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.

SUZUKI MOTOR CO., LTD.

Service Department
Overseas Operations Division

Quoting, copying or otherwise using any put or lhis manual without explicit authorization from Suzuki Motor Co., Ltd. is not
permitted as all rights to the publication are re.served under copyright law.
 CONTENTS

VIEW OF SUZUKI FZSO"T" .................................................................. 2

SPECIFICATIONS .................................................................................... 3

TRANSMISSION OIL .............................................................................. 5

"PEI'' SYSTEM ...................................................... ................................. 6

FLYWHEEL MAGNETO ........................................................................ 7

CHASSIS ELECTRICAL ............. ........... ......... ...... .. ............................... 8

SPECIAL MATERIALS .......................................................................... 11

SPECIAL TOOLS ................................................................................... 12

WIRE AND CABLE ROUTING .............................................................. 14

WIRING DIAGRAM ................................................................................ 16

SERVICE DATA ...................................................................................... 17

VIEW OF SUZUKI FZSO"X" ................................................................. 23

IGNITION COIL ...................................................................................... 24

TURN SIGNAL LIGHT SWITCH........................................................... 24

WIRING DIAGRAM ................................................................................ 25

SERVICE DATA ...................................................................................... 26

2
SPECIFICATIONS
DIMENSIONS AND WEIGHT

Overall length 1 650 mm (65. 0 in)

Overall width 665 mm (26. 2 in)
OveralI height 990 mm (39.0 in)
Wheelbase 1 120 mm (44.1 in)
Ground clearance 120 mm ( 4.7 in)
Dry mass ( weight) 59 kg (130 lbs)

ENGINE

Type Two-strok e , 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' (3.0 cu. in)
Corrected compression ratio 6.1: 1
Carburetor MIKUNI VM14SH, single
Air cleaner Polyurethane foam element
Starter system Primary kick
Lubrication system S UZ UKI "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 (31/1 3)
{gear) 3. 647 (62/17)
Gear ratios, Low 2.137 (62/29)
2nd 1.421 (54/38)
Drive chain DAIDO D.l.D. 270H, 64 links
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 h)
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', 18 psi) ( Normal solo riding)
Rear tire pressure 150 kPa (1. 50 kg/cm', 21 psi) I Normal solo riding)

ELECTRICAL

Ignition type S UZUKI "PEI"

Ignition timing 25° B.T.D. C. at 4 000 r/min
Spark plug NGK BP4HA or NIPPON DENSO W14FP-Ul
Battery 6V1 4. 4 kC 14 Ah)/1 0 HR
Generator Flywheel magneto
Fu se 10A

CAPACITIES

Fuel tank including reserve 4.5 L (1. 2 US gal)

reserve 0.2 L (0. 2 US qt)
Engine oiI tank 1.2 L (1. 27 US qt)
Transmission oil 800 ml (0.85 US qt)

• These specifications are subject to change without notice.

4
TRANSMISSION OIL
Use a good quality SAE 20W/4 0 multi-grade
m otor oil.
"PEI" SYSTEM
In the F250 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 ofvolts.
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.

CONNECTING DIAGRAM

Ignition switch
....&....

�
Magneto

BIR {}- BIR

Spark

"� 1 PEI Unit

 FLYWHEEL MAGNETO
SPECIFICATIONS
O Ignition method: 2 sparks per crank shaft 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

0 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 fl
Secondary Approx. 15 - 17 k n

35
>
�
.. 30 v---....
N' 25 I --...
r-...._
0
>
I ---.-
. Secondary voltage

� 20
"
<:
15
I ---
-'--
"'8.. 10
�

Ignition timing
25
,,,..,.. - --v
-- -
V" �
/ r----
,

Night time Battery capacity (V)

,
9
..
8
i..---
-- �
>
7 �
/ ,,.
�- \\ Lighting capacity IV)
..: -
/
g� 6
; -3
:;; >
v
c. -
�� 4 /
-
<:
! Cll
:s.E
:>
u
3 I/
�� 2

�� -- "" "
0 �� Night time Charging capacity !Al

2 3 4 5 6 7 8 9 10
x 1,000 r/min
 Pocket tester 09900-2 5002

• Select the knob to RX "x 1".

