIS ....................3- 5...

• Page 43: Troubleshooting

  TROUBLESHOOTING TROUBLESHOOTING ENGINE Complaint Possible Cause Remedy Engine does not start Fuel deterioration Replace or hard to start No fuel flow to the carburetor • Fuel valve clogged Clean • Fuel hose clogged Clean or replace • Fuel tank cap breather hose clogged Clean •...
• Page 44 TROUBLESHOOTING Complaint Possible Cause Remedy Engine runs poorly in Wide spark plug gap Adjust or replace low speed range Carburetor air screw maladjustment Adjust Incorrect carburetor fuel level Adjust Improper jet needle size Replace Adjust Incorrect ignition timing CDI unit malfunction Replace Ignition coil damage Replace...
• Page 45 TROUBLESHOOTING Complaint Possible Cause Remedy Overheating Low engine coolant level Replenish Engine coolant leak Repair Too lean air/fuel mixture Adjust Incorrect ignition timing Adjust Adjust or replace Water pump malfunction Cylinder head carbon deposits Clean Cylinder head O-ring damage Replace Exhaust pipe carbon deposits Clean or replace Improper spark plug heat range...
• Page 46 TROUBLESHOOTING CHASSIS Complaint Possible Cause Remedy Heavy handling Steering stem nut overtightened Adjust Steering head bearings damaged or rusted Replace Steering stem distortion Replace Front wheel wobbling Loose spoke nipples Adjust Wheel distortion Replace Front wheel bearing damage Replace Incorrect axle tightening torque Retighten Rear wheel wobbling Loose spoke nipples...
• Page 47 – MEMO –...
• Page 48 MACHINE TUNING MACHINE TUNING CONTENTS CARBURETOR TUNING ................4- 2 PRINCIPLES OF CARBURETOR TUNING .......... 4- 2 CARBURETOR TUNING IN PRACTICE ..........4- 5 FRONT FORK TUNING ................4- 8 FRONT FORK ..................4- 8 FRONT FORK SPRING REPLACEMENT AND OIL LEVEL ADJUSTMENT ..................

• Page 49: Carburetor Tuning

  Riders who are not familiar with the operation and jetting procedures of the KEIHIN carburetor should have their local authorized Suzuki dealer perform these alterations. Mechanically experienced riders can alter the carburetor settings based on the fol- lowing information and specifications.
• Page 50 MACHINE TUNING As shown below, each tuning parts is located between the air/fuel passage and has its own air/fuel mixture adjustable range in terms of the throttle valve opening. The chart indicates that the carburetor can supply correct air/fuel mixture to the engine in any range because of the overlapping adjustable range of the each part.
• Page 51 MACHINE TUNING NEEDLE CLIP POSITION JET NEEDLE Lean Needle O.D. of Needle clip Rich Clip The jet needle is linked to the throttle valve by NEEDLE NUMBER means of the needle clip. Its lower part is tapered 24NAAH and it has five grooves cut in the upper part where O.D.

• Page 52: Carburetor Tuning In Practice

  MACHINE TUNING CARBURETOR TUNING IN PRACTICE In the previous section, basic principles of carburetor tuning have been discussed. Described in this section are the bases for carburetor tuning required when coping with variations in air (oxygen) concentration. VARIATION IN AIR (OXYGEN) CONCENTRATION AND CARBURETOR CONDITIONS As the air, affected by the temperature, altitude and humidity, gets expanded or compressed, air (oxygen) concentration varies accordingly.

• Page 53: Judging Air/fuel Mixture

  MACHINE TUNING JUDGING AIR/FUEL MIXTURE INCLUDED PARTS AND OPTIONAL PARTS For proper carburetor tuning, it is necessary to Main jet know how to judge the air/fuel mixture made in the Air/fuel carburetor; whether too rich, too lean or properly SIZE P/NO mixture mixed.

• Page 54: Tuning Procedure

  MACHINE TUNING 1 Adjustment of slow system 1) Adjust the air/fuel mixture by tuning the air 1) Set the air screw as specified. screw within 1/2 – 2 turns out. 2) See if the selected slow jet is correct or not by 1/2 turn out judging the air/fuel mixture.

• Page 55: Front Fork Tuning

  MACHINE TUNING FRONT FORK TUNING FRONT FORK The front fork compression and rebound damping force, and oil quantity are adjustable for rider’s preference, rider’s weight and course condition. NOTE: * Break-in new front forks before attempting adjustment. * Be sure to adjust both right and left front forks equally. COMPRESSION DAMPING FORCE ADJUSTMENT •...

• Page 56: Front Fork Spring Replacement And Oil Level Adjustment

  MACHINE TUNING FRONT FORK SPRING REPLACEMENT AND OIL LEVEL ADJUSTMENT • Remove the front forks, left and right. (16-3) • Thoroughly clean the fork before disassembly. CAUTION Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak. Avoid scratching or damaging the inner tube or the oil seal.
• Page 57 NOTE: When adjusting the fork oil level, compress the outer tube fully without the fork spring.  09943-74111: Front fork oil level gauge  99000-99001-SS5: SUZUKI FORK OIL SS-05 or an equivalent fork oil  STANDARD OIL OIL LEVEL...
• Page 58 MACHINE TUNING 4-11 • Adjust the height H of the inner rod threads by turning the lock-nut 1. H: 14 mm • Set the rebound damping adjuster 1.5 mm (0.06 in) as shown before assembling the front fork cap. • Slowly turn the fork cap bolt 2 to seat at the lock-nut 3 by hand tightening.
• Page 59 4-12 MACHINE TUNING FRONT FORK TUNING PROCEDURE Test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil capacity and compression/rebound damping following the instructions below.

• Page 60: Rear Suspension Tuning

  • Tighten the lock-nut 1.  Standard spring set length: 3.1 mm (0.12 in) compressed from spring free length (RM85) Standard spring set length: 4.8 mm (0.19 in) compressed from spring free length (RM85L)  Spring set length adjustable range: 2 –...
• Page 61 • Adjust the rear suspension according to the rider’s weight and preference by referring to the table below. (Spring replacement 17-4) Spring Spring rate Part No./Marking paint 44 N/mm (4.4 kgf/mm) RM85 62211-03B80/GREEN (2 line) Soft (Option) 46 N/mm (4.6 kgf/mm) RM85L 62211-03B90/GREEN 46 N/mm (4.6 kgf/mm) RM85...
• Page 62 MACHINE TUNING 4-15 SYMPTOM SECTION ADJUSTMENT PROCEDURE Bottoms • Jump 1. Adjust the compression damping to a harder • Large bump (H) setting. (See note below.) 2. Adjust the sag to a smaller measurement. (closer to 85 mm) 3. Replace the spring with an optional stiffer one. Kicks up •...

• Page 63: Suspension Balance

  4-16 MACHINE TUNING SUSPENSION BALANCE Balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

• Page 64: Engine Removal And Installation

  ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION CONTENTS ENGINE REMOVAL AND INSTALLATION ..........5- 2 REMOVAL ..................... 5- 2 INSTALLATION ..................5- 5...

