Suzuki TS200R Manuel utilisateur

FOREWORD

The

SUZUKI

TS200R

has

been developed

new

generation motorcycle to the TS-models.

packed

with

highly

advanced design concepts

including a

liquid

cooled engine, a crankcase reed

valve, a

Automatic

Exhaust Timing

Control

(A.

T.C.) a Digital C.D. ignition system a

link

type

rear suspension. Combined

with

precise

control

and

easy

handling the TS200R provides excellentperfor-

mance andoutstanding riding comfort.

This service manual

has

been produced

primarily

for

experienced mechanics whose

job

inspect,

adjust, repair

and

service

SUZUKI

motorcycle.

Apprentice mechanics and

"do

yourself"

mechanics

will

also

find

this manual to be an

extremely usefulguide.

The TS200R, manufactured to standard specifica-

tions,

the main subject

matter

this manual.

However, the TS200R machines distributed

your

country

might

differ

minor

respects from the

standard-specification and,

they do,

because

some

minor

modifications (which are

consequence

most

cases

far

servicing

concerned) had to be made to

comply

with

the

statutory

requirements

your

country.

This manual contains up-to-date

information

the

time

its

issue.

Later made modifications and

changes

will

be explained to

each

SUZUKI

distrib-

utor

in respective markets, to whom

you

are

kindly

requested

make query

about

updated

information,

any.

SUZUKI MOTOR CORPORATION

Motorcycle

Department

Overseas Service

Division

©COPYRIGHT SUZUKI MOTOR CORPORATION 1990

GROUP INDEX

GENERAL

INFORMATION

PERIODIC MAINTENANCE

AND

TUNE-UP PROCEDURE

IENGINE n

L___

Llc_o_o_L_IN

G_s_v_s_~_EM

·--~-------~

FUEL

AND

LUBRICATION SYSTEM

IELECTRICAL SYSTEM Ill

CHASSIS

s_E_R_"'_Jc_I_N_G_IN_F_o_R_M_~_~_~_o_N

___

L..._T._S_2_o_o_R_N_f_'9_2_-M_O_D_E_L_J

___

___.q

TS200RP

('93-MODEL)

L_____

______jllliil

VIEW

TS200R

For Conventional

front

fork

model

For

Inverted

front fork

model

GENERAL

INFORMATION

~----------------CONTENTS----------------~

VIN

AND

SERIAL NUMBER

LOCATIONS..............................

1-1

FUEL, OIL

AND

COOLING SOLUTION

RECOMMENDATIONS ....................................................... 1-1

BREAKING-IN PROCEDURES .............................................. 1-2

SPECIAL MATERIALS........................................................ 1-3

PRECAUTIONS

AND

GENERAL INSTRUCTIONS ................... 1-5

SPECIFICATIONS

..............................................................

1-j'

,:The

frame serial number or V.I.N. (Vehicle Identification

Number)

stamped on the steering

head

pipe. The engine

serial number

located

the left side

the crankcase.

These

numbers

are

required especially

for

registering the

machine

and

ordering

spare

parts.

FUEL, OIL

AND

COOLING SOLUTION

RECOMMENDATIONS

FUEL

For

CANADA

model

Use

only

unleaded gasoline

least

pump

octane

( R

method) or

octane

or higher rated by

the

Research

Method.

For

other

models

Gasoline used should be graded

85-95

octane or higher.

unleaded gasoline is recommended.

ENGINE OIL

Use SUZUKI

"CCI"

oil

SUZUKI CCI Super oil.

They

are

formulated

give

best

engine

performance

with

least

com-

bustion chamber deposits, least preignition,

maximum

spark

plug life and best lubrication.

they

are

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.

FRONT FORK OIL

Use

fork

oil

99000-99044-10G

SUZUKI FORK

OIL#

BRAKE FLUID

Specification

and

classification :

DOT

99000-2311

0 :

SUZUKI BRAKE FLUID

COOLING SOLUTION

Use an anti;.freeze

Summer coolant compatible:·

with

aluminum radiator, mixed

with

distilled

water

only,

ratio

50:

50.

WATER FOR MIXING

Use distilled

water

only.

Water

other than distilled

water

can

corrode and clog

the

aluminum radiator.

ANTI-FREEZE & SUMMER COOLANT

The

coolant

performs

corrosion and

rustinhibitor

well

anti-freeze. Therefore, the coolant should be used at all

times

even

though

the atmospheric temperature in

your

area

does

not

down

freezing point.

SUZUKI recommends

the

use

SUZUKI GOLDEN CRUISER

1200NA

anti-freeze

summer coolant.

this

not

availa-

ble, use an equivalent

which

is compatible

with

aluminum

radiator.

99000-99032-10X

:SUZUKI

GOLDEN CRUISER 1200NA

{Non-Amine type)

REQUIRED

AMOUNT

WATER/COOLANT

Solution

capacity

{total) : 900 ml {0.95/0.79 US/Imp

qt)

CAUTION:

Mixing

anti-freeze &

summer

coolant

should be

limited

60%.

·Mixingbeyond

would

reduce

its

efficitmcy.

the anti-

freeze &

summer

coolant

mixing

ratio is

below

30%,

rust

inhibiting

performance is greatly reduced,

sure

mix

above

30%

even

though

the

atmospheric temperature does

not

down

freezing point.

BREAKING-IN PROCEDURES

During manufacture only the best possible materials.are used

and all machined parts are finished

a very high standard,

but

is still necessary

allow

the

moving

parts

"BREAK-

IN"

before subjecting

the

engine

maximum

stresses. The

future

performance and reliability

the

engine depends on

the

care and restraint exercised during

its

early life. The

general rules are

follows.

•

Keep

these

breaking-in engine

speed

limits.

