Suzuki GS1100EX 1981 Manuals

Manuals and User Guides for Suzuki GS1100EX 1981. We have 1 Suzuki GS1100EX 1981 manual available for free PDF download: Service Manual

Suzuki GS1100EX 1981 Service Manual (495 pages)

Brand: Suzuki | Category: Motorcycle | Size: 38.51 MB

View of Suzuki GS1100
3
Right Side
3
Left Side
3
Group Index
4
General Information
8
Serial Number Locations
9
Fuel and Oil Recommendations
9
Frame Number
9
Engine Number
9
Breaking-In Procedures
11
Cylinder Identification
11
Front Fork Oil
11
Special Features
12
Transistorized Ignition System
12
Transistor
12
Signal Generator
13
TSCC (Twin Swirl Combustion Chamber)
14
Check Panel
18
Basic Diagram
18
Brake Fluid Level and Battery Electrolyte Level Circuit Diagram
19
Circuit Check
19
Normal Condition
19
Brake Light Circuit
20
Checking Defect
20
No Defect
20
Precautions and General Instructions
21
Specifications
22
Service Specifications
24
Service Data
25
Periodic Maintenance
38
Periodic Maintenance Schedule
39
Periodic Maintenance Chart
39
Lubrication Chart
40
Maintenance and Tune-Up Procedures
41
Air Cleaner
41
Battery
42
Valve Clearance
43
Spark Plug
45
Engine Oil and Oil Filter
46
Necessary Amount of Engine Oil
46
Carburetor
47
Throttle Cable Play
47
Starter Knob Adjustment
47
Idling Adjustment
47
Clutch
48
Drive Chain
48
Brakes
50
Brake Fluid Level
50
Brake Pads
51
Brake Pedal Height
51
Brake Light Switches
52
Air Bleeding the Brake Fluid Circuit
52
Tires
54
Tire Tread Condition
54
Tire Pressure
54
Steering
55
Front Forks
56
Cylinder Head Nuts and Bolts
56
Chassis Bolts and Nuts
57
Special Materials
60
Special Tools
62
Troubleshooting
68
Indicator Light and Lighting Circuit
73
Checking of Battery Electrolyte Level Check Circuit
74
Checking of Brake Fluid Level Check Circuit
74
Checking of Headlight Bulb Check Circuit
75
Checking of Tail Light Bulb Check Circuit
76
Checking of Brake Light Bulb Check Circuit
76
Chassis
77
Engine
80
Engine Removal
81
Engine Reinstallation
85
Engine Component Removable with Engine in Place
88
Compression Check
89
Compression Test Procedure
89
Top End Removal
90
Cylinder Head
91
Cylinder Head Components Reassembly
94
Cam Sprocket Reassembly
96
Top End-Inspection
103
Camshaft
103
Cam Wear
103
Camshaft Journal Wear
103
Camshaft Runout
104
Valve Face Wear
105
Valve Stem Runout
105
Valve Head Radial Runout
105
Valve Guide - Valve Stem Clearance
105
Valev Stem Wear
106
Valve Seat Width
106
Valve Seat Servicing
106
Valve Springs
108
Valve Spring Free Length
108
Cylinder Head Distortion
109
Cam Chain 20 - Pitch Length
109
Valve Spring Tension
109
Cam Chain Tensioner Disassembly
110
Cylinder Removal
112
Cylinder Installation
113
Cylinder Inspection
115
Cylinder Bore
115
Cam Chain Guide
115
Cylinder Distortion
115
Piston and Rings Removal
116
Piston and Rings Installation
116
Piston and Rings Inspection Piston Diameter
117
Piston - Cylinder Clearance
117
Piston Ring - Groove Clearance
118
Piston Ring Free End Gap and Piston Ring End Gap
118
Piston Pin O.D. and Pin Bore I.D.
119
Lower End
120
Generator Stator
120
Starter Clutch Removal
121
Clutch Removal
126
Clutch Drive Plates and Driven Plates
127
Clutch Spring Free Length
128
Clutch Bearings
128
Sleeve Hub Wave Washer
129
Gearshift Shaft Removal
131
Gearshift Shaft Installation
132
Lubrication System
133
Main Gallery
133
Oil Pan
133
Oil Pump Removal
135
Oil Pump Inspection
135
Oil Pump Assembly
136
Oil Pump Installation
136
Oil Pressure
137
Oil Pump Pressure Specification
137
Oil Filter Removal
138
Oil Filter Installation
138
Sump Filter Removal
138
Crankcase Installation
139
Crankcase Removal
139
Crankshaft Inspection
144
Connecting Rod Small End Bore I.D.
144
Connecting Rod Big End Thrust Clearance
144
Crank Pin Wear and Big End Bearing Wear
144
Crankshaft Runout
145
Primary Drive - Driven Gear Backlash
145
Transmission
146
