JR 50

JR50
JR50
OWNER’S MANUAL
This owner’s manual contains
important safety information.
Please read it carefully.
99011-04493-03A
Part No. 99011-04493-03A

June, 2005 TK EN
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IMPORTANT WARNINGs and CAUTIONs are
arranged like this:
WARNING/CAUTION/NOTE
Please read this manual and fol- WARNING-or-CAUTION
low its instructions carefully. To
emphasize special information,
The first part will describe a
the symbol  and the words POTENTIAL HAZARD and
WARNING, CAUTION and NOTE WHAT CAN HAPPEN if you
have special meanings. Pay spe- ignore the WARNING or CAU-
cial attention to the messages TION.
highlighted by these signal words:
The second part will describe
WARNING HOW TO AVOID THE HAZARD.
Indicates a potential hazard
that could result in death or
injury.
CAUTION
Indicates a potential hazard
that could result in motorcycle
damage.
NOTE: Indicates special informa-

tion to make maintenance easier
or instructions clearer.

FOREWORD It is important that this manual
remain with the motorcycle when
Motorcycling is one of the most you sell it. The next owner will
exhilarating sports and to ensure need this manual also. Store the
your youngster’s riding enjoy- owner’s manual with your motor-
ment. You and your youngster cycle.
should become thoroughly famil-
iar with the information presented Review the “Parents, Youngsters
in this Owner’s Manual before and Off-Highway Motorcycles”
your youngster rides the motorcy- handbook supplied with this
cle. owner’s manual (for owner’s in
U.S.A.). This special handbook
The proper care and maintenance contains a variety of safety tips,
that your motorcycle requires is helpful hints, and practice exer-
outlined in this manual. By follow- cise that can increase your
ing these instructions explicitly youngster’s riding enjoyment and
you will ensure a long trouble-free safety.
operating life for your motorcycle.
Your authorized Suzuki dealer Suzuki Motor Corporation
has experienced technicians that believes in conservation and pro-
are trained to provide your tection of Earth’s natural
machine with the best possible resources. To that end, we
service with the right tools and encourage every vehicle owner to
equipment. recycle, trade in, or properly dis-
pose of, as appropriate, used
All information, illustrations, pho- motor oil, coolant, and other flu-
tographs and specifications con- ids: batteries, and tires.
tained in this manual are based
on the latest product information
available at the time of publica-
tion. Due to improvements or
other changes, there may be
some discrepancies in this man-
ual. Suzuki reserves the right to
make production changes at any
time, without notice and without
incurring any obligation to make
the same or similar changes to
motorcycles previously built or
sold.
© COPYRIGHT SUZUKI MOTOR
CORPORATION 2005

IMPORTANT ADVICE TO Your Suzuki JR50 was designed
for use by children, but this
PARENTS owner’s manual is written for the
adult who will be supervising the
This motorcycle is designed for children. Suzuki strongly recom-
use only as follows: mends, therefore, that you review
• Read this owner’s manual this entire manual with your child.
carefully. Carefully explain the instructions
• Off-road use only – Not for use requirements, and warnings this
on public roads. manual contains so your child can
• Single rider only – Weight understand them. Question your
limit 30 kg (65 pounds). child as you go through the man-
• Not recommended for children ual to make sure he or she under-
under age 7. stand what you are saying. It is
• Parental supervision required your responsibility to ensure that
during operation. this motorcycle is properly and
• Parent and rider to perform safely ridden and maintained.
daily inspection before riding –
refer to applicable sections of Children differ in skills, strength
this owner’s manual. and judgement, and some chil-
• Observe periodic maintenance dren may not be able to operate
requirements outlined in this youth-size motorcycles safely. You
owner’s manual. should always supervise your
• Do not touch any moving parts child’s use of the motorcycle. Per-
or heated areas such as the mit continued use only if you
engine, the drive chain and determine that the child has the
exhaust system. ability to operate the motorcycle
• Rider must always wear a hel- safely. Note that children can
met, eye protection (goggles become so excited and impatient
or face shield) and protective that they forget the importance of
clothing (gloves, leather or safety precautions.
heavy cloth pants, long-sleeve
shirt or jacket, boots that fit
over the ankle).
• Rider must always ride safely
and be thoughtful of others.
• Drain the fuel tank and carbu-
retor of fuel prior to transport-
ing the motorcycle.

Tips for supervising the young Wear protective gear.
rider. A helmet is the most important
piece of gear to wear off-highway,
WARNING where visibility and trail conditions
can vary greatly from section to
Allowing a child to operate this section and season to season.
motorcycle without adult These changes are sometimes
supervision can be hazardous. unpredictable, and can cause
Without supervision, the child even an experienced rider to have
may ride beyond his or her abil- an accident. Helmets do not
ities and lose control of the reduce essential vision or hear-
ing.
motorcycle.
Never let your child ride a Generally, helmets do not cause
motorcycle without close adult or intensify injury if the rider
supervision. Take action if your crashes. Helmets simply help
child begins to ride beyond his your child’s skull protect his or her
intelligence, memory, personality,
or her abilities. Introduce new and life.
riding areas slowly and make
sure the riding area matches Your child’s eyesight is equally
your child’s skill level. valuable. Wearing eye protection
can help keep his or her vision
Your child’s safety depends on unblurred by the wind and help
your commitment to take the time shield his or her eyes from
necessary to fully educate him or branches and airborne matter like
her on the proper operation of the bugs, dirt, or pebbles kicked up by
JR50. Remember that proper tires. Have your child wear a hel-
instruction before your child met and eye protection every time
begins to ride is as important as he or she rides.
proper instruction and supervision
during riding.

Outfit your child in proper clothing Go over the INSPECTION
when he or she rides. Avoid loose BEFORE RIDING section with
clothes or scarves, which could your child until he or she knows all
get caught in moving parts. Abra- the items that should be checked
sion injuries can be minimized by and how they should be checked.
wearing protective clothing includ- Give examples of things to look
ing gloves, strong boots that fit for. Before each use, an adult
over the ankle, long pants, and should perform an inspection with
long sleeve shirt or jacket. Experi- the rider.
enced riders often wear a kidney
belt and chest or back protector Starting off and stopping.
for additional comfort and protec- To help your child develop confi-
tion. dence, he or she should PRAC-
TICE FIRST WITH THE ENGINE
Getting to know the JR50. OFF, as follows:
Your child should become com- 1. Have your child sit on the bike
pletely familiar with the names while you balance and push he
and functions of all controls. Let motorcycle from behind.
the young rider sit on the bike, 2. As you push the bike, instruct
with the engine off, and ask him or your child to operate the con-
her to operate specific controls. trols, as described above. The
Demonstrate proper operation of child should be looking straight
the controls. Ask the child to apply ahead, not down at the con-
the brakes, operate the engine trols.
stop switch, shift lever, etc. Prac-
tice this exercise until the child Practice with the engine off until
can operate all the controls with- your child gets the feel of using
out hesitation and without looking the controls without hesitation and
at them. without looking at them. Then
start the engine and have your
SUZUKI recommends first use of child practice starting off, shifting
the motorcycle in a safe, flat open into Drive, riding in a straight line
area so the rider can become and coming to a complete stop.
familiar with the controls, opera- Walk alongside the motorcycle.
tion, and handling characteristics Watch closely to make sure the
of the motorcycle. rider:
1. Operates the throttle smoothly
to start moving gradually.
2. Releases the throttle then
applies the front and rear
brakes evenly and shifts to
neutral when stopping.

Practice this exercise until your • Before first use of the motorcy-
child can start off, accelerate, and cle, read this owner’s manual
stop correctly and with confi- carefully to become familiar
dence. Slowly introduce new with the features, and safety
maneuvers into this routine as the and maintenance require-
child becomes more comfortable ments of the motorcycle,
with the motorcycle, such as turn- instruct and review these items
ing and stopping quickly on your with rider.
signal.
Remember: With your help and
Inspect the machine before supervision, your child can
riding. become a skilled rider.
Review the instructions in the
“INSPECTION BEFORE RIDING”
section of this manual. Perform an
entire pre-ride inspection with
your child before heading out on
the trail. Spending a few minutes
preparing the machine for a ride
can help prevent accidents due to
mechanical failure or costly,
inconvenient breakdowns.
Specific additional safety items to

be considered include:
• Supervise operation of this

motorcycle AT ALL TIMES.
• Do not allow the rider to oper-
ate the motorcycle beyond his
riding ability.
• Use of the motorcycle should
be controlled by the parents in
relation to the rider’s age (not
recommended for children
under 7 years old), physique,
and operating intelligence and
maturity.
• Beware of hazardous situa-
tions and instruct the rider to
beware of hazardous situa-
tions.

