SUZUKI OWNER’S MANUAL RSI75FOREWORD Your SUZUKI RS175 carries the sincere thanks ofits maker for your selection of it from amang the many. Pleste note that your PS178, designed and built with the best of what SUZUKI has in engineering and manu fecturing knowhow, isan offroad machine for providing enjoyment and utility To enhance whet the AS175 can offer, to prolong its life and to secure safety at all times, you have to take ‘are of it, that i, check and service it periodically. This manual contsins the needed information for the owner to determine when and how, but we strongly advise thatthe periodical servicing work be performed by your SUZUKI dealer, whose mechanics are trained by SUZUKI and are thoroughly competent to do each job to your fullest sotisfction. ‘May we assure you that the time you spend in going through this manual will amplify your enjoyment and ‘help you gen more from this offroad machine, ‘SUZUKI MOTOR CO.,LTD. * Copying, auoting or reproducing any part of this manual i not permitted without explicit approval by ‘SUZUKI MOTOR CO,, LTO. "All information, iustrations, photographs and specications contained in this manual are based on the latest product information available at the time of publication. The right is reserved f0 make changes at any time without noticeCONTENTS GENERAL INSTRUCTION SERIAL NUMBER LOCATION. OPERATING INSTAUCTION. . INSPECTION AND MAINTENANCE “ranamizion 0 Throttle able Clutch. Drive chain, Front bake esr brake. Brake lining wear lit indeston.. Tire pres... Light hl replacoment Tool ki. 7 Carburetor. Fear shock shore TROUBLESHOOTING. SPECIFICATIONS .GENERAL INSTRUCTION Fue. The RS175 i of the wosrake dein, whlch requires & remit of goin and ol Premium galine shold bud ENGINE OIL SUZUKI strongly rcemmands the wie of SUZUKI CC! SUPER 2GYCLE MOTOR LUSRICANT. If this ol not ease, wee an equhalent high quality Two Oyee Racing Lutricant, s+ 20 oe ratio ei ‘CAUTION: Do not allow two ferent brad to get ‘mixed inthe ful mixture ‘mxins RATIO 20 pre gaclie to 1 pat ol ete crrct gine toot ‘mistire rato for your ensne, For proper engine perform nce, ite esanal that te above gee intra sould = maintained, CAUTION ‘A mixture coming wo lle ail with cause ovr heating of the engine. Too much ol wil cause sxe sive eatbon formation resulting i praignton, fled ‘srk pl an os of gine power. FUELOILAIXTURE RATIO OF 20: 1 a) (e2) 3e 8 60 26 65 os 70 nz 75 120 30 128 8s 136 80 14s 85 152 100 160 E io 65 216 60 200 es Bs 10 0 75 a8 20 0 a5 25 25 a5 100 500‘xing PROCEDURE “To mx guoline anc ol, svays wea septate, clean con tain Pour the fl amount of oll requires for the wal mixture into the contains, 283 approximately half the mount of oasline to be mnt and shake thorouhy. [ad the remainder of the solie and eatin thoroughly ania the conaine. ‘TRANSMISSION OIL Use 2 good quality SAE 20W/40 multigade motor sil FRONT FORK OIL For the ol in the two lps, use # metro of SAE SW/20. USE OF GENUINE SUZUKI PARTS To replace any pat of the machine, ues genuine SUZUKI replacaant pore Imitation pus oF ar supplied rom ty ether soure than SUZUKI, if sed to replace por of SUZUKI ovigine in the machin, wil lower te inherent ptilty of the machine and, for worn, could indus cont mechanical voubie.SERIAL NUMBER LOCATIONOPERATING INSTRUCTION LOCATION OF PARTS © ciuten ever 2 Engine ston siten | Dimmer swten © Front brake ver @ Trott ap @ Fusteock D Gaarhite ever @ Side Stand @ Kick strer ever (B Rew brake lover ©® ® @® i a“Take the tne of fait your with te opersting prinebes of th following rmotereyee eompenens, BREAKIN ‘The RSIS is manufactured using the Inert tchnolne relating to the o> stroke entice 2! tho eguires aralative Iy shor brecin, No programed bs toking In operation 6 nesesary: the only thing Is eat the mechine should not be contin ‘eunlyoperte in ulead contin for the fist 172 month. Ths proctce wil ep all moving ars to bre in an ‘nce the machine fll broken in you fan be sured of high performance. @ © Been er ENGINE STOP SWITCH No lonition switch is provided. To tre ‘the engine, just copress the kick starr lever. To Sop the engine, DUES the on- sine step awit at shown in photo. ‘CLUTCH LEVER (Clue eer i ed to intrupt the flow of civ fom angine, 0 that wenaison fan be aif. Squsezing the lever diengeps and re Tesi tenaages tho eaten, DIMMER swrrcH The neslight beam con be change both ownward and upward by operating th ‘immer swith to the "LO" and “HI”© twowe 9 @ Front tate eer ‘THROTTLE GRIP Engine sped in controled by the trots ro. If tho tote gip i esta inward ‘ward you ngine spaed ies. FRONT BRAKE LEVER Squezing this lever bakes front whee ‘CARBURETOR CHOKE LEVER WHEN THE ENGINE IS COLD: Push down the choke leer, Depress the kik etter lever without opening he trot, Even opening the throtleaihty may rake the engine hard to start. Always feturn the choke lever to the orginal poston when the engine warm up WHEN THE ENGINE 1s WARN ring the choke Knob ie not necesary. To start a warm angie, open the thot tle 178 to 1/4 and kickstart the engine. FUELCOCK LEVER, The fused lever hat mo postions, (ON and OFF.GEARSHIFT LEVER ‘The RSI75 is eauipped with « 6speod teanemiston whieh operates a shown in Neutral I loeated between low and 2nd Low goat is Tested by fully depresing the Inver Kom the neural poston ‘Shifting into sesedingly higher eae ie secomplined by pulling up on te tite ver tn tor ech. When Siting trom low to. 2nd, peut futomaticly missed. Whar nut e wanted fer stooping, deprse or rats the lever hall of @ eroke betweon low ane REAR BRAKE PEDAL Depresing tis pedal brakes rear whee KICK STARTER LEVER ‘The engine & strtd by ching this lever, You need na if the tension to routal Before Kicking: just squeeze ‘he cuter lever If he Parson ison WARNING: [After firing up the engina, be sure ‘a rere the kick starter lover to ite ormal poston (shown in the tol.INSPECTION AND MAINTENANCE PERIODIC MAINTENANCE SCHEDULE Ptodie inspection ofthe motorycle isthe mort important thing to prolong its fe acto ensure your safety diving. Take your ‘motorevcle wo yout Suzukl dealer fr these inspections without il ‘Alls throttle valve sto | aaa roe ve stop tnd plot sie-—e Ast ‘Aalst Cyiinser hon, CYlinder and exhaust port Retigton einer ha Check the vlinder ad nuts Drive ain ‘Chea the rim enn tension every rng time. Clean andor brat I nabs Spark log = len eploce Brakes ‘adja ay ‘Adjust ley = ‘Tranemision a henge 2 | ‘Curse ‘Steering stem Check play n = Check play. Bolt and ut Retahten a etiahton Fuel seeing op les a lean Fuel hose Replace every 2 yours Brake cama Throtle, brake & Suteh cable brit (Grea) Lubrite (Motor at) Trot wip ‘Lubriate (Grease)a; SPARK PLUG When carbon sezumulates on the spark lg, hot, strong wark wil not be eo: ‘en. Remove carton deport with & sre or pin and ejus te spare plug fo t9 06 — O8 mm (0.024 ~ 0031 In) by messating with « felor goug Generali, wen the spire plug heat Tange it|correct, the plug electrode {hone # lie brown o© tan calor Spek plug of a ifferant heat may be enosen ‘eoording tote folowing abe ‘CAUTION: 11. The heat ange selection may be made only endor the eondition {at tho abortion et prom | ey. 2, Wanother brand of spa plug it to br used othor than NGK. ot NIPPON DENSO, consult your tutheriaed SUZUKI desler 2 When snag the spark po, seren in with. your fingers to Provent swiping the threads, thon tghten with 2 torque wrens to 25.