(Service Bulletin RE9 contained the complete midyear revision to tuning procedures.
These are the recommended procedures for tuning any RE5.
As with bulletins RE-1 through RE-16, the number had no connection with the name of the bike, it was just the chronological order of the bulletins.
Table of Contents for all Bulletins)
SUBJECT: RE5 SERVICE PROCEDURES
This bulletin contains the latest information necessary to correctly service the RE5 after it has been set up.
This bulletin is designed to cover the latest carburetor protractor, throttle cables, throttle grip, carburetor specifications, and adjustment shortcuts.
Proper empoyment of the procedures outlined in this bulletin will ensure you of the smoothest possible running RE5
If the Carburetor Modification Kit (99104-09050) has not been installed, install it first in accordance with Service Bulletin #RE-8 before proceeding with the servicing of the RE5.
Use ONLY Suzuki Rotary Engine Motor Oil 10W-20W-50 or Shell Super X 10W-20W-50 in the Sump AND Metering Pump Oil Tank. Use of other than recommended oils may cause engine damae and possibly void the warranty.
(Note: Suzuki brand Oil was a promotional gimmick; today the oil recognized as best for the RE5 is Castrol 20W-50; its low ash content minimizes buildup inside the power unit.)
Use ONLY unleaded regular or low-lead regular gasoline.
NOTE: Charge the battery with the battery on the bench. Leave the vent tube in the frame. DO NOT OVERFILL. After charging, bring the battery cells up to the full mark with distilled water.
Check the coolant level. If low bring it up to the plate with a 50% mixture of Golden Cruiser #1200 and distilled water.
(comment on antifreeze)
(comment on filling trans oil)
ENGINE OIL INSTALLATION:
A. Metering Pump Oil Tank:
Fill the metering pump oil tank with one of the two recommended oils.
(comment on oil, filling)
NOTE: Always ensure that nothing is placed on top of the oil tank cap vent hole such as gloves, maps, etc.
Bleed the metering pump oil line with the bleeder screw on the pump.
B. Engine Sump:
NOTE: ALWAYS follow this procedure when checking the sump oil level on the RE5, otherwise accurate measurements cannot be obtained.
a. File the points faces with a #120 grit flex-stone, .024" thick
b. Clean the point faces off with electrical contact cleaner
c. Blow the point faces off with compressed air
d. Draw a strip of thin slick card board (business card) through the point faces to burnish the point faces.
e. Lube the point cams with a small quantity of high quality point cam grease.
CARBURETOR AND PORT VALVE ADJUSTMENTS:
NOTE: The nuts may be removed by using a 12 point, 12mm, box end wrench from the left side or a 3/8" drive 12mm socket, universal, extension, and ratchet from the right side. It is not necessary to remove the fan.
(comment about metering oil line)
NOTE: If the adjusters are run all of the way in, the idle speed screw is completely out, and the choke lever is in the "off" position and the primary throttle plate still will not close completely, check the part number printed on the pull cable close to the cable adjuster at the throttle grip. If the cable is stamped 37000 it may be neccesary to remove the throttle grip stopper piece from inside the throttle grip housing to obtain a compeltely closed primary throttle plate. Be sure to reinstall the stopper piece after completing all adjustments.
a. Early Style accelerator pump: This pump can be identified by the right angle bend in the pump arm.
To adjust this style accelerator pump the excess play must be manually removed from lever to accurately determine when the diaphragm begins to be compressed.
1) Lightly press down on the accelerator pump arm as shown. Press just hard enough to remove the slack from the linkage.
2) Slowly twist the throttle until the accelerator pump just begins to move. This should be 28 (degrees).
NOTE: Be sure that there is fuel in the float bowl and accelerator pump before checking touch timing..
3) If the lever begins to move either before or after 28 (degrees), adjust the timing by bending the brass-colored tab located beside the carburetor cable pulley on the primary throttle shaft.
