Suzuki GS850G Service Manual Download Page 1

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Summary of Contents for GS850G

Page 1: ......

Page 2: ...GROUP INDEX GROUP INDEX 1 2...

Page 3: ...GROUP INDEX GROUP INDEX 2 2...

Page 4: ...roperly inspect and service the GS850G in accordance with the EPA regulations Prim trily tlie cnlission components which can effect the emission output of the GS850G consist of Ihc carhuretorq and cra...

Page 5: ...SIDE VIEW VIEW OF SUZUKIGS85OG Right side Left side...

Page 6: ...GENERAL INFORMA TION GENERAL INFORMATION CONTENTS IDENTIFICATION TABLE 1 2 FUEL OILS AND BRAKING IN PROCEDURE 1 2 ORIENTATION 1 3 SERVlCE SPECIFICATIONS 1 4...

Page 7: ...d brake flttid b v he tnanufacrurer do noI vse or mix different rypes of JIi4id such as silicone based and petroleurn haspd fluid forrefilling he sysfern of herwise serious damage will resrrlr 2 Do no...

Page 8: ...ngine speed limits Upon reaching an odometer reading of 1 000 miles 1 600 km you can subject the rnotorsyclc to full throttle operation However do not exceed 9 0 0 r min at any time Do not maintain a...

Page 9: ...ion CHASSIS Front suspension Rear suspension Steering angle Caster Trait 2 230 rnm 87 8 in 865 mm 34 1 in 1 190 rnrn 46 9in 1 490 rnrn 58 7in 160 mrn 6 3 in 253 kg 558 lbs 455 kg 1 003 lbs Four stroke...

Page 10: ...0H17 4PR 1 75 kg cmZ 125 psi Normal solo riding 7 00 kg cmz 28 psi Normal solo riding Battery ignition 17 B T D C below 1 500 r rnin and 37 B T D C above 2 500 r rnin NGK B8ES or NIPPON DENSO W24ES 0...

Page 11: ...S 2 2 ETOPEND 2 2 E LOWER END 2 4 ICATION SYSTEM 2 4 CLUTCH 2 4 TRANSMISSION 2 5 SHAFT DRIVE 2 5 CARBURETOR 2 6 ELECTRICAL 2 6 BRAKE WHEEL 2 7 TIRE PRESSURE 2 7 SUSPENSION 2 7 FUEL ICCAPACITY 2 8 TORQ...

Page 12: ...470 1 3965 0 150 0 0059 Item 0 8646 0 8652 Camshaft Deflection Cam Chain 20 Pitch Length 157 80 6 213 Standard EX Camshaft JournatClearance IN EX Camshaft Journal Holder T D INlEX Camshaft Journal O D...

Page 13: ...PlSTON RING CYLINDER SER VICESPECIFICA TIONS Unit rnm in Piston Pin Bore 1 D 16 002 16 008 0 6300 0 6302 Piston Pin O D 15 995 16 000 0 6297 0 6300...

Page 14: ...87 49X 33 34 1 723 Standard 0 006 0 019 0 0002 0 0007 CLUTCH Unit rnm in Connecting Rod Small End Bore E D 16 006 16 014 Piston Pin O D Connecting Rod Rig End Side Clearance Connecting Rod Big End We...

Page 15: ...OP Shifl Fork Groovc Clearance Shift Fork Groove Width Limit Item Standard 0 961 25126 0 4 0 6 0 0 16 0 024 5 45 5 55 0 215 0 2 19 Secondary Bevel Gear Backlash 0 8 0 831 Shift Fnrk TEiickness 0 08 0...

Page 16: ...SER VICESPECIFICA TlONS CARBURETOR Unit mrn in ilot Air J ELECTRICAL Unit rnm in e...

Page 17: ...1 686 38 15 1 502 I 3 50H19 4PR 4 50H17 4PR Tire Tread Depth Front Rear COLD INFLATION TIRE PRESSURE 0 26 0 27 0 24 Brake Disc Runeut Frontlreat 0 30 0 012 2 0 0 08 SUSPENSION Unit mm in Master Cylind...

Page 18: ...SER VICESPECrFICA TIONS FUEL AND OIL CAPACITY method or 89 octane or hi er rated These specifications subject to change without notice...

Page 19: ...9 10 3 7 6 0 9 h 1 O 36 0 50 5 4 5 7 5 13 0 20 0 9 5 16 5 65 0 72 5 87 0 108 5 14 5 19 0 65 O 79 5 14 5 19 0 24 6 14 8 12 32 8 14 8 Crankcase holt Starter n otor bolt Oil pan nut Engine mountingboll...

Page 20: ...liper mounting bolt 10 2 O 3 O 14 5 21 S Rear brake caliper axle bolt 10 2 5 3 5 18 0 25 5 8 I Rear brake master cylinder mounting bolt 1 5 2 5 11 0 18 0 Final drive gear housingnut 10 3 54 5 25 5 32...

Page 21: ...NUTS AND EXHAUST PIPE BOLTS 3 3 AIR CLEANER ELEMENT 3 4 TAPPET CLEARANCE 3 5 SPARKPLUGS 3 9 FUELLlNE 3 9 CONTACT BREAKER POINTS 3 9 I IGNITIONTIMING 3 9 ENGINEOIL 3 11 ENGINE OIL FILTER 3 12 ENGINEID...

Page 22: ...cycles that are used under exfremeservice condilions SIO wever it is net necessary ro ensureemission level compliance The chart below lists the recommended intervals for all the required periodic serv...

Page 23: ...S G reading of 1 22 at 2Q C or fnder means chat the battery needs recharging off the machine take it off and charge it from a recharger Charging the battery in place can lead ro failure of the rectif...

Page 24: ...wing screw O 2 Fill a washing pan of a proper size with non flammable cleaning solvent Immerse the element in the cleaning solvent and wash it clean 3 Squeeze the cleaning solvent out of the washed el...

Page 25: ...hafts are disturbed by removing them Fig 3 6 forservicing Fig 3 7 Tappet clearance specification Tor both intake and exhaust valves 0 001 0 003 in 1 Turn crankshaft to bring the exhaust cam CHECKING T...

Page 26: ...n the crankshaft a further 180 bringing the intake cam of No 4 cylinder to the position indicated Similarly check and adjust the clearance at the intake tappets of Nos 3 and 4 cylinders TAPPET CLEARAN...

Page 27: ...cted shim to the ti tith numbers toward tappet Be sur ck shim size appet u e to che PERIODIC MAINTENANCE Taanet shim sire chart Before fitring fhe tappet shim t o fhe tapper be sure ro apply engine oi...

Page 28: ...w 2 2 2 E E E E E E u 0 0 z 5 222 p I l l 2 E k n r n W Y1 X fJ d U u a w 2 2 5 d C E O 5 k G X U fi 22 w _ 5 k g E u 2 Z Z d 0 g 2...

Page 29: ...apt to get wet a hotter plug should be used If the standard plug is apt to overheat with the porcelain having a whitish appearance Check and adjust the contact points as replace with a colder one out...

Page 30: ...siclc of the advance governor is alipnecl with timing mark T Corresponding to T D C of No I R 4 pistons 3 Timing index mark F1 4 3 Ignition advance timing mark Timing terter At 2 22 4 With the piston...

Page 31: ...speed to sec if tlrc iynition is correctty tinled or not The proccdurc is as follows 1 Run the engine at a speed not exceeding I 500 r min Under this condition F mark and timing mark should be in perf...

Page 32: ...bed in the previous section After draining engine oi and sccurelv tightening the engine oil drain plug perform the follo ving 1 Remove three nuts 2 and rcmove the cover 1 Pull out old filter 3 replace...

Page 33: ...will come out i f rhe play is excessive 1 Loosen Iock nut 0 2 Turn adjusting nutEdto obtain a cable play of 0 5 1 Om m 0 02 0 04 in 3 Tighten lock nut 0 PERIODIC MAINTENANCE Fin 3 33 Returning cable...

Page 34: ...and secondary cover 6 3 Drain oil by removing filler cap and drain plug a 4 Refit drain plug 4 remove oil level screw C5 and pour the specified oil in through the filler hole until it runs out from th...

Page 35: ...4 h r In hydraulrc system RRAKF SQUEAKING I Carhon adhesion on pad urfacc 7 Silted pad 3 Dnmofcd wheel hearing 4 I oose Front wllccl axle nr rear wheel axle CI Worn pad 6 Forcien materia In broke llui...

Page 36: ...a the limit in terms of tread depth must be replaced 1 6 tnm 0 06 in Fig 3 39 Check the tire pressure and examine the valve for evidence of air leakage FRONT REAR COLD INFLATION TIM PRESSURE b llNG DU...

Page 37: ...is manual FRONT FORKS Check the front fork air presruse when the fork is cold cvery 6 months in the following I manner 1 Place the motorcycle on its center stand and keep the front wheel off the groun...

Page 38: ...age scoring and scratches on the outer surface of the inner tube every 12 000 km 7 501 miles and replace the defectiveparts if necessary CHASSIS NUTS AND ROLTS The nuts and bolts Iistcd below arc impo...

Page 39: ...Fig 3 46 Fig 3 47 Fig 3 48...

Page 40: ...ntersEiaft Big retainer screw 3 pcs Drive shaft plate screw 3 pcs Generator stator screw 3 pcs Generator lead wire guide screw 3 pcs Engine oil pump screw 4 pcs Oil gallery plate screw 3 pcs Starter m...

Page 41: ...1 5 7 25 7 56 7 56 7 56 SUZUKl CALIPER AXLE CREASE 99000 25 1 10 Valve stem Can1 slrafi journal Chain tensioner adjuster shaft i Countershafl wasllel L Outcrcounterslaaft SEE PAGE SUZUKI MOLY PASTE 9...

Page 42: ...used exclusivelyfor the GSseries I m 1 installer PI 0 5 y Setondnrtdrtvr h r r l gcsr holder IllOY24 5451I 0 1mmswlrel wrench 109910 237TO f k a r i n n n f r racerrmovct 10Wd1 845103 m b Rrarinl in...

Page 43: ...r 109924 745303 lkarin oufrrnrrrtmvver Valve stem seul and valve i tin aikr handk 40994 1 5491 ll Fin gearcaw nilsrnl rn lnller 0992J 715503 0 qf j4 7 1 Pilnl 109014 74540 3 0 Mi 3 g r r Cinsl a s r c...

Page 44: ...SPECIAL TOOLS a band 63 75 mm Carbumlorbahnccc F m t tork mmMlng loot nrhrntnl D...

Page 45: ...SPECIAL TOOLS ng pllem langk closed lsr rt drc Shock dtlvff set...

Page 46: ...SPECIAL TOOLS 69 Ruce and brnrlngdrlvrr fI J941 74 J1 I 7 7 I Tmhg light 1099130 27311 J p41 Hydrometer 09900 28403 1 cila d c r 7 LJ VJve acn camrsrt 99103 45011 Stterhg nulm k t t ch 09940 14911...

Page 47: ...TROUBLE SHOOTING TROUBLE SHOOTING CONTENTS ENGINE AND CHASSIS 6 2 ELECTRICAL 6 6 1...

Page 48: ...pipe or suction petcock pipe Clean Engine stalls I Foulcd qpark pl rgr I Clean or replace easily 2 Dirty contact point CIean or replace 3 Ignltion timing out of adlustment Adjuct 4 Clopped file1 pipe...

Page 49: ...r resul inp in weak spark in 8 Float chamber f rellevel 0111 crf adjustmen1in carburetors w r y in hiph 1 sped mnge I Dirty or heavy exhaust smoke Replace Replace Ar pist Replace Replace Adjust Adjust...

Page 50: ...incorrect tire 4 Lmxc nut on axle I Wenkened springs 2 Not cnough fork oil Replace Retighten Replace Refirl Noisv shaft drive Nnise seemr rc 1 come from secnndarj hrvel gear and Final hcvt 1eear aswm...

Page 51: ...1 1 Distorted wheel rim 1 Replscc 2 Worn do rbn rear wheel bcnrings Replace 1 3 Dcfectivc or incorrect tiie Replace 1 Weakened springs I Replace too soft 1 2 Rear uspension adj istors improperly sel...

Page 52: ...nerator dues I Lead wires tend to ger shorter or open I charge bul circuited or loosely connectcd at terminals chargingrate is 2 Grounded or open circuited stator coils of generator 3 Defectivesilicon...

Page 53: ...rcscrihed level or adjust Zhc S G by constrltinp the battery maker s directions 3 The hntrcry left rnuscdb r too long Replace the bat ery Iespeciallv in cold climates if badly sulfated Ratter dircharp...

Page 54: ...VALVE GUIDE VALVE STEM SEAL VALVES VALVESPRINGS VALVE COTTER TO VALVE STEM CYLINDER HEAD INSTALLATION CYLINDER HEAD SPROCKETS ON CAMSHAFTS POSITIONING CAMSHAFT IN PLACE CAM BEARINGCAPS CAM CHAIN IDLER...