• Make a following continuity test.

Unit : Approx. t f!J

COLOR CODE APPROX. (fl)

B/W-Y 0.4
B/W-WIA 0.75
BIA - RIB 230

CHASSIS ELECTRICAL

IGNITION COIL

• Using the pocket tester check the ignition

coil.
Knob
Resistance
position
Core- BIY 0-1!1 x1!1
Core - High tension Approx. 15·17 kl1 xkn
B/Y - High tension Approx. 15·17 k.Q xkn
"PEI" UNIT I I
PEI test lead (coupler typei 09900-28607 1
• 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.

i'ndicator light

I
Main switch
ON
PEI Inspection by Pocket Tester

Positive (+) pointer to touch:

Black/White Black/Yellow Black/Red Red/Black

------- OFF
.s::;
u Black/White 5-7n 4-Sn
-5
I ..
., ..
�o
Black/Yellow OFF ------- OFF OFF

OFF OFF
> �
.., $ Black/Red 4-Sn
�-=
"'0
z D. Red/Black OFF OFF 15- 17 n ------

Test conditions
• The pocket tester's selector knob should be set at "X 1n" or "X 1 k!l" 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 vert ical column.

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

10
 SPECIAL MATERIALS

MATERIAL REQUIRED FOR o Screws (securing read valve)

MAINTENANCE o Crankshaft RH oil seal

The materials listed below are required for

(to outer surface of oil seal)
o Magneto rotor nut
maintenance works on the M odel FZ50 ,
o Crankshaft left end nut
and should be kept on hand for ready use.

-�-I
o Muffler clamp bolt
In addition, such standard materials as o Horn adjusting screw
cleaning fluids, lubricants, etc., should also o Cylinder stud bolts

be available. Methods of use are discussed

in the text of this manual.

Material Use
Thread lock cement
I oQil seals 99000-32040
o Cable (speedometer!
O Brake cam shaft
o Speedometer gears
o Front shock absorber arm
and arm shaft

Suzuki super grease

"A" 99000·25010
o Crankcase mating
surface

Suzuki bond 1215

99104·31110

o Muffler fitting bolt

Suzuki lock super

"1363C "
99104·32050

11
SPECIAL TOOLS

Snap ring pliers (opening type)

09900·06107

Micrometer
Dial gauge
09900-20201 (O - 25 mm} Cylinder gauge set
09900·20202 (25 - 50 mm) 09900-20508
09900-20606 10 - 10 mm.
b
1 0
mm)

Torque wrench
Thickness gauge 09009-21102 to- 120 kg·cm)
09900·20803 09900·21103 (100-900 kg·cm)

Pocket tester Hydrometer

09900·25002 09900·28403

PE I test lead Stud bolt installer Piston pin puller

09900-28607 09910-10110 09910·34510

Bearing installer Crankshaft remover Clutch holder

09913·75820 09920·13111 09920-30220

12
 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 09930·401 13 09940-10122

Spoke nipple wrench Steering race installer

/'>:SJ'
\
.

Steering race and swing arm

baring installer
09940·60113 09940-53111 09941 ·34511

Tire pressure gauge

96200-41330

13
 Turn signal relay
=: :E
:ii
m :II
lJ m
0
c )>
-t z
z c
C)
()
)>
IXI
r
m
:II
0
c
:::f
z
G')

:;:
 (")
)>
tu
r
m
:x:J
0
c
Front brake cable Rear brake cable -I
z
"
Front fork

Rear brake cable

pivot

Cable guide plate

�'¢�""'' �
I -�-- ....a,
97--.tRc:g--
Rear brake cable
 =e
:::0
z
G')
�:;,�T�i::,���

iIFmiiiiii ""'
PEI UNIT
MAGNETO
c
rll nii?i
WIRE COLOR �GNITION crnL

'ff 1 m ,l Nfl
)>
G •.•.................... Green REAR BRAKE LIGHT
Gr ..................... Grev
II G')
.!!' .!!' i'� ,l.
'< SPARK PLUG
o: m
:::0
O ....................... Orange '<>-

ii �:6� �m
..
R .. ... ................Red m >-
)>
, ... .....
W.,,., Whi1C
................

