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Suzuki GS850G Manuals
Manuals and User Guides for Suzuki GS850G. We have
1
Suzuki GS850G manual available for free PDF download: Service Manual
Suzuki GS850G Service Manual (455 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 162.67 MB
Table of Contents
Group Index
2
View of Suzuki Gs85Og
5
Right Side
5
Left Side
5
General Information
6
Identification Table
7
Serial Number Location
7
Fuel
7
Engine Oil
7
Orientation
8
Breaking-In Procedure
8
Cylinder Identification
8
Location of Parts
8
Service Specifications
9
Dimensions and Weight
9
Table of Contents
11
Engine Top End
12
Service Specifications
12
Clutch
14
Ication System
14
Transmission
15
Shaft Drive
15
Carburetor
16
Electrical
16
Brake + Wheel
17
Tire Pressure
17
Suspension
17
Fuel and 0 1 Iccapacity
18
Torque Table
19
Chassis
19
Tightening Torque Chart
20
Periodic Maintenance
21
Periodic Maintenance Schedule
22
Periodic Maintenance Procedures
23
Battery
23
Cylinder Head Nuts and Exhaust Pipe Bolts
23
Air Cleaner Element
24
Tappet Clearance
25
Checking the Tappet Clearance
25
Tappet Clearance Adjustment
26
Shim Selection Chart
28
Spark Plugs
29
Fuel Line
29
Contact Breaker Points
29
Ignition Timing
29
Checking Ignition Timing with the Timing Light
31
Engineoil
31
Engine Oil Filter
32
Engine Idle R/Min
32
Clutch
33
Throttle Cable Adjustment
33
Clutch Cable Adjustment
33
Pulling Cable Play
33
Drive Shaft Gear Oil
34
Secondary Gear Oil
34
Final Gear Oil
34
Brakes
35
Tires
36
Steering
37
Front Forks
37
Chassls Nuts and Bolts
38
Special Materials
40
Special Tools
42
Trouble Shooting
47
Engine Removal
58
Engine Remounting
61
Compression Check
62
Top End-Removal
62
Cylinder Head Cover
62
Chain Tension Adjuster
62
Cam Chain Idler
63
Tachometer Drive Gear
63
Camshaft
63
Cylinder Head
63
Valve Guide Service
64
Valve Removal
64
Valve Guide Repiaacement
64
Valve Guide Hole Reaming
65
Valve Guide
65
Valve Stem Seal
65
Valve Springs
66
Valve Cotter to Valve Stem
66
Cylinder Head Installation
67
Sprockets on Camshafts
67
Positioning Camshaft in Place
68
Cam Bearing Caps
70
Cam Chain Tensioner Adjuster
70
Tensioning Action Check
71
Top End - Inspection
72
Tapper Clearance Adjustment
72
Camshaft Wear
72
Camshaft Journal Wear
73
Camshaft Runout
73
Cam Chain 20 Pitch Length
73
Valve Face Wear
74
Valve Stem Runout
74
Valve Head Radial Runout
74
Valve Guide - Valve Steam Clearance
74
Valve Seat Width Measurement
75
Valve Seat Servicing
75
Cylinder Head Distortion
77
Cam Chain Tension Adjuster
77
Reassembling
78
Cylinder, Piston and Rings Removal
79
Cylinder Bore Inspection
80
Piston Diameter
80
Piston-Cylinder Clearance
80
Piston Ring-Groove Clearance
80
Piston Ring Free End Gap and Piston Ring End Gap
81
Piston Pin - Pin Bore Clearance
81
Connecting Rod Small End Bore I.D.
