Table Of Contents - Suzuki VS700 Service Manual

Table of Contents

Engine2
View Of Suzuki Vs700Glf4
View Of Suzuki Vs700Glp4
Group Index5
Supplements6
Table Of Contents6
General Information7
Serial Number Locations8
Fuel8
Engine Oil8
Gear Oil (Final Drive)8
Breaking-In Procedures9
Cylinder Identification9
Coolant9
Anti-Freeze/Coolant9
Special Materials10
Precautions And General Instructions12
Replacement Parts12
Specifications13
Dimensions And Dry Mass13
Chassis13
Periodic Maintenance And Tune-Up Procedures14
Periodic Maintenance Schedule15
Periodic Maintenance Chart15
Lubrication Point16
Maintenance And Tune-Up Procedures17
Battery17
Air Cleaner18
Front Side Air Cleaner18
Rear Side Air Cleaner18
Valve Clearance19
Valve Clearance Specifications19
Inspection Of The Rear Side Valve Clearance20
Spark Plug21
Engine Oil And Oil Filter22
Necessary Amount Of Engine Oil22
Carburetor23
Throttle Cable Play23
Fuel And Vapor Hose23
Clutch24
Clutch Fluid Level24
Bleeding Air From The Clutch Fluid24
Cooling System25
Coolant Capacity25
Final Gear Oil26
Brakes26
Front Brake26
Brake Fluid Level26
Brake Pads27
Bleeding Air From The Brake Fluid Circuit27
Bleeder Valve Tightening Torque27
Rear Brake28
Front Brake Light Switch28
Brake Pedal Height And Free Travel28
Brake Light Switch28
Tires29
Tire Tread Condition29
Tire Pressure29
Brake Shoe Wear29
Steering30
Front Fork30
Chassis Bolts And Nuts31
Compression Check34
Compression34
Compression Test Procedure34
Engine Components Removable With The Engine In Place35
Engine Removal36
Engine Reinstallation42
Tightening Torque43
Engine Disassembly44
Bearing And Oil Seal (Except For Crankshaft)59
Drive Gear60
Driven Gear61
Cooling System Relation Part62
Engine Components Inspection And Servicing63
Cylinder Head Cover Disassembly63
Cylinder Head Cover Distortion63
Rocker Arm Shaft O.d.63
Rocker Arm I.d.64
Camshaft64
Camshaft Cam Wear65
Cam Chain Tensioner65
Cam Chain Guide65
Cam Chain 20-Pitch Length65
Camshaft Journal Wear66
Camshaft Journal Oil Clearance66
Cylinder Head Cover Tightening Torque66
Camshaft Runout67
Cylinder Head Disassembly67
Cylinder Head Distirtion67
Valve Face Wear68
Valve Stem Runout68
Valve Head Radial Runout68
Valve Guide - Valve Stem Clearance69
Valve Stem Wear69
Valve Guide Servicing69
Valve Seat Width71
Valve Seat Servicing71
Parts List Of Valve Seat Servicing Tools71
Valve Stem End Condition73
Valve Springs (Refer To Service Data)73
Valve Spring Free Length Limit73
Valve Spring Tension73
Reassembly74
Cylinder Distortion74
Cylinder Bore74
Piston Diameter75
Piston-Cylinder Clearance75
Piston Ring-Groove Clearance75
Piston Ring76
Free End Gap And End Gap76
Piston Ring Groove Width76
Piston Ring Thickness76
Piston Pin And Pin Bore77
Oversize Piston Rings77
Oversize Oil Rings77
Oversize Side Rail77
Connecting Rod Small End Bore I.d.78
Connecting Rod Big End Thrust Clearance78
Connecting Rod - Crank Pin Bearing Selection79
Bearing Selection Table80
Oil Clearance80
Connecting Rod I.d. Specification80
Crank Pin O.d. Specification80
Bearing Assembly81
Bearing Thickness81
Crankshaft82
Crankcase-Crankshaft Bearing Selection82
Crankshaft Thrust Clearance83
Clutch Drive Plates And Driven Plates84
Clutch Spring Free Length85
Clutch Bearings85
Clutch Cylinder85
Clutch Reassembly86
Generator And Signal Generator86
Starter Clutch86
Oil Pump88
Transmission Gears And Related Parts88
Gear-Shifting Fork Clearance89
Countershaft Reassembly89
Shift Fork - Groove Clearance89
Shift Forks Groove Width89
Driveshaft Reassembly90
