Suzuki RV50 Motorcycle Service Manual for Engine, Electrical and Body 1971-1981

Suzuki RV50 Service Manual - 1971-1981 Edition

This technical publication provides authorized factory procedures for the maintenance, disassembly, and reassembly of the Suzuki RV50 series. Proper adjustment of the oil pump lever alignment—a critical step to prevent engine seizure—ensures precise lubrication delivery and maximizes long-term engine reliability. Technicians must adhere to the specified clearance and torque parameters contained herein to maintain factory-grade performance and safety standards.

Model Series Applicability & Technical Generations

The specifications and procedures within this manual apply to the following machine configurations:

• RV50 Series (1971–1981): Covers the standard 49cc air-cooled two-stroke motorcycle across its production lifespan.
• Regional Variations: Includes specific wiring schematics and equipment compliance data for Germany, Austria, Switzerland, Belgium, and France.

Maintenance ROI & Operational Integrity

• Factory Clearance Benchmarks: Access exact tolerances for piston-to-cylinder clearance and crankshaft runout to eliminate guesswork during top-end overhauls.
• Electrical System Precision: Utilize high-resolution wiring diagrams to diagnose charging system faults and ignition timing drift, preventing unexpected roadside failures.
• Component Lifecycle Management: Follow the structured break-in and periodic maintenance schedules to extend the service life of internal transmission gears and clutch plates.

Document Metadata

• Print Number: Not Specified / Factory Original
• Page Count: 84 Pages
• Language: English (Primary), including German/French technical supplements.

Technical Depth & Factory Benchmarks

Mechanical integrity is maintained through strict adherence to the performance curves and calibration data provided for the 49cc power plant. Ignition timing is established at 20° (2.03mm) B.T.D.C., ensuring optimal combustion efficiency and throttle response across the RPM range.

System Architecture & Navigation Aids

Diagnostic procedures are supported by detailed cross-sectional views of the engine, transmission, and carburetor assemblies. Labeled exploded views facilitate the identification of internal shim placements and oil seal orientations, while dedicated wiring schematics for different export markets allow for accurate electrical troubleshooting based on regional lighting and ignition configurations.

Table of Contents

• Specifications
• Performance Curves
• General Instructions (Breaking-in, Fuel and Oil, Genuine Parts)
• Special Tools
• Necessary Materials (Thread Lock, Grease)
• Troubleshooting (Engine Start, Abnormal Noises, Overheating, Clutch, Gear Shifting)
• Tune-up (Oil Pump, Spark Plug, Transmission Oil, Clutch, Carburetor, Ignition Timing, Battery, Air Cleaner, Muffler)
• Engine (Removal, Disassembly, Assembly)
• Fuel and Lubrication System (Carburetor, Oil Pump)
• Electrical System (Magneto, Ignition Coil, Battery, Charging System, Silicon Rectifier)
• Chassis (Front Wheel, Rear Wheel, Rear Brake, Front Fork, Steering, Rear Suspension)
• Technical Data for Other Languages (German, French)
• Wiring Diagrams

Operational Limits & Fluid Specifications

• Transmission Oil: 500 – 600 cc (2.1/2.5 US cups) of SAE 20W/40 motor oil.
• Fuel System: Gasoline with a minimum octane rating of 85-95; 2-stroke oil required for the CCI injection system.
• Tire Pressure: Front 0.8 kg/cm² (11 psi), Rear 0.8 kg/cm² (11 psi) for standard solo riding.
• Spark Plug Gap: 0.6 mm – 0.7 mm (0.024 – 0.028 in) using NGK BP-4H or equivalent.