— 30 kgen fia0 ~ 22040. HOT TYPE | STANDARD TYPE: aes oes woes wa7es "2 SS [AIR CLEANER, ‘A closed sr cleaner is often responsi ‘er poor engine performance. Open the tir cleaner and lan ie element a regular Incevals Here's now todo tis ob: 1 Remove the sat securing bots from both de. 2. raw out the eleanor cst ca. 3. Remove the bolt and draw out the How to clean the element 1. FIl-a washing pan of 2 proper size with nan Hammabla cleaning solvent. Invmerse the slamant in the solvent ‘nc wath it elaan, Squeeze the solvent off the washed ‘loment by pesing it benween the palms of hande! do not twist and ‘wring the element, it wll dovslep ‘curr 3. Immerse tho sloment in a post of motor oll, and squeeze the oil off ‘the element to make Ht slighty wet ‘wth motor ol Seine,Je ‘CAUTION: When insaling the ‘eaner cap, be sue to fae0 the ‘CAUTION: Before and during the caning operation, examina the ‘emont to se fi as ruptured ‘or fissured. A ruptured or fiured tlemant mur be replaced + FUEL FILTER. “The fue teri Incorporated in he fue cack which Is mounted on the Bottom of te fuel tank atthe ets. Accum Tation of dirt in the titer wil renit the Tlow of he. fuel and caute the carburetor “to malfunction, theta, ‘he fuel fae shouldbe serviced per cia 1 Dein he fuel rom the fos tank. 2 Remove sho teleock by unscrewing ‘he iting ee, 3. Wash the rem flier In cleaning ‘TRANSMISSION OIL To change the tansmision oll remove the filer exp snd dain lug and grin the ll nal the arin pg and measure 100 mit (1.89 US pt of 2 good quality SAE 200/40 multiyade moter al than our it into the transmission siowiy. 12“ © pone ‘THROTTLE CABLE For correct safe thettle opaation the throttle cable shoud be scusted 10 have 05 ~ 1.0 mm (002 ~ 0.08 in) play at the carburetor. Ths adjustment ‘en be rade at the eable adjuster on the pt euurca [Adjut the clutch with the elute eae lester by lonmning loc nut. The play (ofthe suteheable should be 2 — 3 mm {08 — 1.2 in) mensured at the clutch lever holier before pressure can bo flt indicating diengagement of to clutch,DRIVE CHAIN [ADJUSTING THE DRIVE CHAIN: ‘ahst the dive chain at the rear axe by loosening sieve nut, “Then lower lock nt eed adjust ea tension by tring bol ino out. Bu sro ‘the marks stmpod on the aust yoko ligne wih the same maton tw oing fim on toth eer of the motorvce, Proper eis tension ebtined when there 5 ~ 18 me (02 ~ 0.8 in) up sane down Hace inthe chin wit ing Seen) Ain bae the side stand, sta point micway be loan ‘oven the srockas ‘CAUTION: — When refitting the ‘ive chain, be sre th eve chain || Jolt lp is tached in te wey || tat ee att ena wt fae opposite te the wining direction =a a | is | Gteaing te chan ‘This motoreyele i equipped with a spe lal ive chin which i constructed of the sntrad meal, Sintered buh cin dogs not required te laaring and/or lubecatg 0 frequent, ecowe the bush hae been impresated ith special great he factory To keep tr wall ubriatlon, wipe and ‘uh the chain necenry. ff cain tends to rut or becomes teverly iy, thea it with Keroane,Atherthorughly ashing the chain ard ling i 10 ry. i the links witha hay wait gee al SAE oa. "CAUTION: — De not use gasoline: Inehlens of otter commer sold lesing toler 1816 © peor FRONT BRAKE Measure the amount of the front brake lever stance between the brake lover ‘nd and throttle rp. The distance should