Suzuki GS1000 Manuals

Manuals and User Guides for Suzuki GS1000. We have 2 Suzuki GS1000 manuals available for free PDF download: Service Manual

Suzuki GS1000 Service Manual (478 pages)

Brand: Suzuki | Category: Motorcycle | Size: 29.75 MB

Product View
4
Group Index
6
General Information: Contents
8
Identification Table
9
Serial Number Location
9
Fuel, Oils and Breaking-In Procedure
9
Orientation
10
Braking-In Procedure
10
Location of Parts
10
Cylinder Identification
10
Service Specifications
11
Service Specifications: Contents
14
Engine Top End Specifications
15
Engine Lower End/Lubrication System/Clutch Specifications
17
Transmission/Fuel System Specifications
18
Ignition System/Charging System Specifications
19
Lamp Wattage, Brakes and Wheels Specifications
20
Tire Pressure, Suspension, Frame, Steering Specifications
21
Torque Table: Engine, Chassis
22
Tightening Torque Chart
23
Periodic Maintenance: Contents
24
Periodic Maintenance Schedule
25
Periodic Maintenance Procedures
26
Battery
26
Cylinder Head Nuts and Exhaust Pipe Bolts
26
Air Cleaner Element
27
Checking and Adjusting the Tappet Clearance
28
Tappet Clearance Adjustment
29
Shim Selection Chart
31
Spark Plug
32
Contact Breaker Points
32
Ignition Timing
32
Fuel Line
32
Timing Adjustment for Nos 1 and 4 Cylinders/For Nos 2 and 3 Cylinders
33
Engine Oil
34
Checking the Ignition Timing with the Timing Light
34
Engine Oil Filter
35
Carburetor Idle RPM
35
Throttle Cable Adjustment
35
Pulling Cable Play
35
Clutch
36
Drive Chain
36
Clutch Cable Adjustment
36
Returning Cable Play
36
Chain Cleaning and Oiling
38
Tires
38
Brake Hoses
38
Cleaning by Washing
38
Brakes
39
Steering
39
Front Forks
40
Chassis Bolts and Nuts
41
Special Materials
44
Use of Genuine Suzuki Parts
45
Special Tools
46
Troubleshooting: Contents
50
Engine and Chassis Troubleshooting
51
Electrical Troubleshooting
54
Engine: Contents
56
Engine Removal
58
Engine Remounting
60
Engine Overview
62
Compression Check
64
Top End Removal
64
Cylinder Head Cover Removal
64
Chain Tensioner Adjuster Removal
64
Camshaft, Cylinder Head Removal
65
Top End Installation
67
Valve Guide Hole Reaming
67
Valve Guide, Valve Stem Seal
67
Valve, Valve Springs
68
Installing Valve Cottter to Valve Stem
68
Cylinder Head Installation
68
Sprockets on Camshafts
69
Positioning Camshaft in Place
69
Camshaft Holder
71
Cam Chain Tensioner Adjuster
71
Tensioning Action Check
72
Top End - Inspection
73
Camshaft Journal Wear, Camshaft Wear
73
Camshaft Runout
74
Valve Face Wear
74
Valve Stem Deflection
75
Valve-To-Guide Clearance
75
Valve Seat Width Measurement
75
Valve Seat Servicing
76
Valve Spring
77
Cylinder Head Distortion
77
Cylinder Removal
78
Cam Chain Tensioner Adjuster Reassembling
78
Cylinder Installation
79
Distribution of Ring Gaps
79
Cylinder Wear Inspection
80
Piston and Rings Removal
80
Piston and Rings Installation
81
Piston Wear Determination Inspection
82
Piston Ring Clearance in the Groove Inspection
82
Lower End
83
Piston Ring Gap Inspection
83
Generator Stator Removal/Installation
83
Generator Rotor Removal/Installation
84
Contact Breaker Points Removal/Installation
85
Condenser Installation
85
Automatic Advancer for Contact Breaker Removal
85
Automatic Advancer for Contact Breaker Installation
86
Dismantling/Assembly of Automatic Advancer
86
Clutch Removal
87
Clutch Inspection
88
Free Length of Clutch Spring
88
Clutch Drive Plate Wear
88
Clutch Plate Distortion
88
Clutch Installation
89
External Mechanism for Gear Shift Removal/Installation
90
Engine Lubrication System Overview
91
Oil Pump Removal/Installation
92
Side, Tip Clearance
92
Outer Rotor Clearance in the Body
92
Oil Pump Pressure Test
93
Oil Filter Removal/Installation
94
Sump Filter Removal/Installation
94
Crankcase Removal
95
Crankshaft
96
Crankpin Wear and Big End Side Clearance
96
Transmission
97
Crankshaft Deflection
97
Mounting 2Nd Drive Gear on the Counter Shaft
97
Caution in Installation of Transmission Gears and Crankshaft on Crankcase
99
Gear Backlash
