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GROUP INDEX

GROUP INDEX ( 1/2 )

GROUP INDEX

GROUP INDEX ( 2/2 )

FORE Lj,;I.'O
RD

FOREWORD
@

The SUZU K I GS850G has been dewloped as a companion motarcyclc to the GS750 and GSIMK). 1t
is packed with highly advanced design concepts including a maintenance-free shaft drive
rncchanisrn. Combined with prccise control and easv handling, the GS850G providcs excellent
leriorm:ince a n d outstanding riding comfort.

IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to
Environmental Protection Agency e m i s s i o ~regulations.
~
These regulations set standards for emission
control. and also set specific servicing requirements. This manual contains all of tlie necessary
information that is required to properly inspect and service the GS850G in accordance with the
EPA regulations.
Prim:trily. tlie cnlission components which can effect the emission output of the GS850G consist of
Ihc carhuretorq and crankcase breather device. Emission control information is contained in the
Fucl System chapter and the Emission Control chapter. We strongly suggest that the chapter on
Emission Control be rcviewed hefore any type of service work is performed.

Further informar ion concerning the EPA emission regulations and U .S. Suzuki's emission control
-,rogram can bc found in he U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL.

SUZUKS MOTOR CO.,LTD.


Motorcycle Technical Service Department

Quoting. copying or otherwise osing any part o f Ihis mantra1 withoal explicit arrlhorizalion from
S u z ~ ~ kMotor
i
Co.. I,td. is not permitied as all rights to the publicarinn are reserved under
cop? right law.

SIDE VIEW

VIEW OF SUZUKI GS85OG

Right side

,-

Left side

GENERA L INFORMA TION

GENERAL INFORMATION
CONTENTS
IDENTIFICATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

FUEL. OILS AND BRAKING-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2


ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SERVlCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

GENERAL INFORMATION
IDENTIFICATION TABLE
SERIAL NUMBER LOCATION
The frame serial nurnberv is stamped on the
steering head pipe. The engine serial number @is located on the right side of the
crankcase, These numbers are required
especially for registering the machine and
ordering spare parts.

GEAR C)II,
Use SAE 90 hypoid gear oil which is rated
GL-5 under API classification system. I f you
operate the motorcycle where ambient
temperature is below 0C (32"F}, use SAE 80
hypoid gear oil.

BRAKE FLUID (for Ront and rear brakes)

DOT 3,

DOT 4

FUEL, OILS AND BREAKING- r%j IN PROCEDURE


3

??-

$;

FUEL
Use only l~nlendedor low-lead type gasolinc
R + %I
of a t lea~z85 - 95 p u m p octane I-TmethodS or 89 octanc or higher rated by the
Rcscarcli method.

NOTE:
JISirzce rhe hrakp system of rhis
rnotorcr?cleis filled with a glvcol-based
brake flttid b-v [he tnanufacrurer, do
no I vse or mix different rypes of JIi4id
such as silicone-based and petroleurnhaspd fluid +forrefilling [he sys fern,
of her wise serious damage will resrrlr.
2) Do not use any brake flriid taken
from old or used or unsealed conruiners.
3) Never re-use brake fluid lefi over
from the previous servicin~ and
siored for o f o npriod.
~

FRONT FORK OIL


SAE 10Wi'ZO
--

ENGINE OIL
Be sure that the engine oil used comes under
API classification oi SE and that its viscosity
rating is SAE 10W,'40.Tf SAE 1 OW140 nlotor
oil is 1104 availaide, select the oil viscosity
according to tl~cfollowing chart:

- -

GENERAL INFORMA TION

m
e

RREAK1NC-IN PROCEDURE
During manufacture only the best possibIe
materials are used and all machined parts are
finished to a very high standard but i t is still
necessary to allow the moving parts to
"BREAK-IN" before subjecting the engine
to maximum stresses. The Future performance and reliability of the engine
depends on I he care and restraint exercised
during its early fife. The general rules are as
fol!ows:

F . Keep to these break-in

LOCATION OF PARTS
,T Tachometer
8 lenition switch
1
3 Choke knob
@ Front brake lever
C3 Throttle grip
GI Rear brake pedal
8 Foot rests
#,PISpeedometer
@ Clutch lever
K@ Fuel tank cap
@ Gear shift lever

engine speed limits:

".Upon reaching an odometer reading of


1 000 miles (1 600 km).you can subject the
rnotorsyclc to full throttle operation.
However, do not exceed 9 0 0 r/min at any
time.

Do not maintain a constant speed for a


long period. Try to vary throttle position.

ORIENTATION
CY Ll NDER IDENTlFlCATlON
The four cylinders o f this engine are identified as No. f , No. 2. No. 3 and No. 4
cylinder, as counted from left to right (as
viewed by the rider on the seat).

Fig. 1-4

Left -Right

GENERAL INFORMA TION

SERVICE SPECIFICATIONS
DIMENSIONS A N D WEIGHT
Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry weight
Gross vehicle weight rating
ENGINE
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

2 230 rnm (87.8 in)


865 m m (34.1 in)

1 190 rnrn (46.9in)


1 490 rnrn (58.7 in)
160 mrn 6.3 in)
253 kg (558 lbs)
455 kg (1 003 lbs)

Four-stroke cycle, air-cooled, DOHC


4
69.0 mrn (2.71 7 in)
56.4 m m (2.220 in)
843 cm' (51.4 cu.in)
8.8 : 1
MIKUNI VM26SS, four
Polyurethane foam element

Electric and kick


Wet sump

TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary seduction
Gear ratios, Low
2nd
3rd
4th
TOP

Wet multi-plate type


5-speed constant mesh
1-dawn 4-up
1.775 (87/49$
2.500 (?5/ 14)
1 -777 (32/ 18)
1.380 (29/21)
1.125 (27/24)
0.961 (25/26)

SECONDARY DRIVE
TY
Secondary reduction
Final reduction

Shaft drive
1.062 ( I 7/16)
3,090 (34/11)

CHASSIS
Front suspension

Steering angle

Telescopic, pneumatic/cail spring,


oil dampened
Swinging arm, oil dampened,
damper 4-way/spring 5-way adjustable
40" (right and left)

Caster
Trait

62" 00
1 I3 nrn (4.45in)

Rear suspension

GENERAL INFORMA TION

rn (8.5 ft)
Disc brake, twin
Disc brake
3 .SOH 19 4PR
4.50H 17 4PR
1 -75 kg/cmZ 125 psi)
(Normal solo riding)

Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure

2.6

Rear tire pressure

7.00 kg/cmz (28 psi)


(Normal solo riding)

ELECTRICAL
Ignition type
Ignition timing
Spark plug
Spark plug gap

Battery
Generator
Fuse
CAPACITIES
Fuel tank including reserve
Reserve fuel
Engine oil
change
filter change
overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil
(At time of overhaul and replacement)

Battery ignition
17' B.T.D.C. below 1 500 r/rnin and
37' B.T.D.C. above 2 500 r/rnin
NGK B8ES or NIPPON DENSO W24ES
0.6-0.8 m m (0.024-0.031 in) balh NGK and
NTPPON DENSO
12V 50.4 kC 114 Al1)/10 HR
Three-phase A.C. generator

10/10/10/15A

22L(5.8 US gal)
4.2 Lt I . 1 US gal)
2.8 L (3 .O US qt)

280-330 rnl ( 9.5-1 1.2 US oz)


0.6-1.2 kg/crn2(8.5-1 7 psi)
25 1 mI (8.48 US oz) in each leg

* Specifications subject to change without notice.

SER VICE SPECIFJCA TlONS

SERVICE SPECIFICATIONS
CONTENTS
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 2 - 2
(ETOPEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 2
(E LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 2 - 4
..
ICATION SYSTEM . . . . . . . . . . . . . ,
.. . . . . . . . . . . .
. . .2 4
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-2- 5
SHAFT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 2 - 5
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 6
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 6
BRAKE + WHEEL ............................................ 2. 7
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 7
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. 7
FUEL AND 01ICCAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 2 - 8
TORQUE 'I'ABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 9
ENGiP4E
-.
. .. .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 9
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
TIGHTENING TORQUE CHART .............................. -2-10

.
.
.

SER VICE SPECI'FSCATIONS

SERVICE SPECIFICATIONS
ENGINE TOP END
VALVES -t GUIDES

Unit: mrn (in.)

Unit: rnm (in)

CAMSHAFT
Standard

Item

EX

36.320-36.360

36.020

( I .4299- 1.43 1 5 )

(1.4181)
35.470
(1.3965)

35.770-35.8 1E
(1.4083- I .4098)

Camshaft-Journat Clearance IN /EX

0.0374.065

Camshaft Journal Holder T.D. INlEX

(0.00154.0026)
22.012-22.025
(0.8664-0.867 I )

Camshaft Journal O.D.