82
Installation
82
Lower End
84
Positioning of Ring Gaps
84
Generator Stator Removal
84
Generator Rotor Removal
85
Contact Breaker Points Removal
86
Contact Breaker Points Installation
86
Condenser Removal
86
Automatic Advancer for Contact Breaker Removal
87
Automatic Advancer for Contact Breaker Installation
87
Dismantling of Automatic Advancer
87
Clutch Removal
88
Clutch Assembly
88
Drive Plate Thickness Inspection
89
Clutch Plate Distortion
89
Driven Plate Distortion
89
Drive Plate Claw Width
90
Clutch Spring Free Length
90
Installation
90
Secondary Bevel Gear Assembly
92
Secondary Drive Gear Assembly
92
Bearing Preload Adjustment
94
Secondary Driven Gear Assembly
95
Rearing Preload Adjustment
97
Secondary Gear Set Clearancing Operations
98
Racklash
98
Tooth Contact Checking
99
External Mechanism for Gear Shift
100
Final Assembly
100
Engine Lubrication System
101
Oil Pump Removal
101
Outer Rotor Clearance in the Body
102
Tip Clearance
102
Side Clearance
102
Oil Pump Pressure Test
103
Oil Filter Removal
103
Oil Filter Installation
104
Sump Filter Removal
104
Sump Filter Installation
104
Crankcase Removal
105
Crankshaft Inspection
107
Transmission Removal
108
Transmission Installation
108
Drive Shaft Gear Assembly
110
Drive Shaft Gear Installation
110
Drive Shaft Gear Inspection
111
Kick Shaft
112
Notes on Installation of Transmission Gears and Crankshaft in Crankcase
112
Shaft Drive
115
Final Drive Bevel Gear Assembly
118
Final Gear Case Breather Circuit
120
Breather Circuit
120
Air Passage
120
Oil Passage
120
Final Drive Gear Preload Adjustment
124
Final Gear Bearing Cover Shim Adjustment
127
Backlash Measurement
127
Tooth Contact Adjustment
128
Installation of Propeller Shaft & Final Drive Gear Assembly
130
Fuel System & Carburetors
131
Fuel Cock
132
Fuel Tank
132
Starter Unit
133
Fuel-Air Mixture too Lean
133
Fuel-Air Mixture too Rich
133
Pilot Circuit
134
Main Circuit
134
Float Unit
135
Needle Valve
135
Full-Closed Position
138
Full-Open Position
138
Checking Fuel Level in each Float Chamber
138
Fuel Level Measurement
139
Fuel Level Adjustment
139
Balancing the Carburetors
140
Gs850Gd/Gld
143
View of Suzukl GSSSOGD
144
View of Suzukl GS850GLD
164
Emission Control & Regulations
187
1978-1979 Emission Limits
188
1980 Emission Limits
188
Emission Control Carburetor Components
189
General Emission Information
190
Carbon Monoxide
190
Carburetion Malfunction
190
Engine Malfunctions
190
Hydrocarbons
191
Ignition System Malfunctions
191
Mixture-Related Malfunctions
191
Chassis
192
Handlebars Removal
193
Handlebars Mounting
193
Clutch Cable Removal
194
Clutch Cable Mounting
194
Throttle Cable Removal
194
Throttle Cable Mounting
195
Choke Cable Removal
196
Choke Cable Installation
196
Speedometer Cable Removal
196
Tachometer Cable Removal
196
Speedometer and Tachometer
197
Headlight
197
Adjustment of Horizontal Angle
198
Adjustment of Vertical Angle
198
Ignition Switch Removal
198
Front Fork
200
Front Fork Removal
201
Front Fork Mounting
201
Disassembly of Front Fork
202
Front Fork Assembly
203
Method of Measuring Fork Oil Level
203
Adjusting the Air Fork
204
Air Pressure Gauge
204
Steering Stem Removal
206
Steering Stem Assembly
207
Steering Stem Nut Tightening Method
208
Removal of Steering Stem Race
210
Steering Stem Bearing Removal
210
Front Wheel Removal
211
Front Wheel Inspection
212
Tire Warning
213
Removal of Tube and Tire
215
Front Brake Master Cylinder
216
Air Bleeding the Brake Fluid Circuit
217
Master Cylinder Disassembly
218
Inspection of Master Cylinder
219
Front Brake Caliper
220
Caliper
221