TABLE OF CONTENTS
INSTRUCTING THE YOUNG RIDER 1
FUEL AND OIL RECOMMENDATION 2
CONTROLS, EQUIPMENT AND ADJUSTMENTS 3
BREAK-IN AND INSPECTION BEFORE RIDING 4
RIDING TIPS 5
ACCESSORY USE AND MOTORCYCLE LOADING 6
INSPECTION AND MAINTENANCE 7
TROUBLESHOOTING 8
STORAGE PROCEDURE AND APPEARANCE CARE 9
CONSUMER INFORMATION 10
SPECIFICATIONS
INDEX

1
INSTRUCTING THE YOUNG RIDER
OPERATING SKILL ............................................................................................. 1-2

CLOTHING ........................................................................................................... 1-4
1-1
INSTRUCTING THE OPERATING SKILL
YOUNG RIDER Know the mechanism.
Memorize the name of each con-
trol. The name suggests its func-
tion. Know the path of power from
the engine to the rear wheel.
Learn the sequence of checking
the items listed in the INSPEC-
TION BEFORE RIDING section.
WARNING
An incomplete understanding
of motorcycle controls can be
Children are impatient; the sight hazardous. An improperly con-
of a new motorcycle excites their trolled motorcycle may cause
imagination; and in their excite- an accident.
ment they may forget the impor-
tance of safety precautions. Check to be sure the young
rider has perfectly learned: let
Please go through this manual
him or her demonstrate after
with your youngster, page by
page, and help him or her under- you.
stand not only the mechanisms
but also the rules of courtesy and
safety precautions. Here are six
rules to be impressed upon the
mind of the young rider before you
begin the training:
1-2
Rehearse before riding out for
the first time. WARNING
Let the young rider mount the
machine and do a dry rehearsal Operating this motorcycle with-
with the engine off. The rider out proper instruction can be
should be fully outfitted with hel- hazardous. The risk of having
met, eye protection (goggles or an accident greatly increases if
face shield), and protective cloth- you do not train the youngster
ing (gloves, leather or heavy cloth how to operate this motorcycle
pants, long sleeve shirt or jacket, properly in different situations
boots that fit over the ankle). and on different types of ter-
Watch the way he or she operates rain.
the controls (particularly throttle
and brakes). Make sure the shift-
ing sequence is perfectly memo-
Train your young rider in a
rized. Smooth simultaneous level, open area free of any traf-
braking (front and rear) is particu- fic so he or she can become
larly important. familiar with the operation of
controls and the handling char-
Learn the techniques of acteristics of the motorcycle.
standing-start and stopping
with both brakes.
Practice makes perfect. Let the
young rider repeat after you, as
many times as necessary, until
you are sure he or she has
learned the technique.
1-3
CLOTHING
WARNING
Operating this motorcycle with-
out wearing an approved
motorcycle helmet, eye protec-
tion and protective clothing
increases your chances of a
severe injury or death in the
event of an accident.
As stated before, the minimum
acceptable riding outfit includes Always wear an approved
helmet, eye protection, and pro- motorcycle helmet that fits
tective clothing. Some guidelines properly. Always wear eye pro-
for protective clothing are: tection (goggles or face
shield). You should also wear
Wear simple clothes. gloves, boots, long sleeve shirt
Dangling belts and scarves, rib- or jacket, and long pants.
bon-like trimmings, etc., are haz-
ardous since they can get caught
in moving parts.
Wear full-coverage clothes.

Do not ride with bare arms or
legs. Abrasion injuries can be
minimized by wearing clothing
that fully covers the limbs. Off-
road gloves and over-the ankle
boots help protect hands and feet.
Loss of body heat to wind can
contribute to riding fatigue. Proper
clothing can help keep the rider
warm and alert.
Wear flexible clothes.

Make sure that riding clothes
allow a full range of knee, elbow,
and torso movement. Unrestricted
body movements are essential for
safe riding.
1-4
FUEL AND OIL
RECOMMENDATION
2
FUEL .................................................................................................................... 2-2

ENGINE OIL ......................................................................................................... 2-3
TRANSMISSION OIL ........................................................................................... 2-3
2-1
FUEL AND OIL Gasoline/Methanol Blends
Fuel containing 5% or less metha-
RECOMMENDATION nol (wood alcohol) may be suit-
able for use in your motorcycle if
FUEL they contain co-solvents and cor-
Your motorcycle requires regular rosion inhibitors. DO NOT USE
unleaded gasoline with a mini- fuels containing more than 5%
mum pump octane rating of 87 methanol under any circum-
((R+M)/2 method). In some stances. Fuel system damage or
areas, the only fuels that are motorcycle performance prob-
available are oxygenated fuels. lems resulting from the use of
Oxygenated fuels which meet the such fuels are not the responsibil-
minimum octane requirement and ity of Suzuki and may not be cov-
the requirements described below ered under the New Vehicle
may be used in your motorcycle Limited Warranty.
without jeopardizing the New
Vehicle Limited Warranty. Fuel Pump Labeling
In some states, pumps that dis-
NOTE: Oxygenated fuels are pense oxygenated fuels are
fuels which contain oxygen-carry- required to be labeled for the type
ing additives such as MTBE or and percentage of oxygenate, and
alcohol. whether important additives are
present. Such labels may provide
Gasoline Containing MTBE enough information for you to
Unleaded gasoline containing determine if a particular blend of
MTBE (Methyl Tertiary Butyl fuel meets the requirements listed
Ether) may be used in your motor- above. In other states, pumps
cycle if the MTBE content is not may not be clearly labeled as to
greater than 15%. This oxygen- the content or type of oxygenate
ated fuel does not contain alco- and additives. If you are not sure
hol. that the fuel you intend to use
meets these requirements, check
Gasoline/Ethanol Blends with the service station operator
Blends of unleaded gasoline and or the fuel suppliers.
ethanol (grain alcohol), also
known as GASOHOL, may be
used in your vehicle if the ethanol
content is not greater than 10%.
2-2
NOTE: ENGINE OIL
• To help clean the air, Suzuki
recommends you to use the
oxygenated fuels.
• Be sure that any oxygenated
fuel you use has octane rat-
ings of at least 87 pump
octane ((R+M)/2 method).
• If you are not satisfied with the
driveability of your motorcycle
when you are using an oxy-
genated fuel, or if engine ping- Use SUZUKI CCI SUPER 2-
ing is experienced, substitute CYCLE MOTOR LUBRICANT or
another brand as there are dif- an equivalent good quality syn-
ferences between brands. thetic based 2-stroke engine oil
rated FC under the JASO classifi-
CAUTION cation.
Spilled gasoline containing
alcohol can harm your motor- TRANSMISSION OIL
cycle. Alcohol can damage Use a good quality SAE 10W-40
painted surfaces. multi-grade motor oil.
Be careful not to spill any gas-

oline when filling the fuel tank.
Wipe spilled gasoline up imme-
diately.
2-3
CONTROLS, EQUIPMENT AND
ADJUSTMENTS
LOCATION OF PARTS ....................................................................................... 3-2

3
LEFT HANDLEBAR ............................................................................................. 3-5
RIGHT HANDLEBAR .......................................................................................... 3-5
THROTTLE LIMITER ........................................................................................... 3-5
FUEL TANK CAP ................................................................................................ 3-6
FUEL VALVE ....................................................................................................... 3-7
ENGINE OIL LEVEL ............................................................................................ 3-8
CHOKE LEVER ................................................................................................... 3-9
KICK STARTER LEVER ...................................................................................... 3-9
GEARSHIFT LEVER .......................................................................................... 3-10
REAR BRAKE PEDAL ...................................................................................... 3-10
SIDE STAND ...................................................................................................... 3-10
POWER REDUCTION PLATE ........................................................................... 3-11
POWER REDUCTION PLATE REMOVAL INSTRUCTIONS ............................ 3-11
SEAT HEIGHT ADJUSTMENT .......................................................................... 3-13
3-1
CONTROLS, EQUIPMENT AND ADJUSTMENTS
LOCATION OF PARTS
1 Engine stop switch

2 Front brake lever
3 Throttle grip
4 Fuel tank cap
3-2
5 Fuel valve
6 Spark plug
7 Gearshift lever
8 Footrest
9 Side stand
0 Drive chain
3-3
A Kick starter lever
B Engine oil inspection window
C Transmission oil filler cap
D Air cleaner
E Choke lever
F Carburetor
G Rear brake pedal
H Transmission oil level screw
3-4
LEFT HANDLEBAR THROTTLE LIMITER
Engine Stop Switch 1 Use the throttle limiter to restrict

To stop the engine, push the maximum engine power by limit-
engine stop switch. ing throttle opening. Adjust this
limiter according to the rider’s skill
and experience.
RIGHT HANDLEBAR
To adjust the throttle limiter:
1. Loosen the lock nut 1.
2. Turn the throttle limiter screw
2 clockwise to restrict maxi-
mum engine power or counter-
clockwise to increase the
maximum engine power.
3. Tighten the lock nut 1.
When the maximum engine power

Throttle Grip 1 is required, remove the throttle
Engine speed is controlled by the limiter screw and lock nut and
position of the throttle grip. Turn it install the throttle case plug.
toward you to increase engine Throttle case plug: screw 5 × 5
speed. Turn it away from you to mm.
decrease engine speed.
Front Brake Lever 2