INlEX

Limit

2 1.960-2 1.975
(0.8646-0.8652)

Camshaft Deflection

Cam Chain 20 Pitch Length

0.150
(0.0059)

157.80

(6.2 13)

SER VICE SPECIFICA TIONS


PlSTON

+ RING + CYLINDER

Piston Pin Bore 1.D.

Unit: rnm (in)

16.002-16.008
(0.6300-0.6302)

Piston Pin O.D.

15.995-16.000

(0.6297-0.6300)

SER VICE SPECIFICA TIONS

ENGINE LOWER END


Unit: mrn tin)

CRANKSHAFT
Connecting Small End Bore Piston Pin Clearance

Standard

Limit

0.006-0.0 1 9
(0.0002 -0.0007)

0.08
(0.003 1)
-

Connecting Rod Small End Bore E.D.

16.006-16.014

Piston Pin O.D.

15.995-16.000
(0.6297-0.6300)

Connecting Rod Rig End Side Clearance

I .O
(0.039)

0.10-0.55
(0.004-0.026)

Connecting Rod Big End Wear

0.08
(0.003)

Crankshaft Runout

0.05

(0.001)

LUBRICATION SYSTEM
OIL PUMP

Unit: m m (in)
Standard

Item
I

Oil Pressure (For 60C)

Above 0.1 kg/cm2 (1.4 psi


-:
000 rlmin

(7.1 psi) at

Tip Clearance

Outer Rotor CTearance

Side Clearance

Oil Pump Reductian Ratio

87/49X 33/34 = 1.723

CLUTCH
1tern

Unit:

Stnndnrd

Drive Plate Thickness

2.7-1.9

10. t 06-0.1 14)

Driven Plate Thickness


-

Driven Plate Distortion

7 .O
(0.08)
-

Limit
2.4
(0.094)
-

0.1
(o.004)

Drive Piate Claw Width


(0.46-0.43)
Clutch Spring Free Length

40.4
(1-59)

(0.43)
38.8
( 1 .S3)

rnm (in)

SER VICE SPECIFICA TIONS

TRANSMISSION

Unit: rnm (in)

Standard

Ttem

Limit

Primary Reduction

3.775 (87/49)

Secondary Reduction

1.062 (17116)

Final Rctluction

3.090 (341 t 1)

Gear Ratios

2.500 (35114)
1.777 (321 18)
1.380 (2912 1)
1.1 35 (27124)
0.96 1 (25126)

Low
2nd
3rd
4th
TOP

Shifl Fork-Groovc Clearance

Shift Fork Groove Width


Shift Fnrk TEiickness

0.8

0.4-0.6

(0.016-0.024)

(0.83 1)

5.45-5.55
(0.2 15-0.2 19):

4.95-5.05

(0.195 -0.199)

SHAFT DRIVE

Item

Secondary Bevel Gear Backlash

Unit:

Limit

Standard

0.08-0.13
(0.003-0.005)

Final Bevel Gear Backlash

0.03-0.64

.(o.oei -0.025)

Sccondary Drive Bevel Gear Preload

3-5 krcm (2.40-4.35 Ib-in)

Secondary Driven Bevel Gear Preload

4-7 kg-cm (3.45-6.05!bin)

Final Drive Bevel Gear Preload

4-8 kg.cm (3.45-6.9s Ib-in)

mrn (in)

SER VICE SPECIFICA TlONS

CARBURETOR

Unit: mrn (in)

'ilot Air J

ELECTRICAL

Unit: rnm (in)

SER VICE SPECIFICA TiONS

BRAKE + WHEEL
FrontlRear

Brake Disc Thickness

Front

Rear

Brake Disc Runeut

Limit

Standard

Item
Axle Runout

Unit : m m (in)
0.25

(0.010)
5.5

5.9-6.1
(0.23-0.24)
6.5-6.9
(0.26-0.27)

Frontlreat

(0.22)
6.0
(0.24)

0.30

(0.01 2)
-

Master Cylinder
Piston Dia.

Front

15.80
(0.622)

Rear

13.96

(0.550)
Brake Caliper
Cylinder Bore

Front

42-85

(1.687)

Brake Caliper
Piston Dia.

Rear

38.18
(1.5 03)

Front

42.82
(1.686)

Rear

38.15
( 1 -502)

Wheel Rim Runout


(Radial W Axial)
Tire Size

Tire Tread Depth

2.0
(0.08)

3.50H19 4PR
4.50H17 4 P R

Front
Rear
Front

Rear

1.6

(0.06)
2.0

(0.08)

TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE

SUSPENSION
Item

I60
(6.3)
100
13-91

Rear Wheel Travel

Front Fork Oil Level

Limit

Standard

Front Fork Stroke

Front Fork Spring Free Length

Unit: mm (in)

42 1
(16.6)

416

(16-4)
140
(5.5)

SER VICE SPECrFICA TIONS

FUEL AND OIL CAPACITY

method) or 89 octane or hi$er rated

* These specifications subject

to change without notice.

SER VICE SPECIFPCA TIONS

TORQUE TABLE
ENGINE
Thread
dia.
Camshaft holder holt

Cylinder head bolt


Cylinder head nut
Cylinder head cover

6
10

Crankcase holt

Crankcase hol t
Starter n ~ o t o bolt
r
Oil pan nut

Engine mounting boll


Engine mounting bolt
Starter clutc1-1ho!t
Cam chain guide No. 2 bolt
Cam chain ~dlerbolt
Air cleaner bolt
Exhaust pipe bolt
Muffler bolt
OiI pressure switch housing bolt
Clutc.11 spring bolt
Clutch sleeve hub nut
Clutch release arm bolt
Gear shifting cam stopper spring holder bolt
Gear shift lever bolt
Generator rotor hoIt
Secondary (lrive gear nut

Secondary (l rive gear housing bolt


Secondary driven gear nut
Secondary driven gear housing bolt

6
h
8

6
6
10
12
8

6
6
6
8
10
6
6
24
6
14

8
12
32
8
14
8

kg-m

I b-ft

I .O
0.9
3.7

7.5
6.5
27.0
6.5

0.9
1 .O

2.0

0.6-0.9

0.6-0.9
3.5
3 -5

I
1

7.5
14.5
4.5-6.5
4.5-6.5

25.5
25.5

1.5-2.0
0.4-0.7

1 1 -0-14.5

3.0-5.0
4.5-7.5
3.0-5.0
6.5- 10.0

0.6-1 .O
0.4-0.7
0.9- 1.4
1.8-2.8
1.1-1.3

13.0-20.0
4.5-6.5
8.0-9.5

5 -0-7.0

36.0-50.5

0.6-1.0
1.8-2.8
1.3-2.3
9.0-10.0
12.0-15.0
2.0-2.6
9.0-1 1 .O

4.5-7.5
13 -0-20.0
9.5-16.5

0.6-0.9

65.0-72.5
87.0-108.5
14.5-19.0
65 .O-79.5

2.0-2.6

14.5-19.0

kg-rn

Ih-ft

1.2-2.0
1.S-2.5
2 .O-3.0
1 .S-2.5
3.5-5.0
3-6-52
1 .S-2.5

8.5- 14.5
1 1.0- 18.0

CHASSIS
Thread
dia.

H;~ndEeholdIcr bolt
Fton! fork 1lpper bracket rear bolt
Fronl IOFK, .lube upper pinch bolt ( R , L)
Fronl fork tube lower pinolr bolt (R, L)
.

Steering stem head nut

Front axle shaft nut


Front axle Ilolder nut
Swinging arm pivot shaft bolt
Swinging am] pivot shaft nut
Rear torqirc link nut .
Rear axle nut
Rear sliock absorber nut
Rear wheeE driven joint nut
Front step bolt

8
8

10
8
18

1 I?
8

24
24

0.35-0.45

10
10

11.0-13.0
2.0-3.0
8.5-1 1.5
2.0-3.0
5.0-6.0

10

2.7-4.3

10

I6

'

14.5-2 1.5
? 1.0-18.0
25 .S-36.0

76.0-37.5
11.0-18.0
2.5-3.5
79.5-94.0

14.5-2 1.5
61.5-83.0
14.5-2 1.5
3h.O-43.5
10.5-31.0

SER VJCE SPECIFICA TIONS

Thread
dia.