99
Fuel Cock/Fuel Tank Cleaning
101
Carburetors
101
Carburetors Description
102
Starter Unit
102
Fuel-Air Mixture too Lean/Too Rich
102
Pilot/Main Circuit
103
Float Unit
104
Needle Valve
104
Fuel System Disassembly
105
Fuel System Reassembly
106
Fuel System Adjustment
107
Fuel Level Measurement/Adjustment
108
Balancing Carburetors
108
Fuel System and Carburetor Troubleshooting
111
Emission Control and Regulations: Contents
112
Emission Control and Regulations
113
Emission Control Carburetor Components
114
General Emission Information
115
Carbon Monoxide
115
Engine/Carburetion Malfunction
115
Hydrocarbons
116
Mixture-Related/Ignition System Malfunctions
116
Chassis: Contents
118
Handlebar Removal/Mounting
119
Clutch Cable Removal
119
Clutch Cable Mounting
120
Throttle Cable Removal
120
Speedometer/Tachometer Cables Removal, Mounting
121
Throttle Cable Mounting
121
Headlamp Removal
122
Cautions in Mounting: Headlamp
122
Adjustment of Headlamp in Horizontal/Vertical Angle
122
Ignition Switch Removal, Mounting
123
Front Fork
124
Front Fork Removal/Mounting
125
Disassembly of Front Fork
126
Assembly of Front Fork
127
Measuring Method of Fork Oil Level
127
Handling the Front Fork
128
Adjusting the Air Fork
128
Inspection of Front Fork
129
Steering Stem Removal
129
Steering Stem Assembly
131
Steering Stem Tightening Method
131
Removal/Mounting of Steering Stem Race
133
Steering Stem Bearing Removal/Mounting
134
Front Wheel
134
Front Wheel Removal, Assembly
135
Front Wheel Inspection
136
Tire Warning
137
Removal of Tube and Tire
138
Front Wheel Mounting
139
Front Brake Master Cylinder Removal/Mounting
140
Air Bleeding the Brake Fluid Circuit
141
Master Cylinder Disassembly/Assembly
142
Inspection of Master Cylinder
143
Front Brake Caliper Removal/Mounting
144
Caliper
144
Caliper Disassembly/Assembly
145
Caliper Inspection
146
Brake Parts to be Periodically Replaced
146
Rear Brake Caliper Removal, Mounting
147
Air Bleeding of the Brake Fluid Circuit
148
Brake Pedal Adjustment
148
Pad Replacement
149
Disassembly/Assembly of Rear Brake Caliper
149
Pad Inspection
150
Rear Master Cylinder Removal
151
Rear Master Cylinder Mounting
152
Disassembly of Master Cylinder
152
Master Cylinder Assembly/Inspection
153
Rear Wheel
154
Rear Wheel Assembly
156
Rear Wheel Inspection, Chain Cleaning and Oiling
157
Rear Wheel Mounting
158
Checking the Sprockets for Wear
158
Adjustment of Wheel Alignment
158
Swing Arm Removal/Mounting
159
Disassembly of Swing Arm Bearing
160
Use of Special Tool
160
Swing Arm Mounting
161
Rear Shock Absorber
162
Spring/Damper Adjustment
162
Combination of Spring Setting and Damper Setting
163
Suspension Math between Front and Rear
163
Removal of Rear Shock Absorber
163
Swing Arm Assembly, Inspection
164
Electrical System: Contents
166
Ignition System: Data, Coils
167
Schematic Diagram of Ignition System
167
Contact Breakers
168
Charging System
170
Method of Testing Rectifier, Regulator and Alternator
170
Inspection of Charging System Components
171
Rectifier, Alternator
171
Starter System Inspection
172
Regulator
172
Starter Clutch and Generator Rotor
172
Inspection of Components
173
Carbon Brushes
173
Armature Coil, Commutator
173
Starter Motor Specifications
173
Battery Description, Specification
174
Relay for Starter Motor
174
Initial Changing Method
175
Initial Electrolyte Filling, Charging Current/Duration
175
Battery Servicing
176
Electrolyte Adjustment
176
Battery Removal, Installation, Inspection
176
Recharging Operation Based on S.G. Reading
176
Electrical System Troubleshooting
178
Utility Switches and Devices
178
Ignition Switch, Front Brake Lamp Switch
178
Rear Brake Lamp Switch, Lighting and Dimmer Switches
179
Turn Signal
179
Left Handle Switch, Kill Switch and Starter Switch
179
Horn
179
Oil Pressure Switch
180
Inspection of Headlamp
180
Lamp Wattage Data
180
Inspection of Tail Brake Lamps and Turn Signal Lamps
180
Rear Combination Lamps
181
Fuel Gauge
181
Inspection of Speedometer and Tachometer
181
