Suzuki GS1000 (1980) [281/477] Use of genuine suzuki parts to replace any part of the machine use a genuine suzuki replacement part imitation parts or parts supplied from any other source than suzuki if used to replace suzuki parts will reduce the machine s performance and even worse could induce costly mechanical trouble

Engine oil using a premium quality four stroke motor oil will increase the service life of your motorcycle use only oils which are rated se under the api classification system the viscosity rating should be sae 10w 40 if the sae 10w 40 motor oil is not available select an alternate ac cording to the following chart 9

Front fork oil 9

Fuel oils and breaking in procedure 9

Fuel use only unleaded or low lead type gasoline of at least 85 95 pump octane method or 89 octane or higher rated by the research method if engine pinging is experienced sub stitute another brand as there are differences between brands 9

General information 9

Identification table 9

Sae 10w 20 9

Serial number location the frame serial number j is stamped on the steering head pipe the engine serial number is located on the right side of the crankcase these numbers are required especially for registering the machine and ordering spare parts 9

Specification and 9

General information 10

Orientation 10

Service specifications 11

General information 12

Contents 14

Service specifications 14

Engine top end 15

Service specifications 15

Clutch 17

Engine lower end 17

Lubrication system 17

Fuel system 18

Transmission 18

Charging system 19

Ignition system 19

Brakes wheels 20

Lamp wattage 20

Suspension frame steering 21

Tire pressure 21

Torque table 22

Tightening torque chart 23

Contents 24

Periodic maintenance 24

Important the periodic maintenance intervals and service requirements have been established in accordance with epa regulations following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle 25

Note more frequent servicing may be performed on motorcycles that are used under extreme service con ditions however it is not necessary for ensuring emission level compliance 25

Periodic maintenance 25

Periodic maintenance schedule 25

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and to maintain proper emission levels mileages are expressed in terms of kilometers miles and time for your convenience 25

Battery 26

Cylinder head nuts and exhaust pipe bolts 26

Periodic maintenance procedures 26

1 kg m 6 10 ib ft 27

Air cleaner element 27

Carefully use an air hose to blow the dust 27

Case cover t by unscrewing the fixing screw 27

Clean every 3 000 km 2 000 miles and replace every 12 000 km 7 500 miles 27

Exhaust pipe bolt tightening torque 27

From the cleaner element 27

Ment in the reverse order of removal mak ing sure that the spring bracket is properly engaged with the securing spring 27

Miiiiw 27

Open the seat and remove the air cleaner 27

Reinstall the cleaned or new cleaner ele 27

Take out the air cleaner element by pulling 27

The air cleaner element is a paper type if the air cleaner element is clogged with dust intake resistance will increase with a resultant decrease in power output and increase in fuel consump tion check and clean the air cleaner element every 2 000 miles 3 000 km observing the following procedures 27

Up the spring retainer bracket 27

Tappet clearance 28

64510 tappet depressor 29

84510 forceps 29

Again turn over the crankshaft another 29

Bringing the intake cam of no 4 cylinder to the positon indicated similarly check and adjust the clearance at the in take tappets of nos 3 and 4 cylinders 29

Ing the exhaust cam of no 4 cylinder to the position indicated under this condi tion repeat the checking and adjusting process outlined in step 1 at the exhaust tappets of nos 3 and 4 cylinders 29

It in place to bring its notch j to the posi tion indicated 29

Pick out the tappet shim from the tappet 29

Put your fingertips to the tappet and turn 29

Tappet 29

Tappet clearance adjustment the clearance is adjusted by replacing the ex isting tappet shim by a thicker or thinner disc 29

Turn over crankshaft another 180 bring 29

Using a pair of forceps 29

Using the tappet depressor push down the 29

A clearance coming without the specified range 0 3 0 8 mm for the purpose of this adjustment a total of 20 sizes of tappet shim are available ranging from 2 5 to 3 0 mm in steps of 0 5 mm each fit the selected shim to the tappet 30

After replacing the tappet shim check the 30

Beforèjïtting the 30

Check the figures punched on the shim 30

Clearance again to make sure that it is 30

Fig 3 17 30

H n ik h b 30

Periodic maintenance 30

Select a replacement shim that will provide 30

Tappet shim size chart 30

These figures indicate the thickness of the shim as illustrated 30

Within the specified range 30

Shim selection chart 31

Contact breaker points 32

Fuel line replace every two years 32

Ignition timing 32

Spark plug 32

Engine oil 34

Carburetor idle rpm 35

Engine oil filter 35

Clutch 36

Drive chain 36

Adjust the drive chain by turning the right 37

After adjusting the drive chain tighten the 37

And left chain adjuster bolts 3 after loosen ing the lock nut turning adjuster bolt in tightens chain 37

Axle nut securely and lock it with a cotter pin be sure to use a new cotter pin 37

Check the drive chain for wear and adjust the chain tension as follows loosen axle nut after pulling out cotter 37

Dicate the same position to show that the front and rear wheels are correctly aligned 37

Loose pins 2 damaged rollers 3 dry or rusted links 4 kinked or binding links 5 excessive wear 6 improper chain adjustment 37

Mark on both chain adjusters must in 37

The number of pitches and links of the gs1000 drive chain is the same as for the gs75o drive chain however as they differ from each other in precision and material do not use the gs750 drive chain for the gs1000 37

Visually check the drive chain for the below listed possible malconditions set up the machine on its center stand and turn the rear wheel slowly by hand with the transmission shifted to neutral 37

4 000 7 500 11 000 15 000 miles 38

6 000 12 000 18 000 24 000 km 38

After washing and drying the chain oil it with a heavy weight motor oil 38

At intervals of 1 000 km clean and lubricate the chain as follows 38

Brake hoses replace every two years 38

Chain cleaning and oiling 38

Check the tire inflation pressure and examine the valve for evidence of air leakage 38

Cleaning by washing wash the chain with kerosene if the chain tends to rust faster the intervals must be shortened 38

