Suzuki Madura GV700GL Service Manual Download Page 253

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Summary of Contents for Madura GV700GL

Page 1: ...SUZUKI SERVICE MANUAL GV700GL SUZUKI MOTOR CORPORATION OCTOBER 90 PRINTED IN JAPAN 99500 36040 03E 99500 36040 0JE...

Page 2: ...s manual at any time IMPORTANT All GS and GV model Suzuki motorcycles that were manufactured after January 1 1978 are subject to Environmental Protection Agency emission regulations These regulations...

Page 3: ...VIEW OF SUZUKI GV700GL RIGHT SIDE LEFT SIDE...

Page 4: ...GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE UP PROCEDURES ENGINE SERVICING SHAFT DRIVE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM EMISSION CONTROL REGULATIONS ELECTRICAL SYSTEM CHASSIS SERVICING...

Page 5: ...NTENTS SERIAL NUMBER LOCATIONS 1 1 FUEL OIL AND COOLING SOLUTION RECOMMENDATIONS 1 1 BREAKING IN PROCEDURES 1 2 CYLINDER IDENTIFICATION 1 2 SPECIAL MATERIALS 1 3 PRECAUTIONS AND GENERAL INSTRUCTIONS 1...

Page 6: ...0W 50 I 10W 50 10W 30 I 20W 10W Temp oc 20 10 0 10 20 30 40 I OF 4 14 32 50 68 86 104 I GEAR OIL SECONDARY AND FINAL DRIVE Use SAE 90 hypoid gear oil which is rated GL 5 under API classification syste...

Page 7: ...e sure to mix it above 30 even though the atmospheric temperature does not go down to freezing point Every new unit contains Bar s leak GENERAL INFORMATION 1 2 BREAKING IN PROCEDURES During manufactur...

Page 8: ...shaft journal bearing Countershaft Drive shaft Propellar shaft splines Mating surfaces of upper and lower crankcase Mating surface of crankcase and clutch cover generator cover Cylinder head cover gas...

Page 9: ...ve screw 6 16 8 10 Generator lead wire guide screw 3 52 Starter motor housing screw Countershaft bearing retainer screw Chain tensioner bolt Gearshift fork shaft stopper screw Gearshift cam guide scre...

Page 10: ...ening torque o Use special tools where specified o Use genuine parts and recommended oils o When 2 or more persons work together pay attention to the safety of each other o After the reassembly check...

Page 11: ...717 in Stroke 46 7 mm 1 839 in Piston displacement 698 cm3 42 6 cu in Compression ratio 10 5 1 Carburetor MIKUNI BDS33 four Air cleaner Polyester fiber element Starter system Electric Lubrication sys...

Page 12: ...D8EA or NIPPON DENSO X24ES U Battery 12V 50 4 kC 14 Ah 10 HR Fuse 10 1 0 1 0 1 0 1 OA Circuit breaker 30A Headlight 12V 60 55W Tail Brake light 12V 8 23W Turn signal light 12V 23W Speedometer light 12...

Page 13: ...MAINTENANCE AND TUNE UP PROCEDURES 2 2 BATTERY 2 2 AIR CLEANER 2 3 SPARK PLUG 2 4 FUEL LINES 2 5 ENGINE OIL AND OIL FILTER 2 5 CARBURETOR 2 6 CLUTCH 2 7 COOLING SYSTEM 2 8 SECONDARY AND FINAL GEAR OI...

Page 14: ...s miles and time for your convenience PERIODIC MAINTENANCE CHART INTERVAL km 1 000 6000 12 000 18 000 24000 THIS INTERVAL SHOULD BE JUDGED mile 600 4000 7 500 11 000 15 000 BY ODOMETER READING OR MONT...

Page 15: ...on 09900 28403 Standard specific gravity Hydrometer An S G reading of 1 22 at 20 C or under means that the battery needs recharging Remove the battery from the machine and charge it with a battery cha...

Page 16: ...to the pores of the cleaner element thus restricting air flow through the cleaner element Reinstall the cleaned or new cleaner element in the reverse order of removal When installing the air cleaner e...

Page 17: ...the requirements of speed actual load fuel etc If the plugs need to be replaced it is recommended that the standard plugs listed in the table be selected Remove the plugs and inspect the insulators Pr...

Page 18: ...to the gasket of the new filter before installation Install the new filter turning it by hand until you feel the filter gasket contacts the mounting surface Then tighten 5 6 turn using the oil filter...

Page 19: ...ration is performed by carburetor manufacturer THROTTLE CABLE PLAY There should be 2 3 mm 0 08 0 12 in play on the throttle cable To adjust the throttle cable play Remove the seat and fuel tank Push t...

Page 20: ...n the bleeder valve by turning it a quarter of a turn so that the fluid runs into the receptacle this will remove the tension of the clutch lever causing it to touch the handlebars grip Then close the...

Page 21: ...lush the radiator with fresh water if necessary PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 8 Tighten the drain plug securely and loosen the air bleeder Install the specified cooling solution upto t...

Page 22: ...l by removing the filler cap and drain plug Refit the drain plug remove the oil level screw and pour the specified oil in through the filler hoie until it runs out from the oil level hole Refit the oi...

Page 23: ...his motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage w...

Page 24: ...e pipe into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a tu...

Page 25: ...0 6 in Brake pedal free 20 30 mm 0 8 1 2 in travel Brake light switch Check to be sure that rear brake light comes on when the pedal is depressed to take up the play To adjust the brake light switch...

Page 26: ...ous situation It is highly recom mended to replace the tire when the remaining depth of tire tread reaches the following pecifi cations FRONT REAR 1 6 mm 0 06 in 2 0 mm 0 08 in TIRE PRESSURE If the ti...

Page 27: ...tubes near the axle and pull forward If play is found perform steering bearing adjustment as described in page 9 24 of this manual FRONT FORK Inspect 12 000 24 000 km 7 500 15 000 mi Check air pressu...

Page 28: ...nut 15 25 1 5 2 5 11 0 18 0 Handlebars clamp bolt 12 20 1 2 2 0 8 5 14 5 Clutch master cylinder mounting bolt 5 8 0 5 0 8 3 5 6 0 Front brake master cylinder mounting bolt 5 8 0 5 0 8 3 5 6 0 Front c...

Page 29: ...PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 16...

Page 30: ...NSIONER 3 38 CYLINDER 3 39 PISTON 3 39 PISTON RING 3 40 CONNECTING ROD 3 42 CRANKSHAFT 3 46 STARTER PINION 3 50 CLUTCH 3 50 GENERA TOR AND SIGNAL GENERA TOR 3 52 OIL PUMP 3 53 TRANSMISSION GEARS AND R...

Page 31: ...n the following cases Compression pressure in one of the cylinders is less than 900 kPa 9 kg cm2 128 psi Difference in compression pressure between any two cylinders is more than 200 kPa 2 kg cm2 28 p...

Page 32: ...0 Cylinder head breather cover 3 14 Generator rotor 3 20 Cam chain tensioner Front 3 14 Gear position indicator switch body 3 24 Cylinder head cover Front 3 14 Generator stator 3 52 Thermostat 3 14 Si...

Page 33: ...plug to drain out engine oil Remove the radiator cap and drain plug and drain cooling solution completely Remove the seat and remove the right and left frame covers NOTE To prevent damage to the fram...

Page 34: ...tor to water pump hose Radiator to reservoir tank hoses Cylinder head to radiator hose Disconnect the electric fan lead wire Remove the radiator with electric fan and fan motor Remove the reservoir mo...

Page 35: ...s and remove the exhaust pipes for Nos 2 and 4 cylinders Remove the left muffler with mounting bracket When removing the right muffler remove the rear brake cable guides from the mounting bracket Remo...

Page 36: ...ear brake pedal Disconnect the various lead wires CD Oil pressure switch lead wire Engine ground lead wire Starter motor lead wire Gear position indicator lead wire Generator lead wire Signal generato...

Page 37: ...hift lever link Remove the union bolt and disconnect the clutch hydraulic line from the clutch cylinder CAUTION Completely wipe off any clutch fluid adhering to any part of motorcycle The fluid reacts...

Page 38: ...g caps from the spark plugs Remove the choke cable holder screws and disconnect the two choke cables right and left from the carburetors Loosen the throttle cable holder nuts and disconnect the thrott...