Initial 800 km {500 miles) : Below 5 000

r/min

1 600 km

000 miles) : Below 7 000

r/min

Over 1 600 km

000 miles) : Below 12 000

r/min

GENERAL

INFORMATION

1-2

1·3

GENERAL

INFORMATION

SPECIAL MATERIALS

The materials listed below

are

needed

for

maintenance

work

on the TS200R,

and

should

kept on

hand

for

ready

use.

They supplement

such

standard materials

cleaning fluids, lubrications, emery cloth

and the like. How

use

them

and

where

use

them

are

described in the

text

this manual.

Material

SUZUKI

SUPER

GREASE

"A"

99000-25010

SUZUKI

BOND No. 1207B

99000-31140

SUZUKI

BOND No. 1215

99000-31110

THREAD

LOCK

SUPER

"1322"

99000-32110

THREAD

LOCK SUPER

"1303"

99000-32030

THREAD

LOCK

SUPER

"1324"

99000-32120

Part

•

Throttle

grip

• Clutch lever

• Speedometer cable

and

tachometer cable

• Speedometer

gear

box

• Brake pedal shaft

• Side stand

• Kick starter lever

• Crankcase oil

seal

• Water

pump

mechanical

seal

• Crankcase mating surface

• Water thermo-gauge

• Engine sprocket

bolt

• Exhaust pulley

bolt

• Exhaust valve arm screw

• 2nd drive

gear

• Gearshift

arm·

stopper

• Magneto

rotor

nut

Page

Part

Page

2 • Wheel bearings

2 7- 1

2- 2 7- 2

7-31

2 • Steering stem bearing and

race

7-25

7- 1 7-29

7·

2 • Swingarm bearing and dust

seal

7-40

2 7-47

2 • Cushion lever and rod bearing 7-40

2 7-47

3-27

3-31

3· 5 •

Kick

lever

bolt

3-40

3-18

3-26

3-32

3-37

Material

THREAD

LOCK

SUPER

"1360"

99000-32020

THREAD

LOCK

"1342"

99000-32050

~········.A

SUZUKI SILICONE

GREASE 99000-25100

SUZUKI

BRAKE

FLUID

99000-23110 (0.5L)

~~~o.2.'-~

...

'···'<~

SUZUKI GOLDEN

CRUISER 1200NA

(Non-Amine type)

99000-99032-1

•

OIL

SUZUKI FORK

OIL#

99000-99044-1

Part

• Disc

bolt

Page

7- 1

7- 2

7-31

• Gearshift retainer screw

and

bolt

3-32

• Pawellifter

nut

and

cam

guide screw 3-33

•

Cam

driven

gear

bolt

3-33

• Front

fork

damper rod

bolt

7-13

• Caliper axle

• Brakes

• Cooling solution

•

Front

fork

7-16

7- 5

7-34

2-10

7-17

7-22

GENERAL

INFORMATION

1-4

Part

Page

1-5

GENERAL

INFORMATION

PRECAUTIONS

AND

GENERAL INSTRUCTIONS

Observe

the

following

items

without

fail

when

disassembling and reassembling

motorcycles.

o Do

not

run engine indoors

with

little

or no

ventilation.

sure

replace packings, gaskets, circlips,

0-rings

and

cotter

pins

with

new

ones.

CAUTION:

Never reuse a

circlip

after

a circlip has been removed

from

shaft,

should be discarded and a

new

circlip

must

be installed.

When

installing a

new

circlip, care

must

be taken

not

expand

the

end gap larger

than

required

slip

the

circlip

over

the

shaft.

After

installing a circlip,

always

insure

that

completely

seated in

its

groove and securely

fitted.

o Tighten cylinder head and case bolts and

nuts

beginning

with

larger diameter and ending

with

smaller

diameter, and

from

inside

outside diagonally,

the

specified

tightening

torque.

o Use special

tools

where

specified.

o Use genuine parts and recommended oils.

When

than

2 persons perform

work

together,

pay

attention

the

safety

each other.

After

the

reassembly, check parts

for

tightness

and operation.

o Treat gasoline,

which

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.

WARNING

.................

The personal

safety

ofthe

rider

bystanders

may

be involved. Disregarding

this

information

could result in personal injury.

CAUTION..................

These instructions point

out

special service procedures

precautions

that

must

followed

avoid damaging

the

machine.

NOTE

...

;...................

This

provides

special

information

make

maintenance

easier

important

instructions

clearer.

REPLACEMENT PARTS

When

you

replace

any

parts, use

only

genuine SUZUKI

replacement parts, or their equivalent. Genuine SUZUKI parts

are high

quality

parts

which

are designed and

built

specifi-

cally

for

SUZUKI vehicles.

CAUTION:

Use

replacement parts

which

are

not

equivalent in

quality

genuine SUZUKI parts can lead

performance problems

and damage.

ASBESTOS INFORMATION

Note

the

following

when

handling a

supply

part

with

the

above WARNING LABEL or

any

part

the

parts

list

this

section

which

contains

asbestos.

• Operate

possible

out

doors in a

well

ventilated

place.

• Preferably use hand

tools

low

speed

tools

equipped,

necessary,

with

appropriate

dust

extractor

facility.

· high speed

tools

are used,

they

should

always

be so

equipped.

•

possible, dampen before

cutting

drilling.

• Dampen

dust

and place

in a properly closed receptacle

and dispose

safely.

Any

domestic

asbestos

product

which

the

above does

not

apply,

but

which

is likely

release fibres during use should

be replaced

new

one

when

worn.

Exhaust pipe gasket

GENERAL

INFORMATION

1-6

WARNING

CONTAINS

ASBESTOS

Breathing

ubeatoa

duet

dang8f'OUI

tohnhh

safety

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