Front brake caliper mounting bolt


Front and rear brake disc plate bolt
Front brake caliper axle bolt
Front brake master cylinder mounting bolt
Front and rear brake hose union bolt
Front and rear brake oil bleeder bolt
Rear brake caliper mounting bolt
Rear brake caliper axle bolt
Rear brake master cylinder mounting bolt
Final drive gear housing nut
Final drive gear nut
PropelIer shaft bolt
Final case oil filler plug
Final gear bearing case bolt

Final gear case shock mount stud bolt

2.5-4.0
1.5-2.5
2.5-3.5
0.5-0.8

I0
8
I0
6
10

8
10
10
8

Ib-ft

kg+"

1.3-1.8

10
14

0.6-0.9
2 .O-3 .O
2.5 -3.5
1 -5-2.5
3.54.5
9.0-1 1.0

2.5-3.0

:I

2.0-3.0
2.0-2.6
9.0-1 1 .O

18.0-29.0
I 1 .O-18.0
18.0-25.5
3.5-6.0
9.5-13.0
4.5-6.5
14.5-21 .S

18.0-25.5
11.0-18.0
25.5-32.5
65.0-79.5

t 8.0-2 1 "5
14.5-21.5

14.5-I9,O

65.0- 79.5

TIGHTENING TORQUE CHART


For other bolts and nuts not listed above, refer to this chart:

TIGHTENING TORQUE

Conventional Bolt

"4" Marked Bolt

''7'' Marked Bolt

PERIODIC MA INTENA K E

PERIODIC MAINTENANCE
CONTENTS
.

PERIODJC MAINTENANCE SCHEDULE ............................... 3 - 2


PERlODIC MAINTENANCE PROCEDURES ............................ 3 - 3
RATTERY ...........................................
............. 3 - 3
CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS ................... 3 - 3
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
TAPPET CLEARANCE .............................................. 3 - 5
SPARKPLUGS ....................................................
3-9
FUELLlNE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
CONTACT BREAKER POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
IGNITIONTIMING .................................................
3-9
ENGINEOIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
ENGINE OIL FILTER ............................................... 3-12
ENGINEIDLERIMIN
3-62
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13
DRIVESHAFTGEAROIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
BRAKES ..........................................................
3-15
B R A K E HOSES ....................................................
3-15
. . . . . . . . . . . . . . . a * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIRES ............................................................
STEERING ........................................................
FRONTFORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSlS NUTS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-16

3-17
3-17
3-18

PERIODIC MAJNTENA NCE

PERIODIC MAINTENANCE
IMPORTANT: The periodic maintenance intervals and service requirements have been established
in accordance with EPA regu1ations. Following these instructions will ensure that the motorcycle
will not exceed emission standards and it will also enhance the reliability and performance of the
motorcycle.

h'O TE:
M o r fsequen
~
I servicing may he performed on rnororcycles that are used under exfreme service
condil ions, SIO wever, it is net necessary ro ensure emission level compliance.
The chart below lists the recommended intervals for all the required periodic service work necessary
to keep the motorcycle operating at peak performance and to maintain proper emission levels.
Mileages are expressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE


I, SHOULD BE JUDGED
READING OR
FSEVER COMES IYIRST

Brakc

I
~

Tire

Stwring

Froni fork
I

Chasri~holts and ntrrs

NOTE: T=Tiphtrn, A = Adjurt. I= Inspect,

R = Rcplacc,

C =Clean

PERIODIC M A INTENANCE

PERIODIC MAINTENANCE
PROCEDURES
This section describes the service procedures
for each section of the Periodic Maintenance
requirements.

BATTERY

An S.G. reading of 1.22 (at 2QC) or ~fnder


means chat the battery needs recharging off
t h e machine: take i t off and charge it from

a recharger. Charging the battery in place


can lead ro failure o f the rectifier.

CYLINDER HEAD NUTS AND


EXHAUST PIPE BOLTS

1 . Remove right frame cover to check battery.


2. Check that the breather pipe is tightly
secured and undamaged, and is routed as
shown below.

1. CYLINDER HEAD
Remove [he fuel t a n k .
Tighten the tweIve 10 m m

nuts (14 rnm


wrench) to the specified torque with a
torque wrench sequentially in ascending
numerical order with t lie engine cold.
3.5-4.0 kg-m
('75.5-2Q.O lh-ft)

Cylinder head nut


tigh t e n i t ~ grcirqrle

After firmly tightening the 12 nuts. tighten


three 6 mrn bolts (indicated as A ) to the
torque value below:
3. Check electrolyte for level and specific
gravity. Add distilled water, as necessary,
to keep the surface of the electrolyte above
the LOWER level line but not above the
UPPER level line.

Fig. 3-2
For checking specific gravity,
hydrometer ro determine the

use a
charge

condizian.
Stantlard spcci tic
gnvity:

1
Head bolt
tig~teningtorque

2 0 ' ~(68' F)

0.7- I . l kg-m
(5.0-8.0Ih-i't)

'2. EXHAUST PIPE


Tighten the exhaust pipe bolts to the
specified torque with a torque wrench.
E x h ~ u s plpe
t
bolt
tightening torque

1 . 3

O.cl- - 2 kptn
((1.5-X.5 Ih-ft)

PERIODIC M A INTENANCE

AIR CLEANER ELEMENT


6 000 1 2 0 0 18 000 24 000krn
4 000 7 500 1 1 0 0 15 000 miles
If the air cleaner is clogged with dust, intake
resistance will be increased with a resultant
decrease in output and an increase in fueI
consumption.
Check and clean the element in the following
manner.
1. Take out air cIeaner element0 from the air
cleaner case by unscrewing screw O.

Nnn-fIammnhlc
Cleaning rolvcnl

2 . Fill a washing pan of a proper size with

non-flammable cleaning solvent. Immerse


the element in the cleaning solvent and
wash it clean.
3 . Squeeze the cleaning solvent out of the
washed element by pressing i t between the
palms of both hands: do not twist or wring
the element or il will develop tears.
4. Immerse the element in motor oil, and
squeeze the oil out of the element leaving i t
slightly wet with oil.

Motor nil

1
CA UTJON:

Before

and during the cleuning


operotion, inspecr !he element for tears.
A torn element musf be replaced.

TAPPET CLEARANCE
1 000 6 000 12 000 18 000 24

600 4 000

000 km

7 500 I5 000 miles

The tappet clearance specification is the same


for both intake and exhaust valves. Too srnaIl
a tappet clearance may seduce the engine
power; too large a tappet cIearance increases
valve noise and hastens valve and seat wear.
When the tappets are set to the specified
clearance, the engine wilI run without excessive noise from the vaIve mechanism and
will deliver full power. In this engine, the
tappet clearance i s increased or decreased by
replacing the shim disc, made of a special
wear-resistant material, fitted to the top of
the tappet. The shim discs are easy to remove
and refit. Tappet clearance adjustment must
be checked and adjusted 1 ) at the time of
periodic inspection, 23 when the valve
mechanism is serviced, and 3) when the
camshafts are disturbed by removing them
for servicing.
CHECKING THE TAPPET CLEARANCE
Tappet clearance specification
(Tor both intake and
exhaust valves):

(0.001 -0.003 in)

Fig. 3-6

Fig. 3-7

1 . Turn crankshaft to bring the exhaust cam


of No. I cylinder to this position. In this
condition, read the cIearance at the exhaust
tappets of Nos. 1 and 2 cylinders. Use
special tool film all tappets.
Thicknes s gauge

NOTE:
I ) The cam must be at position @) ox
(@ fo check the rappel cIearance or to
remove the shim disc. CIearance
readings should nor be raken with the
cam in any other position than these
two posifions.
2) The clearance specifcarion is for a
COLD en~ine.
3) To turn the crankshaft for clearance
check in^, be sure to use a 19-mm
wrench and ro rolafe in &henormal
running direction. A I / spatk plugs
should be removed.

09900-20803

Fig. 3-8

2. After setting the clearance to thl


specification at the exhaust tappets of Nos
1 and 2 cylinders, turn the crankshaft 180"
(half rotation) to bring the intake cam of
hTo. 1 cylinder to the position indicated

PERIODIC MAINTENANCE

Read the clearance at the intake tappets of


Nos. I and 2 cylinders and, if necessary,
adjust the clearance to each specification.

TAPPET CLEARANCE ADJUSTMENT


The clearance is adjusted by replacing the
existing tappet shim by a thicker or thinner
disc.
1. Place a fingertip on the tappet, and turn it
in place to bring notchfs to the position
indicated.

3. Turn the crankshaft a further 18O0,


bringing the exhaust cam of No. 4 cylinder
to the position indicated. Under this
condition, repeat the checking and adjusting process outlined in step "I " at the
exhaust tappets of Nos. 3 and 4 cylinders.

Fig. 3-12

2. Using the special tool, push down the


tappet.

Make sure the tool exerrs pressure on the


rapper correctly, us shown, with (he tip

i securely.
I appe t depressor
--

4. Again turn the crankshaft a further 1 80,


bringing the intake cam of No. 4 cylinder
to the position indicated. Similarly check
and adjust the clearance at the intake
tappets of Nos. 3 and 4 cylinders.