• Page 65: Engine Removal And Installation

  ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL AND INSTALLATION REMOVAL • Remove the frame covers 1 (left & right) and seat 2. • Remove the clamps 3. • Turn the fuel valve lever to the “OFF” position and disconnect the fuel hose. •...
• Page 66 ENGINE REMOVAL AND INSTALLATION • Remove the muffler mounting bolts. • Remove the exhaust pipe and muffler. • Remove the exhaust pipe and gasket. • Disconnect the radiator hose 1. • Disconnect the radiator hose 2. • Remove the spark plug cap 3 and spark plug 4. •...
• Page 67 ENGINE REMOVAL AND INSTALLATION • Loosen the carburetor clamp screws and remove the carbure- tor. • Remove the magneto cover. • Remove the drive chain. • Remove the clutch release arm 1 and disconnect the clutch cable. • Remove the engine mounting bolts.
• Page 68 ENGINE REMOVAL AND INSTALLATION • Loosen the swingarm pivot nut. • Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in position. NOTE: The swingarm will come off when the swingarm pivot shaft is completely removed. •...
• Page 69 ENGINE REMOVAL AND INSTALLATION • Fit the projection of the carburetor to the depression on intake pipe. • Apply a small quantity of engine oil to the exhaust pipe O-ring. • Install the exhaust gasket and exhaust pipe. After mounting the engine, inspect the following items. •...
• Page 70 CYLINDER, PISTON AND EXHAUST VALVE CYLINDER, PISTON AND EXHAUST VALVE CONTENTS CONSTRUCTION ..................6- 2 CYLINDER, PISTON AND EXHAUST VALVE ........6- 2 ENGINE TOP END ..................6- 3 CYLINDER HEAD REMOVAL .............. 6- 3 CYLINDER REMOVAL ................6- 3 PISTON REMOVAL ................

• Page 71: Construction

  CYLINDER, PISTON AND EXHAUST VALVE CONSTRUCTION CYLINDER, PISTON AND EXHAUST VALVE 28 N . m (2.8 kgf-m, 20.5 lb-ft) 28 N . m (2.8 kgf-m, 21.0 lb-ft) 25 N . m (2.5 kgf-m, 18.0 lb-ft)

• Page 72: Engine Top End

  CYLINDER, PISTON AND EXHAUST VALVE ENGINE TOP END CYLINDER HEAD REMOVAL • Remove the frame covers and seat. (5-2) • Remove the radiator covers and fuel tank. (5-2) • Remove the muffler. (5-2) • Drain engine coolant. (12-3) • Loosen the clamp and disconnect the radiator hose 1. •...

• Page 73: Piston Removal

  CYLINDER, PISTON AND EXHAUST VALVE • Loosen the four cylinder nuts 1. • Remove the cylinder 2. NOTE: Loosen the cylinder nuts diagonally. • Remove the gasket 3 and dowel pins 4. PISTON REMOVAL • Remove the cylinder head and cylinder. (6-3) •...

• Page 74: Cylinder Head Inspection

  CYLINDER, PISTON AND EXHAUST VALVE • Remove the exhaust valve shaft stop retainer 2. • Loosen the bolt 3. Draw out the shaft. • Remove the spacers 4, springs 5 and valve shaft arm 6. • Remove the exhaust valve assembly 7. CYLINDER HEAD INSPECTION •...

• Page 75: Piston And Piston Ring Inspection

  CYLINDER, PISTON AND EXHAUST VALVE • Inspect for cylinder distortion.  Cylinder distortion Service Limit: 0.05 mm (0.002 in) • Measure the cylinder bore for wear with a cylinder gauge 15 mm (0.59 in) from the top surface. NOTE: The cylinder bore must be measured perpendicular to the crank- shaft axis direction.

• Page 76: Exhaust Valve Inspection

  CYLINDER, PISTON AND EXHAUST VALVE • Fit the piston ring into the cylinder and measure the piston ring end gap with a thickness gauge.  Piston ring end gap Service Limit: 0.80 mm (0.031 in) • Measure the piston ring free end gap. ...

• Page 77: Conrod Inspection

  CYLINDER, PISTON AND EXHAUST VALVE CONROD INSPECTION • Measure the conrod small end bore.  Conrod small end bore Service Limit: 18.040 mm (0.7102 in)  09900-20605: Dial gauge • Fit the piston pin and bearing into the conrod small end and check the play.
• Page 78 CYLINDER, PISTON AND EXHAUST VALVE • Install the spacers 1, springs 2, valve shaft arm 4 and shaft. • Tighten the bolt 3. • Tighten the stopper bolt 5. • Install the gasket and cover.

• Page 79: Cylinder Reassembly

  6-10 CYLINDER, PISTON AND EXHAUST VALVE CYLINDER REASSEMBLY • Install the new gasket. Install the dowel pins 1. • Apply engine oil to the cylinder bore. • Hold the piston and piston ring, and insert the piston into the cylinder. CAUTION If the piston pin end is not at the proper position, you can not insert the piston into the cylinder properly and...
• Page 80 CYLINDER, PISTON AND EXHAUST VALVE 6-11 • Install the new O-rings onto the cylinder. • Install the cylinder head. • Tighten the cylinder head nuts to the specified torque accord- ing to the specified tightening order as shown.  Cylinder head nut: 28 N·m (2.8 kgf-m, 20.5 lb-ft) •...

• Page 81: Exhaust Valve Governor Removal And Disassembly

  6-12 CYLINDER, PISTON AND EXHAUST VALVE EXHAUST VALVE GOVERNOR REMOVAL AND DISASSEMBLY • Drain transmission oil. (2-7) • Drain engine coolant. (12-3) • Remove the exhaust pipe. (5-2) • Remove the rear brake pedal. (15-14) • Remove the clutch cover. (7-3) •...

• Page 82: Exhaust Valve Governor Inspection

  CYLINDER, PISTON AND EXHAUST VALVE 6-13 • Remove the spring 5, retainer 6 and bearing 7. • Remove the washers 8, spacer 9 bearing 0 and stator A. • Remove the balls B. EXHAUST VALVE GOVERNOR INSPECTION • Inspect the bearing for wear. •...

• Page 83: Exhaust Valve Governor Reassembly And Installation

  6-14 CYLINDER, PISTON AND EXHAUST VALVE • Inspect the balls and their grooves of governor and actuator for wear or damage. • If they are worn or damaged, replace them with the new ones. EXHAUST VALVE GOVERNOR REASSEMBLY AND INSTALLATION Installation is in the reverse order of removal and disassembly.
• Page 84 CLUTCH CLUTCH CONTENTS CONSTRUCTION ..................7- 2 CLUTCH ....................7- 2 CLUTCH ....................... 7- 3 CLUTCH PLATE REMOVAL ..............7- 3 CLUTCH PLATE INSPECTION ............7- 3 CLUTCH SPRING INSPECTION ............7- 4 CLUTCH RACK AND PINION INSPECTION ........7- 4 CLUTCH PLATE REASSEMBLY ............

• Page 85: Construction

  CLUTCH CONSTRUCTION CLUTCH 70 N . m (7.0 kgf-m, 50.5 lb-ft)

• Page 86: Clutch Plate Removal

  CLUTCH CLUTCH CLUTCH PLATE REMOVAL • Drain transmission oil. (2-7) • Drain the engine coolant. (12-3) • Remove the rear brake pedal. (15-14) • Remove the clutch release arm 1. • Remove the kick starter lever 2. • Remove the clutch cover. •...

• Page 87: Clutch Spring Inspection

  CLUTCH CLUTCH SPRING INSPECTION • Measure the clutch spring free length.  Clutch spring free length Service Limit: 39.4 mm (1.55 in) NOTE: Replace five clutch springs together even if only one spring is exceed the service limit. CLUTCH RACK AND PINION INSPECTION •...

• Page 88: Clutch Sleeve Hub Removal

  CLUTCH • Replace the gasket with a new one. • Install the dowel pins. • Align the clutch release rack teeth with the pinion gear. • Align the water pump empeller to the crankshaft end. • Install the clutch cover. •...