Page 55: ...ADVANCER FOR CONTACT BREAKER 7 34 CLUTCH 7 35 REMOVAL 7 35 INSPECTION 7 36 INSTALLATION 7 37 SECONDARY BEVEL GEAR ASSEMBLY 7 39 SECONDARY DRIVE GEAR ASSEMBLY 7 39 SECONDARY DRIVEN GEAR ASSEMBLY 7 42...

Page 56: ...ENGINE Fig 7 1 7 3...

Page 57: ......

Page 58: ...ear of the fuel tank Remove the tank rearwards Set the fuel cock lever to the ON hr IIES position and shift the fuel pipe clip sideways to remove the two hoses from the fuel cock Remove the Iead wire...

Page 59: ...opening side and the closing side GI to renlove the respective cables from the carburetor lever Loosen the starter cable lock nut 3 and remove both inner and outer cables from the carburetor Loosen th...

Page 60: ...lcn e arm bolt and rernovc tlic clutch rclcncc nrnr hy lifting it upward NOTE The frame on tJrp upper portion of the breather c o v w mav be damaged if the ptt i ne assernh v is morrt ted and dismoltr...

Page 61: ...orc tightening the exhausi pipe bolts install both right and left muffler mounting bolts loowly After tightening the exhaust pipe bolts tighten both right and left muffler mounting bolts Exhaust pipe...

Page 62: ...rements i Inore than 2 kg cm2 and 3 cornpre sion pressure in t hc four cylinders each is belaiv 9 kg cm2 stanrlard even when it measures more than 7 kg crnl Con pression tcst procedure NO TE I R f o r...

Page 63: ...I2 to I numbers are cast on head next to nuts TACHOMETER DRIVE GEAR Remove tachometer drive Rear from head by pulling the assemblv out after removina its stopper sccurcd by n hex phillips screw W 1 Fi...

Page 64: ...in Ihc follo ving manner 1 Using the valve lifter comprers the 4 From the other side pull out the valve _ 2 spring Fig 7 31 Valvc lifter VALVE GUIDE REPIAACEMENT Drive the valve guide out toward cyli...

Page 65: ...tainer 3 09916 34530 VALVE STEM SEAL 1 Oil each oil seal and drive them into position with the valve stem seal installer Be sure to use a valve guide and stem seal installer attachment handle on the p...

Page 66: ...ssively becomes shorter from one end to the other Large pitch portions are indicated as 0 small pitch portions as B ENGINE Fig 7 39 VALVE COTTER TO VALVE STEM 4 Put on the upper valve seat and using t...

Page 67: ...mrn nuts sequentially in the ascending order of numbers on head Tighten the twelve 10 rnm nuts to specification with a torque wrench sequentially in the ascending order of ntrmbers After firmly tighte...

Page 68: ...ainst letters IN for intake Similarly the right end can be distinguished R from the left end L of each camshaft Camshalt sprocket bolt tightening torque POSITTONING CAMSHAFT IN PLACE 0 8 1 1 kg rn h 0...

Page 69: ...ints flush with the gasket surfacc of the cylinder head Engage the rimin2 chain with this sprocket Fig 7 52 The other arrow mark 2 is now pointing straight upward Put the intake cam in place and count...

Page 70: ...with other type of hi h srren p hbolts T a k special care mi fro use o t h r type hrhts insfpad of t k p s p special bolts TO icl nr f l rhese bolrs eczch of t h 1 1 has a frgur 9 on its head CAM CHA...

Page 71: ...7 59 pushrc press CAUTION As srclraci pr viouslv lo 1101 t t t p f 1 0 reverse direction coiancer clnckivise thus cau5iny the chain to push back the ren sioner Fig 7 62 I ttrr over t i mrlk hufi by 1...

Page 72: ...rhnut TAPPET CLEARANCE ADJUSTMENT I After checking tensioning action check all valves for tappet clearance and as necessary ad just the clearance to the specificaton outlined on page 3 6 TOP END INSPE...

Page 73: ...ut with a dial gaugc Re place thc camshaft if thc r t n o u texcccds tlic limit Carnshaft runoirt IN EX Scrvict Limit 0 1 rnm 0 004 in o l camshaft bear in cap and outsicle diameter 1 o l camshaft Rep...

Page 74: ...ness is found to have been reduced to the limit replace it Valve head thickness IN EX Scrvicc Limit 0 5m m 0 02in Service Limit 1 0 03 rnm 0 001 in 1 Fig 7 74 VALVE GUIDE VALVE STEM CLEARANCE Fix 7 72...

Page 75: ...g specification Standard Valve seat width Standard 1 0 1 2mm10 04 0 05in If either requirement is not met correct the seat by servicing it as follows a Fig 7 73 ALVE SEAT SERVICING Fig 7 76 The valve...

Page 76: ...is made The finished valve seat shotlld have a velvcly snlooth finis11 and not a highly polished or shiny Finish This will provide a soft sz rface for the final seating o f the valve which will occur...

Page 77: ...et surface of the cylinut 1 head for distortion with a straigll tedge ancl thickness gauge taking a clearance seading at several places indicated If the largest reading at any position of the straight...

Page 78: ...nto the holder and handle twist the spring by one complete rotation counterclockwise and Tit he handle onto the shaft I F 2 llluYc he nushrod back and forth with Fingers if it moves smoothly as it sho...

Page 79: ...s 1001 curl be used on rite cvlir d r hpad roo REMOVE PISTON Place a rag beneath the piston to prevent parts from falljng into tllc crankcase and remove the circlip with pliers Cylinder disassembling...

Page 80: ...ANCE As a result of the above measurement if the piston clearanceexceeds the limit shown in the table below overhaul the cylinder and use an oversize piston or replace both cylinder and piston PISTON...

Page 81: ...d They bear the foIlowing identification numbers 1 0 mrn NIL NIL Oversize oil rings The following ovcs sizc piston ring sets are available 0 5 mm over size PISTON PTN PIN BORE CLEARANCE Using a calipe...

Page 82: ...ter and the piston pin outside diameter exceeds the ahovementioned Iimit replace both con necting rod and piston pin INSTALLATION Mount the piston ring in the order of oil ring 2nd ring and top ring T...

Page 83: ...sure to remove tthc carbon left on the upper part o f the piston using a soft metal scraper Coat the piston pin with engine oil and insert the piston pin into the piston by pushing it by hand directi...

Page 84: ...in slall No 1 and No 4 pistons and insert lhern into the cylinder NOTi Do lot overti Jrf rr tlte special too hn ldsor he rylind rsu illnot admit t l t l i t 0 1 m To F L P t z ra A sf t f w f I I Z P...

Page 85: ...the rotor with a hammer Rotor remover set 09930 30102 leakage and tighten generator cover screw 4 C 4 k Tg 7 118 Remove roller R spring r2 and push piece from starterclutch GENERATOR ROTOR REMOVAL Th...

Page 86: ...super 1303 99000 32030 CONTACT BREAKER POINTS REMOVAL Remove points cover and gasket Remove the mounting screws and points Thread Iock sllper 1 303 Uolt tightening torque Fig 7 I23 9 0 10 0 kg rn IG5...

Page 87: ...emove mounting screws LUI C U I I L L L breaker assembIy and then remove the assembly and the automatic advancer I Fig 7 127 INSTALLATION Installation is carried out in the reverse order of removal Ma...

Page 88: ...plnrc 24 Oil sen1 10 Driven pl ilv 25 llcnrin 1 1 Prcsqurr plaie 26 Clutch rclcasc ijrm 12 Sprinp 27 Roll 13 Rnlt 18 V IVC rv cltcrwat 14 Waslrcr 19 1Ysvv mnshcr 15 Oil pwnp drivc Fenr 30 Slnppcr rine...

Page 89: ...g and spring seat from the clutch sleeve hub INSPECTION I DRIVE PLATE THICKNESS Measure the thickness of each drive plate with vernier calipers Replace drive plates found to have worn down to the limi...

Page 90: ...e plate confirm both pasts fit snugly while rotating primary driven gearleft and right Fig 7 141 Fig 7 I44 Drive plate claw width 11 0 rnm 0 46 0 47 in 0 43 in CLUTCH SPRING FREE LENGTH Measure the fr...

Page 91: ...er tightening the clutch sleeve hub nut be sure to lock the nut by firmly bending the tongue of the washer Tightening torque for the nut is specified Insert clutch driven plate ant1 drive plate one hv...

Page 92: ...EMBLY REMOVAL AND DISASSEMBLY Remove the secondan unit cover remove drain plug and drain oil into a pan Remove the four mounting bolts and remove the secondary drive gear housing from the crankcase 3...

Page 93: ...i n t i n heasitiff preload adjustment W941 84510 Use special tool O to install the outer bearing races into the drive sear housing Fig 7 156 Bearing instalIer set 09924 84510 Use special tool 2 to in...

Page 94: ...rings Use special tools through dl to measure the torque necessary to turn the gear Thi is the bearing preload Fig 7 159 09924 545 1 09910 23710 12 15 kg m 87 0 108 5 Ib ft 3 5 kg crn I Preload 2 60 4...

Page 95: ...to the crankcase For backlash ant tooth contact ad justments see section 7 46 1 Nut tightening torque SECONDARY DRIVEN GEAR ASSEMBLY REMOVAL AND DISASSEMBLY Remove drive unit cover and drain secondary...

Page 96: ...special tool to install the outer 164 bearing races into the secondary driven gear housing Fig 7 166 Benring and oil real remover Rotor remover shafl set Bearing inner race W941 84510 NOTE It will he...

Page 97: ...r hcaarirlr pwlnad is Correct Install the propeller shaft flange washer and nut on the driven gear and tighten the nut to specification REARING PRELOAD ADJUSTMENT After the nut is tightened to specifi...

Page 98: ...46 SECONDARY GEAR SET CLEARANCING OPERATIONS RACKLASH Install the housing 5hirns removed during disassemldy anto secondary drive genr housing and secondary driven gear housing NOTE No o ringsarp rrs...

Page 99: ...using with correct shim into the crankcase and torque the bolts to specificat ion NOTE No o rirrg is usedai f1li s stage Shift the engine gearbox into 1st gear to provide load and turn thc secondary d...

Page 100: ...he irrsralied with the f rters UP focirtg n pward as shown in Fi s 7 169 7 170 a Use SUZWKI THREAD LOCK 1342 on the threads of the housing bolts and tor que to specificstion Reinstall secondary gear d...

Page 101: ...emove oil pump drive gear needle bearing and spacer Remove the circlip of oil pump gear and then the gear Remove three oil pump mounting bolts and r r 7 s remove oil pump body from crankcase 2 Remove...

Page 102: ...0 008 in Side clearance INSTALLATION I Installation is carried out in the reverse order of removal Thoroughly wash the oil pump inner and outer rotors and oil pump case with solvent and apply engine...

Page 103: ...ToIlowing manner Install the oil pressure gauge ri in rlic position shown in thc figure Warm up he engine as f o l o w Summer 10min or so at 2 000 r min Winter 20 min or so at 2 000 r rnin After warmi...

Page 104: ...hamber Cap 2 Rr btwrscnl ring Put on the cap T and secure it tightly Install ail drain plug SUMP FILTER REMOVAL Remove screws of oil pan 7 and remove the oil pan from crankcase Fig 7 18 v Remove three...

Page 105: ...shaft B g retainerscrew 3 pcs overarl length 16 mm Drive shaft plate screw 4 pcs overall length 16 mm 3il pump gallev plate screu 3 pcs overall length 16 mm Pull out the spring guide i mounted on the...

Page 106: ...lastic hammer lo separate the upper and lower crankcase halves and then lift the latter Remove the crankshaft sub assembly counter shaft gear and drive shaft gear which are all mounted on the upper cr...

Page 107: ...sure the amount of wear on the connecting rod big end If worn more than specification replace the crankshaft Thickness gauge Connecting rod big end wear 09900 20803 I Crankshaft runout Support the cra...

Page 108: ...tall in the shafts arid gears wash them in a cleaning solvent Before mounting the gears on the outer shaft apply the engine oil to rhe gear bore d For gear installation refer to Fig 7 203 Be sure that...

Page 109: ...unr the 2nd drive gear on the outer counter shaft appfy SUZUKI MOLY PASTE 99000 25240 to both sur faces of the washer sparin and install the washer Sparingly I SW Z W MOL Y PASTE 99000 251401 to the a...

Page 110: ...6 Drive shaft 7 Luck wasl er 17 Washer 8 3rd drivcn gear 18 Bearing 9 Ru5h1ng 19 Spacer 10 IV3rlier 20 Oil seal NOTE Order o f m o u n w of spacer CO washer I b circIip 3rd driven gear I lock washer...