Front_____ 1 mm 0 6 in 38

Inspect the tire for wear and damage and check the tire tread depth as shown replace a badly worn or damaged tire a tire with its tread worn down to the limit in terms of tread depth must be replaced 38

Oiling 38

Replace the brake hoses by new ones 38

______ 2 mm 0 8 in 38

_______ tread depth service limit 38

Brakes 39

Steering 39

Front forks 40

4 000 7 500 11000 15 000 miles 41

6 000 12 000 18 000 24 000 km 41

Chassis bolts and nuts 41

Periodic maintenance 41

The bolts and nuts listed hereunder are important safety parts they must be retightened as necessary to the specified torque with a torque wrench refer to page 3 19 for the position of the following bolts and nuts on the motorcycle 41

Special ma terials 44

Special materials 44

The materials listed below are needed for maintenance work on the gs1000 and should be kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants emery cloth and the like how to use them and where to use them are described in the text of this manual 44

Fig 4 1 45

Special materials 45

Use of genuine suzuki parts to replace any part of the machine use a genuine suzuki replacement part imitation parts or parts supplied from any other source than suzuki if used to replace suzuki parts will reduce the machine s performance and even worse could induce costly mechanical trouble 45

Note asterisked tools are exclusively for gs1000 46

Special tools 46

The special tools listed hereunder are designed to facilitate maintenance work disassembly reassembly servicing checking etc on the gs1000 and protect the parts and components of the motorcycle against damage each shop is advised to keep these special tools as standard shop equip ment 46

Note asterisked tools are exclusively for gs1000 47

Srea ial 1vulû 47

Note asterisked tools are exclusively for gs1000 48

Special tools 48

Note asterisked tools are exclusively for gs1000 49

Special tools 49

Contents 50

Electrical 50

Engine and chassis 50

Trouble shooting 50

Engine and chassis 51

Trouble shooting 51

Trouble shooting 52

Trouble shooting 53

Electrical 54

Trouble shooting 54

Kuuüle shouting 55

Contents 56

Engine 56

Engine 58

Engine removal 58

Engine remounting 60

Engine 62

Compression check 64

I jj en i snu 64

Nude wit hat the 64

Tcmpil ion of the 64

Top end removal 64

14510 valve lifter 65

84510 forceps 65

Camshaft remove the two camshafts intake and ex 65

Cylinder head the cylinder head becomes free for removal when its three 6 mm bolts and twelve 10 mm nuts are removed 65

Each shim up t tappet shim 65

Pull out the tappets with your fingers 65

Remove each valve in the following manner 65

Remove tappet shims using forceps to pick 65

Using the valve lifter compress the spring 65

09916 44150 66

And outer spring 66

Drive the valve guide out toward cam 66

From the other side pull out the valve 66

Shaft use the valve guide remover 66

Take off the two cotter halves from the 66

Take out the valve upper seat inner spring 66

Valve stem using forceps 66

Top end installation 67

Top end inspection 73

And check its deflection with a dial gauge the valve must be replaced if the deflection exceeds the limit 75

And y perpendicular to each other by rigging up the dial gauge as shown if the clearance exceeds the limit specified below then determine whether the valve or the guide should be replaced to reduce the clearance to the standard range 75

Fig 7 68 75

Fig 7 69 75

Fig 7 70 75

If the valve stem is worn down to the limit as 75

Iformly fit the valve and tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating contact in this operation use the valve tapper to hold the valve head 75

Measured with a micrometer where the clearance is found to be in excess of the limit indicated above replace the valve if the stem is within the limit then replace the guide after replacing valve or guide be sure to recheck the clearance 75

Valve seat width measurement coat the valve seat with red lead paste un 75

Valve stem deflection specification 75

Valve stem deflection support the valve with v blocks as shown 75

Valve stem diameter specification 75

Valve to guide clearance measure the clearance in two directions x 75

Valve to guide clearance specification 75

Cylinder 78

74520 piston ring holder body 79

74540 band 79

Big and small ends of each connecting rod and also the sliding surface of each piston check that the 0 rings and are ac curately positoned in the groove 79

Distribution of ring gaps distribute the gaps of the three rings as 79

Installation before putting on the cylinder block oil the 79

No 2 and no 3 pistons and then install piston ring compressor special tool in the manner indicated some light resistance must be overcome to lower the cylinder block 79

Set the ring gaps as shown in fig 7 85 on 79

Shown before inserting each piston into the cylinder check that the gaps are so located 79

Stall no 1 and no 4 pistons and insert them into the cylinder 79

With no 2 and no 3 pistons in place in 79

Inspection piston and rings 80

Engine 82

Fig 7 95 82

Fig 7 97 82

Inspection piston wear determination measure with a micrometer the piston at the places and in the directions indicated if the service limit has been reached or exceeded replace the piston 82

Oversize oil rings 82

Oversize piston rings 82

Piston diameter specification 82

Piston ring clearance in the groove check each ring with a thickness gauge if any of the three rings exceed the clearance limit determine whether the ring or the piston should be replaced by measuring the ring thickness and the groove width limits are specified for the width and thickness 82

Position t that the mating ends of the circlip do not coincide with the groove portion of the piston 82

Ring groove width specification 82

Ring thickness specification 82

Ring to groove clearance specification 82

The circlip should be mounted in such a 82

The following two types of oversize oil rings are used they bear the following identifica tion marks 82

The following two types of oversize piston rings are used they bear the following identification numbers 82

Lower end 83

Generator rotor 84

Automatic advancer for contact breaker 85

Contact breaker points 85

After removal of the several sheets of clutch 87

And cluch cover screw 87

Bearing f and washer from pressure plate 87

Clutch 87

Clutch sleeve hub holder 87

Driven plate and drive plate firmly secure clutch sleeve hub to remove mounting nut with special tool j 87