• Page 89: Clutch Sleeve Hub Inspection

  CLUTCH • Remove the washer 1, primary driven gear ass’y 2. • Remove the needle bearing 3 and washer 4. • Remove the snap ring 5 and kick idle gear 6. CLUTCH SLEEVE HUB INSPECTION • Inspect the clutch sleeve hub and primary driven gear ass’y for wear and cracks.
• Page 90 CLUTCH • Install the primary driven gear ass’y and washer. • Install the clutch sleeve hub, lock washer 1 and clutch sleeve hub nut 2. • Tighten the clutch sleeve hub nut with the special tool to the specified torque. ...
• Page 91 CLUTCH • Reassemble the clutch plates and pressure plate. (7-4) • Install the dowel pins. • Replace the gasket with a new one. • Install the clutch cover and bolts. Tighten the clutch cover bolts diagonally. (7-5) • Connect the radiator hose. •...
• Page 92 KICK STARTER KICK STARTER CONTENTS CONSTRUCTION ..................8- 2 KICK STARTER ..................8- 2 KICK STARTER ................... 8- 3 REMOVAL ..................... 8- 3 INSPECTION ..................8- 4 REASSEMBLY ..................8- 4...

• Page 93: Construction

  KICK STARTER CONSTRUCTION KICK STARTER...

• Page 94: Removal

  KICK STARTER KICK STARTER REMOVAL • Drain transmission oil. (2-7) • Drain engine coolant. • Remove the kick starter lever. • Remove the clutch assembly. (7-5) • Remove the snap ring 1. • Remove the kick idle gear 2. • Remove the kick starter drive gear 3. •...

• Page 95: Inspection

  KICK STARTER INSPECTION • Inspect the oil seal 1 for oil leakage and oil seal lip damage. • Inspect the return spring 2 for damage. • Inspect the kick shaft 3 and drive gear for contact surface wear. • Inspect the kick drive gear teeth for damage. •...
• Page 96 KICK STARTER • Install the kick shaft assembly to the crankcase. • Hook the return spring to the crankcase’s hole. • Install the kick starter to the kick shaft. NOTE: Be sure to align the punch marks on the kick starter and kick starter shaft when installing the kick starter.
• Page 97 – MEMO –...

• Page 98: Gearshifting

  GEARSHIFTING GEARSHIFTING CONTENTS CONSTRUCTION ..................9- 2 GEARSHIFT LINKAGE ................. 9- 2 GEARSHIFT LINKAGE ................9- 3 REMOVAL ..................... 9- 3 INSPECTION ..................9- 4 REASSEMBLY ..................9- 4...

• Page 99: Construction

  GEARSHIFTING CONSTRUCTION GEARSHIFT LINKAGE 19 N . m (1.9 kgf-m, 13.5 lb-ft) 23 N . m (2.3 kgf-m, 16.5 lb-ft)

• Page 100: Removal

  GEARSHIFTING GEARSHIFT LINKAGE REMOVAL • Drain transmission oil. (2-7) • Drain engine coolant. (12-3) • Remove the kick starter lever and clutch assembly. (7-5) • Remove the gearshift lever. • Remove the gearshift shaft 2. • Remove the two screws. Remove the pawl lifter 3. •...

• Page 101: Inspection

  GEARSHIFTING • Remove the gearshift cam stopper 1. • Remove the spring 2. INSPECTION • Inspect the gearshift shaft 1 for bends and damage. • Inspect the return spring 2 for damage. • Inspect the pawls 3, springs 4 and pins 5 for damage. •...
• Page 102 GEARSHIFTING • Align the pin groove A with the pin B when installing the stopper plate 1. • Tighten the gear shift cam bolt 2.  Gearshift cam bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft) • Install the springs, pins and pawls to the shifter. Wider side A of pawl should be positioned outside.
• Page 103 GEARSHIFTING • Reassemble the gearshift cam shifter and pawl lifter. • Apply THREAD LOCK SUPER “1322” to the screws. • Tighten the screws.  99000-32110: THREAD LOCK SUPER “1322” • Reassemble the gearshift return spring 1 to the gearshift shaft properly. •...
• Page 104 TRANSMISSION AND CRANKSHAFT 10-1 TRANSMISSION AND CRANKSHAFT CONTENTS CONSTRUCTION ..................10- 2 TRANSMISSION AND CRANKSHAFT ..........10- 2 ENGINE BOTTOM SIDE ................10- 3 PRIMARY DRIVE GEAR REMOVAL ..........10- 3 CRANKCASE SEPARATION ............. 10- 3 TRANSMISSION REMOVAL .............. 10- 4 CRANKSHAFT REMOVAL ..............

• Page 105: Construction

  10-2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION TRANSMISSION AND CRANKSHAFT 70 N . m (7.0 kgf-m, 50.5 lb-ft)

• Page 106: Engine Bottom Side

  TRANSMISSION AND CRANKSHAFT 10-3 ENGINE BOTTOM SIDE • Dismount the engine. (5-2) NOTE: The following parts must be removed before disassembling the engine bottom side (crankcase). • Remove the engine sprocket cover and engine sprocket. • Remove the gearshift lever. (9-3) •...

• Page 107: Transmission Removal

  10-4 TRANSMISSION AND CRANKSHAFT TRANSMISSION REMOVAL • Remove the gearshift fork shafts 1 and forks 2. • Remove the gearshift cam 3. • Remove the driveshaft ass’y 4 and countershaft ass’y 5. CRANKSHAFT REMOVAL • Remove the crankshaft with the special tool. ...
• Page 108 TRANSMISSION AND CRANKSHAFT 10-5 • Inspect the gearshift forks and shafts for wear and damage. • Measure the gearshift fork thickness with a vernier calipers.  Gearshift fork thickness Standard No. 1 3.80 – 3.90 mm (0.150 – 0.154 in) No.

• Page 109: Crankshaft Inspection

  10-6 TRANSMISSION AND CRANKSHAFT CRANKSHAFT INSPECTION • Measure the crankshaft runout with V-blocks and dial gauge.  Crankshaft runout Service Limit: 0.05 mm (0.002 in)  09900-20607: Dial gauge (1/100 mm) 09900-20701: Magnetic stand 09900-21304: V-block NOTE: Place the crankshaft onto the V-blocks so that it becomes hori- zontally.

• Page 110: Bearing Inspection, Removal And Installation

  TRANSMISSION AND CRANKSHAFT 10-7 • Install each new oil seal with the special tools. Left Right • Apply grease to each oil seal lip. SIDE SIDE  09913-70210: Bearing installer set NOTE: Be sure to check the direction of the crankshaft bearing oil seals before fitting them.

• Page 111: Crankshaft Installation

  10-8 TRANSMISSION AND CRANKSHAFT • Remove the bearing retainers 1, 2. • Remove the bearings with the special tool.  09913-70210: Bearing installer set • Remove the bearing 3 with the special tool.  09921-20220: Bearing remover set CRANKSHAFT INSTALLATION •...

• Page 112: Transmission Reassembly

  TRANSMISSION AND CRANKSHAFT 10-9 TRANSMISSION REASSEMBLY Left Right NOTE: * Seat the snap ring in the groove and locate its end as shown in Thrust the illustration. * Replace the removed snap ring with a new one. Sharp edge • Apply transmission oil to the following parts: driveshaft, coun- tershaft, transmission gears, bearings, gearshift forks, gear- shift shafts, gearshift cam.

• Page 113: Crankcase Reassembly

  10-10 TRANSMISSION AND CRANKSHAFT • Install the gear shift forks 1, 2, 3. • Install the gear shift cam 3 and gearshift shafts 4, 5. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. CRANKCASE REASSEMBLY •...

