Suzuki ALT50 & LT50 SUZUKI U.S. SUZUKI MOTOR CORPORATION 3251 E. Imperial Way Brea, California 92621 ALT50 AND LT50 NOTE: Metric fasteners are used throughtout vehicle. CONDENSED SERVICE DATA ALTSOD, E ALTSOD, E MODELS LT50E,F,G,H © MODELS LT50E, F, G, H General Tune-Up (Cont.) Make Suzuki Ignition: Engine Type Two-Siroke; Type ae : Breakeriess Air-Cooled Timing 22°-26° BTDC Number of Cylinders... 1 @ 3000 rpm Bore 41.0 mm Carburetor: (1.614 in.) Make . Mikuni Stroke 87.8 mm Model”: vMi2sc (1.488 in.) Float Height 24,5-25.0 mm Displacement 49.cc (0.96-0.88 in.) (3.0 cu, in.) Jet Needle... 3E3 ‘Compression Ratio 59:1 Clip Position": 3rd Groove From Top Fuel Recommendation Unleaded or Throttle Cutaway 3.0 Low-Lead Pilot Jet (28-Fig. S1-4) | | #16 Pump Octane Rating 85-95 Pilot Jet (29-Fig. S1-4) 0.38 mm Engine Lubrication Oil Injection (0.015 in.) Engine Oil Needle Jet ‘ ES Recommendation See Text Main Jet ba #875 Transmission Oil Throttle Cable Free Piay 0.5-1.0 mm Recommendation SAE 20W-40 (0.02-0.04 in.) Forward Speeds 1 se Speeds NI a oo i“ Sizes-Clearances Front... es . 145/70-6 Piston-to-Cylinder Wall Rear 148/706 Clearance 0.065-0.075 mm Tire P ie (0.0026-0.0080 in.) rater 26-35 kPa Cylinder Bore Diameter (3.55.0 psi) Measured 20 mm (0.8 in.) Rear : : 25-36 kPa, From Top 41.000-41.015 mm (3.56.0 psi) (1.8142-1.8148 in.) Dry Weight: Wear Limit 41.065 mm ALT5O 41 kg ; (1.6167 in.) (90 Ibs.) Cylinder Bore Distortion TSO ons. 48 ko (Max.) ase 106 It .002 in.) oe Piston Diameter Measured Tune-Up 23 mm (0.9 in.) From Engine Idle Speed 1600-1600 rpm Bottom of Skirt 40.930-40.945 mm Spark Plug: (1.8114-1.6120 in.) Type— Wear Limit 40.880 mm NGK . BP4H (1.8094 in.) Nippon Denso’: | Wi4FP Piston Pin Bore Diameter Electrode Gap 0.6-0.8 mm in Piston 12.002-12.006 mm (0.024-0.031 in.) IMstrations Courtesy U.S. Suzuki Motor Corp. (0.4725-0.4727 in.) 243Suzuki ALT50 & LT50 ALTSOD, E MODELS LTSOE, F, G, H Sizes-Clearances (Cont.) Wear Limit - 12.080 mm (0.4736 in.) 11.996-12.000 mm (0.4723-0.4724 in.) Wear Limit 11.980 mm, (0.4717 in.) Piston Ring End Gap 0.10-0.25 (0.004-0.010 in.) Wear Limit 0.75 mm (0.030 in.) Piston Ring Side Clearance 0.020-0.060 mm (0.0008-0,0024 in.) Connecting Rod Small End Bore Diameter 16,003-16.011 mm (0.6300-0.6304 in.) Wear Limit 46.040 mm (0.6315 in.) Connecting Rod Small End ‘Side Shake (Max.) 3.0 mm (0.12 in.) Crankshaft Runout at Main Bearing Journal (Max.) 0.05 mm (0.002 in.) Cylinder Head Distortion (Max.) an 0.05 mm (0.002 in.) Capacities Fuel Tank . 1.5L (0.4 gal.) Engine Oil Tank . . . 500 mL. (0.53 at.) Transmission Oil ‘See Text Tightening Torques Clutch Shoe Nut : 34.5-54.2 N-m (25.5-40.0 ft-1bs.) Cylinder Head Nut 6.8-10.8 N-m (80-98 in.-Ibs.) Flywheel Nut 89.3-59.0 N-m (29.0-43.5 ft-tbs.) Front Axle Nut: ALTEO 35.2-50.8 N-m (26.0-37.5 ft-lbs.) LT50 48.8-78.6 N.m (36-58 ft-lbs.) il Pump Union Bott 4.0-6.8 N.m (36-60 in.tbs.) LUBRICATION All Models ENGINE. The engine is lubricated by an automatic oil metering system. Recommended oil is Suzuki CCI Super 2-Oycle Motor Lubricant or a good quality synthetic 244 ALT5OD, E MODELS LT50E, F, G, H Tightening Torques (Cont.) Rear Axle Nut 56.9-78.6 N-m (4258 lbs) Spark Plug 24,4-29.1 Nem (18.0-21.5 ft-lbs.) Wheel Nut 17.627. N-m (18-20 ft-lbs.) Wheel Rim Nut 17.627. N-m (18-20 ft-tbs.) Standard Screws: Unmarked or Marked 4mm 0.9:2.0N.m (8.4-18.0 in-tbs.) 5mm 2.0-4.0N.m (18-36 in.-Ibs.) 6mm 4.06.8N.m (36-60 in.lbs.) 8mm 95-156 N-m (84-138 in.bs.) 10mm . 21.7-34.5 N.m (16.0-25.5 ft-lbs.) 12mm .. 24.5-54.2 N.m (25.5-40.0 ft-lbs.) 14mm . 48.8-78.6 N-m (36-58 ft.-bs.) 16mm . 78.6-127.4 N-m (58-94 ft-tbs.) 18mm 127.4-186.4 N.m (9801975 nbs) Marked "7" 4mm 1.3.2.7 N.m (12-24 in.-Ibs.) 5mm. 2.76.1 N.m (24-54 in.-tbs.) 6mm 8.1-11.5N-m (72-102 intbs.) &mm 17.627.1'N-m (18-20 ft-lbs.) jomm .. 