Fig. .?-I1
3-6

099 16-645 10

PERIODIC MAINTENANCE
3 . Take out the tappet shim from the tappet,
using special tool O.
Forceps

099 16-845 10

Taanet shim sire chart


No.

Thickne~s(mm)

Parr No.

2.15

12892-45000

2.20

12892-45W1

2.25

1 2842-45002

2.30

12R92-dJ003

4. Check the figures printed on the shim.


These figures indicate the thickness of the
shim, as illustrated.

Before fitring fhe tappet shim to fhe


tapper, be sure ro apply engine oil ro its
rap and bo(romfuces,
Fig. 3-15

5 . Select a replacement shim that will provide


a clearance within the specified range
(0.03-0.08 mm). For the purpose of this
adjustment, a total of 20 sizes of tappet
shim are available ranging from 2.15 to
3.10 m m in steps of 0.05 mm. Fit the
selected shim to the tiappet, utith numbers
toward tappet. Be sur.e to che:ck shim size
with micrometer to insure .~, t size.
s

6. After replacing the tappet shim, rotate the


engine so that the tappet is depressed fully.
This wilI squeeze out oil trapped between
the shim and the tappet that could cause an
incorrect measurement, then check the
clearance again to confirm that i t is within
the specified range.

22

E E E

E E E

u
z
p

-0 0

5
222
;
I l l

2
E k
n .- r
fJ

- = w

55 : k22;;

W.Y1

d U u a

2d C$-$;E O
G

$ w _ U, . ", fi

::5%

u -2,
Z Z d 0

kgE

g2+

PERIODIC M A INTENA NCE

FUEL LINE
(Replace every two years)

SPARK PLUGS

Replace the fuel hose every two years.

At initial 6 000 km, remove the carbon


deposits with a wise or pin and adjust the
spark plug gap to 0.6-0.8 mrn (0.024-0.03 1
in). measuring with a thickness gauge.
Replace the plugs every 12 000 krn and
remove the carbon deposits and adjust the
gap every 6 000 kin after replacing the plugs.
Whenever removing the carbon deposits, be
sure to observe the appearance of the plug,
noting the color of the carbon deposit. The
color indicates whethet the standard plug is
suitable or not. If the standard plug is apt to
get wet, a hotter plug should be used. If the
standard plug is apt to overheat, with the
porcelain having a whitish appearance,
replace with a colder one.
-

NOTE:
To check the spark pltcgs, keep /he
engine running on unleaded gasoline,
aad $all of the four are either sooty with

Fig. 2-17

CONTACT BREAKER POINTS

Check and adjust the contact points as


outlined on the next page. Inspect the contact
points for wear and burning. If the point
faces are dirty, wipe them clean with a clean
and dry cloth.

carhar~ or hurt~t white, replace rhem


alto~ether.

!
I
NORMAL

WCIIIN

73
I
7
-

Dl R T Y

NOT PARA LLEL

- Fig. 3-18

IGNITION TIMING
-

1000 6000 12 000 18 000 24 000km


600 4 000 7 500 11 000 15 000 miles

0.6-0.8 m m

Gap (0.024-0.031

Ignition timing specifications


in)

Point gap
Spark plug gap

Ignition timing

Fig. 3-16

17" B.T.D.C. &low


1 500 r/rnin and
37' I3.T.D.C. above
2 Sm r/min

PERIODIC !MAINTEEWANCE

NOTE:
I ) Be sure to srse a 19-mtn wrench to turn
rhe crnnksfrrrfrin the direction shown.
2) Retnove all ,foltr plugs rrnlil adjus / men r is c ~ m p f e t ~ d .

2. Connect timing tester G


9 between the (+)
terminal of the breaker and ground.
09900-27003

Timing terter

3 . Slowly turn the crankshaft in the normal


direc~ioniantil index mark T { o n the Nos.
1,524 siclc of the advance governor) is
alipnecl with timing mark :*,.
'T: Corresponding to T.D.C. of
No%.I R 4 pistons
3 : Timing index mark "F1.4"
.3': Ignition advance timing mark

TIMING ADJUSTMENT FOR 'VOS. 1


A N D 4 CYLINDERS
I . Set the contact point gap CO to 0.3-0.4 mrn
(0.012-0.016
in) in the Nos. 1 & 4
breaker. To adjust the gap, loosen
screw @and dispIace terminal (3 .

s - w

/"-{At.

-2-22

4. With the pistons brought to the specified


B.T.D.C. position in Noq. I and 4
cy tinders, as shown above, loosen three
screws~%~securing
the breaker plate and
turn the plate slowly counlerclockwise
until the contacl points begin t o separate.
Secure the plate in that position by
tightening screws ' 4
5. T o check, turn the crankshaft slowly.
observins the timing tesrcr. I f the breaker
contact begins to open just when
markl3comes i n line with m a r k @ . the
adjustment is correct and the ignition is
timed as specified For Nos. 1 and 4

cylinders.

PERIODIC M A INTENA NCE

TIMING ADdUSTMENT FOR NOS. 2


A N D 3 CYLENDERS
The procedure is identical to the foregoing
except for two points:
I . Bring mark "F" (on Nos. 2 & 3 side in the
advance governor) into line with the timing
mark.
2. Loosen hvo screnrs O and move plate Z
con nterclockwise to de terrnine i t s position
at the beginning of opening action.

2. Run the engine at a speed above 2 500


r/rnin, and similarly observe the position
of mark@ relative to mark ($1 lf the two
marks are in line, the ignition is properly
).

advanced.

3. Carry out above steps 1 and 2 for Nos, 2


and 3 cylinders.

F ~ E3-26
.

CHECKING BGNlTION TIMING WITH


T M I TIMING LIGHT
After setting the contact points of the twin
brcakcrs by adjusting in the above-described
manner, check the performance of the timing
riiccliaz~ism using the timing light 109900273 1 11. I tlitminate the adva~lcegovernor with
the timing tight ancl vary the engine speed to
sec if tlrc iynition is correctty tinled or not.
The proccdurc is as follows:
1. Run the engine at a speed not exceeding
I 500 r/min. Under this condition, "F"
mark and timing mark should be in perfect
alignment: if not, readjust the twin breaker
referring to these marks in the advance
governor.

ENGINE OIL
Initial 3 000 krn ( 2 000 mi) and thereafter
Change Every 3 000 km ( 2 000 mi)

The oil should be changed with the engine


hot.
The procedure is as follows:
* Keep the motorcycle upright, supported on
the center stand.
Place an oil pan below the engine and drain
the oil by removing drain plug fi)
and Filler
cap $1.

Oil filler replacement at the abovc in tervnls


should be done together with engine oil
change as described in the previous section.
After draining engine oi! and sccurelv
tightening the engine oil drain plug. perform
the follo~ving:
1. Remove three nuts

'2), and

rcmove

the

cover.

1. Pull out old filter

3 ,

replace w i ~ hnew

one.

* Fit drain plug cilsecurely,

and add fresh oil


l h r o u ~ hthe filler. The ensine ivill hold
about 2.8 L (3.0 US. qt) of oil.
Use API classiFication of SE oiI with SAE
1 O\V/40 viscosity.
Start up t h e engine and allow i t to run for
several seconds at idling speed.
* Turn off the engine and wait about one
minute, then check the oil level in level
gauge 3 . I f the level is below mark 'T",
supply oil to thar level.

3. Replacr covcr, sccurc nuts


ing Thrcad Lock Cement.
4. Add engine oil.

2 : with

apply-

NOTE:
Pour about 3.6 L (3.8 US.qfJof engine
oil i~rto~ I E PU I I ~ DIZIV
~ I ~~zlhenc+lrungirrff
oil arid rep lac in^ oil filter ar rltr same
tirrie.

Fig. .?-30

ENGINE IDLE RSMIN

NOTE:
When r~placing the oil +filres, [he
nnlotrnr qf oil lo be replacsld is 3.6 L.
(3.8 us.qt).
W h ~ nperfortnin~ cttgine overhaul,
the anrnltnt of oil to be replaced is 3.8

(4.0 US.q/J.

I . Starr up t h e engine and warm i t up by


running it ar 2 000 rJrnin for 10 minutes in
summer, when ambienz temperature is
30C (86"F), or for 20 minutes in winter,
when arnbienz temperature is down to
approx. -5C (23F).
2. After the engine warms up, turn the
throttIe stop screw in or out so that engine
runs a1 950- 1 130 r/rnin.
I

ENGINE OIL FILTER

No adjusimen r except the procedure


menr ioned above is necessary because
c~librarionis performed by carburetor

PERIODIC MAINTENANCE

Fin. 3-33
At the same intervals, adjust the throttle
cable play in the following manner:

THROTTLE CARLE ADJUSTMENT


A hvin throttle cable system is used on the
GS85OG: One cable A is for pulling and the
other cable 8 for returning.