• Page 114: Primary Driven Gear Reassembly

  TRANSMISSION AND CRANKSHAFT 10-11 PRIMARY DRIVEN GEAR REASSEMBLY • Install the primary driven gear and washer onto the crank- shaft. • Apply THREAD LOCK SUPER “1322” to the primary driven gear nut and tighten it to the specified torque with the special tool.
• Page 115 – MEMO –...
• Page 116 FUEL SYSTEM 11-1 FUEL SYSTEM CONTENTS CONSTRUCTION ..................11- 2 FUEL SYSTEM ..................11- 2 CARBURETOR ..................11- 3 REMOVAL AND DISASSEMBLY ............11- 3 INSPECTION ..................11- 5 REASSEMBLY ..................11- 5 REED VALVE .................... 11- 5 REMOVAL ................... 11- 5 INSPECTION ..................

• Page 117: Construction

  11-2 FUEL SYSTEM CONSTRUCTION FUEL SYSTEM...

• Page 118: Carburetor

  FUEL SYSTEM 11-3 CARBURETOR REMOVAL AND DISASSEMBLY • Remove the seat and fuel tank. (5-2) • Turn the fuel valve lever to “OFF”. • Disconnect the fuel hose. • Loosen the carburetor clamp screws and remove the carbure- tor. • Remove the carburetor top cap and throttle valve. •...
• Page 119 11-4 FUEL SYSTEM • Remove the air vent hoses 1, overflow hoses 2 fuel hose • Loosen the screws and remove the carburetor float chamber • Remove the float pin 6 and floats 7. • Remove the jet holder 8. •...

• Page 120: Inspection

  FUEL SYSTEM 11-5 INSPECTION • Inspect the following parts for damage: Jet needle Throttle valve Float • Inspect the following jets for clogging: Main jet Slow jet Good Worn Starter jet • Inspect the needle valve for wear. • Measure the float height with a vernier calipers. To measure the float height, tilt the carburetor until the float tip just con- tacts the float valve.

• Page 121: Reassembly

  11-6 FUEL SYSTEM REASSEMBLY Reverse the sequence of removal.
• Page 122 COOLING SYSTEM 12-1 COOLING SYSTEM CONTENTS CONSTRUCTION ..................12- 2 COOLING SYSTEM ................12- 2 ENGINE COOLANT ................... 12- 3 ENGINE COOLANT REPLACEMENT ..........12- 3 RADIATOR ....................12- 3 RADIATOR CAP INSPECTION ............12- 3 RADIATOR REMOVAL ............... 12- 4 COOLING SYSTEM INSPECTION .............

• Page 123: Construction

  12-2 COOLING SYSTEM CONSTRUCTION COOLING SYSTEM 2.5 N . m (0.25 kgf-m, 1.8 lb-ft) 2.5 N . m (0.25 kgf-m, 1.8 lb-ft)

• Page 124: Engine Coolant

  COOLING SYSTEM 12-3 ENGINE COOLANT ENGINE COOLANT REPLACEMENT  WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. Do not open the radiator cap when the engine is hot. Wait until engine cools.

• Page 125: Radiator Removal

  12-4 COOLING SYSTEM RADIATOR REMOVAL • Remove the seat and fuel tank. (5-2) • Drain engine coolant. (12-3) • Disconnect all the radiator hoses. • Remove the radiator by removing its mounting bolts. COOLING SYSTEM INSPECTION Inspect the following items. •...

• Page 126: Water Pump

  COOLING SYSTEM 12-5 WATER PUMP WATER PUMP REMOVAL AND INSPECTION • Drain engine coolant and transmission oil. (12-3 and 2-7) • Remove the water pump cover 1. • Remove the clutch cover. (7-3) • Remove the snap rings 2 with snap ring pliers. •...

• Page 127: Water Pump Reassembly

  12-6 COOLING SYSTEM WATER PUMP REASSEMBLY • Apply THREAD LOCK SUPER “1322” to the outer surface of the oil seal. Install the oil seal with a proper tool.  99000-32110: THREAD LOCK SUPER “1322” • Apply grease to the machanical seal lip. •...

• Page 128: Electrical System

  ELECTRICAL SYSTEM 13-1 ELECTRICAL SYSTEM CONTENTS CONSTRUCTION ..................13- 2 ELECTRICAL SYSTEM ..............13- 2 ELECTRICAL CIRCUIT ............... 13- 2 IGNITION SYSTEM ..................13- 3 IGNITION COIL INSPECTION ............13- 4 CDI UNIT INSPECTION ..............13- 4 STATOR COIL INSPECTION .............. 13- 5 MAGNETO ROTOR AND STATOR REMOVAL AND REASSEMBLY ..................

• Page 129: Construction

  13-2 ELECTRICAL SYSTEM CONSTRUCTION ELECTRICAL SYSTEM 35 N . m (3.5 kgf-m, 25.5 lb-ft) ELECTRICAL CIRCUIT Engine stop switch Ignition coil Magneto CDI Unit W/Bl Spark plug Color code: B/W : Black with White tracer B/Y : Black with Yellow tracer B/R : Black with Red tracer W/Bl : White with Blue tracer R/W : Red with White tracer...

• Page 130: Ignition System

  ELECTRICAL SYSTEM 13-3 IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE INSPECTION • Remove the seat fuel tank. (5-2) • Remove the spark plug cap and spark plug. • Connect a new spark plug to the spark plug cap and ground it to the cylinder head.

• Page 131: Ignition Coil Inspection

  13-4 ELECTRICAL SYSTEM IGNITION COIL INSPECTION • Remove the seat and fuel tank. (5-2) • Measure the ignition coil electrical resistance.  09900-25008: Multi-circuit tester Tester knob indication: Resistance (W)  0.2 – 1.0 Ω Primary White/Blue – Ground Secondary Plug cap –...

• Page 132: Stator Coil Inspection

  ELECTRICAL SYSTEM 13-5 STATOR COIL INSPECTION • Remove the seat and fuel tank. (5-2) • Disconnect the magneto lead wire coupler. • Measure the stator coils electrical resistance.  240 – 380 Ω Black/Red – Black/White 140 – 230 Ω Red/White –...
• Page 133 13-6 ELECTRICAL SYSTEM MAGNETO ROTOR AND STATOR REASSEMBLY • Install the key onto the crankshaft. • Install the magneto rotor. • Hold the conrod with the special tool. • Apply THREAD LOCK SUPER “1322” to the nut and tighten the nut to the specified torque. ...
• Page 134 FRONT AND REAR WHEELS 14-1 FRONT AND REAR WHEELS CONTENTS CONSTRUCTION ..................14- 2 FRONT AND REAR WHEELS ............14- 2 FRONT WHEEL ..................14- 3 REMOVAL ................... 14- 3 INSPECTION ..................14- 3 FRONT WHEEL BEARING REMOVAL ..........14- 4 FRONT WHEEL BEARING REASSEMBLY ........

• Page 135: Construction

  14-2 FRONT AND REAR WHEELS CONSTRUCTION FRONT AND REAR WHEELS 65 N . m 6.5 kgf-m 47.0 lb-ft 8.5 N . m 4 N . m 0.85 kgf-m 0.4 kgf-m 6.0 lb-ft 3.0 lb-ft 40 N . m (4.0 kgf-m, 29.0 lb-ft) 8.5 N .

• Page 136: Front Wheel

  FRONT AND REAR WHEELS 14-3 FRONT WHEEL REMOVAL • Place the motorcycle on a block to lift front wheel off the ground. • Remove the cotter pin. • Loosen the axle nut 1. • Remove the axle. • Remove the front wheel and collars. INSPECTION AXLE SHAFT •...

• Page 137: Front Wheel Bearing Removal

  14-4 FRONT AND REAR WHEELS FRONT WHEEL BEARING REMOVAL • Fit the bearing remover into the wheel bearing.  09921-20220: Bearing remover set • Remove the bearings and spacer. FRONT WHEEL BEARING REASSEMBLY • Apply grease to the bearings. • Reassemble the spacer and bearings with the special tool. ...