Page 39: ...d remove the boot from the secondary drive gearcase Use a jack and wooden block and hold the engine assembly CAUTION When holding the engine with jack place a piece of wood on the jack or oil pan may...

Page 40: ...ngine by pulling slightly forward and to the right side NOTE When removing the engine hold the carburetor assembly in place or it may fall down Remove the exhaust pipes for Nos 1 and 3 cylinders NOTE...

Page 41: ...n the engine mounting bracket bolts and engine mounting bolts Insert the all upper long bolts from left side and bottom lower bolt from the right side Install the brackets bolts and nuts properly as s...

Page 42: ...gas leakage incorrect air fuel ratio and unsatis factory engine operation may result CARBURETOR TO INTAKE PIPE CLAMPS FRONT Install the exhaust pipes pre muffler and muf flers properly When securing e...

Page 43: ...our 4 2L 4 4 US qt when overhauling engine of engine oil SAE 10W 40 under API classification SE or SF into the engine Several minutes after starting and stopping the engine check that the oil level re...

Page 44: ...roups so that each will be restored to the original location during assembly Remove the water temperature gauge ground lead wire and disconnect the water hose from the union Remove cylinder head cover...

Page 45: ...move the four camshafts NOTE Be sure to loosen camshaft hol er bolts evenly by shifting the wrench diagonally Remove the cam follower pivots CD and lash adjusters Pull out cam chain guide The cylinder...

Page 46: ...rings and pressure plate with clutch push piece 09930 40113 Rotor and sprocket holder Remove the clutch push rod After removal of several clutch driven and drive plates flatten clutch sleeve hub nut l...

Page 47: ...ain tensioner Hold the idler sprocket with special tool and remove the water pump drive sprocket bolt by turning the bolt clockwise 09930 40113 Rotor and sprocket holder CAUTION This bolt has left han...

Page 48: ...lt by turning it clockwise 09930 40113 Rotor and sprocket holder CAUTION This bolt has a left hand thread When loosen ing it turn it clockwise Remove the idler shaft drive chain tensioner Remove the i...

Page 49: ...s 09900 061 07 Snapring pliers Remove the oil pump driven gear Remove the pin washer and oil pump assembly Remove the gearshift shaft CD by pulling Remove the countershaft bearing retainer by using im...

Page 50: ...econdary gear case and clutch cylinder Remove the starter pinion starter drive gear and its thrust washer Using 36 mm off set wrench loosen the rotor securing bolt by several turns At this stage do no...

Page 51: ...er bolt while holding the remover with 36 mm off set wrench Remove the rotor remover from the rotor and remove the rotor securing bolt NOTE Do not hit the rotor with a hammer 09930 30720 Rotor remover...

Page 52: ...ove oil guide and O ring CAUTION Do not miss the O ring located under the oil guide Remove the crankcase securing bolts from the upper crankcase Remove the crankcase securing nut CD Extract the clutch...

Page 53: ...eparating the crankcases is made easier by the use of the cylinder disassembling tool 09912 34510 Cylinder disassembling tool NOTE Beware of dropping crankshaft journal bear ings Remove the countersha...

Page 54: ...ft cam guide and pawl screws CD 09900 09003 Impact driver set Remove the gear position indicator switch body NOTE Do not miss the 0 ring switch contact and its spring Unhook the gearshift cam stopper...

Page 55: ...9900 061 07 Snapring pliers Extract gearshift cam from the lower crankcase Using snapring pliers closing type remove the bearing stopper snapring 09900 06105 Snapring pliers Remove the cam bearing wit...

Page 56: ...le shaft sprockets Remove the idle shaft from the upper crank case Using the special tools and remove the idle shaft bearing 09930 301 02 09913 60710 CAUTION Rotor remover slide shaft Bearing remover...

Page 57: ...ginal location during assembly Using special tools compress valve springs and take off two cotter halves CD from valve stem 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84510 Twe...

Page 58: ...ter for wear dent and or damage If any defect is found replace it with a new one Compress and stroke the plunger with your finger by using air bleeding tool and remove the oil completely from the lash...

Page 59: ...place the lash adjuster with a new one Lash adjuster plunger stroke VALVE FACE WEAR 0 0 2 mm 0 0 008 in Visually inspect each valve for wear of its seating face Replace any valve with an abnormally wo...

Page 60: ...the standard range Valve Service Limit Intake valves 0 35 mm 0 014 in Exhaust valves 0 35 mm 0 014 in VALVE STEM WEAR If the valve stem is worn down to the limit as measured with a micrometer where th...

Page 61: ...st and both oil seals are identi cal in shape 11115 05AOO Valve guide 09289 05003 Valve guide oil seal Oil the stem hole of each valve guide and drive the guide into the guide hole with the valve guid...

Page 62: ...thout any break and in addition to this requirement the width of the dye ring which is the visualized seat width must be within the following specifi cation Valve seat width Seat width Standard 0 9 1...

Page 63: ...If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area After the desired seat position and width is achieved use the 45 cutter very lightly to clean up any...

Page 64: ...reduced engine power output and often account for the chattering noise coming from the valve mecha nism Check the springs for strength by measuring their free lengths and also the force required to c...

Page 65: ...ifter press down the spring fit the two cotter halves to the stem end and release the lifter to allow the cotter CD to wedge in between seat and stem Be sure that the rounded lip of the cotter fits sn...

Page 66: ...ce Limit Front Intake cams 32 42 mm 1 276 in Rear 32 75 mm 1 289 in Exhaust cams Front 32 17 mm 1 267 in Rear CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by m...

Page 67: ...of camshaft bearing holder and outside diameter of the camshaft journal Replace whichever the difference from specification is greater 09900 20205 Micrometer 0 25 mm Standard Journal holder 22 012 22...

Page 68: ...Front cam chain tensioner Rear cam chain tensioner Idle shaft drive chain tensioner Rachet CAM CHAIN 20 PITCH LENGTH Pull the chain tight to remove any slack then using vernier calipers measure the 2...

Page 69: ...limit overhaul the cylinder and replace the piston with an oversize or replace the crankcase assembly Once the reboring is done on any one cylinder which measurements is beyond the limit the remaining...

Page 70: ...rvice Limit 1st 0 18 mm 0 007 in 2nd 0 15 mm 0 006 in Piston ring groove width Piston ring Standard 1st 1 01 1 03 mm 0 0398 0 0406 in 2nd 1 21 1 23 mm 0 0476 0 0484 in Oil 2 51 2 53 mm 0 0988 0 0996 i...

Page 71: ...ngs are available as optional parts They bear the following identification marks SIZE COLOR STD Painted Red 0 5 mm O S Painted Blue 1 0 mm O S Painted Yellow Oversize side rail Just measure outside di...

Page 72: ...end bore J D Service Limit I 18 040 mm 0 7102 in If the connecting rod small end bore inside diameter exceeds the above mentioned limit replace connecting rod CONNECTING ROD BIG END THRUST CLEARANCE...

Page 73: ...ve or loosen the connecting rod big end stud otherwise it will displace the stud and will not fit the bearing cap properly Place plastigauge axially on the crank pin avoiding the oil hole and at the T...

Page 74: ...3 The crank pin O D code number is on the left crank web Bearing selection table Code Conrod 1 I D code 2 Oil clearance Standard Crank pin O D code 1 2 3 Green Black Brown Black Brown Yellow 0 032 0 0...

Page 75: ...gine oil or SUZU Kl Moly Paste to the crank pin and bearing surface 99000 25140 SUZU Kl Moly Paste NOTE Never try to remove or loosen the connecting rod big end stud otherwise it will displace the stu...

Page 76: ...case and tighten the crankcase securing bolts with specified torque value in the indicated order Tightening torque Initial Final 12 mm 40 50 N m 60 70 N m bolt 4 0 5 0 kg m 6 0 7 0 kg m 29 0 36 0 lb...

Page 77: ...n 1 0 code B Black Brown Yellow Crankcase 1 0 specification Code I 0 specification A 44 000 44 008 mm 1 7323 1 7326 in B 44 008 44 016 mm 1 7326 1 7329 in Bearing thickness specification Right and lef...