39.3-58.9 N.m (28.0-43.5 ft-lbs.) j2mm . 68.4-98.3 N-m (50.5-72.5 ft-lbs.) 14mm . 107.7-166.6 N.m (79.5-115.5 ft-lbs.) 16mm .. : 166.7-245.4 N.m (128-181 ft-lbs.) 18mm . 196.0-274.5 N.m (144.5-202.5 ft-lbs.) based cil designed for use in two-stroke air-cooled engines. Ensure all dirt and debris is removed from ‘around oil reservoir filer cap before adding oll ( ‘TRANSMISSION. The transmission is lubricated by oil ‘contained within the clutch cover and crankcase halves, Recommended oil is @ good quality multigrade SAE 20W- Imystrations Courtesy US. Sunuki Metor Cor,40 moto it Oil's poured through plug (Fig S1-1) poring in clutch cover and should be maintained a evel » oil level plug (L) opening. Transmission is drained by removing pug in underside of crankcase. Dry capactt of cases is §50 mL. (0.58 qt.). Retling transmission i cases have not been cisassembled requires only 500 mi. (0.53 qt) of oles epproximataly 59 mL (0.053 gt.) wil be retained by case castings, ‘The transmission Aid Should be changed ater the frst month of operation and very si months thereate. DRIVE CHAIN. The final drive chain should be lubri= ‘cated with a suitable chain lube or motor oil prior to every vehicle operating interval. Once a month the chain should be removed and washed in a suitable solvent then Immersed in oll Install and adjust drive chain as outlined in DRIVE CHAIN section. THROTTLE AND BRAKE. The throttle and brake ‘cables should be lubricated with motor oil upon initial operation of vehicle and every 6 months thereafter. The throttle lever and brake camshaft should be greased every 12 months. Do not excessively grease the brake camshaft as grease may contact brake linings reducing braking ability, Fig. $1-1—Transmission is fled with oll through flr plug ‘opening (F). Oil level should be maintained at level of plug ‘pening (L). Fig. $1-2—Loosen locknut (L) and tum adjuster. (A) as required to adjust throtto cable free play. Iystrations Courtesy US. Suzuk Motor Core. Suzuki ALT50 & LT50 AIR CLEANER ELEMENT All Models The air cleaner element should be removed and cleanad every month or more often depending on operat- ing conditions. To remove air cleaner, first remove the seat, body and air cleaner cap. Withdraw air cleaner element. ‘Thoroughly clean element in suitable solvent. Com- press element between hands to remove solvent. Satu- rate element in OC! Super 2-Cycle Motor Lubricant or ‘equivalent oil. Compress element to remove excess cil. Reinstall element by reversing removal procedure. FUEL SYSTEM All Models CARBURETOR. Models ALTSO and LT50 are equipped with a Mikuni VM12SC carburetor. Refer to CONDENSED SERVICE DATA tor carburetor specitioa- tions. Before performing carburetor adjustments, throttle cable should be carefully adjusted to provide 0.5-1.0 mm (0.02-0.04 in.) free play at idle position. Cable adjust- ment is accomplished by first removing seat and fuel tank. Loosen locknut (L—Fig. $1-2) and rotate adjuster (A) a8 required. Intial setting of idle mixture screw (21—-Fig. S1-3) is 11 tums out from a lightly seated position. Rotating idle mixture screw clockwise will ean ‘the mixture while counterclockwise rotation richens the mixture. Final adjustment should be made with engine at normal operating temperature and running. Adjust ile speed sorew (23) so engine idles at 1500-1600 rpm. ‘Adjust idle mixture sorew so engine idles smoothly and accelerates cleanly. If necessary, readjust idle speed ‘screw to obtain 1500-1600 rpm idle speed. After adjust- = Fig. $1.3—View of idlo mixture (21) and idle speed (23) adjusting screws. Refer to text for carburetor adjustment procedure. 