• Page 138: Rear Wheel

  FRONT AND REAR WHEELS 14-5 REAR WHEEL REMOVAL • Place the motorcycle on a block to lift the rear wheel off the ground. • Remove the axle nut 1. • Hold the rear wheel and remove the rear axle shaft. •...

• Page 139: Rear Wheel Bearing Removal

  14-6 FRONT AND REAR WHEELS REAR WHEEL BEARING REMOVAL • Remove the dust seals and snap ring from the wheel hub. • Fit the bearing remover into the wheel bearing.  09921-20220: Bearing remover set • Remove the bearings and spacer. REAR WHEEL BEARING REASSEMBLY •...

• Page 140: Disc Plate Replacement

  FRONT AND REAR WHEELS 14-7 DISC PLATE REPLACEMENT • Remove the front and rear wheels. (14-3 and -5) • Replace the disc. • Apply THREAD LOCK SUPER “1322” to the screws.  99000-32110: THREAD LOCK SUPER “1322” • Tighten the screws and nuts 1 (front only) to the specified torque.
• Page 141 – MEMO –...
• Page 142 FRONT AND REAR BRAKES 15-1 FRONT AND REAR BRAKES CONTENTS CONSTRUCTION ..................15- 2 FRONT AND REAR BRAKES ............15- 2 BRAKE FLUID ................... 15- 3 BRAKE FLUID AIR BLEEDING ............15- 3 BRAKE FLUID REPLACEMENT ............15- 4 BRAKE PAD REPLACEMENT ............15- 4 BRAKE DISC .....................

• Page 143: Construction

  15-2 FRONT AND REAR BRAKES CONSTRUCTION FRONT AND REAR BRAKES 10 N . m (1.0 kgf-m, 7.3 lb-ft) 23 N . m 2.3 kgf-m 16.5 lb-ft 23 N . m 2.3 kgf-m 16.5 lb-ft 10 N . m 1.0 kgf-m 7.3 lb-ft 10 N .

• Page 144: Brake Fluid

  FRONT AND REAR BRAKES 15-3 BRAKE FLUID BRAKE FLUID AIR BLEEDING WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children.

• Page 145: Brake Fluid Replacement

  15-4 FRONT AND REAR BRAKES • Tighten the air bleeder valve.  Brake caliper air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) • Pour brake fluid up to the UPPER line. • Reassemble the reservoir cap. BRAKE FLUID REPLACEMENT •...

• Page 146: Brake Disc

  FRONT AND REAR BRAKES 15-5 • Remove the clamp 1. Remove the pad mounting pin 2. NOTE: Replace the two pads as a set. • Install the new brake pads to the caliper. NOTE: Make sure that the tip A of the spring is fitted to the inner pad •...

• Page 147: Brake Caliper

  15-6 FRONT AND REAR BRAKES BRAKE CALIPER  WARNING The use of any brake fluid except DOT 4 brake fluid from a sealed container can damage the brake system and lead to an accident. Use only DOT 4 brake fluid from a sealed container. Never use or mix different types of brake fluid.

• Page 148: Rear Caliper Removal And Disassembly

  FRONT AND REAR BRAKES 15-7 • Apply low-pressure air into the caliper through the hole to remove the piston.  WARNING Fingers can get caught between piston and caliper body when removing the piston. Do not place your fingers on the piston when remov- ing the piston.

• Page 149: Caliper Inspection

  15-8 FRONT AND REAR BRAKES • Remove the brake pads and spring 3 from the caliper. • Remove the caliper bracket 4. • Wrap the caliper with a rag to prevent brake fluid scatter and piston pop-out. • Apply low-pressure air into the caliper through the hole to remove the piston.

• Page 150: Caliper Cleaning

  • Install the piston into the caliper. • Apply silicone grease to the caliper axles.  99000-25100: SUZUKI SILICONE GREASE • Install the boots and caliper bracket. • Install the spring and brake pads. (15-4) •...

• Page 151: Master Cylinder

  15-10 FRONT AND REAR BRAKES MASTER CYLINDER  WARNING Brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. Keep brake fluid away from children. Call your doctor immediately if brake fluid is swallowed, and induce vomiting.

• Page 152: Rear Master Cylinder Removal And Disassembly

  FRONT AND REAR BRAKES 15-11 • Remove the bolt 1 and brake lever 2. • Remove the dust boot 1. • Remove the snap ring 2 with snap ring pliers. • Remove the washer 3, piston/cup set 4 and spring 5. REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY •...

• Page 153: Master Cylinder Inspection

  15-12 FRONT AND REAR BRAKES MASTER CYLINDER INSPECTION • Inspect the cylinder bore and piston for scuffing. • Inspect the piston rod and spring for damage. If any abnormal condition is noted, replace the master cylinder. • Inspect the dust boot, if any damages are found, replace it with a new one.

• Page 154: Rear Master Cylinder Reassembly

  FRONT AND REAR BRAKES 15-13 • Tighten the brake hose adaptor 1 to the specified torque.  Brake hose adaptor: 18 N·m (1.8 kgf-m, 13.0 lb-ft) NOTE: Hold the brake hose with a wrench to prevent the brake hose from twisting when tightening the adaptor. •...

• Page 155: Brake Pedal

  15-14 FRONT AND REAR BRAKES BRAKE PEDAL BRAKE PEDAL REMOVAL AND REASSEMBLY REMOVAL • Remove the nut from the brake pedal pivot. • Remove the cotter pin and pin from the push rod end. • Remove the return spring. REASSEMBLY •...
• Page 156 FRONT FORK AND STEERING 16-1 FRONT FORK AND STEERING CONTENTS CONSTRUCTION ..................16- 2 FRONT FORK AND STEERING ............16- 2 FRONT FORK .................... 16- 3 REMOVAL ................... 16- 3 DISASSEMBLY ................... 16- 3 INSPECTION ..................16- 5 REASSEMBLY ..................16- 7 REINSTALLATION ................

• Page 157: Construction

  16-2 FRONT FORK AND STEERING CONSTRUCTION FRONT FORK AND STEERING 26 N . m (2.6 kgf-m, 19.0 lb-ft) 65 N . m (6.5 kgf-m, 47.0 lb-ft) 35 N . m 23 N . m (3.5 kgf-m, 25.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft) 23 N .

• Page 158: Front Fork

  FRONT FORK AND STEERING 16-3 FRONT FORK REMOVAL • Place a block under the chassis tubes. • Remove the fork covers, brake hose guide and brake hose cover. • Remove the brake caliper. (15-6) • Remove the front wheel. (14-3) •...
• Page 159 16-4 FRONT FORK AND STEERING • Compress the front fork spring 3 and loosen the lock-nut 1. • Remove the fork cap 2. • Remove the fork spring 3. • Remove the lock-nut 4 and the spring guide 5. • Invert the front fork and stroke the inner rod several times to let out fork oil.

• Page 160: Inspection

  FRONT FORK AND STEERING 16-5 • Remove the dust seal 1 and the stopper ring 2. • Pull out the inner tube from the outer tube. • Remove the slide bushing 3 from the inner tube. • Remove the following parts from the inner tube. Slide bushing 3 Seal retainer 4 Oil seal 5...
• Page 161 16-6 FRONT FORK AND STEERING • Inspect the inner tube for scratches. If it has scratches, replace it with a new one. • Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one. •...

