Suzuki GS1000 (1980) [49/477] Special tools

Содержание

• Foreword 2
• Important 2
• Suzuki motor co ltd 2
• Ervice specifications 6
• Lectrical system 6
• Pecial tools 6
• Periodic maintenance 6
• Trouble shooting 6
• Contents 8
• General information 8
• Orientatio 8
• Brake oil for front and rear brakes 9
• Classification dot 3 dot 4 9
• 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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SPECIAL TOOLS Valve seat cutter set 99103 45011 NOTE Asterisked tools are exclusively for GS1000 5 4 Bearing and oil seal installer 09914 79610