Suzuki GS1100G 1982 Manuals

Manuals and User Guides for Suzuki GS1100G 1982. We have 1 Suzuki GS1100G 1982 manual available for free PDF download: Service Manual

Suzuki GS1100G 1982 Service Manual

Suzuki GS1100G 1982 Service Manual (349 pages)

Brand: Suzuki | Category: Motorcycle | Size: 88.48 MB

Table of Contents

View of Suzuki GS1100G
3
Left Side
3
Right Side
3
Group Index
4
Table of Contents
6
General Information
6
Serial Number Locations
7
Fuel
7
Engine Oil
7
Gear Oil
7
Special Features
8
Precautions and General Instructions
11
Special Materials
12
- Specifications
  14
- Periodic Maintenance and Tune-Up Procedures
  16
- Periodic Maintenance Schedule
  17
- Air Cleaner
  18
- Maintenance and Tune-Up Procedures
  18
  - Battery
    19
  - Cylinder Head Nuts and Exhaust Pipe Bolts
    20
  - Checking the Tappet Clearance
    21
  - Tappet Clearance
    21
  - Tappet Clearance Adjustment
    22
  - Shim Selection Chart
    25
- Spark Plug
  26
  - Carburettor
    27
  - Choke Cable Play
    27
  - Idling Adjustment
    27
  - Throttle Cable Play
    27
  - Balancing Carburetors
    28
  - Engine Oil and Oil Filter
    31
  - Fuel Line
    31
  - Necessary Amount of Engine Oil
    32
  - Brake Fluid Level
    33
- Brakes
  33
- Clutch
  33
  - Brake Pads
    34
  - Brake Pedal Height
    34
  - Air Bleeding the Brake Fluid Circuit
    35
  - Brake Light Switches
    35
  - Tire Tread Condition
    36
- Tires
  36
- Steering
  37
- Tire Pressure
  37
- Front Fork
  38
  - Front Fork Oil
    38
  - Tightening Torque
    38
  - Front Fork Air Pressure
    39
  - Final Bevel Gear Oil
    40
  - Secondary and Final Gear Box Oil
    40
  - Secondary Gear Oil
    40
- Chassis Nuts and Bolts
  41
  - Servicing Engine
    43
  - Engine Components Removable with Engine in Place
    44
- Engine Removal and Reinstallation
  45
  - Engine Reinstallation
    50
  - Compression
    52
  - Compression Check
    52
  - Compression Test Procedure
    52
  - Oil Pressure
    53
  - Oil Pump Pressure Specification
    53
  - Oil Sump Filter
    53
- ENGINE DISA Ssemgi y
  54
  - Cylinder Head Servicing
    64
  - Engine Components Inspection and Servicing
    64
  - Cylinder Head Distortion
    65
  - Valve Head Thickness
    65
  - Valve Stem Runout
    65
- Servicing
  66
  - Valve Guide to Valve Stem Clearance
    66
  - Valve Head Radial Runout
    66
  - Valve Stem Wear
    66
  - Valve Guide Servicing
    67
  - Valve Seat Servicing
    69
  - Valve Seat Width
    69
- Val Ve Spring
  71
  - Valve Spring Free Length
    72
  - Valve Spring Tension
    72
  - Cam Height
    73
  - Cam Wear
    73
- Camshaft
  73
  - Camshaft Journal Wear
    74
  - Cam Sprocket Reassembly
    75
  - Camshaft Runout
    75
- Cam Chain Tensioner
  76
  - Cam Chain 20-Pitch Length
    78
  - Cam Chain Guide
    79
  - Cylinder Bore
    79
  - Cylinder Distortion
    79
  - Piston Diameter
    80
  - Piston Ring Groove Width
    80
  - Piston Ring to Groove Clearance
    80
  - Piston to Cylinder Clearance
    80
  - Piston Ring Free End Gap and Piston Ring End Gap
    81
  - Connecting Rod Big End Side Clearance
    82
  - Connecting Rod Small End Bore I.D.
    82
  - Piston Pin and Pin Bore
    82
  - Clutch Drive Plates and Driven Plates
    83
  - Crank Pin Wear and Big End Bearing
    83
  - Crankshaft Runout
    83
  - Clutch Bearings
    84
  - Clutch Spring Free Length
    84
  - Sleeve Hub Wave Washer
    84
  - Starter Clutch Removal
    85
  - Oil Pump
    86
  - Shift Fork Groove Clearance
    86
  - Shift Fork Groove Width
    86
  - Shift Fork Thickness
    86
  - Countershaft Disassembly
    87
  - Countershaft Gears
    87
  - Countershaft Reassembly
    88
  - Drive Shaft Disassembly
    90
  - Drive Shaft Gears
    90
  - Drive Shaft Reassembly
    91
  - Engine Reassembly
    92
- Piston
  106
  - Shaft Drive
    115
  - Secondary Bevel Gear Assembly
    118