• Page 162: Reassembly

  FRONT FORK AND STEERING 16-7 REASSEMBLY NOTE: * Clean all fork parts before reassembling. * Replace the O-rings, oil seal and dust seal with the new ones. * Apply specified front fork oil when installing the O-rings, slide bushing, guide bushing, damper unit and other sliding parts. •...
• Page 163 16-8 FRONT FORK AND STEERING • Attach the stopper ring 7 securely to the stopper ring groove of the outer tube. • Attach the dust seal 8. NOTE: After attaching the dust seal, make sure that there are no cracks around the circumference of the seal.

• Page 164: Fork Oil

   09943-74111: Front fork oil level gauge  Fork oil level (Standard): 124 mm (4.88 in)  99000-99001-SS5:SUZUKI FORK OIL SS-05 or an equivalent fork oil  Standard fork oil capacity (each leg): 351 ml (11.86/12.36 US/lmp oz)
• Page 165 16-10 FRONT FORK AND STEERING • Pull up the inner rod with the special tool.  09940-52841: Inner rod holder • Install the fork spring. • Adjust the height H of the inner rod threads by turning the lock-nut 1. H: 14 mm •...

• Page 166: Reinstallation

  FRONT FORK AND STEERING 16-11 REINSTALLATION • Reinstall the front forks. • Set the aligning line T on the outer tube to the upper surface of the steering stem head. • Check that the air valve A is positioned at the front. •...

• Page 167: Steering

  16-12 FRONT FORK AND STEERING STEERING REMOVAL • Remove the front wheel. (14-3) • Remove the brake caliper. (15-6) • Remove the front number plate. • Remove the handlebar holder bolts 1 and handlebars. • Remove the brake hose guide. •...

• Page 168: Inspection

  FRONT FORK AND STEERING 16-13 INSPECTION • Inspect the bearing races for wear. • Inspect the needle bearings for wear. • Inspect the steering stem for distortion. BEARING REPLACEMENT NOTE: Replace the outer race and bearing as a set. • Remove the upper and lower outer races with the special tools.

• Page 169: Reassembly

  16-14 FRONT FORK AND STEERING REASSEMBLY • Apply grease to the bearings and dust seals. • Install the steering stem, upper bearing and steering stem nut. • Tighten the steering stem nut with the special tool.  09940-14930: Steering nut socket wrench ...
• Page 170 REAR SUSPENSION 17-1 REAR SUSPENSION CONTENTS CONSTRUCTION ..................17-2 REAR SUSPENSION ................17-2 REAR SHOCK ABSORBER ................ 17-3 REAR SHOCK ABSORBER REMOVAL ..........17-3 SPRING REMOVAL ................17-4 REAR SHOCK ABSORBER INSPECTION .......... 17-4 SPRING INSTALLATION ..............17-5 REAR SHOCK ABSORBER INSTALLATION ........17-5 OIL REPLACEMENT PROCEDURE .............

• Page 171: Construction

  17-2 REAR SUSPENSION CONSTRUCTION REAR SUSPENSION 60 N . m 6.0 kgf-m 43.5 lb-ft 18 N . m 1.8 kgf-m 13.0 lb-ft 80 N . m 8.0 kgf-m 58.0 lb-ft 80 N . m 8.0 kgf-m 58.0 lb-ft 60 N . m 6.0 kgf-m 43.5 lb-ft 58 N .

• Page 172: Rear Shock Absorber

  REAR SUSPENSION 17-3 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL • Place a block under chassis tubes. • Remove the frame covers and seat. (5-2) • Loosen the air cleaner clamp screw A. • Remove the frame side tube 1. •...

• Page 173: Spring Removal

  17-4 REAR SUSPENSION SPRING REMOVAL • Remove the rear shock absorber unit from the frame. (17-3) • Loosen the lock-nut 1 and turn the adjuster 2 with the spe- cial tool. • Turn the lock-nut 1 and adjuster 2 fully to the end of the thread.

• Page 174: Spring Installation

  • Adjust the spring set length and tighten the lock-nut.  Standard spring set length: 3.1 mm (0.12 in) compressed from spring free length (RM85) 4.8 mm (0.18 in) compressed from spring free length (RM85L)  Spring set length adjustable range: 2 –...

• Page 175: Oil Replacement Procedure

  17-6 REAR SUSPENSION OIL REPLACEMENT PROCEDURE TOOLS AND EQUIPMENT • Following tools and equipment are required to perform oil replacement. 1 Screwdriver or small punch 2 Vise* 3 Drain Pan 4 Oilcan 5 Beaker 6 Specified Shock Oil (SS25) 7 Rags 8 Nitrogen tank 9 Filler Hose and Nozzle 0 Regulator Assembly...
• Page 176 • Tilt the shock absorber unit as shown and pour the fresh rear suspension oil fully into the reservoir tank.  99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25  Oil capacity: Approx. 195 ml (6.6/6.9 US/Imp oz) • Cover the compression adjuster hole by the root of your thumb.
• Page 177 17-8 REAR SUSPENSION • Reinstall the compression adjuster assembly 1 with the spe- cial tool. NOTE: Replace the O-rings on the compression adjuster assembly with new ones.  Compression adjuster assembly: 18 N·m (1.8 kgf-m, 13.0 lb-ft)  09941-53650: Rear shock absorber socket wrench •...

• Page 178: Rear Shock Absorber Disassembly And Inspection

  REAR SUSPENSION 17-9 REAR SHOCK ABSORBER DISASSEMBLY AND INSPECTION • Remove the rear shock absorber unit from the frame. Clean and dry it. (17-3) • Remove the spring from the rear shock absorber. (17-4) • Turn the rebound damping force adjuster to the softest posi- tion.

• Page 179: Rear Shock Absorber Reassembly

  • Install the stopper to the shock absorber body. • Fill the specified rear suspension oil in the rear shock absorber. (17-7)  99000-99001-S25: SUZUKI REAR SUSPENSION OIL SS-25  Oil capacity: Approx. 195 ml (6.6/6.9 US/Imp oz) • Reinstall the compression adjuster assembly. (17-8) •...

• Page 180: Swingarm

  REAR SUSPENSION 17-11 SWINGARM SWINGARM REMOVAL • Remove the rear wheel. (14-5) • Remove the chain guide 1. • Remove the rear brake hose guide 2. • Remove the rear brake caliper 3. • Remove the drive chain. • Remove the rear cushion rod bolt and nut 4. •...

• Page 181: Swingarm Inspection

  17-12 REAR SUSPENSION SWINGARM INSPECTION • Measure the pivot shaft runout with a dial gauge and V-blocks.  Swingarm pivot shaft runout Service Limit: 0.3 mm (0.01 in) • Inspect the swingarm for cracks and damage. • Inspect the bearings, spacers and oil seals for damage. •...

• Page 182: Swingarm Reassembly

  REAR SUSPENSION 17-13 SWINGARM REASSEMBLY • Reassemble the following parts into the swingarm. 1 Spacer 2 Dust seal 3 Washer • Apply grease to the dust seals, bearings and spacers. • Install the swingarm to the frame. • Tighten the swingarm pivot nut 4 to the specified torque. ...

• Page 183: Rear Suspension Linkage Inspection

  17-14 REAR SUSPENSION • Remove the cushion rod 1 from the cushion lever 2. REAR SUSPENSION LINKAGE INSPECTION • Inspect the cushion lever and cushion rod for damage. • Inspect the dust seals and spacers for damage. • Inspect the bearings for damage. •...
• Page 184 REAR SUSPENSION 17-15 • Apply grease to the bearings. • Install the bearings with the special tool and pipes, 24 mm (0.9 in) in diameter and 4 mm (0.2 in) in length.  09941-34513: Bearing installer set NOTE: Position the bearings by refering to the illustration of page 17-16.