245,Suzuki ALT50 & LT50 Fig. $1-4—Exploded view of Mikunl VM12SC carburetor used on both models. Carburetor Idenlification number Is located at (wy. 1. Se 2 Grommet 18, Boy 3. Gap 19) Fol ing 8 iat ate Sorea 20. Washer 5. Data 2h le mist row 8. Grate ver 22. Serna Spacer 25. ibe sped screw 8 Locker 28 Soro 9. Seren 25. Feat 18: Seta 28. Newt 12. Serre 25. att no. 4 19, Rotanee 29. Plott no. 2 4 dete ip 50. Gasket, eset nea 31, at bom 36. That cde 22. Waser 7 ase 35. Dein ps 246 ing carburetor, check throttle cable adjustment as pre- viously described. ‘The carburetor should be removed, disassembled and cleaned annually. Disassembly of the removed carbure tor is evident after inspection of unit and referral to exploded view in Fig. S1-4. Carefully inspect jet needle (15), inlet valve (19), idle mixture screw (21) and idle speed sorew (23) for excessive wear and damage. During reassembly, renew all gaskets and fiber wash- ers. Clip (14) should be in third groove from top on jet needle (15). To check float level, remove float bowl’ | (81) and invert carburetor. Distance (A—Fig. S1-5) ‘between bottom of float and carburetor body with gasket removed should be 24.5-25.0 mm (0.96-1.00 in.) Adjust float level by bending float arm tang, IGNITION AND ELECTRICAL All Models. | SPARK PLUG. Standard recommended spark plug is NGK BP4H or Nippon Denso W14FP. Spark plug elec- trode gap should be 0.6-0.8 mm (0,024-0.081 in.) ‘Spark plug should be removed and inspacted after the first month of operation and every three months there- after, or more often depending on vehicle operation. < ‘Spark plug should be renewed after every six months of operation, or more often if necessary. If after inspection, standard spark plug appears to be overheating, manutac- turer recommends installing a NGK 8PSHS or Nippon Denso W16FP spark plug. IGNITION. Both models are equipped with a capacitor discharge, pointless electronic ignition system. The igni- tion system consists of the flywheel, 2 magneto coil located under flywheel, CD igntion and coil module attached to frame under fue! tank, a spark plug and two engine stop switches. Ignition timing should be 22°-26° BTC and is not adjustable. {ignition malfunction occurs, check condition of spark plug, all wires and connections before troubleshooting ignition circuit. Using Suzuki pocket tester number (09900-25002 or a suitable chmmeter, refer to the follow- (A) should be 24.5-28.0 mm (0.96-1.00 ‘n.). Bond float arm tang to adjust. llstrations Courtesy US. Suzuki Motor Crp.ing test specifications and procedures to aid trouble- shoot To check condition of CD ignition module, first remove module from vehicle. Attach tester positive lead to spark plug high tension wire and negative lead to black /yellow ‘wire terminal on module. Tester should read infinite resistance. Connect tester negative lead to module ground. Resistance between high tension wire and ‘ground should be 15k ohms. Connect tester positive lead to black//yellow wire ter= ‘minal on module and negative lead to high tension wire. Resistance should be 25k ohms. Connect tester negative lead to module ground. Resistance between black/yel- low wire terminal and ground should be 3.4 ohms. Connect tester positive lead to module ground and negative lead to black /yellow wire terminal on module. Tester should read infinite resistance. Connect tester negative lead to high tension wire. Resistance should be 45k ohms. Renew CD ignition module if module falls any test resistance reading. To check condition of magneto coil, disconnect black yellow wire to magneto coil at CD ignition module and attach either tester lead to wire. Attach remaining tester lead to ground. Magneto coil may be considered satisfac tory if resistance reading is 120-160 ohms. WIRING. If wiring requires repair, always use replace- ment wire of the same gage. Wires should be routed away from areas of extreme heat or sharp edges. Plastic. tie straps should be used to retain wires in their original positions to prevent short