NOTE: Be careful when bending the tab not to warp the arm that the tab is on. Check for free movement of this arm after bending the tab.
b. New Style Accelerator Pump: Since there should be little or no play in this system follow procedures 14. a. 2) and 14. a. 3).
a. Return the throttle grip to the closed position. Check to see that the primary throttle plate closes completely to a fully closed position. On some carburetors it may be neccesary to manually close the throttle plate the final 5 or 10 degrees.
b. Press the choke lever down to the full "On" position. The primary throttle should open 25.5 (degrees) + 0.75 (degrees). If it opens more or less than this figure adjsut by bending the fast idle rod.
NOTE: It is neccesary to remove the carburetor cover to do this.
(Cable Adjustment is the crucial tuning procedure on the RE5. The port valve must open just as the secondary begins to open, and this is adjusted by comparing the setting on carb tool C with the mark on the port valve. Carb Tool C is available from Rotary Recycle. Misadjustment of this causes the famous horrendous flat spot between the primaries and the secondaries, which occurs just at freeway cruising speeds. )
a. Turn the throttle grip pull cable adjuster out approximately 1/8" to ¼" and lock it.
b. Adjusting full open.
1) Turn the throttle grip full open and check the primary throttle plate angle. The proper angle is 78 (degrees) to 82 (degrees).
2) If the angle is less than this, turn out the carburetor pull cable adjuster until this figure is reached. Lock the adjuster.
3) Check to see that the carburetor will still return to the 0 (degree) position.
c. Remove the port valve cover.
d. Port Valve Timing
1) Turn the trottle grip slowly and check when the port valve lever #1 touches port valve lever #2. The correct timing is 35 (degrees).
2) Turn out the port valve cable adjuster until this figure is reached.
NOTE: If the port valve opens too soon (approximately 30 degrees) even with the port valve pull cable adjuster run all of the way in, proceed as follows:
1. Turn the throttle grip until lever #1 just touches lever #2.
2. Turn out the carburetor pull cable adjustor until the primary throttle plate indicates 35 (degrees).
3. Lock the port valve pull cable and the carburator pull cable adjustors.
4. This may prevent the primary throttle cable from closing by 5 (degrees) or so. However, since the primary throttle plate is open approximately 18 (degrees) at a 1200 rpm idle, this will cause no problems.
e. Turn the throttle grip full open and tur out the oil pump cable adjuster until the mark on th oil pumparm corresponds with the mark on the oil pump body.
f. Return Cable Adjustment
1) Depress the choke lever fully to the "On" position.
2) Run the carburetor return cable adjuster out approximately the same amount as carburetor pull cable adjuster and lock it.
3) Turn out the throttle grip return cable adjuster until the choke lever just begins to move.
4) Turn in the throttle grip return cable adjustor until you have about 1mm of play and lock it.
5) Turn out the port valve return cable adjuster until only a small amount of slack is left in the return cable.
6) Lock the adjuster.
a. Turn in the primary pilot mixture screw in until the needle lightly bottoms. Back the screw out approximately ½ of a turn.
b. Thoroughly warm up the engine and set the idle to 1200 rpm.
c. With the bike on the center stand quickly open the throttle grip to bring the rpm’s over 5,000 then quickly close the throttle grip.
d. If the exhaust has a popping sound or afterfires on deceleration, turn the primary pilot mixture screw out approximately 1/8 of a turn and repeat step c.
e Continue this process until there is little or no hesitation when the throttle is quickly opened and no popping or afterfiring when the throttle is quickly closed.
f. Reset the throttle to 1200 rpm if it has changed.
NOTE: the correct mixture at idle may cause a slight "lope" to the idle but it will cause no problem.
NOTE: This remove the slack from the carburetor pull cable that resulted from opening th eprimary throttle plate from 0(degrees) to approximately 18 (degrees) to obtain a 1200 rpm idle.
(end of bulletin)