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UF50
Suzuki UF50 User Manual
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3-34
ENGINE
REAR AXLE SHAFT AND
TRANSMISSION
1
Crankcase
2
Gearbox cov
er
3
Rear axle shaft/final driven gear
4
Idle shaft/gear
5
W
asher
6
W
asher
7
Drive shaft
Install the idle shaft/gear
1
, with the thrust washer
2
, into
the gearbo
x.
Install the rear axle shaft/final driven gear
3
.
Install the thrust washer
4
and the O-ring
5
.
3
5
4
62
64
Table of Contents
General Information 1
5
Table of Contents
5
Warning/Caution/Note
6
General Precautions
6
General Information
6
Suzuki Uf50Y/Uf50Zy (2000-Model)
8
Serial Number Location
8
Fuel and Oil Recommendations
8
Fuel
8
Engine Oil
8
Final Gear Oil
9
Brake Fluid
9
Break-In Procedures
9
Information Labels
10
Specifications
11
Chassis
12
Periodic Maintenance Schedule
14
Periodic Maintenance Chart
14
Maintenance and Tune-Up Procedure
15
Battery
15
Air Cleaner
16
Engine
16
Cylinder Head and Cylinder
17
Spark Plug
17
Carburetor
19
Fuel Line
19
Final Gear Oil
20
Brakes
20
Brake Hose
21
Brake Fluid
21
Steering
23
Front Fork
23
Rear Suspension
23
Tires
24
Cylinder Head Nuts and Exhaust Pipe Nut and Bolt
25
Chassis Nuts and Bolts
25
General Lubrication
27
Automatic Clutch Inspection
28
Initial Engagement
28
Clutch Lock-Up
29
Engine
30
Engine Components Removable with the Engine in Place
31
Engine Removal and Remounting
32
Engine Removal
32
Engine Remounting
34
Engine Disassembly
35
Engine Components Inspection and Service
42
Cylinder Head Distortion
42
Cylinder
42
Piston
43
Crankshaft and Conrod
45
Reed Valve
46
Clutch Shoe/Movable Driven Face
47
Movable Drive Face
52
Kick Starter
54
Bearings
55
Oil Seals
57
Engine Mounting Bushings
60
Engine Reassembly
61
Crankshaft
61
Crankcase
61
Rear Axle Shaft and Transmission
63
Generator
65
Starter Pinion and Starter Gear
66
Drive Belt
67
Piston
68
Cylinder
69
Cylinder Head
69
Oil Pump Gear
69
Intake Pipe
69
Exhaust Pipe/Muffler
69
Fuel and Lubrication System
70
Fuel Valve
71
Fuel Tank and Oil Tank
72
Removal
72
Remounting
73
Fuel Tank Cushions
74
Carburetor
75
Construction
75
I. D. No. Location
75
Specifications
76
Removal
77
Disassembly
77
Cleaning
80
Inspection and Adjustment
80
Reassembly
81
Remounting
81
Oil Pump
82
Air Bleeding
82
Discharge Rate Check
82
Chassis
83
Exterior Parts
84
Construction
84
Removal
85
Remounting
87
Front Wheel
88
Construction
88
Removal
88
Inspection and Disassembly
89
Reassembly and Remounting
90
Front Brake
92
Construction
92
Brake Pads Replacement
93
Brake Fluid Replacement
94
Brake Caliper Removal and Disassembly
94
Brake Caliper Inspection
95
Brake Caliper Reassembly and Remounting
96
Brake Disc Inspection
97
Master Cylinder Removal and Disassembly
97
Master Cylinder Inspection
98
Master Cylinder Reassembly and Remounting
99
Front Suspension
100
Construction
100
Removal and Disassembly
100
Inspection
102
Reassembly and Remounting
102
Handlebar Covers and Speedometer Assembly
104
Construction
104
Removal
105
Remounting
106
Steering Stem
107
Construction
107
Removal and Disassembly
107
Inspection
109
Reassembly and Remounting
110
Rear Wheel, Rear Brake, and Rear Shock Absorber
112
Construction
112
Removal and Disassembly
112
Inspection
113
Reassembly and Remounting
114
Tires and Wheels
115
Tire Removal
115
Inspection
115
Installation
116
Electrical System
119
Electrical
120
Fuse
120
Cautions in Servicing
120
Connector
120
Coupler
120
Clamps
120
Semiconductor Equipped Parts
120
Connecting the Battery
121
Wiring Procedure
121
Using the Multi Circuit Tester
121
Location of Electrical Components
122
Charging and Lighting System
124
Description
124
Troubleshooting
125
Inspection
126
Starter System
128
Description
128
Troubleshooting
128
Starter Motor Removal and Disassembly
129
Starter Motor Inspection
130
Starter Motor Reassembly
131
Starter Relay Inspection
131
Ignition System
132
Description
132
Troubleshooting
132
Inspection
134
Fuel Level Indicator Switch
137
Inspection
137
Oil Level Indicator Switch
138
Inspection
138
Thermoelement, Carburetor Heater, and Thermoswitch
139
Inspection
139
Speedometer
141
Removal and Disassembly
141
Inspection
141
Lamps
142
Front and Rear Turn Signal Light
143
Brake Light/Taillight
144
License Plate Light
145
Relays
146
Starter Relay
146
Turn Signal Relay
146
Switches
147
Battery
148
Removal
148
Remounting
148
Specifications
149
Initial Charging
149
Servicing
150
Recharging Operation
150
Service Life
151
Servicing Information
152
Troubleshooting
153
Engine
153
Carburetor
155
Chassis
156
Brakes
157
Electrical
158
Battery
159
Wiring Diagram
160
Wire Harness, Cable, and Hose Routing
161
Wire Harness
161
Cable Routing
163
Fuel System Hose Routing
165
Battery Breather Hose Routing
166
Front Brake Hose Routing
167
Special Tools
168
Tightening Torque
170
Engine
170
Chassis
170
Tightening Torque Chart
171
Turn Signal Light
174
Capacities
176
Engine Oil Tank
176
Final Gear Oil
176
Fuel Tank
176
Note
176
Uf50K1 and Uf50Zk1 ('01-Model)
177
Dimensions and Dry Mass
178
Service Data
180
Brake Disc
182
5
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Suzuki UF50 Specifications
General
Brand
Suzuki
Model
UF50
Category
Scooter
Language
English
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