• Page 185: Rear Suspension Linkage Reassembly

  17-16 REAR SUSPENSION REAR SUSPENSION LINKAGE REASSEMBLY • Reassemble the rear suspension linkage. • Tighten the nuts to the specified torque.  Tightening torque: A: 60 N·m (6.0 kgf-m, 43.5 lb-ft) B: 60 N·m (6.0 kgf-m, 43.5 lb-ft) C: 80 N·m (8.0 kgf-m, 58.0 lb-ft) D: 60 N·m (6.0 kgf-m, 43.5 lb-ft) E: 80 N·m (8.0 kgf-m, 58.0 lb-ft) Right...

• Page 186: Servicing Information

  SERVICING INFORMATION 18-1 SERVICING INFORMATION CONTENTS SERVICE DATA ..................18- 2 SPECIAL TOOLS ..................18- 7 WIRE, CABLE AND HOSE ROUTING ............18- 9 SPECIFICATIONS ..................18-17 SETTING DATA ..................18-19...

• Page 187: Service Data

  18-2 SERVICING INFORMATION SERVICE DATA CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Piston to cylinder clearance 0.040 – 0.050 0.120 (0.0016 – 0.0020) (0.0047) Cylinder bore 48.000 – 48.015 Nicks or (1.8898 – 1.8904) scratches Measure 15 (0.59) from the top surface.

• Page 188: Drive Chain

  SERVICING INFORMATION 18-3 TRANSMISSION Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.444 (62/18) — Final reduction ratio 3.357 (47/14) RM85 — 3.615 (47/13) RM85L — Gear ratios 2.545 (28/11) — 1.933 (29/15) — 1.571 (22/14) —...
• Page 189 Wheel rim runout Axial — (0.08) Radial — (0.08) Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) Tire size 70/100-17 40M RM85 — Front 70/100-19 42M RM85L — 90/100-14 49M RM85 — Rear 90/100-16 52M RM85L —...

• Page 190: Tire Pressure

  Rear shock absorber gas pressure 1 000 kPa (10 kgf/cm , 142 psi) — Rear shock absorber spring pre-set RM85: 3.1 mm (0.12 in) compressed from spring length free length — RM85L: 4.8 mm (0.19 in) compressed from spring free length...
• Page 191 650 ml Overhaul (1.37/1.14 US/Imp qt) Brake fluid type DOT 4 Front fork oil type SUZUKI FORK OIL SS-05 or equivalent fork oil Front fork oil capacity 351 ml (each leg) (11.86/12.36 US/Imp oz) Rear shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25...

• Page 192: Special Tools

  SERVICING INFORMATION 18-7 SPECIAL TOOLS 09900-20101 09900-00401 09900-06107 09900-06108 09900-09003 Vernier calipers Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set (150 mm) 09900-20202 09900-20205 Micrometer Micrometer 09900-20508 09900-20602 09900-20605 (25 – 50 mm) (0 – 25 mm) Cylinder gauge set Dial gauge Dial gauge...
• Page 193 18-8 SERVICING INFORMATION 09930-30141 09930-30211 Flywheel rotor Flywheel rotor 09930-30102 09940-14930 remover, Attach- remover, Attach- 09924-84521 Rotor remover slide Steering nut socket ment ment Bearing installer shaft wrench 09940-30250 09940-52861 09941-53630 Front fork assem- 09940-52841 Front fork oil seal 09941-34513 Rear shock bling Inner rod holder...

• Page 194: Wire, Cable And Hose Routing

  SERVICING INFORMATION 18-9 WIRE, CABLE AND HOSE ROUTING...
• Page 195 18-10 SERVICING INFORMATION Radiator hose must be passed on right side of frame tube. Muffler Radiator Frame Cylinder breather hose Exhaust breather hose Face the clamp screw to up side.
• Page 196 SERVICING INFORMATION 18-11...
• Page 197 18-12 SERVICING INFORMATION When loosening or tighten the adaptor, The front brake hose must be passed in front of the number hold the front brake hose with a wrench plate. to prevent the brake hose from twisting. Front brake master cylinder Washer Front brake hose guide...
• Page 198 SERVICING INFORMATION 18-13 Clamp Clamp No contact Stopper Guide Brake hose No bent Rear caliper Bolt Rear master cylinder Bracket...
• Page 199 18-14 SERVICING INFORMATION...
• Page 200 SERVICING INFORMATION 18-15 Clutch cable Clamp Radiator hose Throttle cable...
• Page 201 18-16 SERVICING INFORMATION Throttle cable Cross the throttle cable and clutch cable above the number plate mounting boss Clutch cable Brake hose...

• Page 202: Specifications

  SERVICING INFORMATION 18-17 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............1 805 mm (71.1 in) ..RM85 1 895 mm (74.6 in) ..RM85L Overall width............735 mm (28.9 in) Overall height ............. 1 100 mm (43.3 in) ..RM85 1 165 mm (45.9 in) ..
• Page 203 Trail ..............87 mm (3.4 in) ....RM85 85 mm (3.3 in) ....RM85L Steering angle............45° Turning radius ............1.9 m (6.2 ft) ....RM85 2.0 m (6.6 ft) ....RM85L Front brake............Disc brake, hydraulically operated Rear brake ............Disc brake, hydraulically operated Front tire size ............

• Page 204: Setting Data

  SERVICING INFORMATION 18-19 SETTING DATA DATE RACE/COURSE TEMP./HUMIDITY WHETHER COURSE COUDITION MAIN JET JET NEEDLE SLOW JET PILOT SCREW FLOAT LEVEL SPARK PLUG OIL LEVEL COMP. ADJ. POSITION RE-BOUND ADJ. POSITION SPRING SPRING SPRING SET LENGTH COMP. ADJ. POSITION LOW COMP.
• Page 205 – MEMO –...
• Page 206 Failure to follow these safety precautions may increase your risk of injury: ! Wear a helmet, eye protection, and bright protective clothing. ! Don’t ride after consuming alcohol or other drugs. ! This owner’s service manual contains important safety information. Please read it carefully. Printed in Taiwan 300 TAKATSUKA, HAMAMATSU, JAPAN...

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1. Plastic

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   Graziano SAG 14 Manual, New owner advice?

   Hello,
   My first real machine will be coming home in a week or so, would anyone have a scanned or PDF manual for a 50s ish SAG 14? I very excited about the lathe and have checked out it's history etc on lathes.UK. I hope to get a 5c nose or collect adaptor for it. It comes with 3 and 4 jaw chucks, both 10' which need cleaning up, and that's about it. I'd love to get a steady rest for it too, are such things ever on eBay? I see a local 7.5 HP rotary phase converter, which I think so be more than I need, but any advice is welcome. It's going in the garage, I'm an IT guy that likes to play with machines, in my spare time.
   Thanks
   Pete

2. Diamond

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   Pete,
   The Sag 14 is a great lathe, a very reliable machine.
   Would be great to see any photos when you get a chance.
   You can download a manual from this excellent web site. Near the top of the page, look for 'Graziano SAG 14 manuel', clicking on this phrase will take you to the list of downloads. It is a 14.2 MB pdf.
   Graziano SAG 14 (+ 17)
   Main page for documents and manuals: Machines Outils: Manuels & Docs

3. Plastic

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   Originally Posted by Peter S

   Pete,
   The Sag 14 is a great lathe, a very reliable machine.
   Would be great to see any photos when you get a chance.
   You can download a manual from this excellent web site. Near the top of the page, look for 'Graziano SAG 14 manuel', clicking on this phrase will take you to the list of downloads. It is a 14.2 MB pdf.
   Graziano SAG 14 (+ 17)
   Main page for documents and manuals: Machines Outils: Manuels & Docs

   Peter,
   Fantastic thank you so much. I don't have the lathe yet, but it looks like this sitting at the dealer
   

4. Stainless

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5. Diamond

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   Pete,
   Thanks for the photos. I notice the slideway guards are missing in the area under the chuck. Maybe the seller removed them while cleaning? They are fairly important, fortunately they wouldn't be too hard to make. They are made from sheetmetal.
   Let me know if you need a drawing.
   Here are the guards on a Sag 12.
   I wonder what happened to the toolpost, maybe in the tray with the other parts?