circuiting. Refer to Fig. S1-6 for ‘schematic wiring diagram. ‘CLUTCH All Models. R&R AND OVERHAUL. The two-shoe centrifugal clutch is mounted on right end of crankshaft. Clutch should begin engagement at 2400-2800 rpm with com- plete lockup at 3300-3700 rpm. To remove clutch assembly for inspection or renewal of individual compo- nents, first remove clutch cover. Remove retaining nut (2—Fig, 81-7), thrust washer (3), small spring washer (4), large spring washer (5) and guide plate (8). Pull clutch shoe assembly (7) from crankshalt. Remove Woodruf key (8), thrust washer (9), clutch drum (10), ‘spacer (11) and thrust washer (12). lean, inspect and renew any components that are damaged or worn excessively. Renew clutch shoe assembly If grooves in shoes are wom smooth or if total clutch spring length exceeds 28 mm (1.10 in,). Clutch rum should be renewed if signs of scoring, cracks or uneven wear are evident or if drum inside diameter ex- ceeds 78.40 mm (3.087 in.). Renew seal (1) located in clutch cover. tions Courtosy US. Suzuki Motor Cop Suzuki ALT50 & LT50 When reinstalling clutch assembly, ensure spring washers (4 and 5) are installed with concave side towards guide plate (6). Tighten clutch nut (2) to 34.5- 54.2 N.m (25.5-40.0 ft-lbs.) torque. Seal (1) should be installed in cover with open side towards clutch assembly. Make sure oil passage in clutch cover is free of debris and clean before installing cover. ‘STARTER INTERLOCK All Models ADJUSTMENT. Both models are equipped with a starter interiock system that prevents manual starter Fig. $1-6—Wiring echomatic typical of both models. 1. Sep ste (ont) 4 ipton eat ad 2. Stop swach (rear) 5 Spates W. neo 3. mene B steak Yt tow Fig. $1-7—Exploded view of centrifugal clutch used on both models. 1 saat 1. Chuch choo one 2 Cate it 8 Woodna hoy 3. Tus wasner 3. Tet washer 4 Sar epg wesnar 10. Gaon rum & Lage sna washer 11 Space 6 Gude pale 12 Thus washer 247Suzuki ALT50 & LT50 ‘engagement until parking brake is applied. To adjust, first ccheck and adjust brakes as outlined in BRAKES section, Loosen locknut (L—Fig. $1-8) and tum interlock adjust er (A) inward to end of travel. Actuate parking brake, then slowly pull starter handle and check for starter engagement. If starter does not engage, back interlock agjuster out 32 tur and recheck. Continue alternating starter engagement checks and turning adjuster out in tum increments until starter operates. After intial engage- ‘ment is achieved, rotate interlock adjuster (A) out an additional 1% tus and secure with locknut (L). Recheck adjustment. MANUAL STARTER All Models R&R AND OVERHAUL. Reter to Fig. S1-9 for exploded view of manual starter assembly. Starter may be removed as a complete unit by first loosening locknut (L-Fig. S1-8) and rotating starter interlock adjuster (A) Fig. $1.8—Loosen locknut (L) and rotate aujuster (A) as out= lined in toxt to adjust starter Interlock. Fig. $1-9—Exploded view of manuel starter assembly used on ‘both models. 2 Gasket 8 Snap ra 15. Rape aly 3 Cap seew 3 Washer 1 Bw spn iio lover 10 Retr 15 Rosana, 5 pera 1 State pant 16, Rose 8 ne 12. Rata Sng 17 Stree rousing 248 inward to end of travel. Remove four retaining screws ‘and separate starter from engine. Detach interlock cable from interiock lever (4—Fig. $1-9). Rotate cable adjust- fer completely out and pull cable free from starter hous- ing, To disassemble starter, proceed as follows: Remove starter interlock components (3 through 7). If starter ‘spring remains under tension, pull starter rope and hold rope pulley (13) with notch in pulley adjacent to rope outlet. Pull rope back through outlet so it engages notch in pulley and allow pulley to slowly unwind. Remove snap ring (8) and disassemble unit. Rewind spring (14) is wound in clockwise direction in rope pulley (13). Rope is