te 20 ~ 30 mm (0.8 ~ 12 inl. Wad: Iestment is necesay, turing the front brake adjster in Ww counterclockwise ‘irmcion wil Increawe the lstance, Dy @ AdigaREAR BRAKE BRAKE LINING WEAR LiNT Before ajsing the brake pede! wave, MoIcATOR adjust the rake pods! poston with the ‘Soe Fig A. You ean eniy check tose it brake pedal aurer “until the mort brake Tinings re worn down to the Emit suitable potion i abtaned for ick fr not on Eoth font anc ant eso. operation. Here's we procedure. ‘Aer adjustment of the brake pa 1) Chock the brake system ie property ston comolead, ast the brake dusted, dal travel with trae acting nut 19 20~ 30mm (08 ~ 12in 2) While operating the brake, check to ‘that extension ine ofthe ind ‘mark is within fe range on the broke Loa 3) 11 te acenion tne i beyond the ‘ramon neat nae wsitin fgg ona fe Bh the brake thoe asembly replaced by your Suzuki ofaer' insire sat operation.TIRE PRESSURE Inflate the tres properly, depending on ‘tho weight of the rir. Too high an inating prossure makes the machine bounce up and dow; t0 low a premure rakes stuering hard. In either cat, tire ‘ite wit be shortened, Cold inflation tre pressure: Front 1.0 kale? (14 pai Rear 10ka/em? (14 pai ‘Standard tr ee Front 3.00-214PR, Full knobby FReor 4.10-184PR, Fl knobby HEADLIGHT ‘The headlight beam can be adjusted \ertcally if neessiry Loaen the headight housing fitting bolt and move the heslight housing Up and LIGHT BULB REPLACEMENT: ‘The wattage rating ofeach bulb is shown con the hort Below, When replecing ¢ bbumod out bulb, always use the exact samo wartape rating, Using other than the Specified rating can result in overioading ‘he acre syst or promatrofalture of. bu, ev 18foW evaw 8HEADLIGHT ‘To remove the healigt perform the {ellowing se: (1) Remove. the two serewe from the cuter headlight ring. Remove the esa assmby (2) Turn te. socket counterclockwise, an pul oft (3) Remove the bulb and replace. TAILLIGHT ‘To replace the ta directions (1) Remove the wo sere se tae of tho oe (2) Push he bub in, tng Te to the Jef und the engagement pins are Connected aed remove the Bll, To fit the rplaemant Bul into po tion, push the Bulb in firmly and ‘wit ft te Ft wale pushing in oh bulb follow theo ‘CAUTION: When veplecng the | Jans, do. ot ovrtighten the two securing stews.TOOL KIT The toot kit supplied with the ASI75 contain he follwing 0% Toot bea 2 8 mm Open end wranch 10x 12mm Open end wrench 1417 mm Open and wrench |) 21mm Box wrench 24 mm Offer wrench Otte wrench handle (Combination srewctivar @ Crosshesd serewerver {i Serendriver handle Piers | 6mm hoxagon L type wrench ESCARBURETOR H exrburetion i not perfet, the per: formance of the engine willbe acorsly fife, Therfort, the crburtor Should be set coreety to mast such Conditions a waather, ete, Fit, chek the carburetor thorauhly, and aust ho folloming parts a necar ‘CARBURETOR SPECIFICATIONS == | Main jt #160 Jetnowdle 5OPT42 | Nowatejet Ra |ouewey 26 Pitot #0 Pilot air dusting screw 14/2 eum back open Fost vel 78.mm (0.91) FLOAT LEVEL Proper esburetion forthe anit ange of the engine speadeausures fst hat the font sot for the prseribd lev Tht level is xeon in terms of “height ‘A theteight mart be chocked and set Fight store attempting 10 alter the je ting Hold the removed carburetor opie on, taking eae not to allow flst arm pin and erm to slip off. aise the foxt farm with fingertip and tower i rau: Ty until touches she meee al, ease the date A with calipers If the caliper reading i ofthe specication (stated et, ben the tongue. ‘iandard main et Fis, “Option nines #190, #140, #160, F170 ad F100 NAIJET During operation, this jet contol the ‘sippy of fl for rang rom 3/8 tect ‘eto ull theft, Te tee the ein et, trv the mashes fora cirtance of st 40 ke (6 milan, with he svotle ket open in that range, after his test Un, pen the engine te abteve the arboned color of he park pl. lina had and let, IF he eolr i lak orf the su foe ie wot ft means thatthe mature is too rah: fn th ee, the main et must te vepaeed by the one with salir ee geybronnish or whitin color is rote it means tht the mixture I too Teen: in this cate, 2 main jt with lager rumba neededMAIN JET REPLACING 4. Move futlck lever to OFF pion 2. Remove the drain bolt en lot chor bor to empty te chamber of fel 2. Looten clamp serews of) bot ses fof carburetor, and turn te carer fetor around to bring Is Host char bar toward yu. 4, Inca the main jet replacing too! into the drain bolt hole anc, with thi 00, remove the main nt 5. Install the main je of another number in the carburetor. Plug up the fost chamber by refiting he dean bole 6, Restore the carburetor [whichis now tid condition) to the orignal por Silon by wrning it around, and tighten the clamp screws on both fides to. secure the ceourtar in place arenas 2nd noseh JET NEEDLE ‘The nesale controls the supply of fos for 8 throtle range of one quarts’ (1/4) to three quarters (3/4). Whether the xing jot needle it proper of not is to bo erecked by tasting ae In the ease of rain jet towing A test run of about 10 km (6 miles) i suffiient. Dopencng on ‘he olzered color, reposition the jot eae in place The needle has five noses Its se tales standarly at 2nd notch in RSI75. With a clip ited to the notch. To make the mixaut lane, se ha elip tan up- at teh of te needle, and vloe versJot nose sting influences carburetion for the trot range from quart (1/4) fect of the change made in ot neale Setting he plot ar Serew must bo ro featoned ih shee, In ater wore, if tha jot nite he reptlones 12 tion whe mixture (or 14%018 te tle range, ten he sre must be loose tc, aptiy 0 make te mixture leaner Hor vpto-1/4 rag ‘sh the see wil at soporteow TO JUDGE CARBURETION Souk pug | Poros iliahtbrown. | Pores esooy. | Prelim ewe Porcine tan colo. Porsiin is cily. | Poralain i borne any. Engine a Engine doesnot run | Engine rom fuetute ven I the revolution | Eesne run smooth smoothly trot rp lela steady OVERALL CARBURETOR ADJUSTMENT Hilrotde | Rabe need ep poston ever rns, Ciescalee [itive it rah Faher Teles whan ip atom nr ealibration number. _number. arena THe zeTTING TnoTTe Dvn te muti, ming srr lps and vein fe . persia of GHG veer voeed cont ln tm [1m [oe [ron Toe ong then opm tone te cone fe pe = me ‘plug, cylinder head and piston crown. On the basis of this. _—— | ee roi eee ae ecu fae hehe ee eal al ‘chine had to be driven in the test run, set the main jet, jet r & eter ee Pieter ewer | > tron. 2REAR SHOCK ABSORBER bisassemaLy 1. Remove the upper and lower rox shock abterber bok and dimount the sock absorber, 2. While compresing the spring remove te upeor springseat 23. Each unit has thee grooves fo chang ing pring torsion, The hier te lip poston, te ls esion, 1 CAUTION: tn the now shock sbrorber unit oe ep has been fet at the highet potion for optimum shock bvorption for an ‘rape riders weight. Howovsr, ‘ter the machine Res covred the runningin mileage of about 500 lem (300. mies, the component pars could be adjusted and | optimum lip postion wil be hanged to the roots one sap | sown the mia rors [ =—— al | Teal‘CAUTION: Never tow enay ‘hie absorber without depresura it who it becomes 10 used up that