Returning cable play


1. Reduce the play @to zero by turning the
adjusting ntlt while lrolding the tl~rottlc
grip frilly open position, and secrlrcly
tighten thc lock nut.

CLUTCH

Pulling cable play

The throttle cable should be adjusted to have


a slack O of 3-5 mrn (0.12-0.20 in) a t the
middle point between adiustine holder @and
throttle cable end @on the carburetor side.
L,

NOTE:
Inspect r he cable slack periodically, and
if necessary, odjus! it to the specified
value. The cable end will come out if rhe
play is excessive.
1. Loosen Iock nut 0.
2. Turn adjusting nutEdto obtain a cable
play @of 0.5- 1 .Om m (0.02-0.04 in).
3 . Tighten lock nut 0 .

CLUTCH CABLE ADJUSTMENT


Loosen lock nuts n o n the lever side of the
clutch cable and screw adju5t n u t @fully in
on the clutch lever side.

Loosen the cable lock nut, tighten the adjust

nut to provide play in the outer cable. Adjust


the play of the cable with adjusting
nut C3 until play @of the clutch lever is 2-3
rnm (0.08-0.12 in). Next, firmly secure lock
nut @.

PERIODIC MAINTENANCE

If the specified play can not be obtained


with adjusting nut 3 shown in the above
figure, carry out the adjustment using the
adjust nut on the clutch lever side.

DRIVE SHAFT GEAR OIL

Change the drive shaft gear oil in the


following way. Use SAE #90 hypoid gear oil.
SECONDARY GEAR OIL
1. Keep the motorcycle erect, supporting i t on
the center stand.
2. Remove sear shift l e v e r q a n d secondary
cover 6:
3. Drain oil by removing filler cap #%and

drain plug a.
4. Refit drain plug'4), remove oil level
screw C5)and pour the specified oil in
through the filler hole until it runs out
from the oi h level hole.
5 . Refit oil level screw 61,
filler cap tT,
secondary cover Q! and gear shift lever rt: .

FINAL GEAR OIL


1. Drain oil by removing filler cap mand
drain plug 3 .
2. Refit drain plug@and pour the specified
oil in through the filler hole until i t runs
out from the filler hole.
3. Refit filler c a p 1 3.

The utnofrnt of oil to he r~placed is

NOTE:
The amotinr qf oil ro be replaced is

Fig. 3-38

PER IODJC MA INTENA NCE

1000 6000 12000 18000 74000km


600 4 000 7 500 1 I 000 15 000 miles

Check
1.
2.
3.

the front and rear brake systems for the following items:
Insufficient brake power

Rrakesqueaking
Excessive brake lever stroke
4.
Leakage of brake fluid
I f these troubles are detected, repair or replace the damaged parts as indicated in the chart below.
Symplnm and posciblc caure

INSUFFICIENT

B R A K E POWER

1) Leakage nf brake fluid from hvdraulrc Fyslern

Cnunlcrmeasure

....................

Repair or replace

2) Worn pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
I
3 ) Oil adhc~ionon cngaping surface or pads. . . . . . . . . . . . . . . . . . . . . . . .
4) Worndisk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I
4) h~rIn hydraulrc system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace

Clean disk and pndc


Replace
Rleed air

R R A K F SQUEAKING
I ) Carhon adhesion on pad ~ u r f a c c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) Silted pad

Repair surface with

................................................

3) Dnmofcd wheel hearing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4) I.oose Front-wllccl axle nr rear-wheel axle.

<andpaper

Modifv pad fitting


Replace

. . . . . . . . . . . . . . . . . . . . . . .Tighten to specified torque

CI Worn

pad<.

...............................................

6 ) Forcien materia! In broke lluid

Rcplacc

................................

7) Clopgcd return porr of master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .

EXCESSIVE RRAKE LEVER STROKE


I I Air it1 hydratrlic r v ~ t c r n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 Worn hrahe levcr cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
?I In~ufficicnf hrakc fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3) Irnprupcr quality of brake fluid.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replace brake nuid


I

Di~as~emble
and cIcan m a w r cyEindcr

Blccd a ~ r

Rcpiacc brokc lcvcr


Repleni~lifluid to specified level; biccd air
Replace w i ~ hcnrrrc! fluid

I.FAKAC;C OF BRAKE Fl UID

.........-......
............................ .
.
.
.. . . ... . . . .

1 ) Inwl'ficicnr ~ i g l ~ r c n ~oln gconnec~ionjoin~s.

Tiphrcn ro spcciricd lorque

2) Cracked how
3) Worn p i ~ t n nand/or cup

Replace

....................................

Replace p i ~ o nand/or cup

BRAKE HOSES AND FLUD (Replace every two years and change every year)
Replace the brake hoses with new oncs. Change brake fluid every two years.

PERIODIC MA /NTENA NCE

TIRES
-

l 000 6 000 12 000 1'8 000 24 000 km


600 4 000 7 500 1 1 000 15 000 miles

Inspect the tires for wear and damage and check the tire tread depth as shown. Replace a badly
worn or damaged tire. A tire with its tread worn down ta the limit (in terms of tread depth) must be
replaced.

1.6 tnm (0.06 in)

Fig. 3-39

Check the tire pressure, and examine the valve for evidence of air leakage.

COLD INFLATION
T I M PRESSURE

b
W a

FRONT

SOLO
RIDING
DUAL RIDING
llNG
DUAL RIDING
.
lkg/crni P.S.I. kPa kgjcmz P.S.1. kPa kg/crn2 P.S.1. k h kgjem2 P.S.1.
-

NORMAL RIDING
I
CONTINUOUS HIGH
JSPEED RIDING

REAR

173

i 1.75

200

2.00

--

--

- --

25

175

1.75

700

2.00

28

225

5.25

32

28

700

2.00

2R

2.25

32

780

2.80

40

-2

PERIODIC 12.1A INTENA NCE

STEERING
1 000 6 000 12 000 18 000 24 000 km
6004000 7 500 11 000 IS 000 miles

Check that there is no play in the front fork assembly by supporting the machine so that the front
wheel is off the ground. With wheel straight ahead, grasp tower fork tubes near the axle and pull
forward. If play is found. perform steering bearing adjustment as described in section (11-19) of
this manual.

FRONT FORKS

Check the front fork air presruse, when the


fork is cold, cvery 6 months in the following
manner.
1 ) Place the motorcycle on its center stand
and keep the front wheel off the ground.
!) Measure the air preqsure by p l a c i n ~the
pressure gauge on the valve as shown.

Specified air pressure:

0.6- 1 - 2 kg/cm2
(8.5- 17 psi)

.II
;-;

1 . 1 y . .?-

- f s -

-=,:: :.

-,

I/

3) E f necessary, use a hand tire pump


raise the fork air pressure.

tc

CA UTION:

Do not irse compressed air to

adjust

the fork oir pressure, since conrpressed


air is stored at much higher presstires
rJaart rlze forks r e q u i r ~ .and .sc~c~J(!(J~?!QFP

ntqv r ~ s z t l f .

NOTE:
I . Just before cl~arginl:air confirm tlzar
the valve is fiLcllrf.
2. Try ro equalize [he air pressrrre 0-f rile
r wo lens, ri-qhr and Iqfi, as clo.reIy as
possjble. The mu.uitn urn perm issihle
difference is 0.I k ~ / c t ? ?( 1.4
' psi).

Inspect the front fork for oil leakage, scoring


and scratches on the outer surface o f the
inner tube every 12 000 km (7 501) miles) and
replace the defective parts, if necessary.

CHASSIS NUTS AND ROLTS

The nuts and bolts Iistcd below arc important safer? parts. They must be retightened when
necessary to the specified torque with a torque wrench. (Refer to page 3- 1 9 for the locations of the
following nuts and hot ts on the mo~orcycle.)

n bearing holder boll


-.,
.
r-k n u t
1-

- 3

1.45 kg-rn (
1.0 kg-m (7!
C I...

I I

Fig. 3-46

Fig. 3-47

Fig. 3-48

- -

SPECIAL MATERIALS

SPECIAL MATERIALS
The materials listed below ate needed for maintenance work on the GS850G, and shouId be kept on
hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery
cloth and the like. How to use them and where to use them are described in the text of this manual.

..........

CauntersEiaft Big retainer screw . . . . . .


Drive shaft plate screw . . . . . . . . . . . .
Generator stator screw . . . . . . . . . . . .
Generator lead wire guide screw. . . . . .
Engine oil pump screw. . . . . . . . . . . .
Oil gallery plate screw . . . . . . . . . . . .
Starter motor securing bolt . . . . . . . . .
Secondary drive bevel gear assy set boll .