Y . . ..................Yellow
/ vn TUBE
RIB
TU8E
:s:
:�----joT
BIR ... ................elack with Red tracer

BIW ..................e1eck with While U8Cer

,,,
BIY ................ ..Block wi1h Yellow u:icer

11 1 11''":���
R/8 ....................Rod
W/A
with Bh:tck tr<1cor
� �
I
I!
. . .............White whh Red tracer
I w

1ll1l1 ;I
I
Y/R ...................Yellow with Red uacer
TAIL/BRAKE LIGHT

�p=a
�. �..r
I

8 ±
�

1llil l
� IOA

. :
., t� mm
FUSE

HIGH BEAM

.
__cu
�
iii iiJ '°>-0
0:
HORN

�
� 9 �
RECTIF1ER

DIMMER SWITCH

ENGINE KILL $WITCH

N
HO R
SWITCH
a OFF
ON
BATTERY

IGNITION SWITCH

;;;
 SERVICE DATA
CYLINDER+ PISTON+ PISTON RING Unit: mm (in)
ITEM STANDARD LIMIT
0.070 - 0.08 0
Piston to cylinder clearance

Cylinder bore
( 0 .0028 - 0.0031

41 .000 - 41 .015
) I 0.12 0
( 0 .0047 )

41. 060
I 1.6142 - 1.6148 l
( 1.6165 )
Measure at the 15 ( 0 .6 ) from top surface.

Piston diam.
40.925 - 40.9 40 40.88 0
( 1. 6112 - 1.6118 ) ( 1.609 4 )
M easure at the 2 3 ( 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.
( 0.18 ) ( 0. 14 )
1st
5. 0 4.0
T Approx.
( 0.2 0 ) ( 0.16 )
4. 5 3.6
R Approx.
( 0.18 I ( 0 .14 )
2nd
5.0 4. 0
Approx.
0.16
T
I 0 .2 0 I I I
Piston ring end gap 0.10 - 0. 2 5 0.75
I 0.004 - 0 . 010 ) ( 0.030 )
Piston ring to groove clearance 0. 02 0 - 0.060
1 st
( 0.0008 - 0. 002 4
---

I
0. 02 0 - 0.060
2nd ---

I 0 . 0008 - 0.002 4 l
Piston pin bore 1 1.998 - 12 .006 12 .030
I 0.4 72 4 - 0. 472 7 ) I 0 .4736 l
Piston pin 0.0. 11.996 - 12 . 000 11.98 0
( 0.472 3 - 0.472 4 ) I 0.4717 l

17
CONROD+ CRANKSHAFT Unit· mm (in)
ITEM STANDARD LIMIT
Conrod small end l.D. 16. 003- 16. 01 1 16. 04 0
( 0. 6300- 0.6304 ) ( 0.6315 )
Conrod deflection ---
3.0
( 0. 12 )
Crank web to web width 4 0. 0 ± 0. 1
(
---

1.57 ± 0. 004 )
Crankshaft runout ---
0.05
( 0. 002 )

OIL PUMP
ITE M SPECIFICATION

Oil pump reduction ratio 7.000 ( 14 / 2 )

CCI pump discharge rate ml
1. 02 - 1.26
(Full open) !'0.034 10.036- 0.043/ 0. 044 US/Imp oz)
for 6 minutes at 2000 r/min.