Apply the front brake by squeez-
ing the front brake lever towards
the grip.
3-5
FUEL TANK CAP
WARNING
Fuel and fuel vapor are highly
flammable and toxic. You can
be burned or poisoned when
refueling.
• Stop the engine and keep

flames, sparks and heat
sources away.
To open the fuel tank cap, remove • Refuel only outdoors or in a
the end of vent tube from the han- well ventilated area.
dlebar cover and turn the cap • Do not smoke.
counterclockwise. To close the • Wipe up spills immediately.
cap, turn it clockwise and tighten • Avoid breathing fuel vapor.
it securely. Be sure that the vent • Keep children and pets away.
tube is connected securely and
routed properly.
WARNING
Overfilling the fuel tank can
cause the fuel to overflow
when it expands due to heat
from the engine or the sun.
Spilled fuel can catch on fire.
Never fill the fuel above the

bottom of the filler neck.
3-6
FUEL VALVE
This motorcycle has a manually WARNING
operated fuel valve. There are two Leaving the fuel valve in “ON”
positions: “ON” and “OFF.”
position when the engine is off
can be hazardous. The carbu-
retor may overflow and fuel
may run into the engine. This
can cause a fire or cause
severe damage when you start
the engine.
Always move the fuel valve to

the “OFF” position after turn-
“ON” position ing off the engine.
The normal operating position for
the fuel valve is in the “ON” posi-
tion. In this position, fuel will flow
from the fuel valve to the carbure-
tor whenever the fuel level in the
carburetor drops.
“OFF” position
Turn the fuel valve to the “OFF”
position after stopping the engine.
In this position, fuel will not flow to
the carburetor.
3-7
ENGINE OIL LEVEL This motorcycle is equipped with
a two-stroke engine. Two stroke
engines consume oil along with
gasoline in the combustion pro-
cess. Therefore, it is important to
check the engine oil level before
each ride.
CAUTION
Running the engine without an
adequate amount of engine oil
can cause severe engine dam-
age such as overheating and
piston seizure.
Always check the amount of

engine oil before starting the
engine.
The engine oil tank is located

behind the right frame cover.
Check the oil level through the oil
level inspection window 1 each
time before starting the engine. If
the oil level is below the inspec-
tion window, replenish the oil tank
with the specified oil. To replenish
the oil, unscrew the knob 2 to
remove the frame cover and draw
out the oil tank 3 from the frame.
Fill up the tank with the specified
oil. The oil tank holds 0.3 L (0.3
US qt).
3-8
CHOKE LEVER KICK STARTER LEVER
This motorcycle has a choke sys- Depressing the kick starter lever
tem to provide easy starting when with the transmission in neutral
the engine is cold. The choke will start the engine.
works by pushing the choke lever
down. The choke works best
when the throttle is in the closed
WARNING
position. When the engine is An improperly retracted kick
warm, you do not need to use the starter lever can interfere with
choke for starting. rider control.
NOTE: Refer to the STARTING Be sure the kick starter lever is
THE ENGINE section of the man- returned to its home position
ual for the engine starting proce-
dure.
after starting the engine.
3-9
GEARSHIFT LEVER SIDE STAND
The motorcycle has a side stand.

This motorcycle has a single- To place the motorcycle on the
speed transmission which oper- side stand, place your right foot
ates as shown. To shift properly, on the end of the side stand and
close the throttle before you oper- push down firmly until the stand
ate the gearshift lever. Lift the pivots fully through its arc and
gearshift lever to shift to the neu- comes to rest against its stop.
tral position or depress the lever
to shift to the drive position.
CAUTION
Park the motorcycle on firm,
REAR BRAKE PEDAL level ground to help prevent it
from falling over.
If you must park on an incline,

aim the front of the motorcycle
uphill to reduce the possibility
of rolling off the side stand.
WARNING
Pressing the rear brake pedal will Riding with the side stand
apply the rear brake. incompletely retracted can
result in an accident when you
turn left.
Always retract the side stand

completely before starting off.
3-10
POWER REDUCTION PLATE POWER REDUCTION PLATE
The power reduction plate reduce REMOVAL INSTRUCTIONS
the power output of the engine.
This enables the young rider to
develop his riding skills gradually
with reduced power output.
Removal of these plate allows the
engine to deliver full power.
WARNING
Removing the power reduction
plate before the rider has 1. Loosen the knob and remove
developed sufficient skills to right frame cover.
operate the motorcycle safely
is hazardous. Riding at exces-
sive speeds increases chances
of losing control of the motor-
cycle, which can result in an
accident.
Do not remove the power

reduction plate until the rider
develops sufficient skills to
operate JR50 safely at the max- 2. Remove the two bolts securing
the exhaust pipe with 5-mm
imum speed with the power
hexagon L type wrench.
reduction system in place.
WARNING
A hot muffler can burn you. The
muffler will be hot enough to
burn you for some time after
stopping the engine.
Wait until the muffler cools to

avoid burns.
3. Move the oil tank out of the

way.
3-11
4. Remove the bolt securing the 6. Remove the muffler. Remove
muffler at the center of the the power reduction plate from
machine. This bolt needs a 12- exhaust pipe flange. This plate
mm T type wrench. is positioned inside the flanged
end.
7. Reinstall the muffler, making
sure that the exhaust pipe gas-
ket is in good condition.
(Replace the gasket as neces-
sary.)
5. Using a 12-mm T type wrench

and a 12-mm wrench, remove
the bolt securing second muf-
fler.
3-12
SEAT HEIGHT ADJUSTMENT
The seat height of this motorcycle
is adjustable for the rider’s physi-
cal size.
25 mm (1.0 in) higher
STANDARD SETTING 0 mm
If higher seat height is required, 2. Loosen the front fork lower

carry out the following proce- clamp bolts.
dures.
1. Remove the fastener and take 3. Remove the two clamps and
off the front number plate. handlebar cover. Remove the
upper bracket bolts and pull
both forks downward.
NOTE: To remove the fastener,

push in the center pin as B and
pull out the fastener. To install the
fastener, pull the center pin as C 4. Locate the right-side and left-
and fix the fastener by pushing side spacers as shown above
the center pin as A. and replace the bolts with
longer ones.
3-13
NOTE: The spacers and longer Rubber cap and mounting boss
bolts are provided in the tool bag.
8. Remove the lower rear shock

absorber bolt. After taking off
5. Tighten the upper and lower the rubber cap from the higher
bolts securely in that order. boss, set the shock absorber
6. Reinstall the number plate. on it. Tighten the upper and
lower mounting bolts securely.
Do this on both sides.
WARNING
Failure to cover the rear shock
mounting boss with the cap
can cause injury to the rider.
Fit the cap to the lower mount-

7. Remove the frame cover and ing boss of the rear shock.
loosen the upper rear shock
absorber bolt. Do this on right
and left sides. 9. Reinstall the frame covers.
3-14
WARNING
Failure to adjust the seat
height properly could lead to
an accident.
Follow the following instruc-

tions to avoid an accident:
• Adjust the front fork and rear
10.Adjust the side stand in order shock absorbers at the same
to maintain the correct parking time.
lean angle. Remove screw 2 • Check the free travel of the
and extend inner stand 1 so rear brake pedal after height
that the higher clearance hole adjustment procedures are
is visible through the outer complete. Adjust rear brake
stand screw hole. Reinstall pedal free travel if necessary.
and securely tighten screw 2. • Adjust the side stand in order
to maintain the correct park-
ing lean angle.
• Bolts and nuts must be
torqued to the proper specifi-
cations. We strongly recom-
mend that this be done by
your authorized Suzuki
dealer or qualified mechanic.
Tightening torque:
Front fork upper 25 N·m

bolts (2.5 kgf-m, 18.0 lb-ft)
Front fork lower 15 N·m
clamp bolts (1.5 kgf-m, 11.0 lb-ft)
Rear shock
25 N·m
absorber upper
(2.5 kgf-m, 18.0 lb-ft)
bolts
Rear shock
8 N·m
absorber lower
(0.8 kgf-m, 5.5 lb-ft)
bolts
3-15
BREAK-IN AND INSPECTION
BEFORE RIDING
BREAK-IN ............................................................................................................ 4-2

INSPECTION BEFORE RIDING .......................................................................... 4-3
4-1
BREAK-IN AND Allow the Engine Oil to
Circulate before Riding
INSPECTION BEFORE Allow enough idling time after
RIDING warm or cold engine start up
before revving the engine or plac-
BREAK-IN ing the transmission in gear. This
The first 20 hours is the most allows time for the lubricating oil
important in the life of your motor- to reach all critical engine compo-
cycle. Proper operation during nents.
this break-in period will help
assure maximum life and perfor- Observe Your Initial and Most
mance from your new motorcycle. Critical Service
The following guidelines explain The initial service (break-in main-
proper break-in procedures. tenance) is the most important
service your motorcycle will
Maximum Throttle Operation receive. During break-in opera-
Recommendation tion, all of the engine components
The table below shows the maxi- will have mated together and
mum throttle operation during the seated. Maintenance required as
break-in period. part of the initial service includes
correction of all adjustments,
Up to Below 4/5 tightening of all fasteners and
20 hours throttle
replacement of dirty oil. Timely
performance of this service will
Vary the Engine Speed help make sure you get the best
Vary the engine speed during the service life and performance from
break-in period. This allows the the engine.
parts to “load” (aiding the mating
process) and then “unload”
(allowing the parts to cool).
Although it is essential to place
some stress on the engine com-
ponents during break-in, you must
be careful not to load the engine
too much.
4-2
INSPECTION BEFORE RIDING Check the condition of the motor-
cycle to help make sure that you
WARNING do not have mechanical problems
when your youngster rides.
Failure to inspect and maintain Before your youngster rides the
your motorcycle properly motorcycle, be sure to check the
increases the chance of an following items. Be sure your
accident or equipment dam- motorcycle is in good condition for
age. the personal safety of the rider
and protection of the motorcycle.
Always perform a pre-ride
inspection before each ride. WARNING
Refer to the table for check Checking maintenance items
items. For further details, refer when the engine is running can
to the INSPECTION AND MAIN- be hazardous. You could be
TENANCE section. severely injured if your hands
or clothing get caught in mov-
WARNING ing parts.
Using worn, improperly
Shut the engine off when per-
inflated, or incorrect tires will
forming maintenance checks,
reduce stability and can cause
except when checking the
an accident.
engine stop switch and throt-
tle.
Follow all instructions in the
TIRES section in this owner’s
manual.
4-3
WHAT TO
CHECK FOR
CHECK
Steering • Smoothness
• No restriction of movement
• No play or looseness
Brakes • Proper pedal and lever
play
• No dragging
• Brake shoe wear
Tires • Proper pressure
• Enough tread depth
• No cracks, rips or other
damage
Fuel tank • Enough fuel for the
planned run
• Tank cap fastened
securely
Engine stop Proper operation
switch
Engine oil Enough amount
Transmission Correct level
oil
Throttle • Proper play
• Smooth response
• Quick return to idle
position
Gearshift • No damage
lever • Smooth operation
Drive chain • Proper tension
• Adequate lubrication
• No excessive wear or
damage
General • Bolts and nuts tightness
condition • No rattle from any parts of
machine with the engine
running
• No visible evidence of
damage
4-4
RIDING TIPS
STARTING THE ENGINE .................................................................................... 5-2