Engine 87

Fig 7 117 87

Fig 7 118 7 32 87

Fig 7 119 87

Fig 7 120 87

Fig 7 121 87

Removal remove the cam lever bolts for clutch cable 87

Remove clutch cover and gasket remove clutch spring mounting bolts and 87

Remove clutch release rack t needle 87

Remove spring and pressure plate 87

External mechanism for gear shift 90

85210 bearing and oil seal installing tool 98

Aligning the hole on the outside periphery 98

Assembly of each gear pay attention to the gear s direction 98

Drive shaft gear assembly 98

Engine 98

Fig 7 160 98

Fig 7 162 98

Fig 7 163 98

Fig 7 164 98

Fit o ring in the bearing on the engine 98

Ing using special tool 09913 85210 98

Insert lock washer no 2 into the drive 98

Insert spacer into the drive shaft 98

Of the spacer with that of the drive shaft the latter hole is for passing oil 98

Press fit bearings at both sides using the 98

Replace circlip by new one press fit bearing illustrated in the draw 98

See the above drawing with respect to the 98

Shaft and turn it to fit it into the groove then fit the lock washer no 1 in the lock washer no 2 98

Special tool 98

Sprocket side replace o ring by new one 98

The direction of the circlip fit it to the side where the thrust is as shown in the figure 98

Tig 7 161 98

When mounting circlip pay attention to 98

Carburetors 101

Cleaning clean the fuel tank with flushing oil at the same time the fuel cock filter is being cleaned 101

Cleaning the fuel cock filter will collect impurities and therefore must be periodically checked and cleaned 101

Fuel cock 101

Fuel tank the fuel tank has a cap with an air vent which is necessary for the smooth flow of the fuel to the carburetors the fuel will not flow if the air vent is clogged if this occurs clean the air vent with compressed air install the tank filler cap with the arrow mark facing toward the front 101

On normally used functions as auto 101

Pri fuel is directly supplied does not func 101

Repaired shift the lever to the on position when the engine begins to run smoothly 101

Res reserve fuel is used functions as auto 101

The construction of the diaphragm type auto cock is shown below when the engine is not running with the lever in the on or res posi tion the valve is kept in the closed position by applying pressure utilizing a spring so that no fuel will flow to the carburetors when the engine is engaged a negative pressure is generated in the diaphragm chamber through the vacuum negative pessure pipe which is connected to the carburetors and builds up a negative pressure which is higher than the spring pressure so that the diaphragm is forced to open the valve and thus allow the fuel to flow to the carburetors when the lever is set at the pri which stands for priming to supply the fuel to the carburetors of an internal combustion engines position the fuel flows to the car buretors not via the diaphragm unit but directly through the res reserve pipe 101

The pri position is used when the carburetors have little or no fuel for example when filling the fuel tank for the first time or when the carburetors have been disassembled and 101

Tion as auto cock 101

Assembly unhook the throttle return spring from the pin 105

At the right section of the carburetor 105

Bolts and dismount the fuel tank from the frame 105

Cable from the carburetors see page 7 4 105

Carburetor 105

Disassembly shift the fuel cock lever to the on or res 105

Disconnect the fuel pipe and negative 105

Fig 8 10 105

Fig 8 11 105

Fig 8 9 105

Ner chamber body see page 7 3 105

Open the seat remove the fuel tank mounting 105

Position 105

Pressure pipe from the fuel cock 105

Remove five bolts to free the throttle shaft 105

Remove the air cleaner body and the air clea 105

Remove the carburetor top cover from each 105

Remove the carburetors see page 7 4 disconnect the throttle cables and starter 105

13121 carburetor balancer set 108

Balancing carburetors the four carburetors must be balanced after dis assembling the engine or the carburetors as the first step calibrate the carburetor balancer gauge as follows 108

Being it downward b lowers the level in the inverted condition of the carburetor 108

Bending the arm upward raises the level 108

Bolt on no 4 carburetor or no 1 car buretor intake pipe by using a 4 mm hex agon wrench special tool and install the adaptor special tool 09911 70130 hex agon wrench 4mm in the screw hole 108

Float height 23 25 mm 0 0 0 8 in 108

Fuel level adjustment if the distance measured is not within the 108

Fuel level measurement 108

Remove the vacuum inlet screw allen 108

Specified range it means that the float height is off the specification to adjust this height proceed as follows remove float bowl and bend the float arm to increase or decrease the height to this value 108

Before adjusting the carburetors be sure to check that there is nothing wrong with the engine s compres sion ignition timing and sparker performance 111

Troubleshooting 111

1979 emission limits 113

All testing and certification of emission controlled motorcycles will be performed by suzuki motor com pany in compliance with the e p a testing regulations motorcycle dealers are not required to certify emission levels on any motorcycle 113

Cc 170 cc 171 cc 749 cc 750 cc larger 113

Emission control and regulations 113

Emission limits 113

On february 4 1977 federal emission regulations for motorcycles took affect all motorcycles produced after january 1 1978 must meet specific emission limits this act establishes three categories of motorcycles and an emission level for each category the categories are as follows 113

Regulation 113

The emission limits for 1980 are more restrictive than the previous two model years these limits are as follows 113

The emission limits for motorcycles produced during 1978 and 1979 are as follows 113

This regulation affects all motorcycles that may be licensable for highway operation this definition of highway approved motorcycles covers motorcycles equipped with a headlight taillight stop light and which have an engine displacement larger than 50 cc 113

This regulation provides for fines of up to s 10 000 per motorcycle for individuals who alter render in operative or improperly service emission controlled motorcycles it is essential that the individual ser vicing this emission controlled motorcycle review thoroughly the correct service procedures discussed in this manual under no circumstances should the service procedures be deviated from nor adjustments made which are not in accordance with the factory specifications 113