wound on rope pulley in clock- ise rotation as viewed with pulley in housing. Reassem- ble starter assembly by reversing disassembly procedure making certain starter pawl (11) and return spring (12) are installed as shown in Fig. $1-10. To place tension on rewind spring, pass rope through rope outlet in housing nd install rope handle. Pull rope out and hold rape pulley ‘so notch on pulley is adjacent to rope outlet. Pull a loop of rope back through outlet between notch in pulley and housing. Turn rope pulley clockwise @ few revolutions to place tension on spring. Do not place more tension on ‘rewind spring than is necessary to draw rope handle up against housing, Reinstall interlock components (3 through 7—Fig. 1-9) and attach interlock cable to lever (4). Attach starter to engine and adiust starter interlock. «28 outlined in STARTER INTERLOCK section, FRONT AXLE ASSEMBLY Model ALTSO R&R AND OVERHAUL. Refer to Fig. S1-11 for exploded view of front axle assembly used on ALTSO models. To remove front wheel, remove boot (1) and cotter pin (2), Unscrew axle nut (3) and withdraw axle (18). Remove short spacers (5). Remove whee! retait ing nuts (12) and separate wheel hub (6) and wheel Drive seals (7), bearings (8) and spacer (9) from hub if necessary, Fig. S1-10—ensure starter paw! (11) and return spring (12) ‘re installed as shown. Parts are also shown In Fig. 81-9. Mustrations Courtesy U.S. Sunuk Motor CorpInspect bearings and axle for weer. Bearings should be packed with a good quality wheel bearing grease. To reassemble, reverse disassembly procedure. Seals (7) are installed with open sides toward bearings (8). Apply Grease to seal lips bofore inserting spacers (5). Tighten whee! retaining nuts (12) to 17.6-27.1 Nem (19:20 ft lbs.) torque and axle nut (3) to 35.2-50.8 N.m (26.0 8755 ft-lbs.) torque. Model LT50 R&R AND OVERHAUL. Refer to Fig. S1-12 for exploded view of front axle assembly used on LT50 mod als. To remove either wheel hub (34), remove front wheel and axle nut (36). Pull wheel hub (34) off spindle (28). Do not lose spacer (38). Drive seals (32), bear- ings (33) and spacer (35) from hub (34) if neces- sary. To reassemble, reverse disassembly procedure. Bear- ings should be packed with a good quality wheel bearing grease. Seals ($2) are installed with open sides toward bearings (93). Tighten axle nut (38) to 48.8-78.6 N-m (98-68 ft-lbs.) torque and wheel nuts to 17.6-27.1 N-m (18:20 ft-lbs.) torque Fig. 81-11—Exploded view of steering and front axle sseembly ‘used on ALTSO models. 1. Boot 8. Contr spacer 17, Sta os bracket 2 Caters 10. Fu 18 Locwnse Bent 1 Rin cap crew 18. Si mat Waser 12 wea rat 20. Bout bats (60) 5 Space 18 Ase 21. merce Vice 14 Slemcapecew 22. Ouarrace 4 Saal 18. Washer 25, Seti slam 8 tok 8 Bowing 16. Fo ap screw amr Ietrations Courtesy US. Suzuki Motor Corp. Suzuki ALT50 & LT50 STEERING Model ALT50 ADJUSTMENT. The steering stem should be checked land adjusted after the first month of operation and every three months thereafter. To adjust, remove handlebars and steering stem head bracket (17—Fig. $1-11). Loos- fen locknut (18) and tighten stem nut (19) until snug, then loosen stem nut Y4-% turn. Secure stem nut (19) in position with locknut ( 18). Tighten stem head cap screw (14) to 39.4-59.0 N-m (29,0-43.5 ft-tbs.) torque and Fig. $1-12—Exploded view of steoring and front axlo acsombly lused on LT50 models. 