Page 111: ...irclip is correctly installed Fit it to the side where the thrust is as shown in the figure There is an oil hole in the shift fork groove for the 5th driven gear When installing the 5th driven gear th...

Page 112: ...lower crankcase with solvent to remove any sealing compound Firmly insert crankshaft locating pins 3 transmission gear locating C sings for bearings on both sides and locating pin 4 4 6 Fig 7 222 Moun...

Page 113: ...fting forks for 4th and 5th driven gears 9Cam stopper Apply engine oil to gear shifting fork and gear shifting cam Completely wipe off oil on the mating surface of lower crankcase and apply sealing co...

Page 114: ...o f rhr crankcase halves upper altd lower shozrld be 0 I mrn or less ThoroughJy wipe off arl v overflow of the sealing compound applied to the matirtg surfaces of crankcase before installing the s e...

Page 115: ...VAL AND D MBLY 8 7 INSPECTION AND REASSEMBLY 8 9 FINAL DRIVE GEAR PRELOAD ADJUSTMENT 8 10 ElNAL DRIVEN GEAR ASSEMBLY 8 11 FINAL GEAR BEARING COVER SHIM ADJUSTMENT 8 13 BACKLASH MEASUREMI 8 13 TOOTH CO...

Page 116: ...SHAFT DRIVE SHAFT DRIVE...

Page 117: ...SHAFT DRIVE 7 0 kg cm 3 45 6 05 Ih in Clearance 0 05 0 I5 mm 0 002 0 006 in Fig 8 2...

Page 118: ...SHAFT DRIVE Fig 8 3...

Page 119: ...SHAFT DRIVE 1 Part No Shim thickness 1 Part No Shim thickness Shim thickness 27327 45100 0 35 mm...

Page 120: ...hole A to chamber B and passes through the gap between rib RI and bearing case to the atmosphere through the breather hole I F Oil passage When the finJ gear case pressure rises abruptly or when the g...

Page 121: ...o detach it from the swing arm Remove ten final gear bearing case bolts Fig 8 6 To remove the final gear bearing cover from thc housing use two 6 rnm screws screw them into the holes provided and draw...

Page 122: ...hold the coupling and remove the nut FFis 8 12 09900 06 108 Snap ring plier Remove the washer and coupling and tap the drive gear shaft with a plastic hammer to remove it from housing Do not lose the...

Page 123: ...l gear case oil seal use special tools O and I Fig 8 193 Fig 8 I 9 If replacing the final gear case remove the three drive housing studs and shock absorber mounting stud INSPECTION AND REASSEMBLY NOTE...

Page 124: ...ecification measure the bearing preIoad 9 0 1 1 0kg m 65 O 79 5 Fb ft 09924 64510 Bearing 111stalEer using special tool O with a A x d o adapter Socket Fig 8 24 09913 845I 0 NOTE Rofate the gear sever...

Page 125: ...m thickness Correct Increase shim thickness Once the bearing preload is correct remove the nut washer and coupling and remove the final drive gear from the housing Using special tools 3 and 8 install...

Page 126: ...tools O z51 ar d8 Fig 8 29s lnstall the ball bearing onto the final driven gear usin2 specid tool O Fig 8 303 I Thread Lock 1342 Bearing oil seal installer handle Fig 5 30 99000 3 2050 I 09124 745 Pla...

Page 127: ...learance 0 05 0 15 mm 10 002 0 006 in SHAFT DRIVE P rtNumber Fk 8 32 BACKLASH MEASUREMENT Using the shims removed during disassembly install the final drive gear housing witl fouto ring into the final...

Page 128: ...to case shims 1 40mrn 1 05rnrn 2 45mrn Final gear cover to bearing shims 0 50mrn 0 35rnm 0 85mm 3 30mm List of Shims FinaI Gear Covet to Bearing Part Number 27326 45104 45 100 45101 45103 45102 TOOTH...

Page 129: ...ve gear housing and final gear case the final gear backlash may change and shotcld be re checked according fo he procedure ourlined under the Backlash Measurement sub section Both ad jusrments may nee...

Page 130: ...tal1 a new oil seal into the propelIes shaft coupling Snap Ring Pliers Install a new o ring on final drive gear housing lubricate it lightly with Hypoid gear oil and install the housing into the final...

Page 131: ...FUEL SYSTEM R CARRURETORS FUEL SYSTEM CARBURETORS FUELCOCK 9 2 FUELTANK 9 2 CARBURETORS 9 3 STARTERUNET 9 3 TROUBLESHOOTTNG 9 12...

Page 132: ...via the diaphragm unit hut directly lhrot gh thc RES reserve pipe ON Normally used Func ionq as auto cock RES Rcserve fttel i q used Function as auto cock PRE F rclis dircc lysupplied Does not ft r c...

Page 133: ...at medium or high speed and a float unit for maintaining a constant carburetor fuel level The carburetors mix gasoline with air and regulate the mixture Carburetor malfunc tioning or trouble generally...

Page 134: ...n out through the needle jet T h e passage is narrower near the pilot outlet and this is where the negative pressure builds up This negative pressure allows a hiyhly concentrated gas mixtiire to be dr...

Page 135: ...n bore to the surface of the gasoline in the float chamber I t is kept regulated by the opening or closing of the fIoat valve When the gasoline flows in through the float valve the fuel level of the f...

Page 136: ...4 Spring 59 Tlirottlc return spring 25 Plnlc 60 Scrcw 26 King hI Lock rra her 23 Plate 1 2 Throttlc stop diuster 28 Rrackcl 63 Ttimtllr rclurn pr np 29 Scrtw h Throttle h fi 30 Lock washer 67 Choke lc...

Page 137: ...e screw in the slot Draw oul tlic choke shaft Grease the throltle shaft and install it in he carburetor Leave the throttle shaft screw loose Fig 9 17 Remove the plate A total of 8 screws must be remov...

Page 138: ...he rnairl bore Move the throttle valves up and down 2 or 3 times to make sure that the four rt rottle valves are positioned evenly and tighten the locknuts O Fig 9 22 FULL OPEN POSITION Adjust Full th...

Page 139: ...E When checking hefuel level place the machitte on rJw center r a r d The firel level shotrld he 20 m m 10 8 in above rhr rear end ofthefloat clrarnhar Fuel level adjustment If distance A is not withi...

Page 140: ...g at 1500 2000 r min Hexagon wrench 4 rnm 09911 70130 Fig 9 30 Carburetor balancer set 4 Turn the air screw of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball in...

Page 141: ...ove diagram remove the carburetor top cover and correctly sdjust the throttle valve adjusting screw with special tool IT Fig 9 L I Throttle valve adjusr wrench Install the top covers on the carburetor...

Page 142: ...m carburetor s joint 2 Check and adjusr vacuum gauge joint or starter 3 Pilot outlet or bypass is clog 3 Check and clcan 4 Starter plunger is not fully closed 4 Check and adjust Medium nr 1 Main jet o...

Page 143: ...efer to the sections through 78except for the items described in this section CONTENTS I VIEWOF SUZUKlGS850GD SPECJHCATIONS PERIODICMAINTENANCE W R NGDIAGRAM WIREANDCABLEROUTING T GHTENING TORQUE SERV...

Page 144: ...I VIEW OF SUZUKl GSSSOGD L 18 LEFT SIDE...

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Page 147: ...nce e RER IODIC MAINTENANCE SCHEDULE Rewlat NOTE r T i n h 1 Inspect R Replace C Clean INTERVAL THIS INTERVAL SHOULD BE JUDGED BY ODOMETER READING OR MONPMSWHICHEVERCOMESFIRST 4 000 6000 12 Engine oil...

Page 148: ...s j8 7OGfj L I WIRING DIAGRAM...

Page 149: ...WIRE AND CABLE ROUTING Body ground Rear N r n signal Clamps clamps 1 clamp Clarnn Turn signal relay A Rear rurn signal Clamp Clamp motor...

Page 150: ...Throttle c Clutch cable Clutch cahfe...

Page 151: ...rator rotor bolt 1 5 2 0 5 0 7 0 1 1 1 3 0 6 1 0 P P P P Oil strainer screw Gear shifting cam stopper spring holder bolt Gear shift arm stopper bolt 6 10 4 7 60 70 11 0 14 5 36 0 50 5 8 0 9 5 4 5 7 0...

Page 152: ...GS850GDJGLD CHASSIS nt fork i rnt and r It clamp b e oil bled nountin d e r boll F bolt 3r brake a l gear t...

Page 153: ...15 0 3 1 0 2 0 5 2 4 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 6 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 8 10 t6 1 0 7 6 7 0 11 5 18 28 1 8 2 8 43 0 20 0 T 0 22 35 2 2 3 5 16 0 25 5 40 60 4 0 6 0 29 0 43 5...

Page 154: ...Valve guide I D 7 000 7 01 5 I N E X 0 2 7 5 6 0 2 7 6 2 I 1 I Valve stem O D 1 IN Valve stem runout I I IN et EX 1 Valve head thickness Valve stem end length 1 IN EX 1 0 17 1 Valve seat width IN EX...

Page 155: ...n pin at arrow 3 Cylinder head distortion 0 2 I 0 008 YCINPER PlSTON PISTON RING Unit mrn in ITEM STANDARD LIMIT compression pressure 9 12 kg cm2 7 kg cm2 128 171 psi TOO psi Compression pressurediffe...

Page 156: ...1 2 53 0 099 0 100 Piston ring thicknew 1st 1175 1 190 0 0463 0 0469 2nd 1 170 1 190 0 0461 0 0469 Piston pin bore I D 16 002 16 008 16 030 0 6300 0 6302 0 6311 Piston pin 0 0 15 995 16 000 f 5 980 10...

Page 157: ...MIT STANDARD 1 723 87149 x 33134 0 1 kg cm Above 1 4 psi 0 25 kg cm2 Below 3 6 psi at 3000 r rnin Drive plate claw width Clutch cable play Driven plate thickness 2 3 0 08 0 12 Driven plate distortion...

Page 158: ...gear backlash 0 1 3 0 003 0 005 Final bevel gear backlash Drive side 0 03 0 64 0 001 0 025 I Driven side 0 02 0 35 0 001 0 044 Secondary drive bevel gear preload 3 n A 2 60 b in Secondary driven bevel...

Page 159: ...k 0 5 0 20 0 02 I Pilot jet P J 1 I 4fl 1 Float height 22 4 k 1 O 0 88 k 0 04 Main jet IIS 1 0 0 041 0 810 03 0 8 0 031 Pilot outlet P 0 0 7 0 028 Bore size I D No 32 126 45161 I Throttle cable play...

Page 160: ...stance 3 5 SZ Secondary i Plug cap Plug cap 30 40 kfl Generator no load voltage More than 80 V AC at 5000 r min Regulated voltage 14 0 I 5 5 V a t 5000 r min Starter motor IStarter relay resistance 6...

Page 161: ...0 5529 Master cylinder piston diam Front 15 827 15 854 1 0 6231 0 6242 13 957 13 984 Rear 0 5495 0 5506 Brake caliper cylinder bore 38 180 38 256 Front 1 5031 1 5061 Rear 38 180 38 256 1 5031 1 5061...

Page 162: ...M ctane method or 89 octane or higher rateo oy rne Research Method Fuel tank including reserve 22 L 5 8 US gal reserve 4 2 L 4 4 US qt Engine oil type I SAE 1OW 40 Engine oil capacity C 3 000 rnl 3 2U...

Page 163: ...75 24 200 2 00 28 200 2 00 28 REAR 200 2 00 28 225 2 25 32 I 225 2 25 32 280 2 80 40 WAITAGE Unit W Icp I ITEM I SPECIFlCATlON Head ight HI 60 LO 1 55 TailJBrake light 8 23 3 32 License light 8 Turn s...

Page 164: ...GSA SOGDIGLD 11 VIEW OF SUZUKl GS850GLD RIGHT SIDE LEFT SIDE 19 22...

Page 165: ......

Page 166: ...tion type Transistorized Ignition timing 17 B T D C below 1 500 r min and 37 B T D C above 2 350rJmin Spark plug NGK B8ES or NIPPON DENSO W24ES U Spark plug gap 0 6 0 8 mm 0 024 0 031 in both NGK and...

Page 167: ...c 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 P...

Page 168: ...so has improved the timing advance performance during high speed operations Srgnal generator l g n l r o r unlr When the signal rotor is rotated in the system block diagram above the signal A is gener...

Page 169: ...r on the left side and dis connect the coupler from the signal generator As indicated in Fig 1 connect the pocket tester alternately to the terminals provided inside the coupler For this test use the...

Page 170: ...cs usoc csn WIRING DIAGRAM...

Page 171: ...CABLE ROUTING Turn signal control unit Guide Main wiring harness Horn prox 15 To fuse I Starter relay Cramp Handle SIW E R C b handle SIW R 1 Fuel ignit on SlVV lamp Clnrnp Headlight housing Turn sign...