Page 78: ...st bearing Thrust clearance Standard 0 045 0 1 00 mm 0 0018 0 0039 in If the thrust clearance exceeds the standard range adjust the thrust clearance by the following pro cedures Remove the right side...

Page 79: ...AOO OCO 2 995 3 020 mm Green 0 1179 0 1189 in 12228 05AOO ODO 3 020 3 045 mm Yellow 0 11 89 0 1199 in 12228 05AOO OEO 3 045 3 075 mm White 0 1199 0 1211 in 12228 05A00 0FO After selecting a left side...

Page 80: ...place the starter pinion as sembly with a new one CLUTCH DRIVE PLATES AND DRIVEN PLATES Clutch plates in service remain in oily condition as they were lubricated with oil Because of this con dition bo...

Page 81: ...nspect clutch push piece bearing for any abnor mality particularly cracks upon removal from the clutch to decide whether it can be reused or should be replaced Smootn engagement and disengagement of t...

Page 82: ...cylinder in the reverse order of disassembly and by taking the following steps _ CAUTION Wash the clutch cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gas...

Page 83: ...il pump case securing screws are applied with SUZUKI THREAD LOCK SUPER 1363A If attempt is made to overhaul the oil pump assembly screw may be damaged As a replacement only the oil pump unit is availa...

Page 84: ...he gear axially Too much a clearance is therefore liable to cause the meshed gears to slip apart If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both 09...

Page 85: ...MBLY Remove the washer CD I bearing low driven gear I bushing and thrust washer Remove the 6th driven gear Remove circlip 1 washer 4th driven gear and bushing 09900 061 04 Snapring pliers Remove the p...

Page 86: ...napring pliers Remove the bushing J and second driven gear DRIVES HAFT REASSEMBLY Reassemble the drive shaft gears in the reverse order of disassembly and also car ry out the follow ing steps Before i...

Page 87: ...on to the di rection of the circlip Fit it to the side where the thrust is as shown in the figure with the round ed side against the gear surface NOTE Always use new circlip CAUTION Never reuse a circ...

Page 88: ...demand special descriptions or precautionary measures NOTE Apply engine oil to each running and sliding part before reassembling Clean the magnet CD and install it to the lower crankcase Install a ne...

Page 89: ...ft fork for 6th driven gear Gearshift fork for 3rd 4th drive gears Gearshift cam stopper Install the gearshifting cam with the dent for the neutral stopper directed downward and meet the neutral stopp...

Page 90: ...tor switch NOTE When installing gear position indicator switch be sure to locate spring switch contact and 0 ring Check the oil jet fitted on the lower crank case for clogging Mount the piston ring in...

Page 91: ...each either way CAUTION When mounting the spacer be careful not to allow its two ends to overlap in the groove INCORRECT Install the piston to the conrod so that the triangle mark CD on the piston top...

Page 92: ...mark 1 through 4 scribed on the piston Check the oil jet CD for clogging Install the jet so that large diameter end faces inside Install the specified crankshaft journal bearings and conrod big end be...

Page 93: ...1 5 16 0 Final 33 37 3 3 3 7 24 0 27 0 Install the two C rings CD to the upper crankcase Mount both countershaft and drive shaft on the upper crankcase NOTE Be sure to install the bearing dowel pins i...

Page 94: ...rms a comparatively thick film Place the oil guide plate CD as shown in figure When securing the lower crankcase tighten the 12 mm bolts and the 10 mm bolts in the ascend ing order of numbers assigned...

Page 95: ...o the three screws 991 04 32050 Thread Lock 1363C Install the washer and rubber cushion and install the oil pan plate with five bolts Apply thread lock 1361 A to the bolts 99104 32020 Tightening torqu...

Page 96: ...the key CD and install the rotor to the crankshaft After mounting the rotor secure the rotor by tightening the center bolt to the specified torque value Tightening torque 991 04 32030 140 160 N m 14 0...

Page 97: ...secondary gear case to the crankcase NOTE Make sure that clutch push rod is installed properly Apply SUZUKI Bond No 1207B to the securing bolt 99104 31140 I SUZUKI Bond No 1207B I Install the two pos...

Page 98: ...three screws Apply thread lock 1363C to these screws 991 04 32050 Thread lock 1363C Install the gearshift shaft with the center of the gear on shaft side aligned with the center of gear shift cam driv...

Page 99: ...ry drive gear to the crankshaft Using the special tool turn the crankshaft so that the No 1 piston is positioned at T D C 09930 40113 Rotor and sprocket holder Install the spacer and two positioning p...

Page 100: ...e crown NOTE Modification has been made on the idler shaft and its bolt There are two kinds of thread pitch 1 5 mm for early type and 1 25 mm for late type for bolt and idler shaft Confirm the thread...

Page 101: ...and drive pin to the water pump shaft Install the water pump drive sprocket drive chain and driven sprocket as shown in the figure NOTE Engage the drive sprocket with the idler shaft drive sprocket In...

Page 102: ...ack Tightening torque 3 5 mm 0 12 0 2 in 12 17 N m 1 2 1 7 kg m 8 5 12 51b ft When installing the thrust washer to the counter shaft chamfered side of the washer faces inwards Align the notch CD of th...

Page 103: ...k the nut by firmly bending the tongue of the washer Tightening torque for the nut is specified Clutch sleeve hub nut tightening torque 09920 5371 0 50 70 N m 5 0 7 0 kg m 36 0 50 5 lb ft Clutch sleev...

Page 104: ...he order shown in the photo NOTE Tighten the clutch spring set bolts in the manner indicated tightening them by degrees until they attain a uniform tightness Clutch spring bolt tightening torque 11 13...

Page 105: ...as shown CAUTION Always use new 0 rings to prevent sucking air from the joint part Each intake pipe should position properly as shown in the illustration Install the ground lead wire for engine Temp g...

Page 106: ...th compressed air Put cam followers on the valve stem and lash adjuster Identify each camshaft with the Identification letters E F G or H which is pun ched at the right end of the camshaft E Front exh...

Page 107: ...ocket and ending at the 18th pin Engage the chain with intake sprocket locating the 18th pin at and above the engraved line on the intake sprocket NOTE The timing chain is now riding on all three spro...

Page 108: ...it with the timing chain Count out 18 pins and engage the 18th pin with the index mark on the sprocket of the rear exhaust camshaft H Tighten the cylinder head bolts camshaft journal holder bolts and...

Page 109: ...CAMSHAFT TIMING Turn the crankshaft so that the No 1 piston is positioned atT D C Aligning mark Aligning marks on the drive sprocket w co m 2 C 2 m en m a n 2 C...

Page 110: ...m 3 5 kg m 11 0 Ib ft 25 5 lb ft 23 27 N m 46 51 N m 2 3 2 7 kg m 4 6 5 1 kg m 16 5 19 51b ft 33 5 37 0 lb ft When reinstalling the bearing caps align the marks assigned to the bearing caps and cylind...

Page 111: ...Unlock the ratchet mechanism and push in the push rod fully and while holding the push rod in this condition tighten the end bolt with washer by turning it counter clockwise This end bolt hold the pu...

Page 112: ...moving parts such as cam follower camshaft work properly When reinstalling the cylinder head cover apply SUZUKI Bond No 1207B to the mating surface between oil seal and head cover and four cam shaft...

Page 113: ...ck to be sure that by pass hole is not clogged Install the radiator hose union with three bolts NOTE Install the clamp for high tension cord as shown Install the 0 ring to the connector Install the co...

Page 114: ...UZUKI Bond No 1207B l Replace clutch cover gasket with a new one to prevent oil leakage Install the clutch cover Route the oil pressure switch lead wire and clamp it with four clamps as shown Install...

Page 115: ...4 16 PROPELLER SHAFT CONSTRUCTION 4 17 REMOVAL AND DISASSEMBLY 4 17 INSPECTION 4 18 REASSEMBLY AND REMOUNTING 4 18 FINAL BEVEL GEARS CONSTRUCTION 4 20 FINAL GEAR CASE BREATHER CIRCUIT 4 21 AIR AND GEA...

Page 116: ...4 1 SHAFT DRIVE SHAFT DRIVE...

Page 117: ...seal Bearing Bolts 4 pes j Secondary driven bevel gear housing 0 ring Shims 5 kinds Shims 9 kinds jJ Spacer Bearing Secondary bevel gear set Pilot bearing Shim seat Shims 19 kinds 0 ring Bearing l Shi...

