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Table Of Contents - Suzuki GS1100G 1982 Service Manual

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Table of Contents

View Of Suzuki Gs1100G3

General Information6

Table Of Contents6

Serial Number Locations7

Breaking-In Procedures8

Cylinder Identification8

Special Features8

Blowby Gas Recycling8

Camshaft Drive Chain Tensioner9

Push Rod And Lock Screw9

Transistorized Ignition System With Electronic Advance10

Precautions And General Instructions11

Use Of Genuine Suzuki Parts11

Special Materials12

Specifications14

Periodic Maintenance And Tune-Up Procedures16

Periodic Maintenance Schedule17

Maintenance And Tune-Up Procedures18

Cylinder Head Nuts And Exhaust Pipe Bolts20

Tappet Clearance21

Checking The Tappet Clearance21

Tappet Clearance Adjustment22

Shim Selection Chart25

Throttle Cable Play27

Idling Adjustment27

Choke Cable Play27

Balancing Carburetors28

Engine Oil And Oil Filter31

Necessary Amount Of Engine Oil32

Brake Fluid Level33

Brake Pedal Height34

Brake Light Switches35

Air Bleeding The Brake Fluid Circuit35

Tire Tread Condition36

Tire Pressure37

Front Fork Oil38

Tightening Torque38

Front Fork Air Pressure39

Secondary And Final Gear Box Oil40

Secondary Gear Oil40

Final Bevel Gear Oil40

Chassis Nuts And Bolts41

Servicing Engine43

Engine Components Removable With Engine In Place44

Engine Removal And Reinstallation45

Engine Reinstallation50

Compression Check52

Compression Test Procedure52

Oil Pump Pressure Specification53

Oil Sump Filter53

Engine Disa Ssemgi Y54

Engine Components Inspection And Servicing64

Cylinder Head Servicing64

Cylinder Head Distortion65

Valve Head Thickness65

Valve Stem Runout65

Valve Head Radial Runout66

Valve Guide To Valve Stem Clearance66

Valve Stem Wear66

Valve Guide Servicing67

Valve Seat Width69

Valve Seat Servicing69

Val Ve Spring71

Valve Spring Free Length72

Valve Spring Tension72

Camshaft Journal Wear74

Camshaft Runout75

Cam Sprocket Reassembly75

Cam Chain Tensioner76

Cam Chain 20-Pitch Length78

Cam Chain Guide79

Cylinder Distortion79

Cylinder Bore79

Piston Diameter80

Piston To Cylinder Clearance80

Piston Ring To Groove Clearance80

Piston Ring Groove Width80

Piston Ring Free End Gap And Piston Ring End Gap81

Piston Pin And Pin Bore82

Connecting Rod Small End Bore I.d.82

Connecting Rod Big End Side Clearance82

Crank Pin Wear And Big End Bearing83

Crankshaft Runout83

Clutch Drive Plates And Driven Plates83

Clutch Spring Free Length84

Clutch Bearings84

Sleeve Hub Wave Washer84

Starter Clutch Removal85

Shift Fork Groove Clearance86

Shift Fork Groove Width86

Shift Fork Thickness86

Countershaft Gears87

Countershaft Disassembly87

Countershaft Reassembly88

Drive Shaft Gears90

Drive Shaft Disassembly90

Drive Shaft Reassembly91

Engine Reassembly92

Secondary Bevel Gear Assembly118

Secondary Drive Gear Removal And Disassembly119

Bearing Preload Adjustment123

Secondary Driven Gear125

Secondary Gear Set Shim Adjustment130

Tooth Contact Checking131

Final Assembly132

Location Of Shims133

Fllnap Drive Bevel Gear Assembly134

Final Gear Case Breather Circuit135

Air And Gear Oil Flow In Final Gear Case Breather135

Final Drive Bevel Gear Assembly136

Drive Gear And Bevel Gear Housing136

Final Drive Gear138

Shim Adjustment147

Backlash Measurement148

Tooth Contact Adjustment150

Fuel And Lubrication System156

Diaphragm And Piston Operation161

Starter System164

Float System164

Float Height Adjustment168

Needle Valve168

Lubrication System173

Emission Control & Regulations175

Emission Regulations176

Emission Control Carburetor Components177

General Emlssion Information178

Carbon Monoxide178

Carburetion Malfunction178

Engine Malfunction178

Hydrocarbons179

Ignition System Malfunctions179

Mixture-Related Malfunctions179

Electrical System180

Charging Output Check181

Ac Generator No-Load Performance181

Charging System181

Ac Generator Continuity Check182

Regulator/Rectifier182

Ignition System Description183

Ignition System Inspection183

Ignition Coils183

Signal Generator184

Igniter Unit185

Starter System Description186

Starter Motor Removal And Disassembly186

Starter Motor Inspection187

Carbon Brushes187

Armature Coil187

Starter Motor Reassembly188

Brush Holder188

Securing Screws188

Combination Meter189

Headlight Construction190

Tavl/Brake Light191

Turn Signal Light191

Fuel Meter Wiring192

Fuel Gauge Sending Unit193

Ignition Switch196

Engine Stop And Start Switch196

Self Cancelling Device198

Self Cancelling Device Functions199

Timer Specification And Function'199

Battery Specifications200

Initial Charging200

Filling Electrolyte200

Charging Time200

Based On S.g. Reading201

Recharging Operation201

Service Life202

Front Wheel Construction204

Wheel Bearings206

Brake Pad Replacement208

Caliper Removal And Disassembly Construction209

Caliper And Disc Inspection211

Caliper Reassembly212

Master Cylinder Removal213

Master Cylinder Inspection215

Master Cylinder Reassembly215

Front Fork Removal216

Front Fork Disassembly217

Inner Tube And Outer Tube219

Damper Rod Ring219

Inner Tube Metal220

Damper Rod Bolt220

Outer Tube Metal Spacer And Oil Seal220

Front Fork Installation222

Steering Stem223

Caliper Removal And Disassembly233

Master Cylinder Removal And Disassembly236

Rear Suspension239

Servicing Information243

Wiring Diagram252

Wire Routing253

Cable Routing255

Special Tools256

Tightening Torque Chart265

Service Data266

View Of Suzuki Gs1100Gl276

View Of Suzukl Gs1100Gk307

Vin And Serial Number Locations308

Periodic Maintenance Chart311

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