Engine Reassembly91
Camshaft Timing106
Valve Rocker Arm And Shaft109
Cylinder Head Bolt110
Cylinder Head Cover Bolt110
Shaft Drive111
Secondary Bevel Gears Construction113
Shaft Drive Removal And Disassembly114
Secondary Drive Bevel Gear114
Secondary Driven Bevel Gear114
Shaft Drive Inspection115
Shaft Drive Reassembly115
Secondary Gears Shim Adjustment116
Backlash116
Tooth Contact117
Reassembly Information118
Final Vebel Gears Construction119
Final Gear Case Breather Circuit120
Air And Gear Oil Flow In Final Gear Case Breather Circuit120
Air Passage120
Oil Passage120
Final Gear Case Removal And Disassembly121
Propeller Shaft Removal And Disassembly121
Driven Bevel Gear Removal And Disassembly121
Drive Bevel Gear Removal And Disassembly123
Final Gear Case And Bearing Case126
Final Gear Shim Adjustment128
Final Gear Bearing Case Shim Clearance128
Final Assembly And Remounting131
Cooling System Description136
Cooling Solution137
Anti-Leakage Material137
Coolant Density Boiling Point Curve137
Coolant Density-Freezing Point Curve137
Radiator And Water Hoses Removal138
Radiator And Water Hoses Inspection138
Radiator Hose139
Radiator And Water Hoses Installation139
Thermostat Removal139
Thermostat Inspection139
Water Pump Removal141
Water Pump Disassembly142
Water Pump Inspection144
Water Pump Reassembly144
Thermo-Switch Inspection145
Engine Thermo-Switch145
Thermo-Switch Specification145
Thermo-Switch Tightening Torque145
Fan Motor146
Coolant Temperature Gauge Removal146
Coolant Temperature Gauge Inspection146
Coolant Temperature Gauge Reassembly146
Fuel And Lubrication System147
Fuel System148
Fuel System Description149
Fuel Cock149
Starting Engine149
After Start149
Fuel Pump150
Fuel Pump Relay151
Carburetor Construction152
No.2 Front Carburetor152
No.1 Rear Carburetor153
I.d. No. Location154
Diaphragm And Piston Operation155
Slow System156
Transient Enrichment System156
Main System157
Starter System158
Float System158
Needle Valve Inspection165
Float Height Adjustment165
Fuel Level Inspection167
Balancing Carburetors168
In Case Of Changing The Synchronizing Cable168
In Case Of Changing The Throttle Cable170
In Case Of Changing The Carburetors170
Lubrication System171
Oil Pressure171
Oil Sump Filter171
Oil Pressure Specification171
Lubrication System Chart172
Emission Control Informations174
Emission Control Carburetor Components175
Electrical System176
Charging System Description177
Function Of Regulator177
Charging Output Check179
Ac Generator No-Load Performance179
Ac Generator Continuity Check180
Regulator/Rectifier180
Ignition System Description181
Ignition Coils Inspection181
Signal Generator182
Ignitor Unit183
Starter System Description184
Starter Motor Removal And Disassembly184
Starter Motor Inspection185
Carbon Brushes185
Commutator185
Armature Coil186
Oil Seal186
Starter Motor Reassembly186
O-Ring186
Starter Relay Inspection187
Housing Screw187
Speedometer And Instrument Panel Removal And Disassembly188
Speedometer And Instrument Panel Inspection188
Water Temperature Unit And Indicator Inspection190
Lamps191
Headlight191
Tail/Brake Light191
Turn Signal Light192
Switches192
Ignition Switch192
Dimmer Switch193
Turn Signal Switch193
Horn Switch193
Engine Stop And Start Switch193
Clutch Switch194
Front Brake Switch194
Neutral Indicator Switch194
Rear Brake Switch194
Side Stand Check Switch195
Oil Pressure Switch195
Wire Color195
Battery Removal196
Battery Remounting196
Battery Specifications197
Battery Initial Charging197
Battery Servicing197