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT

Clutch wheel 87. 00 - 87. 15 87.40

Low
l.D.
( 3.425 - 3. 4 3 1 ) ( 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. 4 3 ) part
104 . 7 - 104 . 8 N o groore a t any
High
( 4 . 12- 4. 13 ) part
Clutch engagement
2500 t 200 r/min.
---

Clutch lock-up
3700 t 300 r/min. ---

Clutch spring free length 28

Low ---

( 1. 10 )
33
High
1.30
---

( )

18
 TRANSMISSION Unit: mm lin)

ITEM STANDARD LIMIT

Primary reduction ratio 1.000 ---

Final reduction ratio 8. 696 (31 / 1 3 x 62 / 17) --

Gear ratios Low 2.137 ( 62 / 29 ) --

2nd 1.421 ( 54 / 38 ) ---

Shift fork thickness 0 . 0 5 - 0.10 0.15

( 0.002 - 0.004 ) ( 0.006 )

DRIVE CHAIN Unit · mm (in)

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

Links 64

170.0
I ---

173.0
20 pitch length
1 ( 6.69 ) I I 6. 83 )
CARBURETOR Unit: mm lin)
SPECIFICATION
ITEM

Carburetor type MIKUNI VM 14 SH

Bore size 1410 . 6)

l. D. No. 0 2420

Idle r/min. 1500 • 150 r/min.

Float height 22.4 ± 1.0

( 0.88 ± 0.04 )

Main jet (M.J. ) 'f 57.5

Air jet I 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. O. l 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 )
19
ELECTRICAL Unit: mm ( in}
ITEM SPECIFICATION NOTE

Ignition timing
° ±
25 2· B.T. D.C. at 4000 r/min.

Spark plug NGK BP4 HA or NIPPON

Type
DENSO W14FP-UL
0.6-0.8
Gap
{ 0 . 0 24 -0 . 0 31 }

Ignition coil resistance 8/Y - Ground

Primary
Approx. 0 -1 !!

Plug cap - Ground

Secondary
Approx. 1 5 -1 7 k!!

Magneto coil resistance Y/R - Ground

Lighting
Approx. 0-1 n
Charge W/R - Ground
Approx. 0-1 n
B/R - R/8
Primary
Approx. 180 -220 n
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 de signation 6N4-2A

Capacity 6V14.4kC{4Ah}/10HR
Standard °
1.26 at 20 C (68°F)
electrolyte S. G.
Fuse size 10 A

20
 BRAKE+ WHEEL Unit: mm lin)
ITEM STANDARD LIMIT

Front brake lever distance 20 - 30 ---

( 0.8 - 1.2 )
Rear brake lever distance 20 - 30 ---
( 0.8 - 1.2 )
Brak e drum l.D. 100.7
Front ---

I 3.96 )
100.7
Rear ---

I 3.96 )
Brake lining thickness ---
1.5
I 0.06 )
Wheel rim runout 2.0
Axial
0.08
---
I )
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 .0 6 )
---

1.6
Rear ---

( 0.06 )

SUSPENSION Unit: mm lin)

ITEM STANDARD LIMIT NOTE
Engine mounting pivot shaft runout 82 ---

( 3.1 )
Swing a·rm pivot shaft runout 0 .6
( 0 .0 2 )
---

21
FUEL+ OIL
ITEM SPECIFICATI O N 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

( 0.21I 0. 1 8 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
( 0.9 0 I 0.75 US/Imp qt)

TIRE PRESSURE
NORMAL RIDING

COLD INFLATION
SOLO RIDING
TIRE PRESSURE

kPa kg/cm: psi

FRONT 125 1.25 18

REAR 150 1.50 21

WATTAGE W (CP)
SPECIFICATIO N
ITEM

Headlight
I HI 20

I LO 20

5.3 / 17 (3 / 21)
Tail/Brak e light

High beam indicator light 1.7

22
 VIEW OF SUZUKI FZSO"X"
RIGHT SIDE VIEW

LEFT SIDE VIEW

23
IGNITION COIL

• Using the pocket tester check the ignition

coil.

I
Knob
Resistance
position

Core - B/Y -r 0 - in x1D

Core - High tension Approx. 4-6k!1 xk!1

B/Y - High tension Approx. 4 ·6kD xk!1

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
the switch.