Inspection of Fuel Meter and Gauge
183
Electrical System: Wiring Diagram
187
Electrical System: Cable Routing
188
GS1000E: Contents
193
GS1000E Overview
194
GS1000E Service Specifications
195
Front Brake
197
Master Cylinder Inspection
197
Caliper Inspection, Reassembly
197
Air Bleeding from Brake Fluid Circuit
197
Wheel
198
Wheel Disassembly, Inspection and Checking
199
Self-Cancelling Turn Signal: Circuit Diagram, Operation
200
Self-Cancelling Turn Signal: Troubleshooting
201
GS1000E Wiring Diagram
204
GS1000S: Contents
206
GS1000S: Overview
207
Service Data
210
Periodic Maintenance
217
Choke Cable, Choke Knob Adjustment
217
Carburetor Removal
217
Fuel System
218
Carburetor Disassembly
218
Chassis
219
Handlebar Removal
219
Choke Cable Removal, Installation
219
Clutch Cable Installation
219
Cowling Removal
220
Combination Meter Removal
221
Combination Meter Installation
222
Tube and Tire Removal
222
Tube and Tire Mounting
223
Electrical
224
Combination Meter Assembly/Disassembly
224
Power Source Terminal
226
Checking the Thermistor
226
GS1000S Wire and Cable Routing
227
GS1000S Wiring Diagram
229
GS1000L: Contents
231
Overviewing GS1000L
232
GS1000L Specifications
233
Service Data: GS1000L
235
Chassis Bolts and Nuts: Maintenance
242
Fuel Line, Cock
244
Choke Cable/Knob Adjustment
244
Carburetor Disassembly (GS1000L)
245
Chassis Front Fork
246
Front Fork Removal, Mounting
247
Front Wheel Removal, Mounting
248
Gear Shifting Switch and Gear Position Indicator
251
Fuel Gauge Wiring
252
GS1000L Wire and Cable Routing
257
Wiring Diagram for GS1000L
259
GS1000E/ST: Contents
264
GS1000ET Overview
265
GS1000ET Specifications
266
Torque Table
278
Fuel System of GS1000E/ST
291
Fuel Cock
292
Diaphragm and Piston Operation
295
Slow System
296
Main System
297
Starter, Float Systems
298
Float Height Adjustment
301
Fuel Level Measurement
305
Checking Fuel Level in each Float Chamber
305
Fuel Level Adjustment
305
Balancing the Carburetors
306
Fuel-Transistorized Ignition System
308
Signal Generator
309
Signal Generator Removal/Disassembly
310
Ignition Timing Inspection, Specifications
311
Signal Generator Resistance
312
Igniter
312
Charging Output Check
315
AC Generator No-Load Performance
315
Regulator/Rectifier
316
Front Master Cylinder
317
Master Cylinder Removal and Disassembly
318
Master Cylinder Inspection/Reassembly
320
Front Caliper
321
Brake Pad Replacement
322
Caliper Removal and Disassembly
323
Caliper and Disc Inspection
324
Caliper Reassembly
324
Wire and Cable Routing
326
Wiring Diagram of GS1000E/ST
328
GS1000ST Overview
329
GS1000E/ST Specifications
330
GS1000E/ST Service Data
332
GS1000E/ST Wire and Cable Routing
334
GS1000G/L Contents
345
GS1000GT Product View
346
GS1000GT Specifications
347
Engine Removal and Remounting
372
Secondary Bevel Gear Assembly
376
Secondary Drive Gear Assembly Removal and Disassembly
378
Bearing Preload Adjustment
380
Secondary Driven Gear Assembly: Removal and Disassembly
381
Secondary Driven Gear Assembly: Inspection and Reassembly
382
Secondary Gear Set Clearancing Operations
384
Backlash
384
Tooth Contact Checking
385
Final Assembly
386
Clutch Disassembly
388
Drive Plate Thickness, Drive Plate Claw Width
389
Clutch Spring Free Length
390
Crankcase Disassembly
392
Shift Fork - Groove Clearance
395
Drive Shaft and Gears
397
Notes on Installation of Transmission Gears and Crankshaft in Crankcase
398
Lubrication System
402
Shaft Drive
404
Final Drive Bevel Gear Assembly
406
Final Gear Case Breather Circuit
408
Air and Gear Oil Flow in Final Gear Case Breather Circuit
408
Final Drive Gear Preload Adjustment
413
Final Driven Gear Assembly
415
Final Gear Bearing Cover Shim Adjustment
416
Backlash Measurement
416
Tooth Contact Adjustment
418
Installation of Propeller Shaft and Final Drive Gear Assembly
420
Ignition Timing Specifications
424
Front Fork Inspection
431
Rear Wheel Overview
440
Rear Wheel Removal and Disassembly
441
Rear Swinging Arm
445
Disassembly of Swinging Arm Bearing
447
GS100GLT Overview
451