Page 118: ...the generator cover remove the oil drain plug to drain out engine oil Remove the clutch hydraulic line by removing the union bolt NOTE Completely wipe off any clutch fluid adhering to any part of moto...

Page 119: ...rings and draw out the bearing with the secondary drive bevel gear CAUTION The removed 0 rings should be replaced with new ones Remove the secondary drive bevel gear shim Draw out the bearing from the...

Page 120: ...ng the four bolts Remove the 0 ring and shims from the secondary driven bevel gear housing CAUTION The removed O ring should be replaced with a new one Straighten the bent portion of the nut Use the s...

Page 121: ...mmer to remove it from the secondary driven bevel gear housing Remove the shims and spacer from the seconda ry driven bevel gear shaft Remove the bearing from the secondary driven bevel gear shaft by...

Page 122: ...gear housing by using the special tools 09941 54911 Bearing race remover 09913 76010 Bearing installer Remove the secondary driven bevel gear pilot bearing by using the special tools 09923 74510 Beari...

Page 123: ...driven bevel gear pilot bearing by using the special tool 09924 84520 Bearing installer Install a new oil seal by using the special tools 09924 74560 09924 74510 NOTE Oil seal installer Bearing and oi...

Page 124: ...nd then the shims Use the removed spacer and shims NOTE Coat the bearings with hypoid gear oil before installing Install the secondary driven bevel gear shaft into the secondary driven bevel gear hous...

Page 125: ...Refer to the chart at right and make the appro priate adjustment re check the pre load measure ment procedure as necessary NOTE Whenever the pre load is checked after a shim change the gear must be ro...

Page 126: ...BACKLASH Install the secondary drive bevel gear shim removed during disassembly into the shim seat Install the secondary drive bevel gear assembly into the secondary gear case Install the secondary d...

Page 127: ...T After bringing the backlash within specification by changing the secondary driven bevel gear shims it will be necessary to check tooth con tact Remove the drive bevel gear assembly from the secondar...

Page 128: ...t until both backlash and tooth contact are correct Tooth contact Shim adjustment Contact at tooth Decrease thickness top CD of shims or Contact at tooth Increase thickness roof of shims or List of sh...

Page 129: ...ten them with specified torque 991 04 32050 Tightening torque CAUTION Thread lock 1363C 18 28 N m 1 8 2 8 kg m 13 0 20 0 lb ft UP mark on the gear housing should face upward Install the secondary driv...

Page 130: ...ified torque CAUTION Use new gaskets for secondary gear case and generator cover to prevent oil leakage When installing the secondary gear case apply SUZUKI BOND NO 1207B to the threaded parts of bolt...

Page 131: ...mm 24934 05AOO OPO 3 75 mm 1 24934 05AOO OQO 3 80 mm _ _L_ f l_ 2 4 93 4 0 5 A O O Oo R 0 3 0 9 0 o mm m i I J4934 05AOO OSO 24934 05AOO OTO 4 10 mm fF r I r j __l v r 24935 05AOO ODO 0 50mm 24935 05A...

Page 132: ...page 4 22 Remove the rear suspension and swingarm See page 9 32 Compress the cam dog spring with the hy draulic press and remove the two stoppers Separate the universal joint CD from the propel ler sh...

Page 133: ...splin es da ge or wear Cam dog contacting surface wear or damage Universal joint damage REASSEMBLY AND REMOUNTING Reassemble and remount the propeller shaft in the reverse order of disassembly and re...

Page 134: ...cam dog Coat the lip of oil seal with grease 99000 25030 I SUZUKI super grease A Before installing the two stoppers pour about 90 ml 3 0 3 2 US Imp oz of hypoid gear oil into the cover NOTE After reas...

Page 135: ...earmg Oil seal Final gear case O ring Oil filler plug Gasket Oil drain plug Stud bolts c pes l Spring was Nuts 3 p s Pilot bearmg iiill 0 ring Sh ms 4 kinds I I ear set Fina beve g Bearmg Spacer SHAFT...

Page 136: ...e following passages Air flows from hole A to chamber B and passes through the hole C and chamber D to the atmos phere through the breather hole E OIL PASSAGE When the final gear case pressure rises a...

Page 137: ...moving the three nuts DRIVEN BEVEL GEAR Remove the final gear bearing case bolts To remove the final gear bearing case from the final gear case use two 6 mm screws screw them into the holes provided a...

Page 138: ...Remove the shims which are located at both sides of final driven bevel gear Remove the bearing retainer by removing the three screws Remove the final drive bevel gear assembly from the final gear case...

Page 139: ...Remove the 0 ring and shims from the final drive bevel gear housing Removetheoil seal G circlip propeller shaft coupling and spring from the final drive bevel gear coupling 09900 06108 Snap ring plier...

Page 140: ...ool to hold the coupling and remove the nut 09924 6451 0 Final drive gear coupling holder Remove the washer CD and coupling from the final drive bevel gear shaft Tap the final drive bevel gear shaft w...

Page 141: ...uld be replaced with a new one Remove the oil seal by using the special tools and then remove the bearing 09941 64510 Bearing and oil seal remover 09930 301 02 Sliding shaft CAUTION The removed oil se...

Page 142: ...to the final drive bevel gear housing by usingthe special tool 09924 8451 0 Bearing installer Install the bearing onto the final drive bevel gear shaft by using the special tool 09913 80112 Bearing ra...

Page 143: ...the bearing pre load has been adjusted to the specification remove the nut and apply THREAD LOCK SUPER 1363A to the nut and tighten it to the specified torque Bend the collar of the nut over into the...

Page 144: ...VEN BEVEL GEAR Install the pilot bearing for the final drive bevel gear into the final gear case BY using the special tools CD and CD 09924 74510 Bearing and oil seal in staller 09924 74550 Oil seal i...

Page 145: ...ad lock super 1363A 8 10N m Tightening torque 0 8 1 0 kg m 6 0 7 0 lb ft After installing the bearing plate into the final gear bearing case install the bearing by using the special tools 09924 74510...

Page 146: ...is re torqued to specification NOTE When changing the shims measure the thick ness of the old shims Using the thickness of the old shims as a guide adjust the pr load by referring to the chart at righ...

Page 147: ...point 0 ring is installed after backlash and tooth contact are correct Install the final driven bevel gear shims CD and removed during disassembly on the needle bearing and final driven bevel gear and...

Page 148: ...0 40 mm 27327 34220 0 50 mm 27327 34230 0 60 mm BACKLASH Install the backlash measuring tool on the drive bevel gear coupling and set up a dial gauge as shown in Fig 09924 34510 Final gear backlash D...

Page 149: ...gear and final gear case b Decrease thickness of shims between final driven gear and bearing by an amount equal to increase above EXAMPLE Final gear to case shims SHAFT DRIVE 4 34 List of shims Refer...

Page 150: ...otate the final drive bevel gear several turns in each direction while loading the final driven bevel gear This will provide a contact pattern on the coated teeth of the driven bevel gear Remove the f...

Page 151: ...te the teeth with Hypoid gear oil Install new 0 rings to the final gear bearing case and final drive bevel gear housing Coat the 0 rings with grease Install the final drive bevel gear assembly into th...

Page 152: ...60mm 1 62 mm 1 64 mm 1 66 mm 1 68mm 1 70 mm 1 80 mm 1 90mm 2 00mm List of shims Part No Shim thickness 27326 34201 1 05 mm 27326 34211 1 10 mm 27326 34221 1 20 mm 27326 34231 1 25 mm 27326 34241 1 35...

Page 153: ...M 5 1 COOLING SOLUTION 5 3 RADIATOR AND WATER HOSES 5 4 THERMOSTAT 5 7 WATER PUMP 5 8 THERMO SWITCH AND FAN MOTOR RELAY 5 12 ENGINE THERMO SWITCH 5 13 FAN MOTOR RELAY 5 13 FAN MOTOR 5 14 WATER TEMPERA...

Page 154: ...of temperature dependent control over the flow of coolant through the radiator The valve is actuated by the temperature sensitive wax contained in the pellet Referring to the following illustration t...

Page 155: ...COOLING SYSTEM 5 2...