imo longer serves ie purpose To doprssurize it, lace the aes tank ina plate bop witha corer fit off, and cil ito the tank, tthe location indicted, wvough the bag using a 3mm oil, The bag 1 for protection; it prevents the dil clips tom fying off PoTROUBLESHOOTING ‘There can be various causes for problems which might cccuron the motoreyte, The following procecures may be se 1 waunsesnct passin rouble spots ENGINE WILL NOT START FUEL sysreM 1. Chock tat the share is sulfint izle in the fuel 2, Mike sure the fuslaock ver and ue tank breather hose srenotcloomd. SPARK PLUG. 1. Check thatthe spark plun aap has nt been bride and sort cute by carbo, 2, Check hat the plug isnot fouled with wet gasoline oro 3. Clean the spark olup go end ly the connected spark pg asst the evlinder nea Kid ovr te engine and tne if 3 sark Is produced, If not, role the sak Dug ‘or eheck your ition sytem. “Te check the ignition system, remove te spark lug cap “rom the high tnsion wite and Pot abot Tm (028 in) fram the ovlincer head (ound). Kick the engine fover an ve fw epark jumos thie gap. 0, te sytem i fensioning and the problem is probably in the spark lug cap. If this does not produce a spark, have your SUZUKI dele heck our inition syst CLUTCH SLIPPAGE 1 1 there in elute lover ply, ast he cable aster for 2~ 3mm [08 ~ 12in| pay. 2. The clutch val ako slip ifthe plstes are wor oF tho sorings have weakened. If 30, thse items must be re plac. EXCESSIVE ENGINE VIBRATION 1. Lore engine mounting bot 2. rac inthe fare ENGINE OVERHEATS 4. Carburtion it lean caused by she carburetor sting (rin et slacton) not Seng suite fr running core ‘eons and wane. 2, Carbon hs callerid on te combustion camber piston coun, ever exhaust ort and expansion etarbe, 3. Th park pughas to hot eat range. BAD RUNNING STABILITY 1 Imoeoper font a ear tps. 2. Imoroper tonto rear whee! algnent. 3. moropeiy tightened front axle nut or stering stom oak ur ENGINE WILL NOT REV UP OR WILL NOT RUN SMOOTHLY 1. The exrburetor ene levers nt fully returned, 2. Toorieneabureton, 2. Clown ir mane etment,SPECIFICATIONS DIMENSIONS AND WEIGHT Overall tena 2110.9 (63.1 in) Over with 850 mm [335 in) veal nein 1180 mm (469 in) Wieetbase 1420 mm (5.9 in) ‘Ground clearance 300 mm (11.8 in) ‘ry mas (weit) 88 kg [216 ts). ENGINE Toe ‘Twostroke ev, sr coed Iotake system Piston an ved vale Number of eyindor ore 662.0 mu (2.441 in) Stoke 157.0 vm (2.244 in) Pisin dslerement 172 em" (108 x. in) Comectad ec npresion ratio 7.81 Carburetor MIKUNI vieaO5S, since Air clea Polyurethane foam element Storer sytem Primary kick Lubrication system Fell premixcure of 201 ‘TRANSMISSION ccuten Gerhite pater Primary reduction Final reduction Gear ratios, Low on oe cs Top Driv ein CHASSIS Front sosansion Rese suspension Rear bal esr tre size Stering angle Canter Trail “Turning rade Wet mutiptte type {speed constant mesh ‘sown 5:09 22781 (58/21) 3853 (45/12) 3.000 (34/11) 2214 31/14) 1.647 (28/17) 1.300 (2820), 1.045 (2372), 0876 (21/24) DAIOO 0.1.0.520U, 106 inks Tolecopie ol dampened Singing arm, gsi dampened, Boway adjustable Iaral expanding Inurl expanding 30021.49R 410-1840R 45" (igre and leh) 00 50" 125 mm (492 9) 23ma5K)ELECTRICAL SYSTEM Ignition yee lation timing Spark plug ‘CAPACITIES “Tranemision all Front fork a SUZUKI “PEF” Pontos: leone gtion) 175° B.T.D.C. x 8000 rom INGK 89€S or NIPPON DENSO wares 901 (1.6us 800 mi (1.89 U5 50 259 mi (8.78 US 02) 23MEMO,2. a Prepared by SUZUKI MOTOR CO.,LTD. Service Department Oveseas Operations Divison Febroay, 1980 Past No, 99011~40530-03A Printed in Japan eenek nee