Page 172: ...Throttle cable Cable guide Starter cab11 Clamo Clutch cable...

Page 173: ...TIGHTENING TORQUE ENGINE gcam st drive gea A erisk indicates new D model specification...

Page 174: ...lt 15 25 1 5 2 5 1 11 0 18 0 90 110 9 0 11 0 65 0 79 5 35 45 3 5 4 5 25 5 32 5 Propeller shaft bolt 30 40 3 0 4 0 21 5 29 0 Final gear bearing case bolt 20 26 2 0 2 6 14 5 19 0 Final gear case shock m...

Page 175: ...0 2 0 2 4 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 4 7 0 4 0 7 3 0 5 0 8 1 2 0 8 1 2 6 0 8 5 10 16 I 6 7 3 18 28 1 8 2 8 22 35 1 3 5 16 3 40 60 4 0 6 0 3 12 35 55 3 5 5 5 25 5 40 0 70 100 7 0 10 0 50 5 72...

Page 176: ...0 003 1 i IN I 0 025 0 055 0 35 I 0 0009 0 0022 1 1 0 014 1 Valve seat width Valve stem runout Valve head thickness IN EX IValve head radial runout I EX 6 945 6 960 0 2734 0 2740 1 IN EX I IN EX Valv...

Page 177: ...ain 20 pitch length Cam chain pin Iat arrow 3 20 th pin Cylinder head distortion Compression pressure 9 12 kg cm2 128 171 psi Compression pressure difference 0 10 0 004 157 80 6 213 1 0 2 4 0 008 3 Pi...

Page 178: ...15 980 E 0 6291 1st 2nd Piston pin bore 1 D Piston pin 0 D 0 18 Piston ring groove width 16 002 16 008 0 6300 0 6302 75 995 16 000 0 6297 0 6300 1 1 21 1 23 0 047 0 048 I 1r21 1 23 0 047 0 048 2 51 2...

Page 179: ...p reduction ratio 1 723 87 49 x 33 34 1 Oil pressure at 60 C 140 F Above 0 1 kg cm2 1 4 psi1 Below 0 25 kg cm2 I 3 6 psi at 3000 rlrnin CLUTCH Unit mrn tin I ITEM I STANDARD 1 LIMIT I Clutch cable pla...

Page 180: ...roove clearance Shift fork groove width 5 45 5 55 1 0 215 0 219 1 Shift fork thickness 4 95 5 05 0 195 0 1 99 1 SHAFT DRIVE rn in Jnit m LIMIT ITEM STANDARD I I Secondary bevel gear backlash 0 08 0 1...

Page 181: ...CARBURETOR e starter jet G S 32 5 Pilot screw P S PRE SET Pilot air jet P A J 180 Throttle cable play 0 5 1 0 0 02 0 04 Pilot c Valve seat GS8SOGDICLD Unit mm in...

Page 182: ...at 1 atm I 140 180R E l Y G B 1 Primary 1 tap tap 3 5 n Plug cap Plug cap Secondary I 30 40 kC2 Fuse size C I 10 A 10 A a Ignition 10 A Main 1 5 A Output terminal 10 A Generator no loadvoltage More t...

Page 183: ...ovt 1 6 0 06 1 2 0 I 0 08 1 0 30 1 0 012 1 Master cylinder bore Master cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam Wheel rim runout Front Rear Front Wheel axle runout T...

Page 184: ...er rated by the 1 Research Method 17 L T Fuel tank including reserve I 4 513 7 US lrnp gal 1 reserve L I 1 4 E 0 USilrnp qtl 1 I SAE 10W 40 Engine oil type I Engine oil capacity 3000 ml L 3 212 6 LlSl...

Page 185: ...FRONT 175 REAR 200 2 00 28 250 SPEC FIGATION kg crnz psi kPa kglcrn2 psi 2 00 28 2 2 5 2 25 32 2 25 32 280 2 80 40 kglcrn2 1 75 2 50 Headlight H1 60 Lo I 55 TaillBrake light 8 2313 32 RunninglFronttur...

Page 186: ...Prepared by SUZUKI MOTOR CU LTD Motorcycle Tecl nical Sentice Department 6th Ed June 1983 1st Ed January 1979 Manual No 99500 38002 03E Printed in Japan...

Page 187: ...EMISSlON CONTHOL R REG TI A 7 10NS EMISSION CONTROL REGULATIONS CONTENTS REGULATION 10 2 EMISSION CONTROL CARBURETOR COMPONENTS 3 0 3 GENERAL EMISSION INFORMATION 10 4...

Page 188: ...Categories Hydrocarbons HC Carbon Monoxide C0 All motorcycles 5 0Gram Kilon eser 12 Grams Kilomcter 50 cc Larger 8 0 Grarn JMiIe 19 3GramrJMile j This reguIation affects all motorcycles licensable fo...

Page 189: ...vided that they are the same size The car buretor specifications for the emission controlled GS850G are as follows CanvcntionaI Figure Used On Standard Tolerance ktCompc nents Emis inn Typc Figure Usc...

Page 190: ...ion from motorcycles by 1990 will only amount to approximately 0 5 NOx is formed during the combustion process at high combustion chamber temperatures CARBON MONOXIDE Carbon monoxide is a product of a...

Page 191: ...operly adjusted pitted worn or sticking 3 Ignition Timing Advanced or Retarded 4 Timing advance Too fast or too slow an advance rate 5 Battery Low charge or faulty Carburetion can also lead to high HC...

Page 192: ...AND TACHOMETER 1 1 1 HEADLIGHT 1 I IGNlTlONSWITCH 1 1 7 FRONTFORK I 1 9 STEERINGSTEM 11 15 STEERJNGSTEM BEARING 11 19 FRONT WHEEL 11 20 REMOVALOFTUBEANDTIRE 11 24 FRONT BRAKE MASTER CYLINDER 1 1 25 FR...

Page 193: ...and lower portions of the switch Remove themaster cylinder clamp bolts Remove the four screws two each on both right and left sides and remove the handlebars pad Remove throttle grip and throttle wire...

Page 194: ...frame MOUNTING Route the clutch cable between carburetors Nos 1 and 2 Next as shown in the drawing below route it along the upper left portion of the ignition coil below the upper steering bracket to...

Page 195: ...guide at the closing side on frc handlebars switch and lightly tighten the lock nuts Mount the throttle inner cables at the opening and closing sides respectively on the front and rear hoIes in the t...

Page 196: ...both ends of the speedometer cable with pliers and remove the cable from the speedometer gear housing and speedometer from the front hub MOUNTING Route the speedometer cable to the brake oil hose joi...

Page 197: ...g IIO I IIC 6 Scrcw Nut F E I 15 Rernove three screws ii securing the headlight Disconnect thelieadlight leadcoupler Remove adjusting screw lo Remove two screws 3 and remove the rim Remove three screw...

Page 198: ...emoval Route the lead wires of the ignition switch leFt handlebars switch front brake switch and turn signal light through the lower hole in the headlight housing and fasten the housing with two bolts...

Page 199: ...CHASSlS Fig I l I Y Secure the headlight with the three screws Adjust the vertical beam angle of the headlight see page I 1 7...

Page 200: ...ONT FORK 0 a 3 2 I 1 Air vdvc cap 6 0 1 1 sen1 2 Spring 7 Outer tube 3 Inncr tube 8 Seui prpc 4 Dusl xal 9 011 lotk piccc 5 Oil MPI slopper ring 10 Bolt Fig 11 20 laincd cnnsianl at 140 mm and charged...

Page 201: ...cle frame using string erc taking care not to bend the brake hoses Pull down the Front fork while rotating it MOUNTING Mount the front fork so that the upper end of the inner tube in the front fork is...

Page 202: ...fly nftes c l e c k i n in I drain oil Remove dust rail Remove Allen bolt mounted on the lower I portion of the front fork using the special tool i At this time firmly secure the cylinder using specia...

Page 203: ...driver Fronr fork oil seal installing tool at tachment METHOD OF MEASURING FORK OIL LEVEL Carry out the measurement with front fork damper assembIy removed from the motorcycle frame Carry out the meas...

Page 204: ...the air valve of the front fork and turn it manually clockwise until it stops Next turn valve G clockwise until it locks Inject air hrough air charging port musing an air pump hand pump Front fork gau...

Page 205: ...r suspension ro he chan edin ac cordance d r h the instructions and vice verm I j verv i nporrunr to hle d oxfa uir pre ssurlJ prior lo clratr irr the air presstire At tlri fitne drcrin fhe air slo l...

Page 206: ...e two bolts fastening the headlight housing and remove the housing from headlight bracket Remove the tachometer cable and speedometer cable on the meter side Rernove handlebar pad Remove the connectio...

Page 207: ...and remove the handle bar assembly with grip cable and handle bar switch together and place them on the upper part ofthe motorcycle frame Remove the steering stem head center bolt and remove steering...

Page 208: ...m porarily tighten the steering stern head center bolt to 2 O 3 0 kg rn 14 5 21 5 Ib it 5 Tighten the steering stem side bolt to 1 5 2 5 kg m 1 1 0 18 0 Ib ft 6 Turn the stem nut back slightly and tig...

Page 209: ...steering stem and tighten the front fork upper pinch bolt and Iower pinch bolt Then align the end of the inner tube with the upper end of the stem head 0 5 0 8 kg rn 3 5 6 0Ib Ft 1 Tightening torque I...

Page 210: ...racc EIICI bearing dri mer Press in the lower and upper races using special tool 3 Using special tool Two of the four tapered guides set in the special tool 9 are to be used Place the one with the la...

Page 211: ...or by raising up the engine with the center stand resting firmIy on the ground Disconnect the speedometer cable from the wheel Pull off cotter pin Q from axle nur a and loosen the nut Remove the axle...

Page 212: ...limit of the disk is specified below Front Brake disk Thickness Standard Limit Under 0 23 0 14 in 5 5mm 0 22 in a With the disk mounted on the wheel check the disk for face runout with a dial gauge a...

Page 213: ...im runout Rvnout Service Limit AXIAL 2 0 mm 0 08 in RADIAL 2 0 mm 0 OR in Fig JI 58 Spin the disk and wheel complete with the brake tire to check dynamic balance Fig 11 57 Uqe a 20 gram or 30 gram bal...

Page 214: ...g lo the wheel Never use a rneral hammer l ig I 1 62 Make sure that tile brake disk i s clean and free from grease Usc only nor1 pezro based cleaner After sccuring it in placc by tightenins the bolts...

Page 215: ...e front fork Maintain a uniform clearance between the axle holder and the fork side front and rear see page 11 10 Axle shaft tightening torque 3 6 5 2 kg m 26 0 37 5 Ib ftj Remove the jack from under...

Page 216: ...to aid checking of the tire balance Apply soapy water to the tire bead Hook the bead protector on the beaa wortion o f the tire Fit the rest of the tire using tire levers in a position well away from...

Page 217: ...brake hose to the master cylinder a REMOVAL Remove the headlight Remove the front brake switch lead wire Fig 1I 74 connected within the headlight housing Connect the front brake light switch lead Rem...

Page 218: ...s erc 0 6 0 9 kg m 4 5 6 5Ib ft r Attach a pipe to the caliper bleeder valve MASTER CYLINDER DISASSEMBLY and insert the free end of the pipe into a 0 receptacle Bleed the left caliper first and then t...

Page 219: ...ith a new one when the master cylinder is disassembled Inspect the primary cup for wear and damage and replace it with a new one if necessary Fig 11 81 Replace the brake hose every two years ASSEMBLY...

Page 220: ...lip removed in disassembly FRONT BRAKE CALIPER 1 Piqton pad se 6 Pisfonboo1 1 t Cap 2 Pad set 7 Caliperholdcr 12 Roll 3 Oring 8 Screw 13 Washer 4 Axlc dust cover 9 Caliper axle 14 Lock washer 5 Pistnn...

Page 221: ...uid into the reservoir up to the High level line w See page I f 26 for air bleeding of the caliper and brake hoses Tichtcning torquc CALIPER 1 S 2 5 kg m I l O 1 8 0 lb ft CALIPER DISASSEMBLY Loosen a...

Page 222: ...l and boof I NSPECTION Check brake pads for wear A pad worn down n o the limit indicated by the red groove on the edge must be replaced I Par1 KO Z 2 Pod U a I 3 Rcd crorn CHA 5 71 7 Fit the caliper h...

Page 223: ......

Page 224: ...d runs into the scceptacle in the ca5e of the front brake 13ie lcvcr touches the handlchar When the pedal is abaul 40 m m 1 6 in from I he footrest whet1 deprcsqing cloxc tlre bleeder valve and rcleaq...