334557090 114

Emission control carburetor components 114

Carbon monoxide 115

General emission information 115

Hydrocarbons 116

Chassis 118

Contents 118

Clutch cable 119

Handlebar 119

Throttle cable 120

Speedometer cable 121

Tachometer cable 121

Headlamp 122

Ignition switch 123

Chassis 124

Fig 10 17 124

Front fork 124

11 18 ib ft 125

A pointed tool to bleed air 125

And lower pinch bolt 125

Chassis 125

Fig 10 19 125

Fig 10 20 125

Loosen the front fork tube upper pinch bolt 125

Lower pinch bolt 1 2 kg m 125

Mount the caliper the tightening torque of the caliper mounting bolt is as follows 125

Mount the front fender on the front fork mount front wheel 125

Mounting mount the front fork so that the upper end of 125

Pull down the front fork while rotating it 125

Removal place a jack below engine remove the front wheel and front fender remove valve cap and hold the valve with 125

Remove the caliper mounting bolt and remove the caliper hang the caliper from the motorcycle frame using string etc taking care not to bend the brake hose 125

The inner tube in the front fork is flush with the upper surface of the stem head 125

Tightening torque 125

Tightening torque 2 4 kg m 18 29 ib ft 125

To remove fork it is preferable to loosen the 125

Upper pinch bolt 125

Upper pinch bolt 2 3 kg m 14 21 ibtt 125

When removing the left side front fork 125

2 kg m 11 18 ib ft 126

34520 front fork assembling tool t handle 126

34561 front fork assembling tool attachment d 126

64910 front fork oil seal remover 126

71510 8 mm hexagon wrench 126

Disassembly of front fork remove the upper cap bolt and the fork 126

Expand and compress the front fork to drain 126

Front axle holder nut tightening torque 126

If necessary 126

Portion of the front fork using the special tool at this time firmly secure the cylinder us ing the special tool 2 so that the cylinder does not rotate 126

Remove dust rail remove allen bolt mounted on the lower 126

Remove the inner tube from the outer tube remove the cylinder unit from the inner tube to be removed from the outer tube remove 126

Remove the oil seal using the special tool t 126

Snapring pliers 126

Spring 126

The oil seal stopper ring and the washer when removing oil seal stopper ring use special tool f 126

Ф 09900 06105 126

Ямии 126

09940 44110 front fork air gauge 128

Adjusting the air fork stand the motorcycle erect on the center 128

And remove the gauge 128

Before attaching air pressure gauge on the 128

Front fork turn valve clockwise until it locks next turn freely valve j counter clockwise until it turns freely mount valve nut 3 on the air valve of front fork and turn it manually clockwise until it stops next turn the valve d clockwise until it locks inject air through air charging port using an air pump hand pump 128

Handling the front fork the gs1000 front fork is mechanical pneumatic type the fork tubes contain compressed air and coil springs are used to augment the pneumatic cushioning action the air pressure is adjustable so that you can obtain a degree of softness to suit running condition by raising or lowering the pressure 128

Inject 2 to 2 kg c 128

Next loosen valve nut and remove the gauge from the front fork finally firmly fasten the valve cap 128

Of air with the air 128

Pii uie t lpu 128

Pump to adjust the pressure to the specified value carrying out fine adjustment with valve 128

Remove the air valve cap 128

Rt ochte 128

Stand and raise the front end slightly by jacking up the underside of the engine 128

When the specified pressure is obtained turn valve clockwise until it locks loosen valve 128

And damper wtfhw of tear suspension to be ihanged accpiaing to the iihtutc tun 129

And eiia 129

Chassis 129

Chureme the an pnssute siting oj fiant jo k nqunes the opting 129

Draw out the socket connected to the headlamp and remove the headlamp 129

Emtg het 129

Fig 10 29 129

Fig 10 30 129

Housing and remove the housing from headlamp bracket 129

Imtd into the od 129

In p tion ond adjustment of uit picture 129

Inspect the inner tube 129

Inspect the outer tube 129

Inspection inspect front fork spring 129

Inspection of oil leakage 129

Interior of the headlamp 129

L of front fork should be cat cd out a ier onpkkh jr amng ait j omjhe folk it this a o h jn dixies dia at once indf ca e hdiuuhc find to be 129

Measure the free length of the fork spring replace it by new one if it is less than the service limit 129

Mm 16 in 416 mm 16 in 129

Removal remove the fuel tank see page 7 3 remove the three headlamp retaining screws 129

Remove the lead wires connected to the 129

Remove the tachometer cable and 129

Remove the two bolts fastening the headlamp 129

Replace oil seal by new one if oil leakage is found leakage is caused by intrusion of dust or abnormal flaws on the inner tube 129

Shocks 129

Speedometer cable on the meter side 129

Standard service limit 129

Steering stem 129

Visually inspect the outer tube to see whether it is dented or damaged 129

Visually inspect the sliding surface of the inner tube replace the inner tube by new one if any flaws are found 129

Withoit di a n 129

74910 race and bearing driver 134

84910 steering stem bearing puller 134

Chassis 134

Fig 10 44 fig 10 46 134

Fig 10 45 134

Fig 10 47 134

Front wheel 134

Mounting apply a small amount of motor oil to the in 134

Removal remove bearing using the special tool t 134

Special tool are to be used place the one with larger outer diameter below and the other with smaller outer diameter above and press fit the race while rotating it then tighten the nut until it locks completely 134

Steering stem bearing 134

Steering stem bearing next fit the ring into the holder and screw the two shafts into the upper portion of the holder screw attachment 2 into the top of the steer ing shaft and remove the bearing while rotating the handle 134

Use of special tool firmly fit the holder into the roller portion of 134

Use of special tool two of the four tapered guides set in the 134

By hands while fixing it in the wheel hub or wheel rotate the inner race by hands to in spect whether abnormal noise occures or rotating smoothly replace the bearing if there is something unusual 137

Chassis 137

Check the spokes for tightness distortion and 137

Check the tire tread depth as shown replace a badly worn or damaged tire a tire with its tread worn down to the limit in terms of tread depth must be replaced 137