3 pcs
3 pcs
3 pcs
3 pcs
4 pcs
3 pcs

? pcs
4 pcs

THREAD LOCK "1342"

.........

Thread portion at secondary drive gear

* Thread postion o f final drive gear

Propeller shaft joint bolt. . . . . . . . . . . 4 pcs


Rear wheel bushing stud bolt and n u t . . 6 pcs
Starter clutch alren bolt . . . . . . . . . . . 3 pcs
Gearshift stopper. . . . . . . . . . . . . . . .

K SUPER "1333B"

(between head and cylinder)

SPECIAL M A TERJALS

PART NO. & NAME

PART

SEE PAGE

Mating surfaces of upper and lower crankcase


Final gear case
Joint pmtion of rear swinging arm and final pear
case
Front fork allen bolt . . . . . . . . . . . . . 2 pcs

7-60

8-1 5
8-1 6

SUZUKI BOND No. 1207B


99104-31 140

r Apply to the outer peripI~eryof brake pad

11-31

I1-32

S U Z W SILICONE CREASE
99000-25 100

Apply to caliper axle shart

SUZUKl CALIPER AXLE CREASE


99000-25 1 10

* Valve stem
* Can1 slrafi journal
L.

Chain tensioner adjuster shaft

7-25

Coun tershafl wasllel

7-56
7-56
7-56

Outcrcounterslaaft
Input cam dog

SUZUKI MOLY PASTE


99000-25 140

Use of G e n ~ ~ i nSnzaki
e
Paris.
To replace any part of the machine, use a
genuine SUZUKI replacement part. Imitation
para or parts suppBied from any other sorlrce
than SUZUKI, if used 10 replace SUZUKI
parts, will reduce the machine's performance
and, even worse, coulcl inducc costly
mechanical trouble.

7- 13
7-1 5

SPECIAL TOOLS

SPECIAL TOOLS
The special tools listed hereunder are designed to facilitate maintenance work-disassembly,
reassembly, servicing, checking, etc.-on the GS850G, and protect the parts and components o f the
motorcycle against damage. Each shop is advised to keep these special tools as standard shop
equipment.

NOTE:
Tools, @through @ , ire newly designedspecial tools for the GS8SOG.
Tools, m r hraugh 03 , are special tools used exclusivelyfor the GS series.

/,,

%y

Setondnrtdrtvr h r r l gcsr holder

cr

IllOY24-5451I

~ 1 m m s w l r ewrench
l
109910-237TO)

(3

/-

F'

--

fC)

f k a r i n ~~ n nr fracerrmovct
10Wd1-845103

6l

3m
6)

Rrarinl: in

Brariny ~nclallrr$el

t o ~ vJl - R ~

( ~ W Z J 45
- ~~ n )

t
\
p
c+~-/

',

\<-

'
i
.

t7-?'

-..-

'

Torqucwwnch (0-15 kpl-rml


1 0 ~ ~ l l l -lc17)
21

RearEnp! and nll pal rrrnnver (30


((IWdI44510k

- 15 mm)

KQ

@/\- /

t l l l w a l inv~alterandrrl
(O'M?J-~~SZO~

1FC

'i
rf#

((MP13-80 1 l 2)

R ~ a r i n e a n dnil red h e n d l ~
tW921-745 10)

Drlvr pininn recc installer

?
a

4-

4iY'.'-

Ill
I

Final driven ~ ~hcaril


s 1~
r installer
tnt~?1-74~7(~

PInd

rernovcr

Final drlw yemr cupltnpl hnMer


(09~24-64510)

SPECIAL TOOLS

Mi\?

--3gr\r.
\/

Final drlve bevel acar rrnrtl-llia uaa a e ~inrlaller


l
(OP924-74rhrlr

Rrarlng lnrtaller
109924.745303

Fin*! gear caw nil srnl rn\lnller


(0992J-715503

Cinsl a ~ s cr p ~ n
e d l e hearint lnvtallrr
lll'MZ4-045101 -

bye

Q,

qf#j4
-

Pilnl
109014-74540)

~3

l k a r i n ~oufrr nrr rtmvver


40994 1-5491 ll

- *

7- 1
-%

1.;$/

9 ,

34

Backlashmmvuring tnnl (27 - SO mm)


1119'424-30510)

Valve stem seul and valve @i$t i n ~ a i khandk


r

SPECIAL TOOLS

a band (63-75 mm)

Carbumlor bahnccc

F m t tork = m m M l n g loot
#nrhrntnl 'D-

SPECIAL TOOLS

ng pllem langk closed: lsr[rt drc)

Shock dtlvff set

SPECIAL TOOLS

@
-..

69

@J

,I

."

p41.
?

- r-.-7

LJ

- .

(99103-45011)

Stterhg nul m k t t -ch


(09940.1491 1 )

cila,

VJve

acn camrsrt

Ruce and brnrlng drlvrr


(fI'J941-74'J1 (I\

Tmhg light
1099130-2731 1)

Hydrometer

(09900-28403)

TROUBLE SHOOTING

TROUBLE SHOOTING
CONTENTS
ENGINE AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

6-6
-

TROUBLE SHOOTlNG

'
TROUBLE SHOOTING

ENGINE AND CHASSIS


Complaint

Syrnptom and possible causes


Compression too low
1. Tappet clearance out or adjustment.
2. Worn valve guides or poor watlnp of valves.
3, Valve<inktiming.
4. Pi~tonrinec cxce~si\elyworn.

Engine will not


start. a t i5 hard
to start.

5 . Worn-down cyl~nderhorez.
h . Starter motor cranks hu! too slnwly.
Plugs not sparking
I. I-'ouled spark plugs
2. Wct spark plugs.
3. Contact point5 dirry.
4. Impropcr gaps on contact points.
5. Ipnit~ontiming out or adjustment.
h. Uerective ignition coil.
7 . Open or short In h~ph-tenpioncord<.
8. Defective conden~er.

Remedy

Adjust.
Repair. or replace.
Adjust.

Replace.
Replace, or rebore.
Consult "e!cctric~I
complain~s".
Clean.
Clean and dry.
Clean.
Adjust.
Adjust.
Replace.
Replace.
Replace.

No h e l reaching the carburetors


I. Cloggetl holt. in the fucl tank cap.
2. C l o ~ t e dor defective fuel cock.
3. Defective carburetor float valvc.
4. Cloggcd fuel pipe or suction petcock pipe.
-

Engine stalls

I. Foulcd qpark pl~rgr.

easily.

2. Dirty contact point\.


3. Ignltion timing out of adlustment.
4 . Clopped file1 pipe.
5 . Clopped jet\ in carburetors.
6. Tappet clearance out of adjustment.

Noisy engine

1
1

'

B X P ~ * S ~tappel
YP chsll~r
1. Tappcl clearance too large.
2 . Weakencd or hraken valve springs.
Noise appears to cnrne from pistons
I . Piqtons or cylinders worn down.
2. Ccmhuqt~oncharnherr fouled w ~ f hcarbon.
3. Piston pins worn.

1 Noise seems to #me from cam chain


I. Strclchcd cham.
2. Worn spmckcts.
3. Tension adjustor not working.

Noise seems to come From clutch


I. Wbrn yplincs of countershaft or huh.

2. Worn teeth of clutch d i m .


3 , Distorted cIutch dtscs, driven and drive.

Clean.

Clean or replacc.
Replace.

Clean.

I Clean or replace
CIean or replace
Adjuct.
Clean.

Clcan.
Adjust.

Adjust.

Replace.
Replace.

Clean.
Rcpalce.
Replace.
Rcpl ace.

Repair or replace.
Replace.
Replace.
Repair or replace.

Noise seems ta come from cmnkshafl


1. Rattling bearing< due to wtar.
2. Rig-end bearings worn and rapping.

Replace.

Noise seems to come from trlrnsmission


1. Gears worn or rubbing.
2. Radly worn splints.
3. Primary gears worn or rubbing.

Replace.
Replace.

Replacc.

Replace.

TROUBLE SHOOTING

Slipping clutch

I . Clutch control nu1 of adjustm~ntor 105s of play.

Adjust.

1. Weakened clutch springs.

Rep1acc.

3. Worn nr distorted prex~~ire


plate.
4. Distorted clutch disc$. driven and driw.

Replace.
Replace.

Dragging clutch

I . Clutch contrnt out of sdjustmenz or tan milch play.


2. Sonic clutch springs weakened while otl~ersare not.
3. ni~tortcdpresqurc plate ar clu~chdiscs.

Transmission will

1. Rroken gearshift cam.


2. Distnrted gear9hift forks.

not shill

Transmfssiaa shift lcvcr 1 . Broken return spring on qhift shaft.


will not return In
2. Shift shaft? arc r u h h i n ~or stick!.
p n d inn.