STARTING A COLD ENGINE ............................................................................. 5-2
STARTING A WARM ENGINE ............................................................................ 5-3
STARTING OFF AND SHIFTING ........................................................................ 5-5
STOPPING AND PARKING ................................................................................ 5-6
5-1
RIDING TIPS STARTING A COLD ENGINE
STARTING THE ENGINE

Before attempting to start the
engine, make sure:
3. Push the choke lever down as

far as it will go.
1. Turn the fuel valve lever from

OFF to ON.
4. Close the throttle grip com-

pletely.
2. Shift to NEUTRAL.
5-2
STARTING A WARM ENGINE
5. Kick the kick starter lever to

start the engine and, if this 1. Do not use the choke lever on
fails to fire up, kick again. If 3rd a warm engine.
or 4th kick fails, then pull back
choke lever to original position,
open throttle wide (by turning
the grip all the way), and kick
again.
6. Upon firing up, run the engine
for 30 to 60 seconds.
2. Open throttle partially

(1/8 – 1/4).
7. This 30-to-60 seconds idling

warms up the engine. Now pull
the choke lever up to its origi-
nal position.
3. Kick the kick starter lever.

(Engine will fire up).
5-3
WARNING CAUTION
An improperly retracted kick Running the engine too long
starter lever can interfere with without riding may cause the
rider control. engine to overheat. Overheat-
ing can result in damage to
Be sure the kick starter lever is internal engine components.
returned to its home position
after starting the engine. Shut the engine off if you can-
not begin your ride promptly.
WARNING
Running the engine indoors or
in a garage can be hazardous.
Exhaust gas contains carbon
monoxide, a gas that is color-
less and odorless and can
cause death or severe injury.
Only run the engine outdoors

where there is fresh air.
WARNING
This motorcycle can start mov-
ing as soon as you start the
engine with the transmission in
gear. Unexpected movement
can cause you to lose control
of the motorcycle.
Shift into neutral before you

start the engine.
5-4
STARTING OFF AND SHIFTING
WARNING
WARNING Riding this motorcycle at
Carrying a passenger can excessive speed increases
greatly reduce your ability to your chances of losing control
balance and steer this motor- of the motorcycle. This may
cycle. If you carry a passenger, result in an accident.
you can lose control and both
you and the passenger can be Always ride within the limits of
severely injured. your skills, your motorcycle,
and the riding conditions.
Never carry a passenger. This
motorcycle has a long seat so
you can change position to
WARNING
maneuver the motorcycle. Removing your hands from the
handlebars or feet from the
footrests during operation can
WARNING be hazardous. If you remove
Operating this motorcycle on even one hand or foot from the
public roads or highways can motorcycle, you can reduce
be hazardous. This motorcycle your ability to control the
does not meet safety standards motorcycle.
for use on public roads.
Always keep both hands on the
Never operate this motorcycle handlebars and both feet on
on any road or highway, even a the footrests of your motorcy-
dirt or gravel one. It is illegal to cle during operation.
operate this motorcycle on
public roads or highway in
many states.
1. Kick up side stand.

2. Apply the front brake.
5-5
WARNING
Riding the motorcycle with the
side stand in the down position
can be hazardous. The side
stand in the down position may
interfere with rider control dur-
ing a left turn.
Check that the side stand is 4. Release the front brake and
returned to its full up position open throttle gently.
before starting off.
STOPPING AND PARKING
3. Push down to shift from NEU-

TRAL to DRIVE position. 1. Turn the throttle grip away from
yourself to close the throttle
WARNING completely.
2. Apply the front and rear brakes
Shifting into DRIVE at too high evenly and at the same time.
engine speed can be hazard-
ous. The motorcycle may lurch
forward, and this unexpected
movement can cause you to
lose control of the motorcycle.
Shut off the throttle completely

and apply the front brake
before shifting into DRIVE.
5-6
WARNING
Hard braking while turning may
cause wheel skid and loss of
control.
Brake before you begin to turn.
WARNING
Hard braking on wet, loose,
rough, or other slippery sur-
faces can cause wheel skid
and loss of control.
Brake lightly and with care on

slippery or irregular surfaces.
3. Attempting to slow down by

using one brake alone is haz-
ardous, particularly braking
the front wheel alone. The
front wheel may slide out (front
wheel braking) or the rear
wheel might skid sidewise
(rear wheel braking).
WARNING 4. Shift into NEUTRAL just

before the motorcycle stops.
Inexperienced riders tend to
underutilize the front brake.
This can cause excessive stop-
ping distance and lead to a col-
lision. Using only the front or
rear brake can cause skidding
and loss of control.
Apply both brakes evenly and

at the same time.
5-7
WARNING
A hot muffler can burn you. The
Park the motorcycle where

pedestrians or children are not
5. Park the motorcycle on a firm, likely to touch the muffler.
flat surface where it will not fall
over by using the side stand.
CAUTION
The motorcycle can roll off the
side stand if it is parked with
the front end facing down an
incline.
Park the motorcycle on firm,

level ground to help prevent it
from falling over. If you must
6. Press and hold the engine park on an incline, aim the
stop switch until the engine front of the motorcycle uphill to
stops. reduce the possibility of rolling
off the side stand.
ADVICE TO THE PARENT:

OFF It takes some time for engine and
muffler to cool off after a long ride.
Warn the young rider of the haz-
ard: a number of adults have
burned their hands by touching a
hot engine or muffler.
ON
7. Turn the fuel valve lever to the

“OFF” position.
5-8
ACCESSORY USE AND
MOTORCYCLE LOADING
MODIFICATION ................................................................................................... 6-3
6-1
ACCESSORY USE AND
MOTORCYCLE WARNING
LOADING Improper accessories or modi-
fications can make your motor-
There are a great variety of cycle unsafe and can lead to an
accessories available to Suzuki accident.
owners. Suzuki can not have
direct control over the quality or Never modify the motorcycle
suitability of accessories you may with improper or poorly
wish to purchase. The addition of installed accessories. Follow
unsuitable accessories can lead
to unsafe operating conditions. It
all instructions in this owner’s
is not possible for Suzuki to test manual regarding accessories
each accessory on the market or and modifications. Use genu-
combinations of all the available ine SUZUKI accessories or
accessories; however, your dealer equivalent designed and tested
can assist you in selecting quality for your motorcycle. Consult
accessories and installing them your SUZUKI dealer if you have
correctly. any questions.
Use extreme caution when select-
• Any time that additional weight
ing and installing the accessories
or aerodynamic affecting
for your Suzuki. We have devel-
accessories are installed, they
oped some general guidelines
should be mounted as low as
which will aid you when deciding
possible, as close to the
whether, and how to equip your
motorcycle and as near the
motorcycle.
center of gravity as is feasible.
The mounting brackets and
other attachment hardware
should be carefully checked to
ensure that they provide for a
rigid mount. Weak mounts can
allow the shifting of the weight
and create a hazardous,
unstable condition.
6-2
• Inspect for proper ground If any load is to be carried on the
clearance and bank angle. motorcycle, mount it as low as
Improperly mounted load possible and as close as possible
could critically reduce these to the machine. An improperly
two safety factors. Also deter- mounted load can create a high
mine that the load does not center of gravity which is very
interfere with the operation of hazardous and makes the motor-
the suspension, steering or cycle difficult to handle. The size
other control operations. of the load can also affect the
• Accessories fitted to the han- aerodynamics of the motorcycle.
dlebars or the front fork area Balance the load between the left
can create serious stability and right sides of the motorcycle
problems. This extra weight and fasten it securely.
will cause the motorcycle to be
less responsive to your steer-
ing control. The weight may MODIFICATION
also cause oscillations in the Modification of the motorcycle, or
front end and lead to instability removal of original equipment
problems. Accessories added may render the motorcycle unsafe
to the handlebars or front fork or illegal. Obey all applicable
of the machine should be as equipment regulations in your
light as possible and kept to a area.
minimum.
• Certain accessories displace
the rider from his or her normal
riding position. This limits the
freedom of movement of the
rider and may limit control abil-
ity.
• Additional electrical accesso-
ries may overload the existing
electrical system. Severe over-
loads may damage the wiring
harness or create a hazardous
situation due to the loss of
electrical power during the
operation of the motorcycle.
6-3
INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE .............................................................................. 7-2