Page 156: ...erized by very high values of permeability and leakage accident of the cooling system is highly likely The anti leakage substance is used to prevent such a possible leakage and every new motorcycle is...

Page 157: ...HOSES REMOVAL Drain the coolant by removing drain plug CD or the other drain plug located on the water hose union See page 3 3 Remove the right and left radiator covers Disconnect the radiator hoses...

Page 158: ...htness by using the radiator tester as follows Remove the radiator cap and connect the tester to the filler Give a pressure of about 1 kg cm2 14 2 psi 100kPa and see if the system holds this pressure...

Page 159: ...is recommended for this cleaning Fins bent down or dented can be repaired by straightening them with the blade of a small screwdriver 4 Any water hose found in a cracked condition or flattened must b...

Page 160: ...mostat in the water contained in the pan as shown in the illustration Note that the immersed thermostat is in suspension Heat the water by placing the pan on a stove and observe the rising temperature...

Page 161: ...start to open temperature and valve lift must be replaced Tighten the thermostat cover bolts to the specification Tightening torque WATER PUMP Tightening torque Item N m kg m 7 11 0 7 1 1 12 17 1 2 1...

Page 162: ...in tensioner Loosen the water pump drive sprocket bolt and remove the water pump drive sprocket Refer to page 3 17 CAUTION When removing the water pump drive sprocket bolt turn the bolt clockwise Remo...

Page 163: ...r pump driven sprocket side NOTE The removed bearing and mechanical seal should be replaced with new ones Remove the mechanical seal by using a suitable drift INSPECTION Visually inspect the mechanica...

Page 164: ...he water pump in the reverse order of disassembly and removal Replace 0 rings with new ones when reassembl ing the water pump CAUTION Use a new gasket CD for impeller center bolt When installing the g...

Page 165: ...lay 0 0 Battery I INSPECTION Before inspecting the individual parts check the following items Disconnect the thermo switch lead wire and connect the jumper lead between lead wire from the main wiring...

Page 166: ...portion of the switch 99104 31140 ISUZUKI Bond No 1207B Thermo switch 6 9 N m tightening torque 0 6 0 9 kg m 4 5 6 5 lb ft CAUTION Take special care when handling the thermo switch It may cause damage...

Page 167: ...tor does not turn replace the motor assembly with a new one Fan motor j 1 Battery I COOLING SYSTEM 5 14 Ammeter WATER TEMPERATURE METER AND TEMPERATURE GAUGE The following circuit diagram shows the el...

Page 168: ...he table must be replaced Temperature gauge specification Water temp C F Standard resistance Q 40 104 Approx 240 60 140 104 80 176 52 1 100 212 27 4 If the resistance noted to show infinity or too muc...

Page 169: ...7 DIAPHRAGM AND PISTON OPERATION 6 8 SLOW SYSTEM 6 9 TRANSIENT ENRICHMENT SYSTEM 6 9 MAIN SYSTEM 6 10 STARTER SYSTEM 6 11 FLOAT SYSTEM 6 11 DISASSEMBLY 6 12 NEEDLE VALVE INSPECTION 6 16 FLOAT HEIGHT...

Page 170: ...the fuel pump relay and the electromagnetic force is used to deliver fuel to the carburetor The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carbu reto...

Page 171: ...flows to the fuel pump relay s control circuit The control circuit receives this current and sends signal to the SCR turning it ON When the SCR turns ON current is sent from the battery through the f...

Page 172: ...RNING Do not use gasoline which is extremely flammable and explosive NOTE The battery must be fully charged Upon completion of the test all the kerosene should be removed from the parts Battery 1111 K...

Page 173: ...between the lead wires in the following table If the resistance checked is incorrect replace the fuel pump relay 09900 25002 Pocket tester Unit kn EB Probe of testerto CD CD 00 00 00 0 Q 00 00 00 cO...

Page 174: ...Cotter pin Washer Spacer Washer j Throttle valve shaft link Overflow pipe Throttle stop screw Breather connector hose Upper bracket Fuel hose from fuel pump Carburetor bracket Rear Fuel hose clamp Fue...

Page 175: ...ew Throttle valve return spring Pilot screw Starter plunger Coasting valve Pilot air jet Carburetor top cap Piston valve spring Jet needle stopper plate Spacer E ring Jetneedle Washer Spring Piston va...

Page 176: ...et Throttle cable play Choke cable play tr I D NO LOCATION Each carburetor has 1 0 Number CD stamped on the carburetor body according to its specifications SPECIFICATIONS MIKUNI BOS33SS 07A10 33 mm 1...

Page 177: ...am side of the venturi Vacuum is admitted into the diaphragm chamber through an orifice provided in the sliding shaft guide Rising vacuum controls the diaphragm movement causing the piston to rise to...

Page 178: ...device which keeps fuel air mixture ratio constant in order not to generate unstable combustion when the throttle grip is returned suddenly during high speed driving For normal operation joining of t...

Page 179: ...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 180: ...vel is up in float chamber floats are up and needle valve remains pushed up against valve seat Under this condition no fuel enters the float chamber with the air coming through a passage extending fro...

Page 181: ...alance the four carburetors Remove the carburetor set upper plate CD by unscrewing 8 screws Remove both carburetor covers by unscrew ing four screws Loosen 4 tightening screws of the rear p ate Remove...

Page 182: ...two screws CD and remove the starter plunger linkage plate Separate the two carburetors each other Remove the carburetor top cap using impact driver set 09900 09003 Impact driver set Remove the sprin...

Page 183: ...lot jet NOTE When replacing the main jets check their size and install them to the proper positions Pull out the float pin and remove the float CAUTION When removing the float pin be careful not to da...

Page 184: ...he main bore side Remove the choke plunger assembly Remove the jet needle stopper plate screws NOTE When replacing the jet needles check their identification codes and install them to the proper posit...

Page 185: ...foreign matter is caught between the valve seat and the needle the gasoline will continue flowing and cause it to overflow If the seat and needle are worn beyond the permissible limits similar trouble...

Page 186: ...ith the pin and replace it When reinstalling the float chamber to the carburetor body install the seal ring to the groove of the float chamber properly Place tongue of diaphragm to the carburetor body...

Page 187: ...control lever correctly Install the starter plunger plate with two screws Apply a small amount of grease to the sliding parts Properly route the fuel pipes and breather pipes and install all the plat...

Page 188: ...ng carburetor plate screws make sure to follow the above steps Failure to do so cause imbalance of carburetors When installing the front plate screws apply thread lock cement to the screw thread 99000...

Page 189: ...engine at the idling speed 1 000 1 200 r min and measure the distance with the middle line of the level gauge aligned with the index line of the carburetor body as shown in the figure should be withi...

Page 190: ...ming up Stop the warm up engine Remove vacuum inspection screw CD for No 1 or No 3 carbure tor and install adapter with gasket Connect one of the four rubber hoses of the balancer gauge to this adapte...

Page 191: ...if not loosen lock nut and turn throttle balance screw to adjust the throttle valve setting to bring its steel ball to the center level line Adjusting order For R No 4 and L No 2 carbs for Nos 3 4 car...

Page 192: ...ed oil seal a defective oil pump or a com bination of these items High oil pressure is usually caused by a engine oil which is too heavy a weight a clogged oil passage improper installation of the oil...

Page 193: ...__ NOS 1 2 CONROD BIG END DRIVE SHAFT r o J 8 rsHAFT 1 FILTER H LAsH ADJusTER h EXHAUST CAMSHAFT L JOURNAL HOLDER I CYLINDER HEAD I CYLINDER WALL PISTON AND n PISTON PIN L____ t H REAR CYLINDER I FRON...

Page 194: ...6 25 FUEL AND LUBRICATION SYSTEM...

Page 195: ...4 EMISSION CONTROL REGULATIONS CONTENTS EMISSION REGULATIONS 7 1 EMISSION CONTROL CARBURETOR COMPONENTS 7 2 GENERAL EMISSION INFORMATION 7 3...

Page 196: ...d with a headlight taillight stop light and which have an engine displacement larger than 50 cc Suzuki Motor Company performed all the necessary testing and certification of emission controlled models...

Page 197: ...ent component Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability Conventional Figures Used on Standard Tolerance 1 Jet Component...