Transmission
jumps out of
gear.

Engine idles
poorly.

I Worn shirtinp gcars on drive ~ l i a for


t col~nter<h;lft.

2. Distorted or worn ~ c a r ~ h irorks.


ft
3. Weakened stopper qprinp nn gearshir~cam.
1. T a p ~clearance
t
out of adjustment.
2. Poor sealrng o f values.
3. Defective valve guides.
4. Ipnit~ontiming out nradjus~mcnt.
5. lrnpmper gaps an contact points.
6. Spark plug gaps too w d e .
7. Defective ignition coil or condenser resul~inpin
weak spark in^.
8. Float-chamber f~rellevel 0111 crf adjustmen1 in
carburetors.

Engine runs
w r ! y in hiphsped mnge.

1.
2.
3.
4.

5.
6.
7.

8.
9.

10.
Dirty or heavy
exhaust smoke.

Engfne lacks
power.

Rtmtdy

Symptom and wssible causes

Cmplaini

Valve springs wakened.


Valve timing oul or adjustment.
Spark plug gaps too narrmv.

Ignitbn not advanced sulficicntly due to poorly


work~ngadvancer.
Wcakcned springs on breaker arms.
Defective ignition coil.
Float chamber fuel level too low.
Clogged air cleaner clemcnt.
Clogged Fuel pipe, resulting in inadequate fuel
supply to carburetors.
Clogged suction cock pipe.

Replace.

!Replace.
Rcplacc.
Repair.

iReplace.
Replace.
Replace.
~Ar!-pist.
Replace.

Replace.
Adjust.
Adjust.
Repair.

Replace.

Adlusr.

Replace.

Adjust.
Repair.
Repa~r.
Replace.

Replace.
Rdju~l.
Clean.
Clean. and prime.
Clem.

I . Too much lubc oil in the engine.

Check with level, gauge:

2. Worn piston rings or c!rlindcrs.


3. Worn valve guides.
4. Cylinder walls scored or scuffed.

drain out excess oil.


Replace.
Replace.
Rep1 ace.

5. Worn valves stems.


6. Defective stem seal.

Replace.
R epl act.

I. Loss of tappet clearance.

Adjusl.
Replace.
Adjust.
Replace.
Repair.
Adjust.
Adjust.
Repair.

2. Weakened valve springs.


3.
4.
5.
h.
7.

Valve timing our of adjustment.


Worn piston rings or cylinders.

Poor seating o i valves.

Ignition timing out of adjustment.


Improper gaps on contact points.
8. Spark plug gaps incorrect.
9. Clogged jets in carburetors.

Clean.

TROUBLE SIJOQTJNG

Symptom and possible causes

Cmplabt

10. Float-charnkr fuel level out of adjustment.


I I. Clogged alr slcaner element.
I2. Carburetot balancing screw hose.
13. Ton much engine lube oil.

Engine larks pnwfr.

..

Engine overheats.

1. Heavy carbon depoqil on piston crowns.


2. Not cnoueh o i l in the cngine.
3. Defective oil pump or clogged oil circuit.
4. Fuel level too 10% in float cliamher~.
5. Ignilion timing ercc~sivelyretarder!. accornpan~ed
hv pinging.

Noisv shaft drive

Nnise seemr rc.1 come from secnndarj. hrvel gear and Final
hcvt.1 eear aswm blips.

Remedy
Adjust.
Clean.
Retighten.
Drain out excess oil.
Clean.
Add oil
Rcpair or clean.
Adjust.
Adjust.

I.Oil level too low.

Refill

2 . Excessive backlash

Adju51

3. 'Improper 100thcontacl

Adjust

4. Damage to bearings

Replace

Utrisc qccrns In tornc Trnm p r i ~ g c l l rsI1aCI


r
area.
1 . Ptopclter ~ h n f joint
t
bolts

loow.

Retighten

2, Ptopcllcr sliart spline$ damaged or warn.

Replace

3. Cnwfficicnt lubricant

Refill

No power

1. Broken propeller shaft

Replace

I~nsrnittedfrom

2. Rroken pcar teeth

Replace

I . Damage to oil ~ e a l s
2. Damage to 0 rings.

Replace

Replace

I. ~ t e c r ~ n
ovcrtigh~ened.
2. Broken
I steering, acm.
3. Dinortcu MCCI 1 1 1 ~~ I c m .
4. Nor enso t ~ g hpressure in tires.
~
in front s~~spension.
5 . lrlwffic:icnt air p ressurc

Adjuqt.
Replace.
Replace.
Adjust.
Adjust.

1. t o m nl balance hctween right and leFt wspcnsion.


2. Distort.erl Front To rk.
3. Distort ed Front aarle or cocked tire.

Replace.
Repair or replace.

engine ta rear whrel

Secnndary h v e l gear
and final hevel gear
1

assemhliw nil lcak

HantllEng-fwls
ton heavy.

Wnlbhly handling

r.

Wohhly front
wheel

Fmnt
suspension
too soh

ti.
-.~ c~~ressurc'
--~ r n ~ in front suspension.
~
n R~ u.. r ~a11
A

Rcplace.
Adjust.

I. Dislorted wheel rim.

Replace.

2 , Worndown froni whcel hearings.


3. Defective or incorrect tire.
4. Lmxc nut on axle.

Replace.
Retighten.

I. Wenkened springs.
2. Not cnough fork oil.
3. I n ~ u f f i c i e nair
t precs~rrci n frnnt suspension.

Replace.
Refirl.
Adjust.

Replace.

TROUBLE SHQOT/'JNC;

Front
suspension
too stiff

Remedy

Symptom and possible causes

Complaint

1
8

1 . Fork oil 00vtscous.


2. Too much lork oil.
3 . Excessive air pressure in Front suspension.

Replace.

I. Not enough fork oil.

Refill.
Retighten.

Remove exceqs oil.


Adjust.

Noisy 60nl
suspension
Wobbly rear

too soft

Rear suspension
too stiff

Noisy rear
suspension

Pmr haking
(FRONT or REAR)

2. Loow nuts on suspension.

1. Distorted wheel rim.


2. Worn do~rbnrear wheel bcnrings.
3. Dcfectivc or incorrect tiie.

1. Weakened springs.
1 2. Rear <uspension adj~istorsimproperly sel.

1
;

1 Replscc.
Replace.
Replace.

I Replace.
Adjust.

Rcar suspension adjustors improperly set.

Adjust.

1I

I Retighten.
I

Lmsc nutson suspension.


1. Not enough brake fluid in the reservoir.
2. Air trapped in brake fluid circuit.

3. Pads or linings worn down.

Refill to level mark.


REccd air out.

ELECTRICAL
Cmplaint

Bemedy

Symptom and possible causes

No sparking or

I. Rcfectivc ignition coil.

Replace.

pmr spnrking

2. Defective spark plugs.

Replace.

Contact pofnts
k n r or pit
prematurely.

Defcctivc condenser.

Replace.

I
1 . Mixture too rich.
2. Idling speed get too high.

Spark plugs soon

bccomc Fouled
with carbon.

Spark plugs

Genmfor does
not charge.

3. Incorrect ~asoline.
4. Dirty element in air cleaner.
5 Spark plugs too cold.

Replace.
Replace.

Replace.
Replace by cold type

I. Spark plups tm hot.

Spark plug elec.


trdes overheat
or burn.

I
h ~ i j u scarburetors.
t
Adlust carbure~ors.
C hanee.
Clean.
Repalce by hot type plugs.

I. Worn piston rines.


2 , Pistons or cylinders worn.
3. Excesrive clearance of valve stems in valve guides.

become fooled
too soon.

plugs.

2. The engine orerheats.


3. Ignition timing out o f adjustrncnt.
4. Spark plugs loosc.
5. Mjxturt too lean.

Tune up.
Adjust.
Reti~hten.
Adjust carburetors.

1. Opcn or short in lead \wrcs. or loose lead

Repair or replace crr


reti~hten.
Replace.

connectlons.
2. Shorted. prounded nr open generator coils.

Rcplace.

3 . Silicon diodes punctured.


4. Shorted rcgulator/rectifier lead wire.

Repair or replace.

I
I

Generator dues
charge, bul
charging rate i s

I. Lead wires tend to ger shorter! or open


circuited or loosely connectcd at terminals.

Repair, or retighten.

2. Grounded or open-circuited stator coils of

Replace.

generator.
3, Defective silicon diodes.
4. Defective regulator/rectifier
5. Not enouph electrolyte in the hartcry.

overcharges.
Unstable

charging

Starter button
is not effective.

Battery
"~ulfatlon"

Replace.

h. Defective ccll plates in the battery.