GENERAL LUBRICATION .................................................................................. 7-4
AIR CLEANER ..................................................................................................... 7-5
SPARK PLUG ...................................................................................................... 7-8
CARBURETOR .................................................................................................. 7-10
FUEL HOSE ....................................................................................................... 7-11
TRANSMISSION OIL ......................................................................................... 7-12
DRIVE CHAIN .................................................................................................... 7-13
BRAKES ............................................................................................................ 7-16
TIRES ................................................................................................................. 7-18
SPARK ARRESTER .......................................................................................... 7-20
7-1
INSPECTION AND
MAINTENANCE WARNING
Running the engine indoors or
MAINTENANCE SCHEDULE in a garage can be hazardous.
It is very important to inspect and Exhaust gas contains carbon
maintain your motorcycle regu- monoxide, a gas that is color-
larly. Follow the guidelines in the less and odorless and can
chart. The intervals between peri- cause death or severe injury.
odic services in months are
shown. At the end of each inter-
val, be sure to perform the main-
Only run the engine outdoors
tenance listed. where there is fresh air.
WARNING NOTE: The MAINTENANCE

CHART specifies the minimum
Improper maintenance or fail- requirements for maintenance. If
ure to perform recommended you use your motorcycle under
maintenance increases the severe conditions, perform main-
chance of an accident or tenance more often than shown in
motorcycle damage. the chart. If you have any ques-
tions regarding maintenance
intervals, consult your SUZUKI
Always follow the inspection dealer or qualified mechanic.
and maintenance recommen-
dations and schedules in this
owner’s manual. Ask your CAUTION
SUZUKI dealer or qualified Using poor quality replacement
mechanic to do the mainte- parts can cause your motorcy-
nance items marked with an cle to wear more quickly and
asterisk (*). You may perform may shorten its useful life.
the unmarked maintenance
items by referring to the Use only genuine Suzuki
instructions in this section, if replacement parts or their
you have mechanical experi- equivalent.
ence. If you are not sure how to
do any of the jobs, have your
SUZUKI dealer or qualified
mechanic do them.
7-2
MAINTENANCE CHART
Interval
Initial 1 month Every 3 months Every 6 months
Item
* Cylinder head and cylinder – – C
* Cylinder head nuts T – T
Spark plug – I R
Air cleaner element C C C
Carburetor I – I
I I I
Fuel line
*Replace every 4 years
Transmission oil R – R
Clean, lubricate and inspect each time the
Drive chain
motorcycle is ridden
* Steering I – I
* Brakes I I I
Tire I I I
Spark arrester – C C
* Chassis bolts and nuts T – T
NOTE: I= Inspect and clean, adjust, replace or lubricate if necessary,

C= Clean, R= Replace, T= Tighten
7-3
GENERAL LUBRICATION 1 Throttle grip
Proper lubrication is important for 2 Front brake lever holder
safe, smooth operation and a long 3 Front brake cable
life for your motorcycle. Be sure 4 Side stand pivot and spring
that all lubrication is performed hook
during periodic maintenance on 5 Brake pedal arm pivot
the motorcycle. Increase fre-
quency when your motorcycle is  ... Motor oil
used in severe conditions.  ... Grease
7-4
AIR CLEANER
The air cleaner element must be CAUTION
kept clean to provide good engine Clean or replace the air cleaner
power and gas mileage. If your
youngster uses the motorcycle
element frequently if the motor-
under normal low-stress condi- cycle is used in dusty, wet or
tions, you should service the air muddy conditions. The air
cleaner at the intervals specified. cleaner element will clog under
If your youngster rides in dusty, these conditions, and this may
wet, or muddy conditions, you will cause engine damage, poor
need to inspect the air cleaner performance, and poor fuel
element much more frequently. economy.
Use the following procedure to
remove the element and inspect Clean the air cleaner case and
it. element immediately if water
gets in the air cleaner box.
WARNING
Operating the engine without
the air cleaner element in place
could allow a flame to spit back
from the engine to the air
cleaner, or could allow dirt to
enter the engine. This could
cause a fire or severe engine
damage.
Never run the engine without

the air cleaner element prop-
erly installed.
7-5
Air Cleaner Element Removal Washing the Element
Wash the element as follows:
1. Remove the cleaner cap.

2. Take out the element.
1. Fill a wash pan larger than the
element with a non-flammable
cleaning solvent A. Dip the
element in the solvent and
wash it.
2. Squeeze the element by
pressing it between the palms
of both hands to remove the
excess solvent. Do not twist or
wring the element or it will
develop cracks.
3. Dry the element.
4. Fill a wash pan larger than the
element with motor oil B. Dip
the element in the oil.
5. Squeeze the element to
remove excess oil.
CAUTION
A torn air cleaner element will
allow dirt to enter the engine
and can damage the engine.
Carefully examine the air

cleaner element for tears dur-
ing cleaning. Replace it with a
new one if it is torn.
7-6
6. Clean any dirt or debris from
inside the air cleaner case. Be CAUTION
sure no dirt enters the carbure- Failure to position the air
tor. cleaner element properly can
7. Reinstall the cleaner element allow dirt to bypass the air
in reverse order of removal. Be
sure that the element is
cleaner element. This will
securely in position and is cause engine damage.
properly sealed.
Be sure to properly install the
WARNING air cleaner element.
New and used oil and solvent

can be hazardous. Children
and pets may be harmed by
swallowing new or used oil or
solvent. Repeated, prolonged
contact with used engine oil
may cause skin cancer. Brief
contact with used oil or solvent
may irritate skin.
• Keep new and used oil and

solvent away from children
and pets.
• Wear a long-sleeve shirt and
waterproof gloves.
• Wash with soap if oil or sol-
vent contacts your skin.
NOTE: Recycle or properly dis-

pose of used oil and solvent.
7-7
SPARK PLUG
To maintain a hot, strong spark,

1. Extract the spark plug cap. keep the plug free from carbon.
2. Remove the spark plug with Remove carbon deposits from the
the spark plug wrench pro- plug, and adjust the gap to 0.6 –
vided in the tool kit. 0.7 mm (0.024 – 0.028 in) for
good ignition. Use a thickness
(feeler) gauge to check the gap.
CAUTION
Dirt can damage your engine if Your motorcycle comes equipped
it enters an open spark plug with NGK BPR4HS or DENSO
hole. W14FPR-UL spark plug. To deter-
mine if the standard spark plug is
right for your usage, check the
Cover the spark plug hole color of the plug’s porcelain cen-
whenever the spark plug is ter electrode insulator after motor-
removed. cycle operation. A light brown
color indicates that the plug is cor-
rect. If the plug tends to overheat
(evidenced by whitening of its por-
celain), replace it by the other
plug according to the chart below:
7-8
Plug Replacement Guide Installation
To install a spark plug, turn it in as
far as possible with your fingers,
CAUTION then tighten it with a wrench.
An improper spark plug may
have an incorrect fit or heat CAUTION
range for your engine. This
may cause severe engine dam- A crossthreaded or overtight-
age which will not be covered ened spark plug will damage
under warranty. the aluminum threads of the
cylinder head.
Use one of the spark plugs
listed below or equivalent. Follow the procedure below to
Consult your Suzuki dealer or avoid damage.
qualified mechanic if you are
not sure which spark plug is Carefully turn the spark plug by
correct for type of usage. hand into the threads until it is fin-
ger tight. If the spark plug is new,
tighten it with a wrench about 1/2
NGK DENSO REMARKS
turn past finger tight. If you are
BPR4HS W14FPR-UL Standard reusing the old spark plug, tighten
To replace it with a wrench about 1/8 turn
standard plug past finger tight.
BPR5HS W16FPR-UL
tending to
overheat.
7-9
CARBURETOR 5. When the idling mixture has
The carburetor is factoryset for been adjusted by turning the
the best performance. Do not air adjusting screw 2, the
attempt to alter its setting. There proper engine idle speed may
are two items of adjustment, how- be obtained by adjusting the
ever, under your care: idle speed throttle valve adjusting screw
and throttle cable play. 1.
Idle Speed Adjustment NOTE: In the event that carbure-

The engine idle speed may be tor adjustment is required due to
adjusted by turning the throttle different altitude or climate condi-
valve adjusting screw 1 and the tions, take your motorcycle to
pilot air adjusting screw 2 in the authorized SUZUKI dealer.
following procedures. Mechanical malfunctions resulting
from the owner tampering with
carburetion adjustment will not be
covered by the warranty.
1. Start the engine and allow it to

warm up.
2. After the engine warms up,
stop it momentarily. Turn the
pilot air adjusting screw 2 all
the way in and then back it out
1-1/4 turns.
3. Start the engine again and
adjust the throttle valve adjust-
ing screw 1 so that the engine
runs at the lowest steady
speed.
4. Turn the pilot air adjusting
screw 2 in or out within 1/4
turn from the standard setting
(1-1/4 turns) to find the opti-
mum position where the
engine runs most smoothly.
7-10
Throttle Cable Adjustment
Measure the throttle cable play by WARNING
turning the throttle grip. The throt-
tle grip should have 2.0 – 4.0 mm Inadequate throttle cable play
(0.08 – 0.16 in) play. can cause engine speed to rise
suddenly when you turn the
handlebars. This can lead to
loss of rider control.
Adjust the throttle cable play

so that engine idle speed does
not rise due to handlebar
movement.
FUEL HOSE
To adjust the throttle cable play:

1. Loosen the lock nut 1.
2. Turn the adjuster 2 in or out to Inspect the fuel hose for damage
obtain the proper amount of and fuel leakage. If any defects
throttle grip free play. are found, the fuel hose must be
3. Tighten the lock nut 1. replaced.
4. Recheck the throttle cable
play. Readjust it if it is not
within the correct limits.
7-11
TRANSMISSION OIL 6. Pour fresh oil of the specified
The transmission oil should type through the oil filler hole
always be changed when the until the oil reaches the oil
engine is warm so the oil will drain level hole. Be sure to check
easily. the oil level with the motorcy-
cle held vertically.
To change transmission oil:
NOTE: Approximately 450 ml (0.5
US qt) of oil will be required.
7. Refit the oil level screw and the

oil filler cap.
WARNING
New and used oil and solvent
can be hazardous. Children
and pets may be harmed by
swallowing new or used oil or
solvent. Repeated, prolonged
contact with used engine oil
may cause skin cancer. Brief
contact with used oil or solvent
may irritate skin.
• Keep new and used oil and

solvent away from children
1. Place the motorcycle on level
and pets.
ground on its side stand.
• Wear a long-sleeve shirt and
2. Remove the oil filler cap 1.
waterproof gloves.
3. Remove the drain plug 3 from
• Wash with soap if oil or sol-
the bottom of the engine. Drain
vent contacts your skin.
the oil into a drain pan while
holding the motorcycle verti-
cally. NOTE: Recycle or properly dis-
4. Reinstall the drain plug 3. pose of used oil and solvent.
5. Remove the oil level screw 2.
7-12
DRIVE CHAIN
The condition and adjustment of
the drive chain should be checked
before each use of the motorcy-
cle. Always follow the guidelines
below for inspecting and servicing
the chain.
WARNING
Riding with the chain in poor
condition or improperly WARNING
adjusted can lead to an acci- Improperly attached chain joint
dent. clip may drop from the chain
and cause the chain to come
Inspect, adjust, and maintain off the sprockets or to be
the chain properly before each caught in the engine. This may
ride, according to this section. cause an accident or severe
engine damage.
Inspecting the Drive Chain
When inspecting the chain, look Be sure to inspect and main-
for the following: tain the chain before each ride,
• Loose pins according to these guidelines.
• Damaged rollers
• Dry or rusted links
Damage to the drive chain means
• Kinked or binding links
that the sprockets may also be
• Excessive wear
damaged. Inspect the sprockets
• Improper chain adjustment
for the following:
• Excessively worn teeth
If you find anything wrong with the
• Broken or damaged teeth
drive chain condition or adjust-
• Loose sprocket mounting nuts
ment, correct the problem if you
know how. If necessary, consult
If you find any of these problems
your authorized Suzuki dealer.
with your sprocket, consult your
Suzuki dealer.
7-13
Drive Chain Cleaning and Drive Chain Adjustment
Oiling
Clean and oil the chain as follows:
1. Wash the chain with kerosene.
Kerosene will lubricate and
clean the chain.
WARNING
Kerosene can be hazardous.
Kerosene is flammable. Chil-
dren or pets may be harmed Inspect the drive chain slack
from contact with kerosene. before each use of the motorcy-
cle. The drive chain should be
Keep flames and smoking adjusted for 20 – 25 mm (0.8 – 1.0
materials away from kerosene. in) of slack, as shown.
Keep children and pets away
from kerosene. If swallowed, WARNING
do not induce vomiting. Call a
physician immediately. Dis- Too much chain slack can
pose of used kerosene prop- cause the chain to come off the
erly. sprockets, resulting in an acci-
dent or serious damage to the
motorcycle.
2. Allow the chain to dry, then
lubricate the links with Suzuki
chain lube or an equivalent. Inspect and adjust the drive
chain slack before each use.
7-14
To adjust the drive chain, follow 6. Tighten adjusting nuts.
the procedure below: 7. Check and, as necessary,
readjust the brake pedal play
as outlined in page 50. This is
because adjusting the drive
chain as above could alter the
pedal play.
Rear axle nut tightening torque:

35 N·m (3.5 kgf-m, 25.3 lb-ft)
1. Remove the cotter pin 1 and

loosen the axle nut 2.
2. Turn the right and left adjuster
nuts 3 until the chain has 20 –
25 mm (0.8 – 1.0 in) of slack
halfway between the engine
sprocket and rear sprocket.
3. At the same time that the
chain is being adjusted, the
rear sprocket must be kept in
perfect alignment with the front
sprocket. To assist you in per-
forming this procedure, there
are reference marks 4 on the
swing arm and each chain
adjuster which are to be
aligned with each other and to
be used as a reference from
one side to the other.
4. Tighten the axle nut 2
securely. Replace the cotter
pin with a new one.
5. Recheck the chain slack after
tightening and readjust if nec-
essary.
7-15
BRAKES
This motorcycle is equipped with WARNING
front and rear drum brakes. Failure to adjust the front brake
lever and rear brake pedal play
WARNING properly can lead to an acci-
Failure to inspect and properly dent or damage your motorcy-
maintain the brakes increases cle. If there is too much play,
your chance of having an acci- the brakes may not stop the
dent. motorcycle when you use
them. This could lead to an
Inspect the brake system accident. If there is too little
before each use according to play, the brake shoes may rub
the INSPECTION BEFORE against the drums when the
RIDING section. Follow the brakes are not applied, causing
MAINTENANCE SCHEDULE damage to the shoes and
section to maintain your brake drums.
system.
Follow the procedure below to
NOTE: Operating in mud, water, adjust the front brake lever and
sand, or other extreme conditions rear brake pedal.
can cause accelerated brake
wear. If your youngster operates Front Brake Adjustment
the motorcycle under these condi- The front brake lever play should
tions, the brake must be be 15 – 25 mm (0.6 – 1.0 in) mea-
inspected more often than recom- sured at the brake lever end when
mend in the MAINTENANCE the lever is lightly pulled in
SCHEDULE. towards the throttle grip. Check
the play every time before riding
and adjust it if necessary, as fol-
lows:
15 – 25 mm
(0.6 – 1.0 in)
7-16
1. Turn the front brake adjuster Adjust the rear brake pedal so
1 clockwise or counterclock- that there is approximately 20 –
wise to obtain the specified 30 mm (0.8 – 1.2 in) of pedal play
play. Turning the adjuster as shown in the illustration. To
clockwise will decrease the adjust the rear brake pedal play,
play. turn the adjusting nut 2. Turning
2. After adjusting the play, check the adjusting nut clockwise will
that there is no dragging when decrease the amount of travel.
turning the front wheel with the
wheel off the ground and that
there is enough clearance
WARNING
between the front brake lever Riding with worn brake shoes
and throttle grip when the lever will reduce braking perfor-
is tightly squeezed. mance and will increase your
chance of having an accident.
Rear Brake Pedal Adjustment
Inspect brake shoe wear before
each use. Ask your SUZUKI
dealer or qualified mechanic to
replace brake shoes if the
shoes are worn to the limit.
7-17
TIRES Tire Pressure and Loading
Tire pressure and tire loading are
WARNING important factors. Overloading
your tires can lead to tire failure
Failure to follow these warn- and loss of motorcycle control.
ings may result in an accident
due to tire failure. The tires on Check tire pressure each time
your motorcycle form the cru- before you ride, according to the
cial link between your motorcy- table below. Tire pressure should
cle and the road. only be checked and adjusted
before riding since riding will heat
Follow these instructions: up the tires and lead to higher
inflation pressure readings.
• Check tire condition and Under-inflated tires make smooth
pressure, and adjust pres- cornering difficult and can result
sure before each ride. in rapid wear. Over-inflated tires
• Avoid overloading your have a smaller amount of tire in
motorcycle. contact with the ground, which
• Replace a tire when worn to can contribute to skidding and
the specified limit, or if you loss of control.
find damage such as cuts or
cracks. 150 kPa
Front & Rear
• Always use the size and type (1.5 kgf/cm2, 22 psi)
of tires specified in this
owner’s manual.
• Balance the wheel after tire
installation.
• Read this section of owner’s
manual carefully.
7-18
Tire Condition and Type Front & Rear
Tire condition and tire type affect
motorcycle performance. Cuts or Type
CHENG SHIN
C-183A
cracks in the tires can lead to tire
failure and loss of motorcycle con- Size 2.50-10 2PR
trol. Worn tires are susceptible to

puncture failures and subsequent Always balance the wheel after
loss of motorcycle control. Tire repairing a puncture or replacing
the tire. Proper wheel balance is
wear also affects the tire profile,
important to avoid variable wheel-
changing motorcycle handling
characteristics. to-ground contact and to avoid
uneven tire wear.
WARNING
An improperly repaired,
installed, or balanced tire can
cause loss of control or
shorten tire life.
Ask your SUZUKI dealer or

Check tire condition each time qualified mechanic to perform
before you ride. Replace tires if tire repair, replacement, and
tires show visual evidence of balancing because proper
damage such as cracks or cuts, or tools and experience are
if tread depth is less than 4.0 mm required.
(0.16 in).
Whenever you replace a tire, use

a tire of the size and type listed
below. If you use a different size
or type of tire, motorcycle han-
dling may be adversely affected,
possibly resulting in loss of motor-
cycle control.
7-19
SPARK ARRESTER
The muffler has a spark arrester
which must be periodically
cleaned to maintain good effi-
ciency. At the intervals shown in
the maintenance chart, clean the
spark arrester as follows.
WARNING
A hot muffler can burn you. The 2. Remove the spark arrester.
Wait until the muffler cools to

avoid burns.
3. Use a brush to remove carbon

deposits from the spark
arrester screen. Be careful not
to damage the spark arrester
screen. Check that the screen
has no holes and breaks.
Replace the screen if neces-
1. Remove the bolts 1. sary.
7-20
TROUBLESHOOTING
FUEL SYSTEM CHECK ...................................................................................... 8-2

