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Suzuki GS850G, Руководство по обслуживанию


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Содержание GS850G

Страница 1: ......

Страница 2: ...GROUP INDEX GROUP INDEX 1 2...

Страница 3: ...GROUP INDEX GROUP INDEX 2 2...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 56: ...ENGINE Fig 7 1 7 3...

Страница 57: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 116: ...SHAFT DRIVE SHAFT DRIVE...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 145: ......

Страница 146: ......

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 165: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 223: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 256: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 267: ...WIRE ROUTING...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 328: ...Clamp Clutch cable able...

Страница 329: ...GSA SOGT WIRING DIAGRAM...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 337: ...WIRE AND CABLE ROUTING...

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

Страница 339: ...WlRllNG DIAGRAM A 8...

Страница 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...

Страница 341: ...Right sic Left sidf...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 400: ...TORQUE TABLE e ENGINE...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 421: ...Clamp...

Страница 422: ...0 WIRING DIAGRAM...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 440: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 454: ...WIRING DIAGRAM...

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