Page 225: ...17i rnn Fig 11 102 Reniovc the pad in pectioncap Draw out the two pins 5 supporting each pad a stop pin 173must he pulled off first from the end of each pin msi A t the samc time remove the two spring...

Page 226: ...ings with fingers insert the other pin through the shims and pad into the caliper body Set thestop pin into rhepin hole Place the inspection cap back on the brake pads Bleed the air from the system as...

Page 227: ...inder to the frame and lower the cylinder Remove bolt Osecuring the reservoir and remove the reservoir from the frame Remove rhe master cylinder by lifting i t up MOUNTING Fasten the reservoir with on...

Page 228: ...e from rhe master cylinder Take off the boor and take out the circlip usirlg special toot ASSEMBLY Reassemble the master cylinder in the reverse order to disassembly with the fallowing additional step...

Page 229: ...s rule is strongly recornrnenderl Replacemcnl interval Two years Components of master cylinder assembly Use Suzuki Genuine parts Master cylinder cup set Component ofcaliper assembly Use Suzuki Genuine...

Page 230: ...wrench to one of the caliper bolts and use the wrench as a lift handle While lifting the swing arrn differen tial Insert the socket wrench handle through the righi mufftcr support and swing arm hole T...

Page 231: ...rea Depress rhc Trot11 fork y r 1 6 filler vnIvcs to rcmovc all air prc iii v from 7 tlie systcm Remcinher to hleccl prcsairc k off slowly To compress thc f nrks tun1 the forks to the right Ibrk stopp...

Page 232: ...6 0 77 in 0 24 in Fi ig 11 128 Reinstall disk on huh With the disk mounted on the wheel check the disk for face runout with a dial gauge as shown Tightening torque Rear brake disk ninnout 2 0 3 0 kg m...

Page 233: ...t Inwrt Ilic avIe through to rhc risht sick o f the swinginy arm Insrnll and tjsIltcn tlic axle riirt securely Fit lhc cotter pin in tllc axlc nur CAUTION ri J1etr reinsraltirl the rerrr caliper he ca...

Page 234: ...Exercise care ro prevent this happening Be coreful not to bend or twist the brake hose the swinging arm tie the rear brake caliper with a string and hook i t on to the frame MOUNTING Install both inne...

Page 235: ...m torque 7 5 C14 0Ib ft Fig 11 139 Install the secondary boot Install the final drive bevel gear assembly See page 8 14 Install nhc rrnr stop light switch Mount the rear wheel Seepage I 1 42 DESASSEMR...

Page 236: ...ach absorber turn the spring seat as shown in the photo to bring the other notch to the supporting lug This alters spring tension The spring seats of both absorbers are factory set at Notch 1 which is...

Page 237: ...Posi ion1 This combination is calculated to provide the best cushioning effect for the average build rider of 68 kg 1515 Ibs for solo riding at about 60 miles h 95 km h on the highway wifihout any ac...

Page 238: ...fl erential up hy allaching the 14 mm wrench to one of he caliper bolts and use tlie wrench as a lifL handle While lifting the swing nrm differenr ial inscr the sockel wrench handle hrouyhtlie righl m...

Page 239: ...CHASSIS ASSEMBLY Carry out assembly in the reverse order to removal Tighten the nuts to the specified torque Rear shock ahqorbes 2 0 3 0 kg rn tightening torque 14 5 2 1 5 Ib f...

Page 240: ...NTENTS IGNITIONSYSTEM 1 2 2 SPARKPLUG 12 3 CHARGING SYSTEM 1 2 5 STARTER SYSTEM 12 8 BATTERY 12 10 SELF CANCELLING TURN SIGNAL SYSTEM 12 14 TROUBLE SHOOTING 12 15 UTILITY SWITCHES AND DEVICES T 2 20 W...

Page 241: ...os 1 and 4 cylinders presents no problem and the same applies to Nos 2 and 3 cylinders Ignition order is 1 2 4 3 counted from left to right by the rider mounted the machine I t should be noted that No...

Page 242: ...ways be used and they should be properly adjusted and cleaned Fgnition timing NPPON NGK DENSO Remarks IT the rlandard pliie i apt lo c t B7ES W22ES wet rcplacc wil h Ihi plug Hor 1YW If thr taltdard p...

Page 243: ...th a pointed end If electrodes are extremely worn or burnt replace the plug Also replace the plug if it has a broken insujator damaged thread etc Fis 12 9 Normal carbon condi ion 1 Thickness gauge Fie...

Page 244: ...switching SCR thyristor on and the current stops flowing to the battery and instead flows to ground In this way the battery is protected from overcharging ELECTRTCAL SYSTEM When the battery is dischar...

Page 245: ...Stop the engine and connect the AC generator lead wires Make sure the battery is fully charged by measuring the specific gravity of the battery electrolyte I f the specif c gravity is less than 1 26...

Page 246: ...ne voltage 14Y 14V t t r u c LII I 5 5V over Fig 12 16 Using the Pocket Tester check continuity between the three lead wires yellow white with blue tracer and w h i ewith green tracer coming from the...

Page 247: ...ctarter motor to the battery The motor draws about 80 amperes to start the engine STARTER SYSTEM T f AGRAM r I 1 A Slam l uw 15 A I I 3 Ignition aifu i S rAKTf K C Fu c FDA 13 Fnvinc kill qiw cli STAR...

Page 248: ...cylinder block and drives the crankshaft through a series of gears and a one way clutch which is mounted on the alternator rotor INSPECTION OF COMPONENTS Carbon brushes When the brushes are worn the...

Page 249: ...the motor and measure the voItngc between the posizive terminal of the motor and pound and also between I IP positivc terminal of the battery and ground I f the two readings ate equal it means that th...

Page 250: ...itial charging duration being 20 hours The charging time is to be delermined according lo the following Datc ol t g i a i i c t u r e is indicated by a three part number Fig 12 29 lie leftmost part Ap...

Page 251: ...ry If signs of cracking or electrolyte leakage from the sides of the battery are noticed replace the battery with a new one 2 If the battery terminals are found to be coated with rust or an acidic whi...

Page 252: ...charged if three con ditions are met Recharging has been carried out to the specification indicated in the graph in Fig 12 35 Efecrrolvte S G has risen to 1 280 or higher and has remained there for at...

Page 253: ...speeds faster than IS km h does the timer operate to switch the turn signal off automatically when the total time above that speed ex ceeds 9 sec r When the Turn Signal Knob is switched on again befor...

Page 254: ...lecrrolytc Rsllcr runs don r quickly I I he charrj g merhod i no1 cnrrccf 2 Ccll plotcc Iiaw lor much of rhrir actrrr material as a r e d l of over rharying 1 h lior3 ircui condirion exiw wrthrn he ha...

Page 255: ...H i t when Turn Signal Knoh i w rclird t 1 I iTT anr acrow I f and R W rvhetl 1 urn Signal Krioh ir rritchetllo RIGHT IIC IO I4V 3CrOlP 1 hl t and R Xi 1 wltcn Dcfcctivc Turn Signal Relay Ttrrn Srpna...

Page 256: ......

Page 257: ...ctivc component Is speed Sen or normal Scc 3 21 AEso check tighreness of connectors 1YES Defective Controt Unit NO 6 Flashing does not go ofl at a speed of 15 krnlll 19 3 mphE or more le and related c...

Page 258: ...he coupler connect the positive I fermind of rhe Pocket Tester to the ferminnl in rite coupler and connecr the negative I termin01 to Ihe orange lead wire If there is no continujty he indicaror l i h...

Page 259: ...e front brake light switch is tested for internal continuity Its lead wires are WHITE3and ORANGE with GREEN tracer Press I I C down on the brake pedal and continuity shouId be obtained 2 4 NOTE To mak...

Page 260: ...1 KILL SWITCH AND STARTER SWITCH These switches are checked in the same way as the lighting switch ELECTRICAL SYSTEM Kill switch ORANGE ORANGE WHFTE Starter switch Switch YELLOW GWEN ORANGENHITE posit...

Page 261: ...Confirm that each connection is tightly fastened Confirm that the beam angle is correct See page 11 7 for adjustment proccrllrre of the beam angle INSPECTION OF TAILIRRAKE LIGHTS AN11 TURN SICNAI LIG...

Page 262: ...ps between the amount of gasoline and meter indications are as follows 3 Construction of each portion and operating meter I Puintcr Tempcr lurcmmpmr ringhimetal 2 Main birnctal 4 c Main operation Curr...

Page 263: ...ration This point separation stops the current until the bimetal begins to cool which causing the point to connect again A large amount of current passes through the hearer wire whcn the supply voltag...

Page 264: ...and obrcrbc mclcr rndlcatbon Meter pornlcr swlngs l o cxlrcmc po ilion Wtrine harneasdelectivc I xruh u rmmal Conlac1of connector terminall Mfasurc rc i taticc raluc hcrwcrn two crmlnalr o f gnupc rt...

Page 265: ...I rnlnal vellow black lead wircl o f mrrcr or Elen uhcn rncrcr 19 normal nterruptcd gauge Icrm nal as it 1s conncc cdl or iollagc can lx obtained Wor cvcr hcrc Lonnector for gaugc and ground rhc mclc...

Page 266: ...tion S c i r u r c metrr Obrcrvc rncler ind calionafrcr corrccrvng is causcd by wlrc harnetq and connecror m h c normal defcclh c w r n g wlrlnp harncsr FLII I MFTFR I GAUGE I Check rtsis anccvaluc bc...

Page 267: ...WIRE ROUTING...

Page 268: ...ELECTRICAL SYSTEM How to route the high tension cord CABLE ROUTING How to routecontact breaker lead wire Thrmrkcahk I REAR BRAKE HOSE ROUTING Rear Inaster cr llnder 1...

Page 269: ...l m c t L kiii 5 I n i t r r c j j L u y E i u r E i m 2 0 c 3 c i r F Z i I z l r i L I 1 i K y F r z L i i i t c i55i p i i i J c o r m n e s m E 4 F t P C m i u 3 j o t m m m m m m 0 9 0 z 5 0 I n...

Page 270: ...y and adjust Idle RPM Check and adjust Exhaust system Lcakage Fuel system connection Cisdip CHASSIS Clutch cable Check and adjust Fronr brake Cable routing Rear brake Brake fluid The contacts between...

Page 271: ...Control cables Operation and proper return Leakage Fuel Oil Exhaust Speedometer and tachometer operation Digital gear indicator operation PREDELIVERY CHECKLIST Brake fluid level Front and rear Paint...

Page 272: ...described in this section CONTENTS VlEWOFGS850GT 1 4 2 SPECIFICATIONS 1 4 3 SERVICE DATA 1 4 5 TORQUE TABLE 14 16 SPEClALMAT ERIALS 14 18 PERIODIC MAINTENANCE 14 20 MOD1FICATIONS 74 21 CARBURETOR 14...

Page 273: ...models are the ignition system starter system and carburetors That is the ignition system has been changed to the maintenance free transistorized ignition system the kick starter system is eliminated...

Page 274: ...duction Gear ratios Low 2nd 3rd 4th Top 0 SECONDARY DRIVE Type Secondary reduction 2 230 mm 87 8 in 865 mm 34 1 in 1 190 mm 46 9 in 1 500 mrn 59 1 in 160 mrn 6 3 in 253 kg 558 Ibs 455 kg 1 003 Ibs Fou...

Page 275: ...arm oil dampened damper 4 wayJspring 5 way adjustable 40 right and left 6 2 00 f 13 mrn 4 45 in 2 6 m 8 5 it Disc brake twin Disc brake 3 50H19 4PR 4 50H17 4PR 1 75 kg crn2 25 psi Normal solo riding 2...

Page 276: ...00281 Q 014 Valve g u i d e r IN EX 7 000 7 015 40 2756 0 2762 Valve stem O D 0 2740 6 960 0 2746 6 975 k I 1 IN I EX 6 945 6 960 0 2734 0 274 Valve stem runout IN EX 0 05 I 0 0021 Valve headickness...

Page 277: ...unout Cam chain 20 pitch length chainr atarrow Cylinder head distortion LIMIT I 36 020 11 4181 35 470 1 3965 STANDARD IN 36 320 36 360 1 4299 1 4315 IN EX lN EX IN EX IN EX EX 0 037 0 065 0 001 5 0 00...

Page 278: ...7 6 880 2 7118 0 2 IO 008 7 2 0 28 7 6 10 30 0 7 0 03 0 7 0 03 0 18 0 0071 0 15 0 0059 16 030 0 637 1 15 980 0 6291 Cylinder distortion Piston ring free end gap Approx 9 0 0 35 Approx 9 5 0 37 Piston...

Page 279: ...clearance LIMIT 16 040 0 6315 STANDARD I 0 10 0 65 0 004 0 026 LIMIT 1 O 10 039 0 05 0 002 1 723 187 49 x 33 34 0 1 kg cm2 Above 1 4 psi 0 5kglcm2 Below 7 1 psi at 3 000 rlrnin LIMIT 2 4 0 094 1 1 0 0...