Page 198: ...at total NOx emission from motorcycles by 1990 will only amount to approximately 0 5 NOx is formed during the combus tion process at high combustion chamber temperatures CARBON MONOXIDE Carbon monoxid...

Page 199: ...gapped 2 Ignition 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 eith...

Page 200: ...YSTEM CONTENTS CHARGING SYSTEM 8 1 IGNITION SYSTEM 8 3 STARTER SYSTEM 8 7 COMBINATION METER AND CHECK PANEL 8 11 WATER TEMPERATURE METER 8 13 FUEL LEVEL INDICATOR SYSTEM 8 15 LAMPS 8 16 SWITCHES 8 17...

Page 201: ...ce and regulator rectifier NOTE When making this test be sure that the bat tery is fully charged condition STD charging output 09900 25002 14 15V DC at 5 000 r min Pocket tester AC GENERATOR NO LOAD P...

Page 202: ...es in the following table If the resistance checked is incorrect replace the regulator rectifier 09900 25002 Pocket tester Unit kn EB Probe of tester to R 0 B W v Y Y R 00 00 00 00 00 0 Approx Approx...

Page 203: ...rcuit is incorporated in the ignitor unit to prevent over running engine If engine r min reaches 11 250 r min this circuit cuts off the ignition primary current for all spark plugs CAUTION Engine can...

Page 204: ...dings are in sound condition their continuity will be noted with these approx imate ohmic values 09900 25002 Pocket tester Ignition coil resistance Primary 3 5n Secondary 10 20 kn SIGNAL GENERATOR Che...

Page 205: ...lug Connect 8 pin of SUZUKI Pocket Tester X1 n range with Blue lead wire and EB pin with Green lead wire The ignitor unit is in good condition if the following is observed The moment the test pins are...

Page 206: ...ignitor lead wire couplers Connect the couplers on the ignitor checker to the ignitor lead wire couplers as shown in the illustra tion Turn the ignition switch to the ON position Turn the ignitor che...

Page 207: ...causing the contact points to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine Starter interlock switch Clutch switch Engine stop switch Start...

Page 208: ...ry paper when it is dirty After polishing it wipe the commutator with a clean dry cloth Measure the commutator under cut CD Service Limit 0 2 mm 0 008 in ARMATURE COIL Using a pocket tester check the...

Page 209: ...OUSING END Inside Apply grease to the lip of oil seal When installing the housing end align the grooves on the housing end with the pawls of washer 99000 25030 SUZUKI super grease A I HOUSING END Outs...

Page 210: ...e wrench to the other terminal Turn on the ignition switch inspect the conti nuity between the terminals positive and negative when squeezing the clutch lever and pushing the starter button If the sta...

Page 211: ...anel as follows CD Speedometer Tachometer Water temp meter Check panel Gear position indicator INSPECTION Using the pocket tester check the continuity between lead wires in the following diagram If th...

Page 212: ...DE STAND W Y 1st B W HI BEAM TEMP ILLU R B 2nd Ml TURN ffi probe of tester to Orange Y HI BEAM BLANK OFF PUSH PUSH PARK ON LOCK 0 IGNITION ITEM e probe of tester to SIDE STAND OIL HIGH BEAM NEUTRAL TE...

Page 213: ...at points L1 and L2 will also vary This in turn will cause the strength of the magnetic field generated in the four coils to increase or decrease causing a related increase or decrease in the force v...

Page 214: ...d engine ground With the ignition switch turned on the water temperature meter should indicate H The second test will check the accuracy of the me ter in the H and C positions Connect a 130 ohm resist...

Page 215: ...el indicator light does not light replace the indicator bulb or repair the circuit connection If the bulb is in good condition the level indicator switch may be faulty replace the indicator switch wit...

Page 216: ...LAMPS HEADLIGHT NOTE Adjust the headlight both vertical and holizontal after reassembling TAIL BRAKE LIGHT CAUTION Do not overtighten the lens fitting screws ELECTRICAL SYSTEM 8 16...

Page 217: ...e lens fitting screws SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart If any abnormality is found replace the respective switch assemblies with new ones 09900...

Page 218: ...TRICAL SYSTEM 8 18 DIMMER SWITCH w y Y W HI 0 0 LO 0 0 TURN SIGNAL SWITCH B Lbl Lg R 0 o L 0 0 HORN SWITCH G B W ON Push 0 0 OFF ENGINE STOP AND START SWITCH 0 W 0 W Y G Red coupler OFF RUN 0 0 START...

Page 219: ...Squeeze lever OFF FRONT BRAKE SWITCH 0 G Red tube w ON Squeeze lever OFF GEAR POSITION INDICATOR SWITCH Gear position Wire color 1st W Y Neutral Bl 2nd R B 3rd G BI Ground 4th Y BI 5th Br R Over Drive...

Page 220: ...COLOR R W Red with White tracer 0 Orange Gr Gray Br Brown W White Y Yellow Y W Yellow with White tracer B Black Lbl Light blue Lg Light green G W Green with White tracer ELECTRICAL SYSTEM 8 20 G Gree...

Page 221: ...n below Maximum charging current 1 4A Charging time The charging time for a new battery is determined by the number of months that have elapsed since the date of manufacture Confirmation for date of m...

Page 222: ...as shown in figure Check the reading as corrected to 20 C with chart to determine the recharging time in hour by constant current charging at a charging rate of 1 4 amperes which is tenth of the capac...

Page 223: ...e per formance sulfation Replace the battery with new one in such a case u 1 28 0 co 1 24 0 0 1 20 1 1 16 1 12 f 5 1 08 c en 2 4 6 8 10 12 14 16 18 Charging time hour When a battery is left for a long...

Page 224: ...CHASSIS CONTENTS FRONT WHEEL 9 1 FRONT BRAKE 9 6 FRONT FORK 9 13 STEERING STEM 9 20 REAR WHEEL AND REAR BRAKE 9 25 REAR SUSPENSION AND SWINGARM 9 32 CLUTCH MASTER CYLINDER 9 42...

Page 225: ...5 REMOVAL AND DISASSEMBLY Support the machine by using center stand and jack with wooden block Remove caliper mounting bolts and dismount the caliper NOTE Do not operate the brake lever while dis mou...

Page 226: ...the opposite side lock the wedge bar in the slit of the adapter Drive out the wheel bearing by knocking the wedge bar CAUTION The removed bearing should be replaced 09941 50110 INSPECTION WHEEL BEARIN...

Page 227: ...arings If bearing replacement fails to reduce the runout adjust the tension of the spokes and if this proves to be of no effect replace the wheel rim Service Limit Axial and Radial SPOKE NIPPLE 2 0 mm...

Page 228: ...arry out the following steps WHEEL BEARING Apply grease before installing the bearings 99000 25030 SUZUKI super grease A Install the wheel bearings as follows by using the special tool CAUTION First i...

Page 229: ...0 3 0 kg m 14 5 21 51b ft Before installing the speedometer gearbox grease it and align the two drive pawls CD for fitting them into the two recesses of the wheel hub and attach the speedometer gearbo...

Page 230: ...hile dis mounting the caliper Pull out brake pads with pad shim CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affect ed NOTE Push in the piston all the way to...

Page 231: ...receptacle CAUTION Never re use the brake fluid left over from the last servicing and stored for long periods WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surf...

Page 232: ...by using air gun CAUTION Do not use high pressure air to prevent piston damage Remove dust boot and piston seal CALIPER AND DISC INSPECTION Inspect the caliper bore wall for nicks scratches or other...

Page 233: ...e service limit 09900 20606 09900 20701 Service Limit Dial gauge 1 100 mm Magnetic stand Not available in USA 0 30 mm 0 012 in CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disasse...

Page 234: ...after reassembling caliper See page 2 11 Tightening torque N m kg m lb ft Union bolt 20 25 2 0 2 5 14 5 18 0 CaIiper mounting 25 40 2 5 4 0 18 0 29 0 bolt Caliper axle bolt 15 20 1 5 2 0 11 0 14 5 MA...

Page 235: ...he union bolt and disconnect the brake hose master cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemically with paint plastics rubber...

Page 236: ...061 08 Snap ring pliers CD Circlip Piston Primary cap Return spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for scratc...

Page 237: ...em Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore Remount the master cylinder on the handlebar as shown in the illustration CAUTION Bleed the air after reass...