1. cap sew 2 Lockwashr 18-0" a 28, Dat sot 3 care 10, Vasher 29, Loker 4 Hane 17 Goexrat 80. Sendo nt 5 cane 18. Lower rut 31. Coter © Stocina shat 19. etter in 32. Seal 7 Cap scew 20. Ted ond 8. Bearing er 21. Lock 34 Whee hss © She etarer 22. Acute 35. Bong eacer 10. Sutera 28. vad end it 38. Avent 1 Cater sin 26 Spndcap svew 37. Catt an 12. "0" 25, Dut oa! 8. Spacer 1 Dont ea 33. Sone 49, Weer 14 Bashing 7. Spacer 20cm 249‘Suzuki ALT50 & LT50 fork cap screws (16) to 21.7-34.6 N-m (16.0-25.6 ft. lbs.) torque. R&R AND OVERHAUL. To remove steering stem head assembly, remove front wheel as outlined in FRONT AXLE section. Remove handlebars and stem head bracket (17—Fig. S1-11). Unscrew locknut (18) land stem nut (18) with a suitable tool and remove steer- ing stem and fork assembly from frame being careful not to lose bearing balls (20) Drive upper and lower bearing inner races (21) from head pipe using a suitable punch. Lower bearing outer race (22) can be removed by carefully driving a suitable wedge between bearing and bearing seat. Inspect and renew any questionable components. Bearing inner Faces (21) should be installed using tool 09941-34511 oF equivalent. Use a good quality grease to lubricate and retain bearing balls (20) in position during installation, ‘The upper and lower stem bearings each contain 25 loose bearing balls. Adjust steering stem as previously described, Model LTSO ADJUSTMENT. The toein should be checked and adjusted after the first month of operation and every three months thereafter. Prior to toe-in adjustment, inspect steering assembly for damaged or excessively worn ‘components. If service to steering assembly is required, refer to R&R AND OVERHAUL section. To check toe-i, inflate tires to recommended pressure of 26-35 kPa (3.6-5.5 psi). Position vehicle on a fiat smooth surface and set handlebars straight forward. Using a suitable tape measure, measure the distance between right and left tire center lines on back side of piiaaaaedsy Waseeees eee ee Somme nama trtoneet en {eriines while maintaining equal distances between front left (L) and sight (R) tre to vehicle centerines. Refer to toxt. 250 tres (B—Fig. 1-13) and record measurement. Locate the same tire centeriine points on front side of tres (F) ‘and record measurement. The front measurement should q bbe 2.5-5.5 mm (0,10-0.22 in.) less than rear measure- ment; note that the distance from a projected vehicle Center line to left (L) and right (R) tire centerines should algo be equal. To adjust, loosen te rod locknuts (21—Fig, $1-12) on both left and right tie rods. Tie rod ond locknuts (21) color-coded yellow have let-hand threads. Rotate adlust ‘ers (22) in equal increments to maintain equal vehicle Ccentertine to left and right tre centerline distances. Tight €entie rod locknuts to 21.7-34.5 N.m (16.0-28.5 {t-Ibs.) torque R&R AND OVERHAUL, Removal and disassembly of steering components is evident after inspection of unit and referral to exploded view in Fig. S1-12. During reas- sembly, renew all cotter pins. Lubricate all friction points with a good quality grease. Tighten steering shaft clamp cap screws (7) to 17.6-27.1 N.m (13-20 ft-lbs.), steering shaft lower nut (18) to 21.7-84.6 Nem (16.0- 26.5 ft-lbs.) and tie rod end retaining nuts (23) and spindle nuts (30) to 9.9-58.9 N.m (29.0-43.5 ft-lbs.) torque. BRAKES q All Models ADJUSTMENT. Models ALT5O and LT5O are equip- Ped with a two-shoe internal expanding drum brake mounted on rear axle and actuated by left handlebar lever. The brake adjustment should be checked after the first month of operation and every three months there- after. Fig. S1-14—Brake lover tree play measured at (F) should be § ‘mim (0.2 in.). Refer to Fig. 81-11 for adjustment location. ystrations Courtesy US. Suzuki Motor Corp.To check brake adjustment, remove protective cover ((C—Fig. $1-14) from lever and measure brake lever free travel. Lever should have § mm (0.2 in.) of free travel between lever base and bracket as measured at (F) in inset. To adjust, rotate adjusting nut (A—Fig. $1-16) at rear brake as required, To check parking brake operation, pull brake lever and engage brake lock button (P—Fig. $1-14). Try to detect. any brake slippage by pushing back and forth on