Page 280: ...roove clearance 0 4 0 6 0 8 0 0116 0 024 10 0311 5 45 5 55 Shirt fork groove width 0 215 0 219 Unit mrn in Shift fork thickness ITEM STANDARD LIMIT Secondary bevel gear backlash 0 08 0 13 0 003 0 005...

Page 281: ...GSSjOGT CARBURETOR Unit mrn Ein It screw rattle cable play...

Page 282: ...90 360n 31 G Ignition coil resistance O W W Primary Apprex 3 5St Plug cap Plug cap Secondary Approx 31 33 kS2 Generator No Load voltage More than 80 V ACF a t 5 000r min Regulated voltage 14 0 15 5 V...

Page 283: ...Rear 7 4999 1 5019 15 870 15 913 0 6248 0 6265 14 000 14 043 0 5512 0 5529 15 827 15 854 0 6231 0 6242 13 957 13 984 0 5495 0 5506 0 25 0 010 Wheel ax6runout Brake caliper cylinder bore Brake caliper...

Page 284: ...ENSION Unit rnm in LIMIT 416 I16 4 ITEMSTANDARD Front fork stroke 160 16 31 Front fork oil level Front fork spring free length 140 55 Front fork air pressure 0 6kg crn2 I 8 5psi Rear wheel travel 100...

Page 285: ...reserve Engine oil type Engine oil capacity 22 L 15 8 US gal 4 2 t 4 4 US qt SAE 10W140 Change Filter change 3 800 rnl 4 0 US st 2 800ml 3 0 US qt 3 600 rnl 3 8 US qt Front fork oil type SAE 1OWJ20 F...

Page 286: ...TlON Headlight HI 60 I LO 55 TaillBsake light 8 23 3 32 cp Turn signal light 23 32 cp Speedometer light 3 4 Tachometer light 3 4 Turn signal indicator light 3 4 I High beam indicator light 3 4 I Neutr...

Page 287: ...TORQUE TABLE ENGINE r head n ft bearir Camsha Cam ch et bolt bolt motor b ifting cal...

Page 288: ...ar torque link nut Rear axle nut Front brake caliper mounting bolt 2 0 3 0 5 2 5 4 0 Front and rear brake hose union bolt Front and rear brake disc plate bolt 1 3 1 8 1 5 2 5 9 5 13 O Front and rear b...

Page 289: ...4 pcs 99000 32050 SUZUKl THREAD LOCK CEMENT 1342 L SUZUKI THREAD LOCK CEMENT SUPER 13338 Gearshift cam guide screw 2 pcs Gearshift pawl screw 2 pcs Counter shaft BIG retainer screw 3 pcs Drive shaft...

Page 290: ...Rear Mating surfaces of u p p t and lower crank case Final gear wse Joint portion of rear swinging arm and final gear case 99104 3 114 SuZUKl BOND No 1207E Apply to caliper axle shaft 99000 25100 SUZ...

Page 291: ...rformance and to maintain proper emission levels Mileages are xpressed in terms of kilometers miles and time for your convenience PERIODIC MAINTENANCE SCHEDULE 3ner eler THIS INTERVAL SHOULD BE JUDGED...

Page 292: ...4 GS850GT MODEL GS850GN MODEL To make the valve timing better suited to the engine the mounting angles of both intake cam shaft and intake cam shaft sprocket are partly changed The result is the follo...

Page 293: ...a pre muffler GS850GT MODEL GS850GN MODEL FUEL SYSTEM The carburetor has been changed from MlKUNl VM26SS to MlKUNl BS32SS 5 fhrortle valve GS850GT MODEL 1 3 Jet needle 2 Needle jet 3 Main jet 1 1 4 N...

Page 294: ...d from the battery ignition system to the maintenance free transis torized ignition system rrh SIGNAL GENERATOR GS850Gf MODEL GS850GN MODEL I i The left handlebar switch has been changed as shown belo...

Page 295: ...fuse box and output terminal have been changed from the separate type to the combined type GS850GT MODEL GS850GN MODEL The headlight bulb has been changed to the halogen type GS85OGK MODEL GS850GN MO...

Page 296: ...N MODEL The front and rear brake disc plates are newly provided with holes and the resultant larger surface area provided better heat dissipation for improved braking efficiency GS850GT MODEL GS850GN...

Page 297: ...the clutch cable carburetor and cylinder has been reinstalled in relation ro the routing of the clutch cable make sure that the clutch cable is correctly routed through two guides and between the cyl...

Page 298: ...CARBURETOR fir E ring 95 Gasket k9 Seat 17 Needle valve 1q O ring 9 Filter 4lP Plats I Main jet Z Washer Needle jet 2L Plug 9 5 Gasket 36 Pilot jet 21 Float 2fl Ptn 139 Throttle valve Shaft 31 Lever...

Page 299: ...SPEC FICATIONS 32 mm 1 26 in I050k 100 r min Pilot outlet 0 7 50 0 5mrn Valve seat 2 0 0 20 1 0 02 in Starter jet 32 5 22 4 1 0 mrn 0 88 0 04 in Pilot screw PRE SET Jet needle 5050...

Page 300: ...of the venturi Vacuum is admitted into the diaphragm chamber through an orifice provided in the piston Rising vacuum overcomes the spring force causing the piston to rise to increase the said area and...

Page 301: ...through main jet and metered by pilot jet where it mixes with air corning in through pilot air jet This mixture rich with fuel then goes up through pilot pipe to pilot screw A part of the mixture is...

Page 302: ...mixes with the air admitted through main air jet to form an emulsion The emulsified fuel then passes through the clearance between needle jet and jet needle and is discharged into the venturi in whic...

Page 303: ...fuellair mixture for starting is produced when the mixture is sprayed out through starter outlet into the main bore FuellAir Mixture FLOAT SYSTEM Floats and needle valve are associated with the same...

Page 304: ...cock through passageway provided in the carburetor main bore and vacuum pipe and dia phragm builds up a negative pressure which is higher than the spring pressure Fuel valve is forced to open due to d...

Page 305: ...d remove the plate a Separate four carburetors remove nut and remove adjuster lever r Remove three screws and remove adjuster bracket Remove four screws and remove float cham ber Remove four screws an...

Page 306: ...le are worn out beyond the permissible 22 4 t f Ornm 0 88 k 0 04 in limits similar trouble will occur Conversely if the needle sticks the gasoline will not flow into the float chamber Remove the carbu...

Page 307: ...1 8 3 0 1bVft 1 0 25 0 45 kg m Tightening torque 1 8 3 0tb ft Thread lock cement a Secure adjuster lwer with nut 14 36 99000 32040 Connect the carburetors correctly and secure top of each carburetor...

Page 308: ...hrough carburetors and starter levers and secure starter lever with SCTEWS Before tightening the screws coat it with THREAD LOCK CEMENT 99000 32040 Align the end of screw with recess in starter shaft...

Page 309: ...ll the special tool 4 Move fuel cock lever to TRI position to When checking the fuel Iwel place the machine an the center stand The fuel admit fuel into float chamber 5 With the float chamber filled w...

Page 310: ...so that the vacuum acting on the tube of that hose will bring the steel ball in the tube to the center Carburetor balancer set 6 On the three other screws follow the same procedure as above 7 Remove...

Page 311: ...s adjustment adjust the idling speed to somewhere between 950 and 1 150 r rnin with throttle stop adjusting xrew CAUTION This check should be done as quick as pos sible If adjustment requires a longer...

Page 312: ...Larger Suzuki Motor Company performed all the necessary testing and certification of emission controlled models in strict compliance with the E P A testing regulations Suzuki motorcycle dealers are no...

Page 313: ...ement component Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability The carburetor specification for the emission controlled GS85...

Page 314: ...s sion from motorcycles by 1990 will only amount to approximately 0 5 NOx is formed during the combustion process at high combustion chamber temperatures CARBON MONOXIDE Carbon monoxide is a product o...

Page 315: ...on timing Advanced or Retarded 3 Timing Advance Too fast or too slow an advance rate 4 Battery Low charge or faulty Carburetion can also lead to high t4C emissions if the mixture is either excessively...

Page 316: ...o the ON or 0FF itching The collector is the terminal where voltage is supplied to the transistor and the emitter is the terminal for passing this current for usage when the base has the proper signal...

Page 317: ...ft side and disconnect the lead wire from the signal genera tor Turning the ignition switch to the ON positior Now connect pin of SWZUKI Pocket Teste X1n range with Blue lead wire on the ignftc side a...

Page 318: ...FRONT MASTER CYLINDER 711 Reservoir cap 2 Diaphragm 3j3 Reservoir 4 0 rine 5 Spring 161 Prrmary cup 7 1 Piston I Tightening torque 1...

Page 319: ...o catch spilled drops of brake fluid Unscrew the union bolt and dis connect the brake hosehaster cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid...

Page 320: ...a Pull out the reservoier and 0 ring Draw out dust seal boot GSh fOCT a Pull out piston primary cup and sprin m Remove circlip by using special tool 09900 06108 Snap ring pliers...

Page 321: ...solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internalsto be inserted into the bore I When remount the master cylinder to the handlebars first tighten the clamp...

Page 322: ...ton seal 3 Plston boot 4 Pad set 5 Pad shim 1 6 Caliper holder 7 Pad spring N Pad quide 5 Caliper axle No 1 rlu Caliper axle No 2 11 Awle boot 112 Bolt 113 Bleeder 14 cap 15 Cover 16 Bolt Tightening t...

Page 323: ...pads with pad shim Replace the brake pad with a set otherwise braking performance will be adversely affected Do not apply pad grease when installing the brake pads Push in the piston all the way to t...

Page 324: ...ceptacle m Remove caliper axle bolts and take off caliper Place a rag over the piston to prevent popping up Draw out the piston by using air gun a Do not use high pressure air for preventing piston da...

Page 325: ...ning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore r Apply grease to the caliper axles 8 Inspect the piston surface for any flow or oth...

Page 326: ...s and separate the driven joint from the wheel a Remove the bushings from the wheel REAR WHEEL REASSEMBLY Drive bushings into the wheel 5 5 6 5 mm GSfY 70GT Insert driven joint into wheel bushing m Pl...

Page 327: ...GScYSOGT WIRE AND CABLE ROUTING I U a rn 2 0 2 E m C...

Page 328: ...Clamp Clutch cable able...

Page 329: ...GSA SOGT WIRING DIAGRAM...

Page 330: ...of the GS855GNIGT and describes the new features of GS850GLT Refer t o the sections 1through 14 except for the items described in this section VIEWSOFGS850GLT 15 2 SPEClFlCATlONS 15 3 SERVICE DATA 15...

Page 331: ...tight sidl Left side 15 2...

Page 332: ...uction Gear ratios Cow 2nd 3rd 4th TOP SECONDARY DRIVE Secondary reduction 2 280 mrn 190 0in 900 mm 35 4 in 1 230 rnm 48 4 in 1510 mm 159 4 in 0 mrn 5 9 in 245 kg 540 IbsJ 455 kg 1 003Ibs Four stroke...

Page 333: ...rm oil dampened damper CwayJsprEng 5 way adjustable 40 right and left 6T040 105 rnm 4 13 in 2 6 m 8 5 ft Disc brake twin Disc brake 3 50H19 4PR 4 50H19 4PR 1 75kg crn2 I25 psi Normal solo riding 2 00k...

Page 334: ...I 00 1 3 9 l T fM Fuel type Fuel tank Engine oil type 426 16 8 I SPECIFICATION Use only unleaded or low lead type lfasoline of at least 85 95 pump octane JzF method or 89octane or higher rated by the...

Page 335: ...60 55 Tail Brake light Turn signal light 8 23 3 32 cp 23 32cp Speedometer light 3 4 3 4 Turn signal indicator light 3 4 High beam indicator light 3 4 Neutral indicator light Oil pressure indicator li...

Page 336: ...agm is forced to open the fuel valve and thus allow the fuel to flow to the carburetors On the other hand setting the valve in the ON position keeps the air return orifice open Negative pressure does...

Page 337: ...WIRE AND CABLE ROUTING...

Page 338: ...P T ghtenwlrlng harness together with clutch cable...

Page 339: ...WlRllNG DIAGRAM A 8...

Page 340: ...ICATIONS 16 3 SERVICE DATA 1 6 5 TORQUE TABLE 16 15 SPECIALMATERIALS 16 18 PERIODIC MAINTENANCE 16 20 CAMSHAFT SPROCKET AND BOLT 16 21 DRIVEN GEAR SHIFT FORK 76 22 GEAR SHIFTING SPRING 36 22 UNIVERSAL...

Page 341: ...Right sic Left sidf...

