Introduction

My 1984 Suzuki FA50 was exhibiting some interesting problems. Although it ran fine a year ago, I could not get it running for the life of me. The problem was most likely a stuck throttle cable that I unstuck using some brute force. However, I figured it would also be nice to get my hands dirty and do an overhaul of the carburetor and engine. So here it is!

Note: The teardown was done backwards. I already disassembled the moped, and then took pictures reassembling it together. You may notice that some parts look new -- it's because they are.

Note #2: I figured it would be good to ring in the new year with a solid teardown, so I published it right on 12:00 AM PST, January 1, 2010 :)

This teardown is not a repair guide. To repair your Suzuki FA50 Moped, use our service manual.

  1. There's no rage against this machine.
    • There's no rage against this machine.

    • Looks great, except it doesn't run.

    • Its 50 cc engine lets me go downhill at almost 28 MPH when it does run. Uphills, not so much. Depending on the hill (and my head start), I may or may not have to walk it up.

      • The seat advertises "185 LB max." In the USA??

      • The above weight limit can be used in a "Yo mamma" joke. Note that I said can be, and not should be.

  2. Safety first. Disconnect the battery and store it in a safe place.
    • Safety first. Disconnect the battery and store it in a safe place.

    • The battery's readily accessible underneath the seat.

    • In retrospect I figured out i that I didn't need to remove the exhaust cover, but what the heck... When in Rome, right?

    • Took off the air intake box.

    • That's contractor-grade 3M packing tape holding the airbox together. Only the best for my moped.

    • I went to the other side of the bike and removed the carb/oil pump protective cover.

    • The foot rest came off next, in order to gain access to the engine and spark plug.

    • While down there, I unplugged the spark plug cover.

    • I then proceeded to access the wiring underneath the gas tank.

    • The wires needed to be disconnected in order to remove the frame away from the engine/crankshaft.

    • First I removed the protective brace on top of the oil/gas tanks using a 10 mm socket wrench.

    • I had to take off both oil and gas caps in order to remove the plastic protective cover.

    • I set aside the fuel tank and bam! -- the wires were ready to be disconnected.

    • The wires must have been minding their own business since '84... Separating them was quite a challenge. Thankfully they had those round connectors on them, so I didn't have to solder or crimp anything when reassembling the moped.

    • I then unplugged the emergency fuel valve .

    • The valve should remain in the "On" position while working on the moped.

    • I paused for a minute to enjoy a cold cup of Diet Coke, and to drain all the 2-cycle oil...

    • I got the Goliath "freezer" mug in Six Flags Magic Mountain about 6-7 years ago. Best investment I ever made, aside from marrying the wife. It's the gift that keeps on giving!

    • Ikea bowls come in quite handy. Turns out there was enough 2-cycle oil to fill the entire bowl to the brim!

    • I had a difficult time figuring out what I was doing in these pictures. According to the manual, I was removing the oil pump cover and oil hose.

    • Unscrewing the smaller valve, which I believe to be the carburetor choke cable.

    • My culprit resides beneath the carburetor top cover. Even though I reassembled the moped, I'll have to investigate the throttle cable going into the carburetor.

    • Rear brake gets disconnected next. The cable needs to be free since the brake lever will come off with the rest of the frame.

    • The rear spring gets unsprung using a 14 mm socket wrench.

    • Disconnecting the spring may be potentially dangerous, as it may be under tension.

    • Nothing crazy happened when I disconnected it, however.

    • Finally, the large frame screw can be removed. This is the last piece of hardware holding the frame to the rear wheel / engine.

    • I had to use two 17 mm wrenches -- a socket on one side, and a ratcheting wrench on the other.

    • And just like that, the frame comes off!

    • A 12 mm and 10 mm hex socket take care of the muffler.

    • Now on to the engine.

    • Spark plug comes out with a strong flick of the wrist.

    • The plug looked like it was the original one that came with the moped. Dirty dirty!

    • I continued by removing the front part of the engine using a 10 mm socket wrench. I found plenty of buildup inside.

    • I wanted to see what a "flywheel magneto" looked like, so I decided to remove this cover. I figured anything named after an X-Man is worth a look...

    • I stripped the Phillips originals while taking the cover off. I replaced them with appropriately-sized 20 mm hex-head screws.

    • This is a 65 mm replacement I ordered online, along with news seals and stuff.

    • Some shots of the engine...

    • The reed valve comes right off. You can see the engine internals from the hole -- cool!

    • I was careful not to accidentaly put any crap inside the engine. I figured the Shuttle wouldn't run well on dirt and Cheerios.

    • The reed valve is a very important part of the moped, according to the service manual. The metal bars have to be bent a certain way, and other stuff.

    • I had quite a difficult time shooting a "final layout" shot. I gave up after 5-10 pictures; this one was the best of the bunch.

    • That's it! Hope you enjoyed my teardown!

4 Comments

I am looking for some close up pictures of where exactly the wiring harness runs, I am putting a shuttle back together that I did not take apart, both front and rear photos would be helpful

eric - Reply

I am looking for a manual how to replace my spark plug of my Suzuki FA50. Can you help me?

Tiest Ryckoort - Reply

Do you know if the crank case would be the same for a 84 as it would be for a 83 im purchasing a new crank case for my 83 but found a 84 crank case for cheap

Jacob Rogers - Reply

Hello everyone my Suzuki FA 50 has a rubber line plugged exactly under the carburetor but i have no idea where other ends goes on the top

Cam anyone help?? Here is my email Gemini54302@aol.com

Thank you

Antonio - Reply

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