Mounting 2Nd Drive Gear
146
Transmission Gear Backlash
147
Shift Fork - Groove Clearance
147
Transmission Gear Assembly
148
Top Driven Gear
149
3Rd Driven Gear
149
Lower End Assembly
151
Fuel System and Carburetors
158
Fuel System
159
Fuel Cock
160
Carburetor Specifications
162
Diaphragm and Piston Operation
163
Slow System
164
Main System
165
Starter System
166
Float System
166
Fuel Level Inspection
169
Float Height Adjustment
170
Needle Valve
170
Balancing Carburetors
171
Reassembly
173
Emission Control & Regulations
176
1980 Emission Limits
177
Emission Control Carburetor Components
178
General Emission Information
179
Carbon Monoxide
179
Carburetion Malfunction
179
Engine Malfunctions
179
Hydrocarbons
180
Ignition System Malfunctions
180
Mixture-Related Malfunctions
180
Front Wheel Construction
183
Front Wheel Removal and Disassembly
184
Wheel Bearings
186
Axle Shaft
186
Wheel and Wheel Rim
186
Brake Disc
188
Speedometer Gearbox
188
Rear Wheel Construction
189
Sprocket Mounting Drum Bearing
193
Wheel or Wheel Rim
194
Rear Drum Shock Absorbers
194
Sprocket
194
Sprocket Mounting Drum Oil Seal
196
Front Brake Construction
197
Brake Pad Replacement
198
Caliper
199
Caliper Removal and Disassembly
200
Caliper and Disc Inspection
201
Caliper Reassembly
203
Master Cylinder
204
Master Cylinder Removal and Disassembly
205
Master Cylinder Inspection
207
Master Cylinder Reassembly
208
Rear Brake Construction
209
Front Fork
222
Front Fork Removal and Disassembly
223
Damper Rod Ring
227
Fork Spring
227
Inner Tube
227
Outer Tube
227
Oil Seal
228
Free Piston
228
Valve Stop and Valve
228
Air Joint
228
Inner Tube Metal
229
Damper Rod
229
Detent
230
Damper Adjuster
230
Fork Oil
231
Damping Force and Spring Setting
232
Fork Air
232
Outer Races
238
Stem Nut Adjustment
239
Handlebars
239
Rear Suspension Construction
240
Swing Arm Bearings
243
Swing Arm Pivot Shaft
243
Shock Absorber Bushing
243
Rear Shock Absorbers
244
Electrical
246
Ignition System Description
247
Ignition Coil Inspection
248
Ignitor Unit (Transiostor Unit)
249
Main Wire Harness
250
Charging System Description
251
Function of Regulator
251
Charging Output Check
253
AC Generator No-Load Performance
253
AC Generator Stator Coil
254
Regulator/Rectifier
254
Battery Description
255
Battery Specifications
255
Initial Charging Method
255
Initial Electrolyte Filling
255
Battery Servicing
256
Initial Charging Current
256
Electrolyte Adjustment
256
S.G. Reading to Corresponding Temperature
257
Starter System Description
258
Starter System Disassembly
259
Starter Motor Construction
259
Carbon Brushes
260
Commutator
260
Armature Coil
260
Starter Relay
261
Brush Holder
262
Housing End
262
Securing Screws
262
Combination Meter Disassembly
263
Diagram Inspection
264
Fuel Meter Wiring
265
Fuel Gauge
266
Brake Fluid Level Sensor
268
Battery Electrolyte Level Sensor
268
Bulbs
268
Lamps
269
Headlight
269
Turn Signal Light Front
270
Turn Signal Light Rear
270
Tail/Brake Light
271
Self Cancelling Device Description
272
Self Cancelling Device Diagram
272
Self Cancelling Device Functions
273
Switches
274
Ignition Switch
274
Right Handlebar Switch
274
Engine Stop Switch
274
Starter Switch
275
Left Handlebar Switch
275
Dimmer Switch
275
Turn Signal Light Switch
275
Horn Switch
276
Rear Brake Light Switch
276
Oil Pressure Light Switch
276
Neutral Indicator Light Switch
276
Gs1100Lt
278
View of Suzuki GS1100LT
279
Engine Sprocket
297
Clutch Sleeve Hub
300
Instruments
301
Fuel Meter
304
Gs1100Ex
322
Vire of Suzuki GS1100EX
323
Piston Oil Ring Spacer
337
Gs1000Sz
349
Emission Regulations
362
View of Suzuki GS1100EZ
394
View of Suzuki GS1100SD
452
Gs1100Ed/Esd
483

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Suzuki GS1100EX 1981 Manuals

Suzuki GS1100EX 1981 Service Manual (495 pages)

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