Check tire inflation and general tire condi tion frequently suzuki recommeds replace ment only with the specified size inoue brand v rated tire 137

Damage 137

Fig 10 55 fig 10 57 137

Fig 10 58 137

Front 1 mm 0 6 in 137

Front and rear axle shaft runout 137

Inspect the play of wheel bearing inner race 137

Inspect the tire for wear and damage and 137

Mm 0 06 in 0 5 mm 0 10 in 137

Rear 2 mm 0 8 in 137

Runout and replace it if the deflection exceeds the limit 137

Service limit 137

Standard service limit 137

Tire tread depth 137

Tire warning 137

Using a dial gauge check the axle shaft for 137

Visually inspect the wheel hub bore from 137

Which the bearings have been extracted for evidence of abnormal wear caused by creeping of bearing outer races 137

And front brake switch lead wire connected within the headlamp housing 140

Brake hose to the master cylinder 140

Front brake master cylinder 140

Llllllp 140

Mounting mount the master cylinder on the handlebar 140

Refer to the illustration to reconnect the 140

Removal remove the headlamp remove the left handlebar switch lead wire 140

Remove the union bolt 140

2 kg m 11 18 ib ft 144

4 kg m 18 29 ib ft 144

And brake hose 144

Brake hose union bolt tightening torque 144

Caliper 144

Caliper and catch the brake fluid in a suitable receptacle squeeze the brake lever to push out the fluid 144

Caliper mounting bolts tightening torque 144

Chassis 144

Do hot splash ilk htalejhad vhcn icmoxing ku 144

Fig 10 82 144

Fig 10 83 144

Fig 10 84 144

Fig 10 85 144

Front brake caliper 144

Low level 144

Mounting tighten two caliper mounting bolts 144

Pour brake fluid into the reservoir up to the 144

Removal disconnect brake hose no 2 j from the 144

Remove two mounting bolts securing 144

See page 10 24 for air bleeding of the caliper 144

The caliper to the fork take off the caliper assembly 144

Tighten the brake hose union bolt 144

U rc t 144

3 kg m 14 21 ib ft 147

Assembly into the upper portion of the brake disc 147

Caliper body be sure to point the hose in the direction shown to keep the hose away from other parts 147

Caliper mounting bolt tightening torque 147

Component of caliper assembly 147

Cycle frame by drawing it upwards 147

Link bolt and rear caliper and remove the wheel side bolt towards the wheel side 147

Mounting with the disc pad opened insert the caliper 147

Put the rear torque link bolt from the wheel secure it with the fastening nut temporarily next tighten the caliper mounting bolt 147

Rear brake caliper 147

Removal remove the oil hose union bolt 147

Remove the caliper assembly from the motor 147

Remove two caliper mounting bolts 2 remove nut together with the rear torque 147

Replacement interval two years components of master cylinder assembly 147

Use suzuki genuine parts master cylinder cup set 147

Use suzuki genuine parts pad and piston set 147

When reconnecting the brake hose to the 147

Years is justified from standpoints of safety and economy adherence to this rule is strongly recommended 147

Chassjs 151

Cylinder to theframe and lower the cylinder 151

Di a itig 151

Dii hth fl i d ikin ihe 151

Fig 10 111 151

Fig 10 112 151

Fig 10 114 151

Hi kt inu 151

I paa 1 i 151

Ii re vtpe it i 151

Kfnh and w 151

Lower the rear brake pedal 151

Pull off the split pin from the lower end of 151

Pushrod and disconnect the master cylinder rod from the brake pedal arm 151

Rear master cylinder 151

Removal remove the right hand front step and 151

Remove bolt securing the reservoir and 151

Remove the reservoir from the frame 151

Remove the right frame cover 151

Remove the spring for the rear brake lamp 151

Remove the two bolts securing the master 151

Remove the union bolt securing the brake 151

Switch 151

U flow oil hk ih mt io idlou iht hidi fluid mill s iiiohhki idi hi ihn flume if n hi it ßhia ntkhis fit 151

After fitting the circlip try to turn it in place 153

And damage and if necessary replace them 153

Assemble the check valve coil spring and 153

Assembly reassemble the master cylinder in the reverse order to disassembly with taking the follow ing additional steps be sure to apply brake fluid to the cylinder 153

Bore and all the internals to be inserted into the bore 153

Bore and piston to see whether their diameters are within the limits if not replace the cylinder or piston or both 153

Inspect the primary cup and boot for wear 153

Inspection using a micrometer measure the cylinder 153

It is advisable to replace the primary cup un 153

Less the cup removed in disassembly is in perfect condition 153

Primary cup from the cylinder 153

Primary cup outside the cylinder and insert the assembly into the bore taking care not to unseat the coil spring off the check valve remember the spring can easily come off the valve be careful not to allow the primary cup to cock inside the bore 153

Take out piston check valve coil spring and 153

To make sure it is snugly seated in the groove use of a replacement circlip is ad visable to re using the one removed in dis assembly 153

And also the torque link rear nut and split pin 154

And take it off the machine 154

Case and take off the case 154

Chassis 154

Fig 10 122 154

Fig 10 123 154

Fig 10 124 154

Fig 10 125 154

Loosen the nut and remove the two chain ad justor support bolts right and left 154

Pull the cotter pin off the axle nut 154

Rear wheel 154

Removal remove the two bolts securing the chain 154

Remove the two bolts securing the caliper 154

Separate the caliper assembly from the disc 154

Iîssgsisês 156

After firmly tightening the axle nut and lock 157

After washing and drying the chain oil it with heavy motor oil 157

Different from the one of gs750 in accuracy material etc while similar in pitch and number of links do not use the drive chain of gs75o for gs1000 157