Page 238: ...bolt to facilitate later disassembly after loosening the front fork upper clamp bolt Loosen the front fork upper and lower clamp bolts Pull off the front fork DISASSEMBLY Tightening torque Item N m k...

Page 239: ...t out the fork oi I Under the condition inverted condition hold the fork for a few minutes Remove damper rod securing bolt by using the special tools Draw out damper rod and rebound spring 09940 34520...

Page 240: ...tion metals may be damaged and replace them with new ones Remove inner tube anti friction metal INSPECTION FORK SPRING Measure the fork spring free length If it is shorter than service limit replace i...

Page 241: ...f the inner tube as shown CAUTION Use special care to prevent damage to the Teflon coated surface of the Anti friction metal when mounting it OIL LOCK PIECE Install the retainer to the oil lock piece...

Page 242: ...L For the fork oil be sure to use a front fork oil whose viscocity rating meets specifications below Fork oiI type Fork oil 15 Fork oil capacity 479 ml 16 2 US oz Hold the front fork vertical and adju...

Page 243: ...handle clockwise and charge the air Let the air out by loosening the handle till the specified air pressure is left inside and re move the air lock screw STD Air pressure 30 kPa 0 3 kg cm2 4 3 psi CA...

Page 244: ...1 Remove the front fork See page 9 13 Remove the brake hose joint part Disconnect the horn lead wires Tightening torque Item N m 12 20 15 25 20 30 20 30 15 25 CHASSIS 9 20 kg m lb ft 1 2 2 0 8 5 14 5...

Page 245: ...9 21 CHASSIS Remove the headlight Disconnect the lead wires Remove the headlight brackets Remove the handlebar clamp bolts and then remove the handlebar...

Page 246: ...e the ignition switch Loosen the steering stem head bolt and clamp bolt Remove the front fork upper bracket Tightening torque N m kg m lb ft Steering stem 20 30 head bolt 2 0 3 0 14 5 21 5 Steering st...

Page 247: ...al tool CAUTION The removed bearing should be replaced 09941 84510 Bearing inner race remover Push out steering stem bearing outer races up per and lower by using the special tools 09941 54911 Steerin...

Page 248: ...09941 74910 Steering bearing installer Apply grease upper and lower bearings before remounting the steering stem 99000 25030 SUZUKI super grease A STEM NUT Tighten the steering stem nut by using the s...

Page 249: ...the handlebars are equalized Tightening torque 12 20 N m 1 2 2 0 kg m 8 5 14 5 lb ft REAR WHEEL AND REAR BRAKE CONSTRUCTION Tightening torque Item N m kg m lb ft 50 80 5 0 8 0 36 0 58 0 8 12 0 8 1 2 6...

Page 250: ...e off the rear wheel DISASSEMBLY Flatten the lock washers Remove fitting bolts and pull off driven joint Tightening torque Remove the 0 ring 8 12 N m 0 8 1 2 kg m 6 0 8 5 lb ft Take off the dampers by...

Page 251: ...9 27 CHASSIS Remove the wheel bearings with same manner as that of front bearing Refer to page 9 2 REAR BRAKE Remove the brake shoe Remove the cam lever brake shoe wear indicator and 0 ring...

Page 252: ...e shoe wear indicator when extended will fall within the range embossed on the brake panel when brake is on First check that the brake system is properly adjusted Then check the indicator extension li...

Page 253: ...of this limit is indicated inside the drum Service Limit 180 7 mm 7 11 in Inspect the drum I D for scratch marks If the I D surface is scratched or otherwise roughened smoothen it with sandpaper REAS...

Page 254: ...e installing the driven joint Apply grease to the final gear spline before installing the rear wheel 99000 25030 ISUZUKisupergrease A I Tighten the driven joint bolts Tightening torque 8 12 N m 0 8 1...

Page 255: ...m 0 5 0 8 kg m 3 5 6 0 lb ft Align the two aligning marks CD each other When tightening the axle nut hold the axle shaft to prevent turning with plain screw driver insert ing in the axle groove as sh...

Page 256: ...he rear wheel See page 9 25 Remove the front seat by using the key and remove the rear seat by depressing the seat locks Take off the seat lock by unscrewing the retainer screws Disconnect the tail br...

Page 257: ...9 33 CHASSIS Remove the right and left muffler brackets Remove the frame molding retaining bolts Disconnect the rear brake cable Remove the final gear case...

Page 258: ...the spring pre load adjuster by removing the securing bolts Remove the swingarm pivot covers Right and left Loosen the cushion lever center bolt and swing arm bearing holder bolt lock nuts Remove the...

Page 259: ...ngarm bearing Loosen and remove the bolts and nuts Remove the swingarm bearing outer race by using the special tools 09941 6451 0 Bearing puller 09930 301 02 Sliding shaft REAR SHOCK ABSORBER Remove t...

Page 260: ...Remove the ring Remove the bearing by using the appropriate socket as shown in the photograph CUSHION LEVER Remove the dust seal and washer Remove the spacer CHASSIS 9 36 0...

Page 261: ...ing by using the special tool 09941 6451 0 Bearing puller 09930 301 02 Sliding shaft CUSHION LEVER ROD Remove the spacer and dust seal Remove the ring Remove the bearing by using the appropriate socke...

Page 262: ...d DUST SEAL Inspect the dust seal if they are found to be damaged replace them with a new dust seal REASSEMBLY Reassemble and remount the swingarm and rear shock absorber in the reverse order of disas...

Page 263: ...aring to the cushion lever by using the special tool 09924 84510 Bearing installer set NOTE When installing the bearing stamped mark of bearings is positioned outside Apply grease to the dust seal and...

Page 264: ...ts with specified torque and tighten the lock nuts CAUTION Both sides of the clearance between the frame and swingarm should be even Bearing holder bolt tightening torque 3 5 4 5 N m 0 35 0 45 kg m 2...

Page 265: ...0 ISUZUKI BOND No 1207B I 35 45 N m Tightening torque 3 5 4 5 kg m 25 5 32 5 lb ft FINAL INSPECTION AND ADJUSTMENT After installing rear swingarm shock absorber brake and rear wheel following adjustme...

Page 266: ...h Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the clutch hose master cylinder joint CAUTION Completely wi...

Page 267: ...9 43 CHASSIS Remove the two clamp bolts and take off master cylinder assembly Remove the clutch lever Remove reservoir cap and diaphragm Drain brake fluid Remove the push rod and boot...

Page 268: ...scratches or other damage Inspect the primary cup and dust boot for wear or damage MASTER CYLINDER REASSEMBLY Reassemble and remount the master cylinder in the reverse order of disassembly and removal...

Page 269: ...paste Align the push rod with hole of lever piece Mount the clutch master cylinder on the handlebar as shown in the illustration CAUTION Bleed the air after reassembling master cylin der See page 2 7...

Page 270: ...SERVICING INFORMATION CONTENTS TROUBLESHOOTING 10 1 WIRING DIAGRAM 10 9 CABLE HARNESS AND HOSE ROUTING 10 10 SPECIAL TOOLS 10 17 TIGHTENING TORQUE 10 22 SERVICE DATA 10 25...

Page 271: ...buretor float valve Replace 6 Clogged fuel pipe or suction pipe Clean 7 Defective signal generator ignition coil ignitor Replace Engine stalls 1 Fouled spark plugs Clean easily 2 Defective signal gene...

Page 272: ...nsmission will 1 Broken gearshift cam Replace not shift 2 Distorted gearshift forks Replace 3 Too much play on gearshift lever Adjust 4 Worn gearshift pawl guide Replace Transmission will 1 Broken ret...

Page 273: ...gged air cleaner element Clean 10 Carburetor balancing screw loose Retighten and balance the carbs 11 Sucking air from intake pipe Retighten or replace 12 Too much engine oil in the engine Drain out e...

Page 274: ...eck and adjust Idling or low speed 1 Pilot jet pilot air jet are clogged or loose Check and clean trouble 2 Air leaking from carburetor s joint vacuum gauge Check and adjust joint or starter 3 Pilot o...

Page 275: ...n 3 Incorrect gasoline Change 4 DirtY element in air cleaner Clean 5 Spark plugs too cold Replace by hot type plugs Spark plugs 1 Worn piston rings Replace become fouled 2 Pistons or cylinders worn Re...