Filling Electrolyte197
Recharging Operation Based On S.g. Reading198
Service Life199
Front Wheel Construction201
Front Wheel Removal And Disassembly201
Brake Disc202
Wheel Bearing202
Wheel Bearings Inspection202
Axle Shaft Inspection203
Wheel Rim Inspection203
Spoke Nipple Inspection203
Tire Inspection203
Wheel Bearing Reassembly204
Brake Pad Replacement206
Caliper Removal And Disassembly206
Caliper And Disc Inspection208
Caliper Reassembly209
Master Cylinder Removal And Disassembly209
Master Cylinder Inspection211
Master Cylinder Reassembly212
Front Fork Removal212
Master Cylinder Disassembly213
Fork Spring Inspection215
Inner Tube And Outer Tube Inspection215
Damper Rod Ring216
Inner Tube Metal Reassembly216
Oil Lock Piece Reassembly216
Damper Rod Bolt Reassembly216
Outer Tube Metal, Oil Seal And Dust Seal217
Fork Oil217
Fork Spring217
Inner Tube218
Steering Stem Construction218
Steering Stem Disassembly218
Outer Races Reassembly221
Bearing Reassembly221
Stem Nut222
Handlebar Holder222
Handlebars223
Rear Wheel And Brake Construction223
Brake Shoe226
Brake Drum227
Wheel Damper227
Brake Rod Link Removal And Disassembly230
Brake Rod Link Inspection231
Brake Rod Link Remounting And Reassembly232
Rear Suspension And Swingarm Removal233
Dust Seal236
Rear Shock Absorber236
Swingarm Bearing Reassembly236
Clutch Master Cylinder237
Clutch Master Cylinder Removal And Disassembly238
Servicing Information241
Engine Troubleshooting242
Shaft Drive Troubleshooting244
Carburetor Troubleshooting245
Radiator Troubleshooting246
Electrical Troubleshooting246
Battery Troubleshooting247
Chassis Troubleshooting248
Brakes Troubleshooting249
Wiring Diagram250
Cable, Harness And Hose Routing251
Front Brake Hose Routing254
Clutch Hose Routing255
Periodic Maintenance256
Maintenance Chart256
Service Data256
Vapor Hose Routing256
Special Tools257
Engine Tightening Torque262
Cooling Tightening Torque263
Shaft Drive Tightening Torque263
Chassis Tightening Torque263
Tightening Torque Chart264
Valve + Guide Service Data265
Camshaft + Cylinder Data Service Data265
Cylinder + Piston + Piston Ring Service Data266
Conrod + Crankshaft Service Data267
Oil Pump Service Data267
Clutch Service Data268
Transmission Service Data268
Shaft Drive Service Data269
Carburetor Service Data269
Electrical Service Data269
Wattage Service Data270
Brake + Wheel Service Data270
Suspension Service Data271
Tire Pressure Service Data271
Fuel + Oil Service Data272
Thermostat + Radiator + Fan Service Data272
Vs700Gle273
View Of Vs700Gle274
Vs700Gle Specifications275
Vs700Gle Periodic Maintenance Schedule277
Vs700Gle Periodic Maintenance Chart277
Vs700Gle Lubrication Point278
Vs700Gle Maintenance And Tune-Up Procedure279
Vs700Gle Battery279
Vs700Gle Engine And Oil Filter280
View Of Suzuki Vs700Glh295
View Of Suzuki Vs750Glj319
Left Side319
Right Side319
View Of Suzuki Vs800Gln364
Vs800Gly/K1/K2/K3 ('00/'01/'02/'03-Model)458
Steering Stem469
Cable Routing470
Vs800Glk4 ('04-Model)471
Vs800K5 ('05-Model)483
Wiring Harness Routing494
Handle Balancer Installation496
Tool Holder Installation496
Evaporative Emission Control System (For E-33)497
Vs800K6 ('06-Model)499
Vs800K7 ('07-Model)512
Primary Reduction Ratio517
2Nd517
3Rd517
4Th517
Top517
Secondary Reduction Ratio517
Electrical519
Brake Light/Taillight520
License Plate Light520
Neutral Indicator Light520
High Beam Indicator Light520
Turn Signal Indicator Light520
Oil Pressure Indicator Light520
Speedometer Light520
L (3.2/2.6 Us/Imp Gal)522
Vs800K8 ('08-Model)523