IGNITION SYSTEM CHECK ................................................................................ 8-3
8-1
TROUBLESHOOTING
WARNING
This troubleshooting guide is pro- Fuel and fuel vapor are highly
vided to help you find the cause of flammable and toxic. You can
some common complaints.
be burned or poisoned when
handling fuel.
CAUTION
Failure to troubleshoot a prob- When draining the carburetor:
lem correctly can damage your • Stop the engine and keep
motorcycle. Improper repairs flames, sparks, and heat
or adjustments may damage sources away.
the motorcycle instead of fixing • Drain fuel only outdoors or in
a well-ventilated area.
it. Such damage may not be • Do not smoke.
covered under warranty. • Wipe up spills immediately.
• Avoid breathing fuel vapor.
If you are not sure about the • Keep children and pets away.
proper action, consult your • Dispose of drained fuel prop-
Suzuki dealer about the prob- erly.
lem.
c. Tighten the drain screw.
COMPLAINT: Engine is hard to d. Turn the fuel valve to the
start or does not start at all. “ON” position for a few sec-
onds and then turn it to the
Something is probably wrong with “OFF” position.
the fuel system or ignition system. e. Loosen the drain screw and
check that the carburetor is
FUEL SYSTEM CHECK filled back up with fuel.
1. Make sure there is enough fuel f. If fuel is reaching the carbu-
in the fuel tank. retor, ignition system
2. Check that the fuel valve is in should be checked next.
the “ON” position.
3. Make sure there is enough fuel
reaching the carburetor from
the fuel valve.
a. Turn the fuel valve to the
“OFF” position.
b. Loosen the drain screw
located under the carbure-
tor. Drain the fuel from the
carburetor into a container.
8-2
IGNITION SYSTEM CHECK COMPLAINT: Engine Stalls
1. Make sure there is enough fuel
in the fuel tank.
2. Check to see that the spark
plug is not fouled. Remove the
plug and clean it. Replace it, if
necessary.
3. Make sure the fuel valve is not
clogged. Also check that the
air vent hose connected to the
fuel tank is not clogged.
4. Check the idle speed. If neces-
1. Remove the spark plug and sary, adjust it using a tachom-
reattach it to the spark plug eter. The correct idle speed is
lead. 1400 – 1600 r/min.
2. While holding a spark plug
with its base firmly against the
engine, depress the kick
starter lever. If the ignition sys-
tem is operating properly, a
blue spark should jump across
the spark plug gap. If there is
no spark, take your machine to
your authorized Suzuki dealer.
WARNING
Performing the spark test
improperly can cause a high
voltage electrical shock or an
explosion.
Avoid performing this check if

you are not familiar with this
procedure, or if you have a
heart condition or wear a pace-
maker. Keep the spark plug
away from the spark plug hole
during this test.
8-3
STORAGE PROCEDURE AND
APPEARANCE CARE
PROCEDURE FOR RETURNING TO SERVICE ................................................. 9-3

CORROSION PREVENTION ............................................................................... 9-3
MOTORCYCLE CLEANING ................................................................................ 9-4
INSPECTION AFTER CLEANING ....................................................................... 9-5
9-1
STORAGE PROCEDURE FUEL
Drain the fuel from the fuel tank
AND APPEARANCE using a commercially available
CARE hand pump or siphon. Drain the
fuel from the carburetor using the
If your motorcycle is to be left carburetor drain screw.
unused for an extended period of
time, it needs special servicing
requiring appropriate materials, WARNING
equipment and skill. For this rea- Fuel and fuel vapor are highly
son, Suzuki recommends that you flammable and toxic. You can
trust this maintenance work to be burned or poisoned when
your Suzuki dealer. If you wish to handling fuel.
service the machine for storage
yourself, follow the general guide-
lines below: When draining the fuel:
• Stop the engine and keep
MOTORCYCLE flames, sparks, and heat
Clean the entire motorcycle. sources away.
Place the motorcycle on the side • Drain fuel only outdoors or in
stand on a firm, flat surface where a well-ventilated area.
it will not fall over. • Do not smoke.
• Wipe up spills immediately.
• Avoid breathing fuel vapor.
• Keep children and pets away.
• Dispose of drained fuel prop-
erly.
ENGINE
Drain the transmission oil com-
pletely and refill the transmission
oil all the way up to the filler hole.
Cover the air cleaner intake and
the muffler outlet with oily rags to
prevent humidity from entering.
TIRES
Inflate tires to the normal pres-
sure.
9-2
EXTERNAL CORROSION PREVENTION
1. Spray all vinyl and rubber It is important to take good care of
parts with rubber protectant. your motorcycle to protect it from
2. Spray unpainted surface with corrosion and keep it looking new
rust preventative. for years to come.
3. Coat painted surfaces with car
wax. Important Information About
Corrosion
Common causes of corrosion
PROCEDURE FOR RETURNING 1. Accumulation of salt, dirt mois-
TO SERVICE ture, or chemicals in hard-to-
1. Clean the entire motorcycle. reach areas.
2. Remove the oily rags from the 2. Chipping, scratches, and any
air cleaner intake and muffler damage to treated or painted
outlet. metal surfaces resulting from
3. Drain all the transmission oil. minor accidents or impacts
Fill the transmission with fresh from stones and gravel.
oil as outlined in this manual. Salt, sea air, industrial pollution,
4. Remove the spark plug. Turn and high humidity will all contrib-
the engine a few times by ute to, corrosion.
depressing the kick starter
lever. Reinstall the spark plug. How to Help Prevent Corrosion
5. Lubricate all places as 1. Wash your motorcycle fre-
instructed in this manual. quently, at least once a month.
6. Perform the INSPECTION Keep your motorcycle as clean
BEFORE RIDING as listed in and dry as possible.
this manual. 2. Remove foreign material
7. Start the motorcycle as out- deposits. Foreign material
lined in this manual. such as chemicals, tar, tree
sap, bird droppings and indus-
trial fall-out may damage your
motorcycle’s finish. Remove
these types of deposits as
quickly as possible. If these
deposits are difficult to wash
off, an additional cleaner may
be required. Follow the manu-
facturer’s directions when
using these special cleaners.
9-3
3. Repair finish damage as soon MOTORCYCLE CLEANING
as possible Washing the Motorcycle
Carefully examine your motor- When washing the motorcycle,
cycle for damage to the follow the instructions below:
painted surfaces. Should you 1. Remove dirt and mud from the
find any chips or scratches in motorcycle with running water.
the paint, touch them up You may use a soft sponge or
immediately to prevent corro- brush. Do not use hard materi-
sion from starting. If the chips als which can scratch the
or scratches have gone paint.
through to the bare metal, 2. Wash the entire motorcycle
have a Suzuki dealer make the with a mild detergent or car
repair. wash soap using a sponge or
4. Store your motorcycle in a dry, soft cloth. The sponge or cloth
well-ventilated area should be frequently soaked in
If you often wash your motor- the soap solution.
cycle in the garage or if you
frequently park it inside when NOTE: Avoid spraying or allowing
wet, your garage may be water to flow over the following
damp. The high humidity may places:
cause or accelerate corrosion. • Ignition switch
A wet motorcycle may corrode • Spark plug
even in a heated garage if the • Fuel tank cap
ventilation is poor. • Carburetor
5. Cover your motorcycle
Exposure to mid-day sun can 3. Once the dirt has been com-
cause the colors in paint and pletely removed, rinse off the
plastic parts to fade. Covering detergent with running water.
your motorcycle with a high- 4. After rinsing, wipe off the
quality, “breathable” motorcy- motorcycle with a wet chamois
cle cover can help protect the or cloth and allow it to dry in
finish from the harmful UV rays the shade.
in sunlight, and can reduce the 5. Check carefully for damage to
amount of dust and air pollu- painted surfaces. If there is
tion reaching the surface. Your any damage, obtain “touch-up”
Suzuki dealer can help you paint and “touch-up” the dam-
select the right cover for your age.
motorcycle.
9-4
Waxing the Motorcycle
After washing the motorcycle,
waxing is recommended to further
protect and beautify the paint.
Observe the precautions speci-
fied by the wax manufacturer.
INSPECTION AFTER CLEANING

For extended life of your motorcy-
cle, lubricate according to “GEN-
ERAL LUBRICATION” section.
WARNING
Wet brakes can cause poor
braking performance and may
lead to an accident.
Avoid a possible accident by

expecting longer stopping dis-
tances after washing your
motorcycle. Apply brakes sev-
eral times to let heat dry the
brake pads or shoes.
Follow the procedures in the

“INSPECTION BEFORE RIDING”
section to check your motorcycle
for any problems that may have
arisen during your last ride.
9-5
CONSUMER INFORMATION
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...................... 10-2