Page 276: ...ge surfaces of cell plates 2 Battery case is cracked Replace the battery 3 Battery has been left in a run down Replace the battery condition for a long time 4 Contaminated electrolyte Foreign matter I...

Page 277: ...eels too 1 Steering stem nut overtightened Adjust heavy 2 Worn roller bearing or race in steering stem Replace 3 Distorted steering stem Replace 4 Not enough pressure in tires Adjust 5 Overtightened s...

Page 278: ...worn down Replace REAR 2 Too much play on brake pedal Adjust Insufficient 1 Leakage of brake fluid from hydraulic system Repair or replace brake power 2 Worn pads Replace 3 Oil adhesion on engaging s...

Page 279: ...t j E G A TOR R SSURE BAtERY BREAKER I FUSE r TEMPERATURE THERMl SWITCH WIRE COLOR W White B Black Y Yellow 0 B Orange with Black tracer Bl Blue B Br Black with Brown tracer 0 BI Orange with Blue trac...

Page 280: ...cover s boss and the car buretor top Clamp Starter cable Right cover Throttle cable Pass the throttle cable between upper side boss and frame head cover Throttle cable Clutch pipe Starter cable Pass t...

Page 281: ...adlight housing Handle switch leads R L Clamp Left handle switch Thermo switch lead Meter leads Clamp Install the cap with the cap end facing rearward Ground Clamp Rear combination light lead wire Tur...

Page 282: ...t breaker SERVICING INFORMATION 10 12 Guide Right handle switch lead wire Clamp Gear position indicator switch Brake hose guide AC generator wire harness Gear position indicator wire harness Clamp Sec...

Page 283: ...ear position indicator lead Secondary breather hose STARTER MOTOR AND OIL PRESSURE SWITCH LEAD WIRES Oil pressure switch Clutch cover Oil pressure switch lead wire Ip Battery ground Clamp Clamp Second...

Page 284: ...n the union bolt After touching the union to the caliper stopper tighten the union bolt 1 Turning radius of the brake hose should be more than 30 mm at the center of brake hose 2 Degrees of hose windi...

Page 285: ...tch hose guide Pass the clutch hose inside the guide Route the clutch hose between the two bosses for securing the head cover Lightly touch the rubber protector of the hose to the air cleaner case Ins...

Page 286: ...ark FRONT L___j__J White dot to the rearward Cylinder head breather cover Hose Radiator side Engine side These aligning marks should be faced to the left side Index mark SERVICING INFORMATION 10 16 AI...

Page 287: ...03 V block set Not available in USA 16 09900 22301 Plastigauge Not available in USA 17 09900 22403 Small bore gauge Not available in USA 18 09900 25002 SUZUKI pocket tester 19 09900 28403 Hydrometer 2...

Page 288: ...iston ring compressor 51 09916 84510 Tweezers 52 09920 5371 0 Clutch sleeve hub holder 53 09920 80710 Secondary driven gear coupling holder 54 09921 2021 0 Bearing remover 55 09923 74510 Bearing pulle...

Page 289: ...2 Fork oil seal installer 76 09941 3451 3 Bearing installer 77 09941 50110 Bearing remover Not available in USA 78 09941 54911 Bearing race remover 79 09941 64510 Bearing and oil seal remover 30 45 mm...

Page 290: ...SERVICING INFORMATION 10 20...

Page 291: ...10 21 SERVICING INFORMATION 9 l...

Page 292: ...bolt Water pump chain tensioner bolt Clutch sleeve hub nut N m 23 27 46 51 13 15 8 12 33 37 60 70 45 55 24 13 20 28 12 16 18 28 25 30 4 7 8 12 140 160 7 9 55 65 7 11 80 110 12 17 50 70 SERVICING INFOR...

Page 293: ...0 Secondary gear case bolt 18 28 1 8 2 8 13 0 20 0 Final drive bevel gear shaft nut 90 110 9 0 11 0 65 0 79 5 Final driven gear bearing retainer screw 8 10 0 8 1 0 6 0 7 0 Final gear bearing case bol...

Page 294: ...wheel driven joint bolt 8 12 0 8 1 2 6 0 8 5 Final case joint nut 35 45 3 5 4 5 25 5 32 5 TIGHTENING TORQUE CHART For other bolts and nuts not listed above refer to this chart Bolt Conventional or 4 m...

Page 295: ...0 35 0 0014 0 0024 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 465 5 480 0 2152 0 2157 EX 5 450 5 465 0 2146 0 2152 Valve stem runout IN EX 0 05 0 002 Valve head thicknes...

Page 296: ...Rear 18th pin Idler chain 20 pitch length 161 0 6 34 Idler chain pin at aligning mark 29th pin Cylinder head distortion 0 10 0 004 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compressio...

Page 297: ...d big end side clearance 0 10 0 25 0 30 0 004 0 010 0 012 Conrod big end width 19 95 20 00 0 785 0 787 Crank pin width 40 10 40 15 1 579 1 581 Conrod big end oil clearance 0 032 0 056 0 090 0 0013 0 0...

Page 298: ...master cylinder bore 14 000 14 043 0 5512 0 5529 Clutch master cylinder piston diam 13 957 13 984 0 5495 0 5506 Clutch release cylinder bore 38 100 38 162 1 5000 1 5024 Clutch release cylinder piston...

Page 299: ...025 Driven side 0 02 0 35 0 0008 0 0138 Secondary drive bevel gear preload 3 5 kg em 2 6 4 4 lb in Secondary driven bevel gear preload 4 7 kg em 3 5 6 1 lb in Final drive bevel gear preload 4 7 kg em...

Page 300: ...8 0 3 at 1 atm Signal coil resistance 90 140Q G Bl B Y Ignition coil resistance Primary 3 5Q EB tap 8 tap Secondary 10 20 kQ Plug cap Plug cap Generator no load voltage More than 65 V AC at 5 000 r m...

Page 301: ...0 0 8 1 2 Rear brake pedal height Above 15 0 6 Brake drum LD Rear 180 7 7 11 Brake lining thickness 1 5 0 06 Brake disc thickness Front 5 0 0 20 4 5 0 20 0 008 0 18 Brake disc runout 0 30 0 012 Master...

Page 302: ...ane or higher rated by the Research Method Fuel tank including reserve 13 0 L 3 4 2 9 US Imp gal reserve 3 0 L 3 2 2 6 US Imp qt Engine oil type and grade SAE 1OW 40 API SE or SF Engine oil capacity C...

Page 303: ...of cylinders 4 Bore 69 0 mm 2 717 in Stroke 46 7 mm 1 839 in Piston displacement 698 cm3 42 6 cu in Carburetor MIKUNI BDS33 four Air cleaner Polyester fiber element Starter system Electric Lubricatio...

Page 304: ...djustable 3r right left 60 30 116 mm 4 57 in 3 0 m 9 8 ft Disc brake twin hydraulically operated Internal expanding 110 80 19 59H 140 80 16 68H 160 mm 6 3 in 115 mm 4 5 in Transistorized 10 B T D C be...

Page 305: ...MAINTENANCE CHART INTERVAL km 1000 6 000 12000 18 000 24000 THIS INTERVAL SHOULD BE JUDGED mile 600 4000 7500 11 000 15 000 BY ODOMETER READING OR MONTHS WHICHEVER COMES FIRST month 2 12 24 36 48 Batt...

Page 306: ...It is connected to the fuel tank and carburetors via hoses and pipes This system prevents HC vapors from the gasoline inside the fuel tank from escaping into the open air As shown in the diagram the...

Page 307: ...10 37 SERVICING INFORMATION VAPOR HOSE ROUTING Vapor hose Vapor canister...

Page 308: ...lamp Hose Wiring Purge harness air hose Harness CORRECT HOSE ROUTING CAUTION Do not place the vapor hose on top of the air vent hose SERVICING INFORMATION 18 38 Clamp Hose Harness INCORRECT HOSE ROUTI...

Page 309: ...Prepared by SUZUKI MOTOR CORPORATION Motorcycle Technical Service Department October 1990 April 1984 Manual No 99500 36040 03E Printed in Japan 312...

Page 310: ......

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Suzuki Madura GV700GL, Service Manual

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Summary of Contents for Madura GV700GL

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