Suzuki GS1000 Service Manual (255 pages)

Brand: Suzuki | Category: Motorcycle | Size: 68.26 MB

Specifications Service

11
- Table of Contents
  11
- Service Specifications
  12
  - Engine Top End
    12
  - Engi?4E Lower End
    14
  - Lubrication System
    14
  - Clutch
    14
  - Transmission
    15
  - Fuel System
    15
  - Charging System
    16
  - SUSPENSION T FRAME
    18
- Torque Table
  19
Engine

52
- Engine Removal
  54
- Compression Check
  59
- Top End - Removal
  59
  - Cylinder Head Cover
    59
  - Chain Tenstoner Adjuster
    59
  - Cylinder Head
    61
- Top End - Installation
  63
  - Valve Guide Hole Reaming Is
    63
  - Valve Guide
    63
  - A L V E Stem Seal
    63
  - Valve
    64
  - VALVE Sprlngs
    64
  - Valve Cotter to Valve Stem
    64
  - Cylinder Head
    64
  - Positioning Camshaft in Place
    65
  - Camshaft Holder
    67
  - Cam Chain Tensioner Adjuster
    67
  - Tensioning Action Check
    68
  - Tappet Clearance Adjustment
    69
- Top End - Inspection
  69
  - Camshaft Journal Wear
    69
  - Valve Stem Deflection
    71
  - Valve-To-Guide Clearance
    71
  - Valve Seat Width Measurement
    71
  - Valve Seat Servicing
    72
  - Valve Spring
    73
  - Cylinder Head Flatness
    73
  - Cam Chain Tensioner Adjuster
    74
- Cylinder
  74
  - Removal
    76
  - Inspection
    76
- Piston and Rings
  76
  - Inspection
    78
- Lower End
  79
  - Generator Stator
    79
  - Generator Rotor
    80
  - Contact Breaker Points
    81
  - Condenser
    81
  - Auto Matic Advancer for Contact Rreaker
    81
- Clutch
  83
  - Removal
    83
  - Inspection
    84
  - Installation
    85
- External Mechanism for Gear Shift
  86
  - Oil Pump
    88
  - Oil Filter
    90
  - Sump Filter
    90
  - Crankcase
    91
  - Crankshaft
    92
  - Transmission
    93
Chassis

114
- Clutch Cable
  115
- Handlebar
  115
- Throttle Cable
  116
- Speedometer Cable
  117
- Tachometer Cable
  117
- Speedometer and Tachometer
  118
- Chassis
  119
- Headlamp
  119
- Front Fork
  120
- Steering Stem
  125
- Front Wheel
  130
- Steering Stem Bearing
  130
- Front Brake Master Cylinder
  136
- Front Brake Caliper
  140
- Caliper
  143
- Rear Master Cylinder
  147
- Rear Wheel
  150
- Swinging Arm
  155
- Rear Shock Absorber
  158
Electrical System

161
- Ignitionsystem
  162
- Spark Plug
  163
- Charging System
  165
- Inspection of Charging System Components
  166
- Starter System
  167
- Battery
  169
- Troubleshooting
  173
- Wiring Diagram
  182
Table of Contents

186
- Generalinformation
  188
  - Service Specifications
    188
- Front Brake
  190
  - Caliper
    190
- Wheel
  191
- Self-Cancelling Turn Signal
  193
  - Circuit Diagram
    193
  - Trouble Shooting
    194
- Wiring Diagram
  197
Table of Contents

199
- General Information
  201
  - Specifications
    201
  - Service Data
    203
224
- General Information
  226
  - Specifications
    226
  - Service Data
    228
- Periodic Maintenance
  237
  - Chassis Bolts and Nuts
    237
- Engine Removal
  239
  - Carburetor Removal
    239
- Fuel System
  239
  - Fuel Line
    239
  - Choke
    239
    
    Choke Cable Adjustment
    239
    
    Knob Adjustment
    239
  - Fuel Systema N D Carburetors
    239
    
    Fuel Cock
    239
  - Carburetor Disassembly
    240
- Chassis
  241
  - Front Fork
    241
  - Front Wheel
    243
  - Tube and Tire
    244
  - Rear Shock Absorber
    245
- Electrical
  246
  - Position Indicator
    246
  - Fuel Gauge
    247
- Wirea N Dcable Routing
  252
- Wire and Cable Rowing
  253

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Suzuki GS1000 Manuals

Suzuki GS1000 Service Manual (478 pages)

Table of Contents

Suzuki GS1000 Service Manual (255 pages)

Table of Contents

Specifications Service

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