Page 342: ...ratios Low 2nd 3rd 4th Top SECONDARY DRIVE TYpe Secondaw reduction Final reduction 2 230 mrn 187 8 in 865 rnm 134 1 in 1 190 rnm 46 9 in 1500 mrn 159 1 in 160 mrn 1 6 3 in 830mrn 32 7in 253 kg 558 Ibs...

Page 343: ...gingarm oil dampened damper 4 waylspring 5 way adjustable 40 right and left 62 30 113 mm 4 45 in 2 6 m 8 5 ft Disc brake twin Disc brake 3 50H194PR 4 50H174PR 1 75 kg cm2 25 psi Normal solo riding 2 0...

Page 344: ...m O D Valve stem runeut Valve head thickness Valve seat width Valve head radial runout Valve spring free length IN EX Valve spring tension IN EX STANDARD I LIMIT I 36 0 IN 1 42 30 0 EX 1 78 IN 1 EX 1...

Page 345: ...60 1 4299 1 43151 35 770 35 810 1 4083 1 4098 Camshaft journal oil clearance Cam chain 20 pitch length Cam chain pin at arrow 3 I Cylinder head distortion IN EX 0 037 0 065 0 007 5 0 0026 20th pin 22...

Page 346: ...he 15 10 59 I from piston skirt end Cylinder distortion I Approx 9 0 10 35 Approx 9 5 0 37 0 30 0 30 0 004 0 072 2nd I Piston ring free end gap 1st N 2nd N Piston ring end gap Ist 0 10 0 30 1 0 004 0...

Page 347: ...D LIMIT Oil pump reduction ratio 1 723 87 49 x 33 34 Oil pressure at 60 C 140 FJ Above 0 1 kg cm2 11 4 psi Below 0 5 kg cm2 7 1 psi at 3 000 rlmin CLUTCH Unit rnm in lTEM STANDARD LIMIT Clutch cable p...

Page 348: ...0 8 I I 0 016 0 024 0 031 Shift fork groove width 5 55 0 219 I Shift fork thickness 4 95 5 05 I 0 195 0 199 SHAFT DRIVE Unit mrn in ITEM STANDARD LIMIT Secondary bevel gear backlash 0 08 0 13 0 003 0...

Page 349: ...CARBURETOR Unit mrn in Pilot air jet P A I 1 Throttle cable play 190 0 5 1 0 0 02 0 04...

Page 350: ...ELECTRICAh e No Loa l voltage dard ele at 5 OOC Unit mm in...

Page 351: ...6248 0 62651 1 ieTr 14 000 14 043 1 0 5512 0 5529 Master cylinder piston diam Front t 5 827 f 5 854 0 6231 0 62421 f 3 957 13 984 f 0 5495 0 5506 2 0 0 08 2 0 0 08 0 25 0 010 Brake caliper cylinder b...

Page 352: ...3 91 Use only or tow lead type gasoline of a t least 85 p octane R fl method or 89 octane or nlgner rated by the Research Method 22 L 5 8 US gal 4 2 7 4 4 US qt SAE 1OWJ4Q 1 I Change 2 800 ml 3 0US qt...

Page 353: ...TAGE sureinc ITEM e Unit W cp SPEC1FICATION 60 Headlight HI LO 55 faiI Btake light Turn signal light I 8 23 3132 I 23 132 3 4 Tachometer light 3 4 Turn signal indicator light 3 4 High beam indicator l...

Page 354: ...UE TABLE ENGINE chain gi ter clutcl 1st pipe rbolt i d e No tor bolt ernor bo r bolt Secondary drlve gear nut 12 0 f 5 0 Secondary driven gear nut 9 0 11 0 Secondary drive housing bolt shift letr e r...

Page 355: ...GS85OGX GLX CHASSIS Rear tor Rear ax shaft bolt 3 0 4 0 21 5 29 0 14 5 19 0 65 0 79 5 Final case oil filler plug 2 0 3 0 14 5 21 5 Propell e Final gez...

Page 356: ...18 Conventional or 4 Marked Bolt kg m 7 Marked Bolt Ib ft kg m 0 15 0 3 0 3 0 6 0 8 1 2 1 8 2 8 4 0 6 0 7 0 1Q O 11 0 16 0 17 0 25 0 20 0 28 0 Ib ft 1 0 2 0 2 0 4 5 6 0 8 5 13 0 20 0 29 0 43 5 50 5 72...

Page 357: ...Camshaft end cap screw 8 Front fork allen bolt 2 W Carburetor adjuster bracket screw 2p a Carburetor plate screw 8 C S Carburetor starter shah screw 4 PCS Driveshaft plal Generator starrer screw Gener...

Page 358: ...cylinder stud bolts Cam chain chamber 0 ring between head and cylinder I Mating surfaces of upper and lower crank case Joint portion of rear swingingarm and final gear case Apply to caliper axle shaft...

Page 359: ...roper emission levels Mileages are expressed in terms of kilometers miles and time for your convenience PERIODIC MAINTENANCE SCHEDULE INTERVAL p 1 6 0 0 4 0 0 0 7500 ll000 15000 THIS INTERVAL SHOULD B...

Page 360: ...Name Part Number Part Number Part Number Bolt 09106 06024 09111 06033 09103 07001 Lock washer 12747 44000 IN Cam sprocket 12741 45110 12741 45111 I IN Camshaft 12711 45110 12711 45117 EX Cam sprocket...

Page 361: ...rk has been changed as shown below EARhY GEAR SHIFTING SPRING The shape of the gear shifting spring when it is set free has been changed as shown below so that gears can be shifted with less effort A...

Page 362: ...tch has been changed and at the same time the bolt has been modified When the universal flange bolt is reused it should be coated with Thread Lock Super 1361A and tightened to specification asls C 990...

Page 363: ...GS QSOGX CLX TURN SIGNAL LIGHT Front and Rear CAUTION Do not overtighten the lens fitting screws...

Page 364: ...WIRE AND CABLE ROUTING m...

Page 365: ...Clamp Clutch cable Throttle cable Make sure that the clutch Viewed from direction A Main wiring harness Pass the stater cabke through interior side of clip...

Page 366: ...81Y Black with Yellow tracer L g R RIG Red w t h Green tracer I R Blue with Red tracer Q I G RIY Red w t h Yellow tracer B l l W Blue with White trecer G I B l Green wttn trlue tracer WIB White with...

Page 367: ...GS8SOGX GLX n VIEW OF SUtUKl GS850GLX Right side di I Left side...

Page 368: ...tion Gear ratios Low 2nd 3rd 4th Top SECONDARY DRIVE TYPE Secondary reduction Final reduction 2 250 mrn 88 6 in 855 mm 33 7 in 1 130rnm 44 5 in 1 510 mm 59 4 in 145 mm 5 7 in 750 rnm 29 5 in 243 kg 53...

Page 369: ...d damper Qwayjspring 5 way adjustable 40 right and left 6 2 30 105 rnm 4 73in 2 6m 8 5ft Disc brake twin Disc brake 100190 19 57H Tubelesstire 130190 16 67H Tubelesstire 1 75 kg cm2 25 psi Normal solo...

Page 370: ...ake pedal height Tire size Front 100 90 19 57H Tubeless tire STANDARD 15 0 61 FUEL OIL CAPACITY ITEM Front fork spring free length STANDARD ITEM Fuel tank including reserve reserve Engine oil capacity...

Page 371: ...W cp ITEM SPEC1FICATFON Headlight HI 60 TaEllSrake tight 8 23 3 32 LO 55 Turn signal light Speedometer light 23 323 3 4 Tachometer light 3 4 furn signal indicator light High beam indicator light Neut...

Page 372: ...OIL JET A 110 oil jet is added to the clutch cover as shown in Fig...

Page 373: ...ipe which is connected to the carburetors and builds up a negative pressure which is stronger than the spring pressure so that the disphragm is forced to open the fuel valve and thus allow the fuel to...

Page 374: ...0 FRONT FORK I I O Outer tube 2 Cylinder 37 Oil lock piece Dust seal 5 Snap ring GI Oil seat c71 Enner tube I Slide metal 3 Spring 1 1 Spring guide IiJ Spacer O ring tll Cap fir O ring...

Page 375: ...tand and a jack a Remove right and left calipers and speedometer cable guide NOTE Do not operate the brake lever after the caliper is removal I Pull off cotter pin O and remove axle nut 53 Loosen axle...

Page 376: ...and push in the relieve the air pressurecompletely Loosen the steering stern upper clamp bolts air valve to and lower Slightly loosen the front fork cap bolt to facilitate later disassembly after loos...

Page 377: ...nvert the fork and stroke it several times to remove the oil inside Under the condition inverted condition hold the fork for a few minutes Draw out dust seal and snap ring m Remove damper rod secur in...

Page 378: ...raw out damper rod and reboundspring a Pull out inner tub Removethe oil seal by using special tool The removed outer tube metal inner tube metal and oil seal should be replaced 09913 50121 Oil seal re...

Page 379: ...and damage FORK SPRING Measure the fork spring free length If it is shorter than service limit replace it INNER TUBE Inspect inner tubeouter surface for any scuffing Service Limit OUTER TUBE a Inspec...

Page 380: ...ack Cement 9 to the damper rod bolt and tighten with specified torque 99104 3 1140 09940 34520 T handle 09940 34580 Attachment F Suzuki Bond No 12078 99000 32040 Tightening torque 2 0 2 6kg m I14 5 19...

Page 381: ...I When adjusting oil level remove the fork spring and compress the inner tube fully Capacity 245 rnl 8 27US 0s 09943 74111 I FORK SPRING When installing the fork spring as shown in Fig Fork oil level...

Page 382: ...clockwise and pump The air Let the air out by loosening the handle till the specified air pressure is left inside Loosen the valve handle 0 and remove the air pres sure gauge CAUTION During the air f...

Page 383: ...GS850GXJGLX WllRE AND CABLE ROUTING...

Page 384: ...Assemble the clutch cable Throttle cable e it sure that the clutch cable oes not coma tn contact with e cly nderhead at this point wlth clutch cable Route guide and clutch Spring...

Page 385: ...WIRING DIAGRAM f 2 I l r i i 2 L L a l L k c m m u e L u p U l x g E x Z F k s w n r g 0 2 urn m 5555 5 3 g o y u u a s m u u V O m m J Z 2 2 3 2 2 2 r r Z m m i m m m m m...

Page 386: ...ction CONTENTS VIEW OF SUZUKl GS850GZ 1 7 2 SPECIFiCATIONS 1 7 3 SERVICE DATA 17 5 TORQUE TABLE 17 15 SPECIAL MATERIALS 17 18 PER IODFC MAINTENANCE 17 20 EMISSIONCONTROL R EG ULATIONS 17 21 COVER TIGH...

Page 387: ..._ Sh 5OGZ VIEW OF SUZUKI GS850GZ 4 I Right side Left side I 7 2...

Page 388: ...3rd 4th TOP SECONDARY DRIVE TYpe Secondary reduction Final reduction 2 195 mm 86 4in 865 mm 34 1 in 1 190 mrn 46 9 in 1 500 mrn 159 1in 1 70 mm 6 7 En 795rnm 31 3 in 245 kg 540 Ibs Four stroke air ca...

Page 389: ...way adjustable 40 right and left 62 10 1 13 mm 4 45 in 2 6 m 8 5 ft Disc brake twin Disc brake 3 501 119 4PR Tubeless tire 4 50H17 4PR Tubeless tire 1 75 kg cm2 24 psi FNormal solo riding 2 00 kg cm2...

Page 390: ...070 1 0 001 6 0 00281 Valve guide 1 D IN EX I Valve stem 0 0 6 960 6 975 IN 0 2740 0 27461 Valve stem runout 1 IN EX I Valve head thickness 1 IN EX Valve seat width 1 0 f 2 IN EX 10 04 0 05 Valve head...

Page 391: ...journal oil clearance IN EX 0 037 0 065 0 15Q 0 001 5 0 0026 Camshaft journal holder 1 Q I IN EX Camshaft journal O D I IN EX I0 0059 22 012 22 025 0 8666 0 8671 21 960 21 975 0 8646 0 8652 1 I Camsh...

Page 392: ...0 59 in 12 7118 from piston skirt end pa Cylinder distortion 0 2 tO 008 I Piston ring free end gap 7 2 0 281 7 6 0 30 Piston ring end gap 0 10 0 30 0 7 1s t 0 004 0 012 L 0 03 0 10 0 30 0 7 2nd 0 004...

Page 393: ...O 0 039 I 0 05 I 0 002 I T fh Oil pump reduction ra Oil pressure at 60 C 140 F CLUTCk Unit mrn in STANDARD 1 723 87 49 x 33 34 Above 0 1 kglcm 1 4 psi Below 0 25kglcm 3 6 psi at 3 000 rimin ITEM STAN...