SERIAL NUMBER LOCATION .......................................................................... 10-3
LOCATION OF LABELS ................................................................................... 10-3
10
10-1
CONSUMER • Removing or puncturing the air
cleaner case, air cleaner
INFORMATION cover, baffles, or any other
TAMPERING WITH NOISE component which conducts
CONTROL SYSTEM intake air.
PROHIBITED Whenever replacing parts on your
Federal law prohibits the following
motorcycle, Suzuki recommends
acts or the causing thereof;
that you use genuine Suzuki
1. The removal or rendering in-
replacement parts or their equiva-
operative by any person other
lent.
than for purposes of mainte-
nance, repair, or replacement,
of any device or element of
design incorporated into any
new vehicle for the purpose of
noise control prior to its sale or
delivery to the ultimate pur-
chaser or while it is in use, or
2. The use of the vehicle after
such device or element of
design has been removed or
rendered inoperative by any
person.
Among those acts presumed to

constitute tampering are the acts
listed below:
• Removing or puncturing the
muffler, baffles, header pipes,
screen type spark arrester (if
equipped) or any other compo-
nent which conducts exhaust
gases.
• Replacing the exhaust system
or muffler with a system or
muffler not marked with the
same model specific code as
the code listed on the Motorcy-
cle Noise Emission Control
Information label, and certified
to appropriate EPA noise stan-
dards.
10-2
SERIAL NUMBER LOCATION LOCATION OF LABELS
You need to know the frame and Read and follow all of the warn-
engine serial numbers to get title ings labeled on your motorcycle.
documents for your motorcycle. Make sure you and your child
You also need these numbers to understand all of the labels. Keep
help your dealer when you order the labels on your motorcycle. Do
parts. not remove them for any reason.
The frame number 1 is stamped

on the steering head tube. The
engine serial number 2 is
stamped on the left side of the
crankcase assembly.
Write down the serial numbers

here for your future reference.
Frame No.:
Engine No.:
10-3
2
WARNING
1
Do not touch hot muffler.
WARNING
Failure to follow these safety
precautions may increase your
risk of injury:
• Wear a helmet, eye protec-
tion, and bright protective
clothing.
• Off-road use only – do not
use on public roads or high-
ways.
• Slow down on slippery sur-
faces, unfamiliar terrain, or
when visibility is reduced.
• Not recommended for chil-
dren under age 7.
• Adult supervision required.
• Single rider only – weight
limit 65 lbs (30 kg).
• Do not touch any moving
parts or heated areas.
• Read owner’s manual care-
fully.
10-4
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ..................................................1245 mm (49.0 in)
Overall width.................................................... 595 mm (23.4 in)
Overall height .................................................. 730 mm (28.7 in)
Wheelbase ...................................................... 860 mm (33.9 in)
Ground clearance............................................ 115 mm (4.5 in)
Dry mass ......................................................... 38 kg (84 lbs)
ENGINE
Type.................................................................Two-stroke, Air-cooled
Intake system ..................................................Piston valve
Number of cylinder ..........................................1
Bore Stroke .....................................................41.0 mm (1.614 in) × 37.8 mm (1.488 in)
Displacement...................................................49 cm3 (3.0 cu. in)
Corrected compression ratio ...........................5.6 : 1
Carburetor .......................................................MIKUNI VM12, single
Air cleaner .......................................................Polyurethane foam element
Starter system .................................................Kick
Lubrication system ..........................................SUZUKI CCI
TRANSMISSION
Clutch ..............................................................Wet multi-plate, Automatic, Centrifugal type
Gearshift pattern .............................................1-down, 1-up
Transmission ...................................................Single-speed constant mesh
Primary reduction ratio ....................................2.650 (53/20)
Final reduction ratio.........................................2.153 (28/13)
Gear ratio ........................................................2.230 (29/13)
Drive chain ......................................................DID 420, 78 links
CHASSIS
Front suspension .............................................Telescopic, coil spring
Rear suspension .............................................Swingarm, coil spring
Steering angle .................................................45° (right & left)
Caster..............................................................25° 00’
Trail..................................................................37 mm (1.46 in)
Turning radius..................................................1.3 m (4.3 ft)
Front brake ......................................................Drum brake
Rear brake.......................................................Drum brake
Front tire size...................................................2.50-10 2PR
Rear tire size ...................................................2.50-10 2PR
ELECTRICAL
Ignition type .....................................................Electronic ignition (CDI)
Spark plug .......................................................NGK BPR4HS or DENSO W14FPR-UL
CAPACITIES
Fuel tank.......................................................... 2.0 L (0.5 US gal)
Engine oil tank................................................. 0.3 L (0.3 US qt)
Transmission oil...............................................450 ml (0.5 US qt)

INDEX
A I
AIR CLEANER ....................... 7-5 IGNITION SYSTEM
CHECK ...................................8-3
B INSPECTION AFTER
BRAKES............................... 7-16 CLEANING .............................9-5
BREAK-IN .............................. 4-2 INSPECTION BEFORE
RIDING ...................................4-3
C
CARBURETOR .................... 7-10 K
CHOKE LEVER...................... 3-9 KICK STARTER LEVER.........3-9
CLOTHING............................. 1-4
CORROSION L
PREVENTION ........................ 9-3 LEFT HANDLEBAR ................3-5
LOCATION OF LABELS.......10-3
D LOCATION OF PARTS ..........3-2
DRIVE CHAIN ...................... 7-13
M
E MAINTENANCE
ENGINE OIL........................... 2-3 SCHEDULE ............................7-2
ENGINE OIL LEVEL............... 3-8 MODIFICATION .....................6-3
MOTORCYCLE
F CLEANING .............................9-4
FUEL ...................................... 2-2
FUEL HOSE ......................... 7-11 O
FUEL SYSTEM CHECK......... 8-2 OPERATING SKILL................1-2
FUEL TANK CAP ................... 3-6
FUEL VALVE.......................... 3-7 P
POWER REDUCTION
G PLATE ..................................3-11
GEARSHIFT LEVER ............ 3-10 POWER REDUCTION
GENERAL LUBRICATION ..... 7-4 PLATE REMOVAL
INSTRUCTIONS...................3-11
PROCEDURE FOR RETURNING
TO SERVICE ..........................9-3

R
REAR BRAKE PEDAL ......... 3-10
RIGHT HANDLEBAR ............. 3-5
S
SEAT HEIGHT
ADJUSTMENT ..................... 3-13
SERIAL NUMBER
LOCATION ........................... 10-3
SIDE STAND........................ 3-10
SPARK ARRESTER............. 7-20
SPARK PLUG ........................ 7-8
STARTING A COLD
ENGINE.................................. 5-2
STARTING A WARM
ENGINE.................................. 5-3
STARTING OFF AND
SHIFTING............................... 5-5
STARTING THE ENGINE ...... 5-2
STOPPING AND PARKING ... 5-6
T
TAMPERING WITH NOISE
CONTROL SYSTEM
PROHIBITED ....................... 10-2
THROTTLE LIMITER ............. 3-5
TIRES................................... 7-18
TRANSMISSION OIL .....2-3,7-12
Total page:88
California Proposition 65 Warning
WARNING
Engine exhaust, some of its constituents, and certain product com-
ponents contain or emit chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
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.
This vehicle is not subject to the phased-in emission standards

and related requirements for model year 2006 [off-highway
motorcycles or all-terrain vehicles] applicable under 40 CFR
1051.

WARNING
Failure to follow these safety
precautions may increase your
risk of injury:
• Wear a helmet, eye protec-
tion, and bright protective
clothing.
• Off-road use only – do not
use on public roads or high-
ways.
• Slow down on slippery sur-
faces, unfamiliar terrain, or
when visibility is reduced.
JR50
• Not recommended for chil-
dren under age 7.
• Adult supervision required.
• Single rider only – weight
limit 65 lbs (30 kg).
• Do not touch any moving
parts or heated areas.
• Read owner’s manual care-
fully.
99011-04493-03A
K6 300 TAKATSUKA, HAMAMATSU, JAPAN Printed in Taiwan

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INSTRUCTING THE YOUNG RIDER 1

FUEL AND OIL RECOMMENDATION 2

CONTROLS, EQUIPMENT AND ADJUSTMENTS 3

BREAK-IN AND INSPECTION BEFORE RIDING 4

ACCESSORY USE AND MOTORCYCLE LOADING 6

INSPECTION AND MAINTENANCE 7

STORAGE PROCEDURE AND APPEARANCE CARE 9

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OPERATING SKILL ............................................................................................. 1-2

Wear full-coverage clothes.

Wear flexible clothes.

FUEL .................................................................................................................... 2-2

Be careful not to spill any gas-

LOCATION OF PARTS ....................................................................................... 3-2

1 Engine stop switch

Engine Stop Switch 1 Use the throttle limiter to restrict

When the maximum engine power

Front Brake Lever 2

• Stop the engine and keep

Never fill the fuel above the

Always move the fuel valve to

Always check the amount of

The engine oil tank is located

The motorcycle has a side stand.

If you must park on an incline,

Always retract the side stand

Do not remove the power

Wait until the muffler cools to

3. Move the oil tank out of the

5. Using a 12-mm T type wrench

If higher seat height is required, 2. Loosen the front fork lower

NOTE: To remove the fastener,

8. Remove the lower rear shock

Fit the cap to the lower mount-

Follow the following instruc-

Front fork upper 25 N·m

BREAK-IN ............................................................................................................ 4-2

STARTING THE ENGINE .................................................................................... 5-2

STARTING THE ENGINE

3. Push the choke lever down as

1. Turn the fuel valve lever from

4. Close the throttle grip com-

5. Kick the kick starter lever to

2. Open throttle partially

7. This 30-to-60 seconds idling

3. Kick the kick starter lever.

Only run the engine outdoors