6. Plastic

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   Peter,
   Thanks, I'll let you know, if I need a drawing. There's no tool post, steady rest or follow rest unfortunately, just a 3 and 4 jaw chuck, plus the single axis DRO, 706Jim it was about $3000. I'm thinking about an import 40 position spline based tool post for it. I'm going to see if the dealer can come up with a spanner wrench for the nose, are they hard to find? What do people do for chip backslashes, I haven't seen any in the images and video I've seen?
   Pete

7. Stainless

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   Originally Posted by otto_pjm

   Peter,
   Thanks, I'll let you know, if I need a drawing. There's no tool post, steady rest or follow rest unfortunately, just a 3 and 4 jaw chuck, plus the single axis DRO, 706Jim it was about $3000.
   Pete

   Thanks. My wife wanted to know what it was worth.

8. Plastic

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   Update I finally got the lathe home. I have a 10 HP VFD to power it, and I believe I have sorted out the oils I need to keeps it going. I'll get some pictures posted soon.
   Questions:
   Do I need a special type of oiler for the little button type oil ports on the lathe, I'm looking at Goldenrod piston pump oil can will that do it?
   Are tool posts for 10-18 inch swing the most appropriate?
   For tooling 1 inch holders? I see an auction coming with a lot of 1' and 1 1/4' tool holders on offer.
   Anyone have a favorite dial setup for the cross feed? It came with a DRO for the Z axis so I'm good there.
   I plan to the have it back up against a wall, but notice the chip pan come off on the back side, I can make a hoe like device for chip removal, will that be sufficient or should I try and spin the lathe around? It's a hobby thing right now, so I don't t anticipate mountains of chips in the near term
   I have the full set of carriage stops, how often do you guys use them? Are they usable for shoulder stops and threading stops? They seem incredibly handy.
   Thanks
   Pete

9. Cast Iron

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   Originally Posted by otto_pjm

   Questions:
   Do I need a special type of oiler for the little button type oil ports on the lathe, I'm looking at Goldenrod piston pump oil can will that do it?

   A goldenrod piston pump works well with Vactra #2 on my Sag 12.
   Don Clement

10. Plastic

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    Originally Posted by Don Clement

    A goldenrod piston pump works well with Vactra #2 on my Sag 12.
    Don Clement

    Thanks Don, I have one on the way.
    I now have the lathe powered up, via the VFD. I have a tool post, and a few holders coming, and most importantly a gas line being trenched in, so I'll have heat. I haven't done much cleaning yet, there are some dings on the ways and leading edge of the compound and the chuckling the lathe has been well used, but everything seems solid. The 3 jaw chuck is a Buck 230mm or 9+ inches and appears to be truable I'm not sure who makes the 4 jaw it is 10' and has plenty of dings but seems to operate just fine.
    I tried to get picture's of all these things. I also investigated the front way covers which I think have been gone for quite awhile, the holes were all packed with crap and a few of the bolts are snapped off. I guess I'll get to try out my left hand drill bits.
    Pete
    

11. Cast Iron

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    The goldenrod oiler works well for me on my SAG 12 unmodified however, if the goldenrod oiler doesn't work well for your lathe here is a modification that helps. I add a piece of Tygon tubing to the end of the oiler spout. This worked on my Chi.com lathe.
    Don Clement
    

12. Plastic

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    Originally Posted by Don Clement

    The goldenrod oiler works well for me on my SAG 12 unmodified however, if the goldenrod oiler doesn't work well for your lathe here is a modification that helps. I add a piece of Tygon tubing to the end of the oiler spout. This worked on my Chi.com lathe.
    Don Clement

    Thanks Don, I have 1 oiler that is bigger, and I can't get it too work so I'll try some tubing.
    Pete

13. Aluminum

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    Originally Posted by otto_pjm

    Questions:
    I plan to the have it back up against a wall, but notice the chip pan come off on the back side, I can make a hoe like device for chip removal, will that be sufficient or should I try and spin the lathe around? It's a hobby thing right now, so I don't t anticipate mountains of chips in the near term
    I have the full set of carriage stops, how often do you guys use them? Are they usable for shoulder stops and threading stops? They seem incredibly handy.
    Thanks
    Pete

    Pete,
    I have my SAG 14 backed up to a wall and I haven't had any issues cleaning out the chip pan from the front.
    I have used the carriage stops on occasion but they don't seem to be really precise enough to trust them for consistent machining to a shoulder. I also find them a bit cumbersome to set up.
    If you plan to use a coolant system, I would highly recommend constructing a back splash shield and install a chuck guard. Otherwise, you will have coolant/cutting oil all over your wall, ceiling, floor and yourself.
    You asked about buying accessories such as steady and follow rests on eBay. I have been watching eBay for Graziano accessories for several years and have never seen anything for these lathes. I purchased both a steady and follow rest on eBay that were for different lathes and machined adapters for them to work on mine.
    If you're interested in seeing what I've done for accessories and a back splash shield, I can post pictures.
    Enjoy your new purchase. They're a great machine.
    Ted

14. Stainless

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    Originally Posted by otto_pjm

    Questions:
    Are tool posts for 10-18 inch swing the most appropriate?
    For tooling 1 inch holders? I see an auction coming with a lot of 1' and 1 1/4' tool holders on offer.
    I plan to the have it back up against a wall, but notice the chip pan come off on the back side, I can make a hoe like device for chip removal, will that be sufficient or should I try and spin the lathe around? It's a hobby thing right now, so I don't t anticipate mountains of chips in the near term
    I have the full set of carriage stops, how often do you guys use them? Are they usable for shoulder stops and threading stops? They seem incredibly handy.

    You may have a problem with 1' tools being above the spindle centerline, depending on the toolpost you end up buying. I would go with 3/4'.
    Placement of the chip pan is dumb if you put the machine up against a wall. The machine balances perfectly just under the chuck allowing one to move at around using a simple automotive floor jack. But not with the chip pan in place.
    Using my machine only on occasion, I just left the chip pan off. If you use coolant you should install it. With carbide tools, you won't really need coolant anyway; mostly for drilling with HSS.
    The shoulder stops wouldn't work for threading. One technique that works well with the clutch driven Sag 14 is just to leave the half nut engaged and reverse the spindle after backing the tool out of the cut when threading. I've used the method for several years with great results.
    A safety chuck cover helps a lot in controlling oil spatter from the chuck. I'll try to post a picture next time I'm at home.

15. Plastic

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    SAG 14 manual

    I have a SAG 14 and an excellent PDF copy of the manual. It's a slightly different edition from the one referenced above, but in color and with a lot of my Acrobat markups (they're editable). PM me and I can shoot a copy over to you.
    And say, if you decide to make a front-unloading chip pan, I'll take your old one, as my lathe doesn't have one.

16. Plastic

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    So, Have you fired it up yet?
    The ABSOLUTE FIRST THING you MUST do is make sure the motor rotates the correct direction.
    The oil pump will not run backwards. If you open the large cover on the left end of the machine, the upper belt sheave will have a directional arrow on it.
    Hope you have many years of great times with this machine. My -17 is a wonderful machine!
    cheers!
    Chris

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Graziano Sag 14 Manual

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