  - Secondary Drive Gear Removal and Disassembly
    119
  - Bearing Preload Adjustment
    123
  - Secondary Driven Gear
    125
  - Secondary Gear Set Shim Adjustment
    130
  - Tooth Contact Checking
    131
  - Final Assembly
    132
  - Location of Shims
    133
  - Fllnap DRIVE BEVEL GEAR ASSEMBLY
    134
  - Air and Gear Oil Flow in Final Gear Case Breather
    135
  - Final Gear Case Breather Circuit
    135
  - Drive Gear and Bevel Gear Housing
    136
  - Final Drive Bevel Gear Assembly
    136
  - Final Drive Gear
    138
  - Shim Adjustment
    147
  - Backlash Measurement
    148
  - Tooth Contact Adjustment
    150
  - Fuel and Lubrication System
    156
  - Fuel System
    157
  - Fuel Cock
    158
  - Carburetor
    159
  - Diaphragm and Piston Operation
    161
  - Slow System
    162
  - Main System
    163
  - Float System
    164
  - Starter System
    164
  - Float Height Adjustment
    168
  - Needle Valve
    168
  - Lubrication System
    173
  - Emission Control & Regulations
    175
  - Emission Regulations
    176
  - Emission Control Carburetor Components
    177
  - Carbon Monoxide
    178
  - Carburetion Malfunction
    178
  - Engine Malfunction
    178
  - GENERAL Emlssion INFORMATION
    178
  - Hydrocarbons
    179
  - Ignition System Malfunctions
    179
  - Mixture-Related Malfunctions
    179
  - Electrical System
    180
  - AC Generator No-Load Performance
    181
  - Charging Output Check
    181
- Charging System
  181
  - Ac Generator Continuity Check
    182
  - Regulator/Rectifier
    182
  - Ignition Coils
    183
  - Ignition System Description
    183
  - Ignition System Inspection
    183
  - Signal Generator
    184
  - Igniter Unit
    185
  - Starter Motor Removal and Disassembly
    186
  - Starter System Description
    186
  - Armature Coil
    187
  - Carbon Brushes
    187
  - Commutator
    187
  - Starter Motor Inspection
    187
  - Brush Holder
    188
  - Housing End
    188
  - Securing Screws
    188
  - Starter Motor Reassembly
    188
  - Combination Meter
    189
  - Headlight Construction
    190
  - Lamps
    190
  - Tavl/Brake Light
    191
  - Turn Signal Light
    191
  - Fuel Meter
    192
  - Fuel Meter Wiring
    192
  - Fuel Gauge Sending Unit
    193
- Switches
  195
  - Engine Stop and Start Switch
    196
  - Ignition Switch
    196
- Self Cancelling Device
  198
- Self Cancelling Device Functions
  199
- Timer Specification and Function'
  199
- Battery Specifications
  200
- Initial Charging
  200
- Filling Electrolyte
  200
- Charging Time
  200
- Based on S.G. Reading
  201
- Recharging Operation
  201
- Service Life
  202
- Chassis
  203
- Front Wheel Construction
  204
- Wheel
  206
- Axle Shaft
  206
- Wheel Bearings
  206
- Brake Pad Replacement
  208
- Front Brake
  208
- Caliper Removal and Disassembly Construction
  209
- Caliper and Disc Inspection
  211
- Caliper Reassembly
  212
- Master Cylinder Removal
  213
- Master Cylinder Inspection
  215
- Master Cylinder Reassembly
  215
- Front Fork Removal
  216
- Front Fork Disassembly
  217
- Fork Spring
  219
- Inner Tube and Outer Tube
  219
- Damper Rod Ring
  219
- Outer Tube Metal Spacer and Oil Seal
  220
- Inner Tube Metal
  220
- Damper Rod Bolt
  220
- Fork Oil
  221
- Front Fork Installation
  222
- Inner Tube
  222
- Fork Air
  222
- Steering Stem
  223
- Outer Rages
  226
- Stem Nut
  226
- Handlebars
  227
- Rear Wheel
  227
- Caliper Removal and Disassembly
  233
- Master Cylinder Removal and Disassembly
  236
- Rear Suspension
  239
- Servicing Information
  243
- Wiring Diagram
  252
- Wire Routing
  253
- Cable Routing
  255
- Special Tools
  256
- Tightening Torque Chart
  265
- Service Data
  266
- Gs1100Gl
  275
- View of Suzuki GS1100GL
  276
- Gs1100Gk
  306
- VIEW of Suzukl GS1100GK
  307
- Vin and Serial Number Locations
  308
- Periodic Maintenance Chart
  311

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