Caliper Disassembly
221
Caliper Inspection
222
Caliper Assembly
222
Rear Brake Caliper Removal
223
Air Bleeding of the Brake Fluid Circuit
224
Brake Pad Adjustment
224
Pad Replacement
225
Disassembly of Rear Brake Calliper
225
Rear Master Cylinder
226
Disassembly of Master Cylinder
228
Rear Wheel
229
Brake Parts to be Periodically Replaced
229
Rear Swinging Arm Removal
234
Rear Swinging Arm Mounting
234
Disassembly of Swingarm Arm Bearing
235
Rear Shock Absorber
236
Spring Adjustment
236
Damper Adjustment
236
Combinations of Spring Setting and Damper Setting
237
Matching of Front and Rear Suspensions
237
Removal of Rear Shock Absorber
237
Electrical System
240
Ignition System Data
241
Ignition Coils
241
Spark Plug
242
Contact Breakers
242
Breaker Cam
242
Checking Advancing Action
242
Charging System Description
244
Charging System Inspection
245
AC Generator Test
245
Regulator/Rectifier Test
245
Inspection of Charging System Components
246
AC Generator
246
Regulator/Rectifier
246
Starter System
247
Starter System Diagram
247
Startkr Clutch and Generator Rotor
247
Inspection of Components
248
Starter Motor Specifications
248
Carbon Brushes
248
Armature Coil
248
Battery Description
249
Initial Charging Method
250
Initial Electrolyte Filling
250
Initial Charging Duration
250
Initial Charging Current
250
Battery Servicing
251
Electrolyte Adjustment
251
Recharging Operation Based on S.G. Reading
251
Self-Cancelling Turn Signal System
253
Circuit Diagram
253
The Turn Signal Lamp Does Not Light
255
Self-Cancelling Turn Signal System
255
The Turn Signal Light Lights Continuously (Does Not Flash)
256
Flashing Does Not Go off after 9 +/- 1 Sec at Speeds Faster than 15 Km/H
256
Flashing Does Not Go off When Manual Cancel Switch Is Pressed
256
Flashing Goes off before 9 +- 1 Sec
257
Gear Shifting Switch and Gear Position Indicator
258
Utility Switches and Devices
259
Ignition Switch
259
Front Brake Light Switch
259
Rear Brake Light Switch
259
Horn and Horn Switch
260
Starter Disconnect Switch
260
Kill Switch and Starter Switch
260
Oil Pressure Switch
260
Light Wattage Data
261
Inspection of Headlight
261
Inspection of Tail/Brake Lights and Turn Signal Lights
261
Rear Combination Lights
261
Fuel Gauge
262
Inspection of Fuel Meter and Gauge
263
Troubleshooting
263
Wire Routing
267
Cable Routing
268
Rear Brake Hose Routing
268
Wiring Diagram
269
Inspection at Setting-Up
270
Road Test Inspection
271
Predelivery Checklist
271
Gs850Gt
272
Views of GS850GT
273
Modifications
292
Diaphragm and Piston Operation
300
Slow System
301
Main System
302
Float System
303
Front Master Cylinder
318
Wire and Cable Routing
327
Wiringdiagram
329
Gs850Glt
330
View of GS850GLT
331
Service Data
334
Wiring Diagram
339
Gs850Gx/Glx
340
View of GS850GX
341
Service Data
344
Torque Table
354
Specialmaterials
357
Periodic Maintenance
359
Camshaft Sprocket and Bolt
360
Interchangeability
360
Driven Gear Shift Fork
361
Gear Shifting Spring
361
Universal Joint Flange and Propeller Shaft
362
Turn Signal Light
363
Wire and Cable Routing
364
View of Suzuki GS850GLX
367
Specifications
368
Service Data
370
Oil Jet
372
Fuelcock
373
Front Fork
374
Inner Tube Metal
380
Damper Rod Bolt
380
Outer Tube Metal and Oil Seal
380
Fork Oil
381
Fork Spring
381
Inner Tube
381
Fork Air
382
Wire and Cable Routing
383
View of Suzuki GS850GZ
387
Cover Tightening Bolts
410
Cylinder Head and Head Cover
411
Wire and Cable Routing
420
Wiring Diagram
422
Gs850Glz
423
View of Suzuki GS850GLZ
424
Cover Tightening Bolt
447
Starter Lever
447
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