B
Left 0
Right

24
N
"'

:e
:!!
WIRE COLOR
9 ............,,.........BhKk
G ... ...................Green TURN SIGNAL RELAV
ENGINE KILL
S'IVITCH

:.:
fl . \l
r&l
RIGHT HAtmLUAR SWITCH

��.���&
RAKE LIGHT
COi UNIT
#i1AGtlETO ICilllTIONCOIL
z
"
c

It Lll
f �J
! � rni1 Ju� � 11
...... ....... ....Gray BIR Red tracer

Q
Gr ....••... •• Black w11h

lbl ............. ......Light bluo

:':.: ::::: ...:...::::::::,,;:·::;;, i>

lg .....................light green

o .. . 011nge
...... ... .... ..... .
RIB ................. . Red with Black tracer ;;; � �
�
� I
�
� "
:D
rl �
A .......................Red WIB ...................WhilO wilh Block uece• !j
0 R� �a: )>
II ;:
\II ......................Y/hlle WJR ......•..........•Wh.11a w11h Red uacor RIB ci::
�
Y ..• .....•••.... .•....Yellow YIR .
...... . . ........ ..Yellow with Rod tracer � 8IY 8/R
m

�..,•• TURN SIGNAC LOGHT

s:
�
I
Ir I 11 11 II I I "------=---'•�

'Lil .Iii111
I 1111
..=-r==s

11111 ���
O O

�� � TAIUBRAKHIG'1T

� 0----c::D-8�
f I

REAR TURN SIGNAL LIGHT

11:� �ii
"

�
�
r1
'"

,.M..... ,.

® uORN
(Hll llOWI

FF
ON
�
BATTERY
RECTIFIER

IGNlTIOt'l SWITCH O

LEFT HANDLEBAR SWITCH

SERVICE DATA

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

ITEM STANDARD LIMIT

Piston to cylinder clearance 0 .070 -0 .0 80 0.120

( 0.0028 - 0 .0 0 31 ) ( 0 . 0 0 47 )

Cylinder bore 41.000 - 41.015

41.060
( 1.6142- 1.6148 )
( 1. 6165 )
M easure at the 15 ( 0 .6 ) from top surface.

Piston diam. 40.925 - 40 . 940 40.880

( 1.6112 - 1.6118 ) ( 1.6094 )
M easure 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

1st
R Approx.

Approx.
(
4.5
0.18
5.0
) I 3.6
( 0.14
4.0
)

T
( 0 .20 ) ( 0.16 )
4.5 3. 6
R Approx.
( 0 .18 ) ( 0.14 )
2nd
5.0 4.0
T Approx.
( 0 .20 I ( 0.16 )

Piston ring end gap 0 .10 -0 . 25 0.75

( 0.004 - 0 .010 ) ( 0 . 0 30 )

Piston ring to groove clearance 0 .0 20 - 0 . 0 60

1st --

( 0.0008 - 0.0024 )
0.020 - 0 . 0 60
2nd ---

( 0.0008 - 0.0024 )
Piston pin bore 11.998 - 1 2.00 6 12. 0 30
( 0 .4724 - 0 . 4727 ) ( 0 . 47 36 )
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 .630 4 ) ( 0 .6315 )
Conrod deflection ---
3.0
( 0 .12 )
Crank web to web width 40.0 ± 0.1 --

( 1.57 ± 0 . 0 0 4 )
Crankshaft runout ---
0 .05
( 0.002 )

26
 OIL PUMP
ITEM SPECIFICATION

Oil pump reduction ratio 7.000 ( 14 / 2 )

CCI pump discharge rate ml

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

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch wheel l.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 28

Low ---
( 1.10 )
33
High ---
( 1.30 )

TRANSMISSION Unit: mm (in)

ITEM STANDARD LIMIT

Primary reduction ratio 1.000 ---

Final reduction ratio 8.69 6 (31 / 13 x 62 / 17) --

Gear ratios Low 2.137 ( 62 / 29 ) ---

2nd 1.421 ( 54 / 38 ) ---

S hift 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.1.0.: 270 H --

Links 64 --

170.0 173.0
20 pitch length
I ( 6.69 ) ( 6.83 )

27
CARBURETOR Unit: mm (in)
·-

SPECIFICATION
ITEM

Carburetor type MIKUNI VM 14SH

Bore size 14 ( 0 .6)

1.0. No. 0 2 421

Idle r/min. 1500 ± 150 r/min.