Page 394: ...125 27 24 I 1 TOP I I 0 961 I25 1261 STANDARD Shift fork to Groove clearance secondaYy driven bevet gear preload 4 7 kg cm 3 45 6 05 Ib in 0 4 0 6 0 036 0 024 Final drive bevel gear preload 4 8 kgcm 3...

Page 395: ...CSS 5 0GZ CARBURETOR bureto e size rter jet Unit mrn in e Asterisk indicates new Z model specifications...

Page 396: ...ce i r o x r l40 180 2 B I Y G 8 Ignition coil resistance I O N W Primary O N B Y Approx 3 5 ptugCap plug cap Secondary Approx 30 40 k a Generator No Load voltage More than 80 V AC a t 5 000 rlrnin Ae...

Page 397: ...Rear Brake caliper cylinder bore Front Rear Rrake caliper piston diam Front Rear Wheel rim runout Axial Radial Wheel axle runout I I Front L 15 870 15 913 1 10 6248 0 6265 14 000 14 043 0 5512 0 5529...

Page 398: ...se only unlead or low lead type gasoline of at least 85 95 pump octane IlLjA4 method or 89 octane or higher rated by the Research Method 22 L 5 8 US gal 4 2L 4 4 US qt SAE I Engine oil capacity I Chan...

Page 399: ...Brake light 8 23 3132 License light 8 Turn signal light 23 132 speedometer light 3 4 Tachometer light 3 4 Turn signal indicator tight 3 4 earn indicator light I _ _ 3 4 I indicator light I 3 4 I ght 3...

Page 400: ...TORQUE TABLE e ENGINE...

Page 401: ...CHASSIS Front br Front an Ir clamp k upper k damp1 E e shaft I adbolt older nu Front tork lower 3er mow 2 union I Asterisk indicates new Z model specifications...

Page 402: ...ntional or q4 Marked Belt 7 Marked Bolt mm Ib fl 4 1 0 2 0 5 1 5 3 0 0 3 0 6 2 0 4 5 6 3 0 5 0 0 8 1 2 6 0 8 5 8 7 0 11 5 1 8 2 8 13 0 20 0 10 4 0 5 0 29 0 43 5 12 25 5 40 0 St0 10 0 50 5 72 5 14 3 6...

Page 403: ...pcs Front fork damper rod bolt 2 pcs Carburetor XI U 2 pm Carburetor plat1 8 99000 32040 Carburetor stad 4 THREAD LOCK CEMENT Gearshift cam guide screw 2 p a Gearshift pawl screw 2 pcs Countershaf t B...

Page 404: ...Camshaft journal Chain tensioner adjuster shaft Counter shaft washer Outer counter shaft Input cam dog USE OF GENUINE SUZWKI PARTS To replace any part of the machine use a genuine SUZUKl replacement...

Page 405: ...tions may require more frequent servicing The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and...

Page 406: ...cessary testing and certification of emission controlled models in strict compliance with the E P A testing regulations Suruki motorcycle dealers are not required to either test or certify emission le...

Page 407: ...ement component Slclzuk i recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability The carburetor specification for the emission controlled G...

Page 408: ...emis sion from motorcycles by 1990 will only amount to approximately 0 5 NOx is formed during the combustion process at high combustion chamber temperatures CARBON MONOXIDE Carbon monoxide is a produc...

Page 409: ...ion timing Advanced or Retarded 3 Timing Advance Too fast or too slow an advance rat 4 Battery Low charge or faulty Carburetion can also lead to high HC emissions if the mixture is either excessively...

Page 410: ...been changed from screws to bolts Clutch cover Signal generator cover Generator cover Secondary drive unit cover Starter motor cover NOTE When unscrewing or tightening bolts use an allen wrench OIL J...

Page 411: ...have been modified as illustrated below to improve seating between cylinder head and head cover EFFECTIVE ENGINE NO GS850G 755015 LATE CAM TIMING EARLY 1 Align the T mark an Nor 1 and 4 cylinder ride...

Page 412: ...re pipe which is connected to the carburetors and builds up a negative pressure which is stronger than the spring pressure so that the diaphragm is forced to open the fuel valve and thus allow the fue...

Page 413: ...GSLYSOGZ CHOKE LEVER Remove the choke lever and choke cable Apply Suzuki Super Grease A to the washer before tighten the screw 99000 25030 Suzuki Super Grease A I...

Page 414: ...improved the timing a advance performance during high speed operations Signal generator When the signal rotor is rotated in the system block diagram above the signal A is generated in the pick up coi...

Page 415: ...on the left side and disconnect the coupler from the signal generator As indicated in Fig 1 connect the pocket tester alternately to the terminals provided inside the coupler For this test use the RX...

Page 416: ...FRONT MASTER CYLINDER 0 0 Piston and cup set 0 i E phragrn 4 Body 5 Holder Tightening torque 3 5 6 0...

Page 417: ...crew the union bolt and disconnect the brake hoselmaster cylinder joint CAUTION Immediately and completely wipe off any brake fluid contacting any part of the motor cycle fhe fluid reacts chemically w...

Page 418: ...ut piston primary cup and spring 09900 06108 MASTER CYLINDER INSPECTION Inspect the cylinder bore wall for any scratch or other damage Snap ring pliers Inspect the piston surface for scratch or other...

Page 419: ...fore reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internal5to be inserted into the bore a When installing the master cvlinder on th...

Page 420: ...e WIRE AND CABLE ROUTING Turn slgnal Body ground Wirlng harness control unlt Wrr ng harness Clamp I A Clamp Clamp Clamp Clamp...

Page 421: ...Clamp...

Page 422: ...0 WIRING DIAGRAM...

Page 423: ...I through I 6 except for the items described in this section VIEW OF SUZUKl GS850GLZ 1 8 2 SPECIFICATIONS 1 8 3 SERVICE DATA 1 8 5 TORQUE TABLE 18 15 SPECIALMATERIALS 38 18 PERIODIC MAINTENANCE 18 20...

Page 424: ...Right side a Left side I 8 2...

Page 425: ...ction Gear ratios Low 2nd 3rd 4th Top SECONDARY DRIVE Secondary reduction Final reduction 2 250 mrn 88 6 in 855 rnm 33 7 in 1 130 m m 44 5in 1 510 m m 59 4 in 145 m m 5 7 in 765 rnm 30 1 in 243 kg 536...

Page 426: ...inging arm oil dampened damper 4 waylspring 5 way adjustable 40 right and left 62 30 105 rnm 4 13 in 2 6 m 8 5ft Disc brake twin 3isc brake 100190 19 57H Tubeless tire 130190 1667H Tubeless tire 1 75...

Page 427: ...0 2756 0 27621 6 960 6 975 0 2740 0 2746 6 945 6 960 0 2734 13 2740 1 0 1 2 10 04 0 053 29 3 34 0 kg 64 59 74 96 Ibsl a t length 23 rnrn 0 91 in 50 4 58 3kg 111 11 128 53 Ibs at length 27 rnm 1 06 in...

Page 428: ...1 3965 Camshaft journal oil clearance 0 037 0 065 IN EX 0 150 0 0015 0 0026 0 00591 Camshaft journal holder I D IN E 12 22 025 5 6 0 867 I 1 I Camshaft journal O D r 1 6 0 21 975 IN EX 10 8646 0 8652...

Page 429: ...iston pin O D 28 psi 0 120 0 0047 69 80 2 7 197 68 880 2 7118 0 2 0 008 7 2 0 281 7 6 0 30 0 7 0 031 0 7 0 03 0 18 0 0071E 0 050 0 060 0 0020 0 0024 69 000 69 075 2 7165 2 7171 68 945 68 960 2 7144 2...

Page 430: ...duction ratio LIMIT ITEM STANDARD Clutch cable play 2 3 0 08 0 12 Drive plate thickness 2 7 2 9 0 106 0 114 Drive plate claw w i t h 11 8 12 0 L 0 46 0 47 Driven plate thickness 2 0 0 06 10 08 t 0 002...

Page 431: ...fANDARD Secondary bevel gear backlash 0 08 0 13 0 003 0 005 Finat bevel gear backiash 0 03 0 64 0 007 0 025 Secondary drive bevel gear preload 3 5 kg cm 2 60 4 35 Ibain Secondary driven bevel gear pr...

Page 432: ...rlmin I I Fuellevel I a t heighr n jet 1 Mai EM J 115 I Jet needle J N 1 I 5D50 I Needle jet I i X 5 I LPilot jet Pile Val I I ve seat 2 0 IG S 32 5 I pilot screw P s PRE SET I Pilot air jet P A S 1 3...

Page 433: ...on coil resistance O W W Primary Approx 3 5R I PIug cap PIug cap I Secondary A p p r o 31 33 k i l I Generator NO Loadvoltage More than 80 FAC at 5 000 rlmin Regulated voltage 14 0 15 5 V a t 5 Starte...

Page 434: ...15 827 15 854 Front 40 6231 0 6242 Rear 13 957 13 984 I d 0 5495 0 5506 1 Brake caliper cyl inderbore 38r180 38 256 Front 1 5031 1 5061 I Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam 38...

Page 435: ...160 6 3 I Front fork spring free length 516 20 31 1 260 110 2 Front fork air pressure 0 8kg cm2 11 4psiF Rear wheel travel 100 3 9 FUEL 01L CAPACITY d or low l np octane Bevel gear oil capacity 340 4...

Page 436: ...TailJBrake light 8 23 3 32 Turn signal light 23 32 Speedometer light 3 4 Tachometer light 3 4 Fuelmeter light 1 7 Turn signal indicator light I 3 4 High beam indicator light I 3 4 1 al indicator ligh...

Page 437: ...TORQUE TABLE ENGINE llnder nead bolt P gine mot...

Page 438: ...8 36 0 58 0 Rear shock absorber nut 2 0 3 0 14 5 21 5 I 2 7 4 3 19 5 31 Q 3 bolt Front brake caliper mounting bolt Front and rear brake disc plate bolt Front brake caliper axle bolt Front brake maste...

Page 439: ...Bolt 4 Marked Bolt onal or 4 Marked Bolt 0 1 0 2 0 2 0 4 0 4 0 7 1 0 1 6 2 2 3 5 3 5 5 5 5 0 8 0 8 0 13 0 13 0 19 0 7 Marked Bolt Ib ft 0 7 1 5 1 5 3 0 3 0 5 0 7 0 11 5 16 0 25 5 25 5 40 0 36 0 58 0...

Page 440: ......

Page 441: ...l BOND No f 20JB Camshaft journal Chain tensionet adjuster shaft Counter shaft washer Outer counter shaft Input cam dog USE OF GENUINE SWZUKl PARTS To replace any part of the machine use a genuine SUZ...

Page 442: ...rfarrnance and to maintain proper emission levels Mileagesare expressed in terms of kilometers miles and time for your convenience NOTE Vehicles operated under severe conditions may require more frequ...

Page 443: ...ki Motor Company performed all the necessary testing and certification of emission controlled models in Rrict compliance with the E P A resting regularionr Suzuki mutorcycle dealers are not requjred t...

Page 444: ...nt performing re placement component Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durabi ity The carburetor specification for the emi...

Page 445: ...sion from motorcycles by 1990 will only amount to approximately 0 5 N0x is formed during the combustion process at high cornbustion chamber temperatures CARBON MONOXIDE Carbon monoxide is a product of...

Page 446: ...on timing Advanced or Retarded 3 Timing Advance Too fast or too slow an advance rate 4 Battery Low charge or faulty Carburetion can also lead to high HC emissions if the mixture is either excessively...

Page 447: ...ing or tightening bolts use an allen wrench a Clutch cover Signal generator Generator coves Secondary drive unit cover Starter motor cover STARTER LEVER Remove the starter lever and starter cable Appl...

Page 448: ...FRONT MASTER CYLINDER Piston and cup set O Cap 3 Diaphragm Body 5 Holder Tightening torque 0 08 0 15 6 6 1 1 0 5 0 8 3 5 6 0...

Page 449: ...screw the union bolt and disconnect the brake hoselmaster cylinder joint CAUTION lrnrnediately and completely wipe off any brake fluid contacting any part of the motor cycle The fluid reacts chemicall...

Page 450: ...piston primary cup and spring 09900 06108 MASTER CYLINDER INSPECTION m lnspect the cylinder bore wall for any scratch or other damage Snap ring pliers Inspect the piston surface for scratch or other...

Page 451: ...uid before reassembly Never use cleaning solvent or gasofine to wash them Apply brake fluid to the cylinder bore and all I the internalsto be inserted into the bore When installing the master cy n the...

Page 452: ...WIRE AND CABLE ROUTING Fuel Handle SIW IR Clamp J Turn s gnel Clamp Cia amp positionretaining tape I Mainwiring harness...

Page 453: ...Raute guide and clutch cable in Cylinder inlet No 1...

Page 454: ...WIRING DIAGRAM...

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Suzuki GS850G, Service Manual

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