vehicle. Readjust brakes as required. R&R AND OVERHAUL. To remove rear brake shoes {or inspection or renewal, first suitably support rear of vehicle and remove right rear tire and wheel, Remove ‘wheel hub retaining nut and withdraw wheel hub (1—Fig. $1-16) from axle (13). Slide spacer (2), brake drum ‘cover (3) and brake drum (4) off axle. Carefully remove brake shoes (5) from backing plate (8) Brake shoes should be renewed if linings are worn to 1.5 mm (0.06 in.) or less. Brake drum should be re- newed if inside diameter exceeds 90.7 mm (9.87 in.) Reinstall brake shoes by reversing removal procedure while noting the following: Lightly coat brake camshaft with grease. Tighten wheel hub retaining nut to §6.9-78,6 Nm (42-58 ft-lbs.) and wheel retaining nuts to 17.6- 27.1. N-m (13-20 ft-lbs.) 1) DRIVE CHAIN AND SPROCKETS. All Models ADJUSTMENT. The drive chain should be inspected and adjusted every month. Improper maintenance and neglect can cause early failure of both drive chain and sprockets. Drive chain free play should be 15-25 mm. (0.5-1.0 in.) measured midway between sprockets. To adjust, loosen rear axle bearing housing retaining cap screws (17—Fig. S1-17) and rotate chain adjusting nuts (17) in equal increments as required. Fig. $1-15—Brake adjustment 16 accomplished by rotating ‘adjuster (A) at rear of vehicle ‘ysttaions Courtesy US. Suze Motor Corp. Suzuki ALT50 & LT50 ‘Once chain free play is correct, tighten rear axle bear- ing housing retaining cap screws and check brake agjust- ment as outlined in BRAKES section, REMOVE AND REINSTALL. To remove the drive chain and sprockets, frst remove dive chin master link ‘and withdraw the chain. Unbolt and remove marual stat- fer assembly from engine. Remove engine sprocket retaining snap ring and pull sprocket from shaft. Suitably support rear of vehicle and remove lett rear tire and wheel assembly. Remove axle nut (34—Fig. $1-16) and slide wheel hub (31) and spacer (30) off axle (13) Bend back tabs on lock plates (28) and remove cap serews (29). Withdraw rear sprocket (27) Carefully examine sprockets for excessive wear. Worn sprockets will usually have @ hooked tooth profile. A ‘900d testis to place @ new chain on a used sprocket and check the ft. Wear on sprocket sides indicates misalign- ment. If sprockets require renewal due to wear, always renew drive chain ig. $1-18—Exploded view of roar axto, brake and related com- ‘ponents used on both models. 4 at ha 2 Rie pacer 18. Boating 28, Lock plane 8 Gover 16. Beara mowing 29. Capecren 4 Bec cm 17 Cap ener 50. Spacer 5. Bese ston 1@ Chaintersonee 3 Let hb ©. Some 18 Washar 2, Specer 5, praca com 20. Utne 55. Waar & Becng pte 2), enorerne Se Hb a © Bakesocscor 22. Caps 5, Covers 1. Anca 25. Bowing epoca 38 Cap 180" 2. Bours Fim ut 12 Beka cam ever 28. Sea ‘8. Fim cap scew 15. Ae 26 Sprocket mount 30. Stor sal 3 Sa 27 oor eprcket 40. Wheat nt 251Suzuki ALT50 & LT50 Fig. $1-17—To adjust final drive chain, loosen besring housing ‘otaining cap screws (17) and rotate adjusting nuts (21). 252 Standard chain is either a Daido D.LD. 420 of a Taka- sago RK420M which has 64 links. Standard engine sprocket has 11 teeth while standard rear sprocket has 87 teeth. Reinstall by reversing removal procedure while noting the following: Tighten rear sprocket retaining cap screws to 17.6-27.1 N-m (13:20 ft-lbs.) torque and secure with tabs on lock plates. Tighten axle nut to 56.9-78.6 Nem (42-58 ft-lbs.) and wheel retaining nuts to 17.6- 27.1 N-m (13-20 ft-lbs.) torque. When installing drive chain, ensure master link retaining clip is installed with closed end of clip toward normal direction of chain move- ment (split end toward rear with master link located on top side of sprockets). Adust chain as previously described in ADJUSTMENT paragraphs. uteations Courosy US, Suzuk! Motor Corp.