Firmly tighten the torque link rear nuts to the 157

Further since the drive chain of gs1000 is 157

G0 rkbw g s 157

I id st klddlu laiik u d iui ht kpl il illt 157

Il i ii is 157

Ing it by inserting the split pin spin the rear wheel by hand and apply the brake lightly to feel the drag of the brake pads adjust the caliper assembly so that its pads exert a minimum of drag if any on the disk with the caliper adjusted to that position firmly tighten its securing bolts to the specified tor que value indicated above 157

Inspection chain cleaning and oiling at intervals of 600 miles 1 000 km clean and oil the chain as follows cleaning by washing 157

Oiling 157

Specified torque and lock each nut by inser ting a split pin 157

Tightening torque 157

Wash the chain with kerosene if the chain tends to rust faster the interval must be shortened 157

Swinging arm 159

Rear shock absorber 162

Absorber from the boss portion 163

Be sure to leave the adjuster in a click posi tion position 1 is for the smallest damper force and position 4 for the largest position 1 is the factory setting 163

Combination of spring setting and damper setting at the factory both spring and damper in the 163

Combinations 163

From the motorcycle frame 163

If two persons on the motorcycle if accessories are fitted to the motorcycle or if the machine is to be driven over rough terrain for stable cushioning both spring and damper must be set similarly the following is a list of recommended 163

Lift the wheel with a jack so that the bolts on 163

Loosen bolts on the lower portion of the rear 163

Rear shock absorber 163

Rear shock absorber must be made harder 163

Rear shock absorbers are set for the softest suspension that is spring in notch 1 and damper in position 1 this combination is calculated to provide the best cushioning effect for the average build rider of 68 kg 150 lbs for solo riding at about 60 miles h 95 km h on the highway without any accessories attached to the motorcycle 163

Removal of rear shock absorber remove the left and right nuts securing the 163

Remove the bolts to remove the absorber 163

Remove the upper portion of the rear shock 163

Shock absorber 163

Suspension match between front and rear 163

The lower part of the rear shock absorber do not interfere with the muffler 163

Contents 166

Electrical system 166

28106 electro tester 167

Electrical system 167

Fig 11 2 167

Ignition coils using the electro tester test each ignition coil for sparking performance test connection is as indicated make sure that the three needle sparking distance is at least of 8 mm 0 in 167

Ignition system 167

Ignition system data 167

Schematic diagram of ignition system 167

There are two ignition coils two contact breakers and two condensers to produce sparking energy for the four spark plugs no 1 breaker is for nos 1 and 4 spark plugs and no 2 breaker is for nos 2 and 3 spark plugs each ignition coil is connected to the plugs as shown 167

When no 1 piston is up on its compression stroke no 4 piston is up on its exhaust stroke the spark ing action occurring at the same time in nos 1 and 4 cylinders present no problem and the same applies tp nos 2 and 3 cylinders ignition order is 1 2 4 3 as counted from left to right by the rider mounted the machine it should be noted that nos 1 and 2 breakers operate 180 degrees apart in terms of crank angle 167

Spark plug 168

Charging system 170

Method of testing rectifier regulator and alternator 170

Inspection of charging system components 171

Starter system 172

Battery 174

Caution attentio 176

Electrical system 178

Fig 11 33 178

Front brake lamp switch see if this switch shows continuity when the front brake lever is squeezed put the tester probe pins to the white and orange lead wires of this lamp switch 178

Ignition switch be sure that the ignition switch when check ed with a circuit tester shows internal continuity as indicated in the chart below and replace it if any continuity or non continuity not indicated in the chart is noted 178

Ignition switch continuity chart 178

Troubleshooting 178

Utility switches and devices 178

Electrical system 184

Electrical system 185

Method of checking 185

Electrical system 186

Wiring diagram 187

Cable routing 188

How to set the high tension cord how to set contact breaker lead wire 188

Electrical system 189

Wire color 189

Contents 193

Gsioooe 193

General information 195

Service specifications 195

Caliper 197

Front brake 197

Master cylinder 197

Exploded view of gs1000e rear wheel 198

Fig 12 5 198

Fig 12 6 198

Joi uwu 198

18 29 ib ft 199

4 kg m 199

Caliper mounting bolt tightening torque 199

Check the wheel balance in the same way as in gs1000 use a balance weight of 20 gr or 30 gr when necessary 199

Checking disc wear front including model gs1000e the front disc of the models equipped with double discs is thinner than those of others 199

Disassembly either right or left caliper must be removed to allow removal of front wheel 199

Gs10ooe 199

I i pt a hi 199

Inspection and checking 199

L ailn if 199

Nd i l u iid ill 199

Note when removing a balance weight or when cutting it for minute adjustment use wheel weight pliers 199

Note when thrusting a balance weight to the wheel rim section use a plastic hammer to prevent damage to the wheel never use a metallic hammer 199

Wheel balance 199

Wheel run out 199

Circuit diagram 200

Operation 200

Self cancelling turn signal 200

Refer to circuit diagram and check the operation at 1 the lead connector of the left handle switch turn signal knob 2 the lead of turn signal relay and 3 the lead of speed sensor according to the following procedure 201

The turn signal lamp does not flash 201

Trouble shooting 201

Usioooe 201

Bi 0 r lg b 204

Wiring diagram 204

Suppléments 205

Suzuki____ ____ 205

Contents 206

Gs1000s 206

General information 208

Specifications 208

Service data 210

Engine removal 217

Periodic maintenance 217

Chassis 219

D t t t nt ikl о pt e 222

Л ht it am m the orjzomalplan und adjust tile utigie of 222

Assembly 224

Combination meter disassembly when replacing the bulbs remove the combination meter for removal of the combination meter 224

Electrical 224

Refer to page 13 16 224

Wire and cable routing 227

Wiring diagram 229

Gsiooo 230

Contents 231

Gs1000l 231

View of suzuki gs1000l 232

General information 233

Specifications 233

Service data 235

4 000 7 500 11 000 15 000 miles 242

6 000 12 000 18 000 24 000 km 242

Chassis bolts and nuts 242

Gs1000l 242

Periodic maintenance 242

The bolts and nuts listed hereunder are important safety parts they must be retightened as necessary to the specified torque with a torque wrench refer to the next page for the position of the following bolts and nuts on the motorcycle 242