Float height 22.4 ± 1.0

( 0.88 ± 0.0 4 )
Main jet (M. J.) ii 57.5

Air jet (A. J.) 2.5

Jet needle (J. N.) 3 0 13-3

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. 5

Starter jet (G. S.) 35

Throttle cable play 0 . 5- 1.0

( 0 . 0 2 - 0.0 4 )

28
 ELECTRICAL Unit· mm (in}
ITEM SPECIFICATION NOTE

Ignition timing
25 ° ± 2• B.T.D.C. at 4000 r/min.

Spark plug NGK BP4HA or NIPPO N

Type
DENSO W1 4FP-UL
0.6 - 0 .8
Gap
( 0 . 0 24 - 0 .031 }
B/Y - Ground.
Ignition coil resistance Primary Approx. 0 -1 n
Plug cap - Ground
Secondary
Approx. 4-6 kn

Magneto coil resistance B/W-Y

Lighting
Approx. o. 4n
B/W -W/R
Charge
Approx. 0.75U - - ----
B/R - R/B
Primary
Approx. 230 U
-
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.
Banery
I Type designation

Capacity
6N4-2A

6V1 4. 4kC(4Ah}/1OHR
Standard
1.26 at 20°C (68'F}
electrolyte S. G.
Fuse size 10 A
i

29
BRAKE+ WHEEL Unit: mm (in)
ITEM STANDARD LIMIT

Front brake lever distance 20 - 30 --

( 0 . 8 - 1. 2 I
Rear brake lever distance 20 - 30
( 0 . 8 - 1. 2
--
)

I
Brake drum l.D. 100 . 7
Front
3.96
--

( )
100.7
Rear
3. 96
--
( )
Brake lining thickness 1. 5
0.06
---

( )
Wheel rim runout 2.0
Axial
( 0.08
--
)
2.0
R adial I --
( 0.08 )
0.25
Wheel axle runout Front
I --
( 0.010 I
Tire size
Front
I 3.00 - 12 4PR ---

Rear
I 3.00 - 12 4PR
--

Tire tread depth 1.6

Front
( 0 .06
--
)
1.6
Rear
0 .06
--

( )

SUSPENSION Unit: mm (in)

ITEM I STANDARD L IMIT NOTE
Engine mounting pivot shaft runout 82
I
---

( 3.1 )
0.6
Swing arm pivot shaft runout
I ---
( 0.02 )

30
 FUEL + OIL
ITEM SPECIFICATION NOTE

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

least 83 - 95 pump octane ( A;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)
L

Engine oil type

reserve
I (
0.2
0 .21 / 0 .18 US/Imp qt)

I I
Use SUZUKI CCI SUPER 2·CYCLE MOTOR
LUBRICANT or an equivalent good qualitV
synthetic based 2-cycle oil.

I I
Engine oil tank capacity 1.2
( 1.3 / 1.1 US/Imp qt)

Transmission oil type SAE 20W/40 I

Transmission oil capacity 800 ml
Change
( 0.85 / 0.7 0
850
US/Imp qt)
ml
I
Overhaul
( 0 . 90 I 0 .7 5 US/Imp qt)

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING
TIRE PRESSURE

kPa I kg/cm' psi

FRONT 125 1 1.25 18

REAR 150 ! 1.50 21

WATTAG E W (GP)
SPECIFICATIO N
ITEM

Headlight HI 20
I
I LO 20

Tail/Brake light
I 5 .3 / 17 ( 3 / 21)

Turn signal light

Turn signal indicator light

I 17

High beam indicator light 1.7

31
 Prepared by

SUZUKI MOTOR CO.,LTD.

Service Department
Overseas Oper:ilions Division

December, 1980

Manual No. 99000-85057-0E3(;ri)SUPPL.

Printed in Japan
SUZUKI MOTOR CO., LTD.
Suzuki FZ50 Supplementary Service Manual

This manual was provided by Donald Small