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Old 09-24-2011, 09:11 PM   #19
eakins
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Joined: May 2002
Location: Fort Collins, Colorado
Oddometer: 19,245
Spark plug – 8 ftlbs (96 in lbs)
Spark plugs:
Denso irdidium - 5364 (IU31)
Standard ngk - CR10E
NGK irdium - CR10EIX

Oil drain – 17.5 ft (210) – use 13mm socket
Oil filter cover – 8flbs (96 in) stock – 4ft (48) w/ AMP alum cover
Oil – 2.5 qt w/ filter (10w-40) – fill to top of view window, less than 2.5q

Valves – engine cold, every 7500 mi.
In: .08 - .13 mm (.003 - .005 in) - .004 ideal (Pro-Cycle has the tools)
Ex: .17 - .22 mm (.007 - .009 in) - .008 ideal
TDC inspection hole plug (look down in and find the T) – 16.5 ft (198)
Magneto/Generator Cover cap (loosen hot, rotate the motor CCW) – 11ft (132)
Valve access cover bolts – 4-7ft - general bolt spec, adjust hand tight
Valve tappet screw lock nut – 4ft (48) – general bolt spec, adjust hand tight

Handle bar clamp bolt – 16.5 ft (198)
Triple clamp bolts: upper – 21 ft (252) / lower 19 ft (228)
Steering stem (top of triple clamp) top nut/cap – 65 ft lbs
Front wheel axel – 47 ft : tighten first, cycle shocks 5x
Front wheel axel clamp bolts – 7 ft (84 in) : tighten next, top bolt first
Fork top cap – 16.5 ft (198)
Fork preload = 10-20mm
Fork oil height = 6.5” / 16 oz (5.9 lowered – need 2 qt)

Front brake caliper bolts – 19ft (228)
Fr brake Bleed nipple – 6 ft (72)
Fr Brake pad mounting pin – 13lb (156)
Fr brake hose banjo bolts – 16.5ft (198)

Rear brake caliper pad – 13 ft (156)
Rear wheel axel nut – 72.5 ft (cotter pin) / 79.5 (fuji nut)
Fuji Lock nut from 2008 and newer: 08319-2118a
Rear shock – upper bolt 40 ftlb , lower bolt 37 Nm (old cogent) 55nm (stock & new cogent)
Rear suspension linkage - Dog bones fuji-nuts (both) – 72.5 flbs
Rear suspension linkage – frame fuji-nuts – 58 ftlbs

Chain – 525, 110 link, 14/42 sprockets
Chain free play – 1.2–1.8 in (30-45 mm) 1.2 to 1.8 inches of slack in the middle of the chain
Chain stretch limit: Loosen your axle nut and adjust your chain so there is no play in it. Count out 20 pitches (21 pins) measure between the centerlines of the 1st and 21st pin. 319.4mm (12.6") is the service limit
Swing arm frame bolt nut – 55.5 flbs

Counter sprocket bolts - 4.5 ft lbs (54 in) (shoulder/raised area goes in towards engine)
Suzuki counter sprocket seal retainer – part# 24751-32E00
Rear Sprocket bolts – 19.5 ftlbs (234 in)

Cogent rear shock
-lower red adjuster – rebound, 42 click total, out/down is softer
-upper small adjuster – compression, out/CCW is softer


Quality Bearings:

-Front wheel bearings: SKF 6003-2RS
2 - 17 x 35 x 10
-Front wheel seal:
2 - 23x35x7 (09284-23001 – Suzuki #)

-Rear wheel bearings: SKF 6204-2RS
2 - 20x47x14
-Rear wheel seal (brake side):
1 - 26x47x7 (09283-26019 – Suzuki #)

-Cush Hub bearing: SKF 6205-2RS
1 - 25x52x15
-Cush Seal:
1 - 35x52x7 (09283-34003 – Suzuki #)
-------------------------------------------
Two 6003-2RS
Two 6204-2RS
One 6205-2RS
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eakins screwed with this post 02-15-2015 at 12:47 PM
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