Engine removal 244

Fuel system and carburetors 244

Although the choke lever has been made obsolete on the carburetor assy the disassembling procedure is the same as that for the gs1000 245

Carburetor disassembly 245

Fig 14 14 245

Fig 14 15 245

Gs1000l 245

On normally used functions as auto 245

Res reserve fuel is used functions as auto 245

Chassis 246

Front fork 246

3 kg m 14 21 ib ft 247

4 kg m 18 29 ib ft 247

And lower pinch bolt 247

Caliper mounting bolt tightening torque 247

Caliper mounting bolts and remove the right and left calipers hang the caliper from the motorcycle frame using string etc taking care not to bend the brake hoses 247

Ch hon lawn the pcedonictet pair hux al the posi tion hov n in the following diawmg and lake uic not to fond the ykutomaci cable cx 247

Fig 14 18 247

Fig 14 19 247

Front fork 247

Gs10o0l 247

In disassembly of fork it is preferable to 247

Loose the upper cap 247

Loosen the front fork tube upper pinch bolt 247

Lower pinch bolt 1 2 kg m 247

Mount front wheel 247

Mount the caliper the tightening torque of 247

Mount the front fender on the front fork install the right and left axle spacers to the 247

Mounting mount the front fork so that the upper end of 247

Pointed tool to bleed air 247

Pull down the front fork while rotating it 247

Removal place jack below engine remove the front wheel and front fender remove valve cap t and hold the valve with 247

The caliper mounting bolts are as follows 247

The inner tube in the front fork is flush with the upper surface of the stem head 247

Tightening torque 11 18 ib ft 247

Upper pinch bolt tightening torque 247

When removing the front fork remove the 247

2 kg m 11 18 ib ft 248

Chassis tubes draw out the axle shaft and take off the wheel 248

Front axle pinch nut tightening torque 248

Front wheel 248

Grease it and align groove for fitting the two drive pawls to the hub with the hub to insert the gear box in the wheel 248

Loosen the nut 248

Mounting before installing the speedometer gear box 248

Place a jack or a block under the engine or 248

Pull off cotter pin from axle nut and 248

Removal lift the front wheel off the floor by raising up 248

Remove either one of two calipers left or 248

Right from the fork by unfastening its two mounting bolts 248

The engine with the center stand resting firmly on the ground 248

Hii uo u ihd tlamui inq the 250

In id rwiq kier loo du ph u 250

J he uhn tun 250

Electrical 251

Checking method 254

Gsioool 254

I 1 i____ 254

Gs1000l 255

Method of checking 255

Fig 14 43 256

Gs1000l 256

Wire and cable routing 257

Wire and cable routing 258

Wiring diagram 259

Foreword 262

Important 262

Suzuki motor c 262

Contents 264

Gs1000e st 264

Gs1000et 265

Specifications 266

Service data 268

Umivwe nt 273

Item specification 274

Torque table 278

Special materials 280

The materials listed below are needed for maintenance work on the gs1000 and should be kept on hand for ready use they supplement such standard materials as cleaning fluids lubricànts emery cloth and the like how to use them and whtere to use them are described in the text of this manual 280

Gsioooe st 281

Use of genuine suzuki parts to replace any part of the machine use a genuine suzuki replacement part imitation parts or parts supplied from any other source than suzuki if used to replace suzuki parts will reduce the machine s performance and even worse could induce costly mechanical trouble 281

Periodic maintenance 282

Bs type 283

Fuel system 283

Jtjl mw u üj 283

Modifications 283

The carburetor has been changed from mikuni vm26ss to mikuni bs34ss 283

The fuel cock has been changed as shown below 283

Vm type 283

Charging system has been changed as shown below 284

Electrical the ignition system has been changed from the battery ignition system to the maintenance free tran 284

Sistorized ignition system 284

As shown below front brake caliper has been changed 286

Gs1000e st 286

Oont msc plutei 286

The front and rear brake disc plates are newly provided with holes 286

Ue laujul not to ft 286

Emission control and regulations 287

3 4 5 6 7 8 9 0 288

Fuel system 291

Carburetor 293

0 mm 0 0 0 2 in 22 1 mm 0 8 0 4 in 294

100 r min 294

Gs1000e st 294

Item specification item specification 294

Jet needle needle jet pilot jet by pass pilot outlet valve seat starter jet pilot screw 294

Mikuni bs34ss 34 mm 1 4 in 294

Pre set 294

Specifications 294

Type bore size i d no idle r min fuel level float height main jet main air jet 294

Uaiouva ht 298

14910 throttle valve adjusting wrench 307

2 in or out to obtain the correct slack 0 1 mm 0 2 0 4 in 307

Adjusting order 307

After adjusting the slack tighten the lock 307

After adjusting tighten throttle valve ba 307

After this adjustment adjust the idling 307

Gs1000e st 307

Lancing screw lock nut 307

Loosen lock nut 2 adjust the cable slack by turning adjuster 307

Loosen throttle valve balancing screw lock 307

Nut and by turning balancing screw with special tool adjust the position of steel ball in balancer gauge 307

Speed to somewhere between 950 and 1 150 r min with throttle stop adjusting screw 307

Throttle cable adjustment 307

Full transistorized ignition system 308

Charging system 313

25002 pocket tester 316

C generator 316

Mg this test it is not neasuir to 316

Rectifier 316

Regulato 316

Specification approx iq 316

Using pocket tester check the continuity between the lead wires of the stator also check that the stator core is insulated 316

Using pocket tester x1q range measure the resistance between the lead wires in the fol lowing table if the resistance reading is incorrect replace the regulator rectifier 316

Front master cylinder 317

Kg m ib ft 317

Tightening torque 317

Umuuul sl 317

4 14 29 321

5 29 40 321

Front caliper 321

Gs1000e st 321

Kg m ib ft 321

Tightening torque 321

Front fork 325

M inn i ng pun al at is the une as jiai ju 325

To 11 a 325

Us1wue st 325

Utk ml tul 325

Wire and cable routing 326

Wiring diagram 328

Gs1000st 329

Dimensions and dry mass 330

Specifications 330

Service data 332

Gsioooe st 334

Wire and cable routing 334

Gs1000e st 335

Wiring diagram 336

Диэ 336

July 1980 340

Suzuki motor co ltd 340

Gsiooogl 342

Supplementary service manual 342

Suzuki 342

Foreword 343

Important 343

Suzuki motor co ltd 343

Contents 345

I gs1000gt 346

Specifications 347

Service data 349

Torque table 360

Torque table 361

32020 thread lo 365

32030 suzuki thf super 1363 365

32040 thread lo 365

32050 thread lo 365

32090 thread lo 1332b 365

Ck 1363c 365

Ckc ement 365

Cks uper 365

Cks uper 1361a 365

Special materials 365

The materials listed below are needed for maintenance work on the gs1000g and should be kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants emery cloth and the like how to use them and where to use them are described in the text of this manual 365

25100 suzuki silicone grease 366

25140 suzuki moly paste 366

31100 suzuki bond no 1201 366

Use of genuine suzuki parts to replace any part of the machine use a genuine suzuki replacement part imitation parts or parts supplied from any other source than suzuki if used to replace suzuki parts will reduce the machine s performance and even worse could induce costly mechanical trouble 366

Periodic maintenance 367

Emission control and regulations 368

N b so 369

Engine removal and remounting 372

Remounting 375

Secondary bevel gear assembly 376

Secondary drive gear assembly 378

Secondary driven gear assembly 381

Secondary gear set clearancing operations 384

Clutch 387

Inspection 389

Crankcase 392

Transmission 394

Final drive bevel gear assembly 406

Final gear case breather circuit 408

Final drive bevel gear assembly 409

Bearing installer set 09913 84510 412

Bearing installer set 09924 84510 412

Drive gear housing use special tool q 412

Drive gear shaft use special tool 412

Inspection and reassembly 412

Install the other inner bearing race the 412

Install the spacer and shims removed from 412

The old final drive gear on the new gear install gear into housing 412

To install the inner bearing race onto the final 412

To install the outer bearing races into the 412

Washer and final drive gear nut and tighten to specification using special tool 412

Final driven gaer assembly 415

45100 0 5 mm 419

45101 0 0 mm 419

45102 0 5 mm 419

45103 0 0 mm 419

And clearance between the bearing cover and the bearing remove the final gear cover clean the mating surfaces thoroughly and apply suzuki bond no 1201 to the final gear case should be limited to the surface shown below 419

Bearing and oil seal installer handle 09924 74510 419

Final assembly after adjusting the backlash tooth contact 419

List of shims final drive gear housing to final gear case 419

Oil seal installer and remover 09924 74520 419

Oil seal into the final gear bearing cover 419

Part no shim thickness 419

Use special tools and to install a new 419

Full transistorized ignition system 421

Charging system 426

25002 pocket tester 429

45 5 7 5 7 5 7 429

7 oo oo 429

Go oo oo 429

Note when making this test it is not necessary to remove the ac generator 429

R w bi w r y 429

Regulator rectifier using pocket tester x1q range measure the resistance between the lead wires in the following table if the resistance reading is incorrect replace the regulator rectifier 429

Specification approx 1q 429

Using pocket tester check the continuity between the lead wires of the stator also check that the stator core is insulted 09900 25002 pocket tester 429

Front fork 430

Front master cylinder 432

Damage 435

Dust seal boot for damage 435

Handlebars first tighten the clamp bolt for the upper portion as shown 435

Inspect the cylinder bore wall for any scratch 435

Inspect the piston surface for scratch or other 435

Inspect the primary cup secondary cup and 435

Master cylinder inspection 435

Master cylinder reassembly reassemble the master cylinder in the reverse 435

Or other damage 435

Orders of disassembly and by taking the following steps 435

When remounting the master cylinder to the 435

Front caliper 436

2 kg m 11 14 lb ft 437

Brake pad replacement remove two bolts and take off caliper 437

Pull out brake pads with pad shim 437

Tighten the caliper axle bolts with specified 437

Tightening torque 437

Torque 437

Rear wheel 440

Rear swinging arm 445

Wiring diagram 450

Ii gs1000glt 451

Specifications 452

0 kg c 454

11 8 psi 454

3 us gal 454

8 8 us oz 454

Front 3 0h19 4pr 454

Front fork air pressure 8 kpa 454

Front fork oil capacity each leg 454

Front fork oil level 260 10 454

Front fork spring free length 516 20 454

Fuel oil capacity 454

Fuel tank 13l 454

Item specification 454

Item standard limit 454

Please refer to the service data of gs1000gt except for the service data shown below 454

Rear 4 0h17 4pr 454

Service data 454

Suspension 454

Tire pressure 454

Tire size 454

Fuel cock 456

Front fork 457

Note please refer to the front fork section ofgslooo service manual when disassembling and reassembling 457

The front fork 457

Front master cylinder 458

Note please refer to the front master cylinder section of gs1000 service manual when disassembling and reassembling the front master cylinder 458

Wire and cable routing 459

Wire color 461

Wiring diagram 461

Contents 464

Gs1000gx 465

Specifications 466

Service data 468

Charging system 469

25002 pocket tester 472

Note when making this test it is not necessary to remove the a c generator 472

Regulator rectifier using pocket tester x1q range measure the resistance between the lead wires in the follow ing table if the resistance reading is incorrect replace the regulator rectifier 472

Specification approx iq 472

Using pocket tester check the continuity bet ween the lead wires of the stator also check that the stator core is insulted 472

Wiring diagram 475

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