Replace.
Add distilled water
to raise its level.
Replace the battery.

Internal short-circuit in rhc battcry.

Replace the battery.

I. Lcnd wire insuIation frayed duc to vihratiun,


resulting in intermittent shorting.

Repair or replace.

2. Gcnerator internally shorted.


3. Defecrive regulator/rcctifier.

Replace.
Replace.

1. Battery run down.


2. Defeaiwe switch contacts,
3. Brushes not seating properly an cnmmutato;
in Starter rnotnr.

Recharge or replace.
Replace.
Repair nr replace.

I. Charging rate too low or too high.


(When not in use batteries should be recharged
at least once a month to avoid sulfation.)

Replace the battery.

Cmplaint

Battery "Sulfation"

Symptom and possible causes

2 . Battcry cfeutroly~cexccss~veor insuflicient.


or i t s specific gravity roo high or too low.

Remedy

Keep the elect rolyrc


up to thc prcscrihed
level. or adjust Zhc
S.G. by constrltinp
the battery maker's

3. The hntrcry left ~rnuscdb r too long


Iespeciallv in cold climates).
Ratter) dircharpw
too rapidly,

1 . n~rt!cnntaincs lop and v d e ~ .


2. trnpuri~iesin the electrolyte o r clcclrolytc
S.G. i s ttm liipli.

directions.
Replace the bat~ery.
if badly sulfated.
Clean.
Change the elecrrcllyte
by consulting rhe
bntrerv maker's
direction$.

ENGINE
CONTENTS
ENGINEREMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSlON CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOP END-REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAIN TENSION ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMCHAIN IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TACHOMETER DR [ V E GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDE HOLE REAMING .
........................
VALVE GUIDE . . . . . . . . . . . . . . . . .
........................
VALVE STEM SEAL . . . . . . . . . . . . . . . .
........................
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVESPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE COTTER TO VALVE STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPROCKETS ON CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POSITIONING CAMSHAFT I N PLACE . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM BEARINGCAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM CHAIN IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM CHAIN TENSTONER ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . .
TENSIONING ACTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAPPET CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOP END-INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT JOURNAL WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFTRUNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM CHAIN 20 PITCH LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE FACE WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE STEM RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE HEAD RADIAL RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE GUIDE-VALVE STEM CLEARANCE . . . . . . . . . . . . . . . . . . . . .

ENGINE

VALVE SEAT WIDTH MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . .


VALVE SEAT SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD DISTORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAM CHAIN TENSION ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER, PISTON AND RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOWEREND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTACT BREAKER POlNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC ADVANCER FOR CONTACT BREAKER ..............
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY BEVEL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY DRIVE GEAR ASSEMBLY ..........................
SECONDARY DRIVEN GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .
SECONDARY GEAR SET CLEARANCING OPERATIONS . . . . . . . . . . .
EXTERNAL MECHANISM FOR GEAR SHIFT . . . . . . . . . . . . . . . . . . . . . . . . .
ENGlNE LURRlCATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OILPUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL P U M P PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OILFILTER ..................................................
SUMPFILTER . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . .
... . . . . . . . . . . . . . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KICK SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES ON INSTALLATION

7-22
7-22
7-24
7-24
7-24

7-75
7-26
7-26

7-27
7-29
7-31
7-31

7-32
7-33

7-33
7-34
7-35
7-35

7-36
7-37
7-39
7-39
7-42
7-45

7-47
748
7-48
7-50
7-50
7-51

7-52
7-54

7-55
7-57
7-59

OF TRANSMISSPON GEAR AND

CRANKSHAFT IN CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-59

ENGINE

Fig. 7-1

7-3

ENGINE

ENGINE REMOVAL
* Place an oil pan under the engine and
remove the engine oil drain plug and oil
filter cap to drain off engine oil.

Open the seat and remove the bolt at the


rear of the fuel tank. Remove the tank
rearwards,

Fig. 7-2
Place an oil pan under the secondary drive
drain plug and remove the gear shifting
lever and secondary drive unit cover. Next.
remove the drain plug and drain off the
secondary gear oil.

Move the intake pipe clamp aff position


and disconnect the intake pipe from the
breather cover.

* Set the fuel cock lever

to the " O N ' h r


"IIES" position and shift the fuel pipe clip
sideways to remove the two hoses from the
fuel cock.
Remove the Iead wire of fuel meter sensor
located at the lower left side of the fuel
tank.

Fig. 7-6

Remove the left and right frame side covers.


First of all, remove the battery
terminal,
then remove @terminal.
Remove the connectors for various lead
wires.
A C generator lead wire.
* Starter relay terminal.

10.

ENGINE
Contact point lead wire.
Neutral switch and gear position lead wires.
* Oil pressure gauge lead wire.
Plug cords.

Loosen the clamp screw securing the


propeller shaft boot, and move the propeller shaft boot rearward.

*
*

Remove the right and left bolts


securin~
the air cleaner body to the frame.
Loosen the four air cleaner clamp screws
i 2 , , move the air cleaner a little rearward,
and remove it from the carburetor. Next,
remove the air cleaner to the right.
t

Remove the four bolts securing the universal joint flange and propeller shaft.

Loosen the throttle cable mounting nuts on


the opening side
and the closing side GI
to renlove the respective cables from the
carburetor lever.
Loosen the starter cable lock nut 3 and
remove both inner and outer cables from
the carburetor.
Loosen the clamps for the intake manifolds
a n d remove the carburetors by puIling
toward the rear.

Remove the brake pedal mounting bolt.


Next. move the pedal rehim spring off the
peg, and remove the pedal.
Remove the right footreqt.

ENGINE

NOTE:
The frame on

tJrp upper portion of the


breather c o v w mav be damaged if the
ptt,i+ne
assernh!v is morrt~ted and
dismoltrtred wirh ?Ir@ hr~aliter cover
mountad on f h p rnp of ihp cylirrd~ri r ~ a d
cover.

Remove the exhaust bolts. remove the right


and left muffler mounting bolts. and
remove the mufflers.
'i

Fig. 7- I5
Support the weight of engine wiih a jack or
stand and remove the engine mounting
bolts and nuts.
* Remove all of the bolt-on engine mounting
brackets (4).

the lead nirec nnil mounting bolts


of the horri rnountiny bracket. then remove
licmovc

the ;i.;sc rn11Iy.


Fully Ion~crathe clutch cnhlc lock nut and
ndjustcr hrslts cln i l ~ ccneine side. Then
Iooscn the cl\!lch rclcn\e a r m bolt and
rernovc tlic clutch rclcncc nrnr hy lifting it
upward.

lienlove the four bolts and take off the


erlgi nc breather cover.

Right side

Left side

Fig. 7-1 7
Lift the engine up and out the right side of
the frame: be careful not to scar the upper
or lower frame tubes.

Bolt tishtening
torque:

Inslall the propeller shaft boot with the


clamp (front side) and spring (rear side).
Firmly secure the carburetor with the
clamps. If the carburetor is not firmly
secured, gas leakage. incorrect air-fuel
ratio and unsatisfactoy engine operation
may result.
Beforc tightening the exhausi pipe bolts.
install both right and left muffler mounting
bol ts.loowly.
After tightening the exhaust pipe bolts,
tighten both right and left muffler
mounting bolts.
Exhaust pipe bolt
tightening torque:

Muffler boll tightening


torque:

Fig. ?-/(q

2.5-3.0 kg-rn
(18.0-21.5 lb-ft)

0.9-1.4

kg+m

(6.5-10.0 Ib-ft)
1.8-2.8 kg-m
( 1 3.0-20.0 I b-ft)

Replace the plug caps on the spark plugs so


that their code markings correspond to the
cylinrler numbers arranged in the order of
1, 2, 3, and 4 from the left.

ENGINE REMOUNTING
For remounting, reverse the order of engine
removal.
Temporarily fasten the engine mounting
bracket before inserting the engine
mounting bolts.
* After inserting the engine mounting bolts,
tighten engine mounting hracket bolts and
engine mounting bolts. Insert all three long
bolts from the left side.

Secure the universal joint flange and


propeller shaft with four bolts at four
places. Be sure to apply SUZUKI LOCK
SUPER "1 333R" to the bolts.

Fig. 7-19
After remounting the engine. adjust the
rear brake pedal ( p a ~ e1 1-33], brake light
switch. clutch Cpage 3-13) 211d throttlc
cable (page 3-1 3).
Before starting the engine, make sure the
amount of oil required, according to the
type of work done, has been put in. Re fer
to page 2-8 for quantities.

D
B

ENGINE

COMPRESSION CHECK
The cnnipression of a cylinder is n good indicator of i t s internaI condition. The decision
to overhaul the cylinders is often based on the
results of a co~npression test. Periodic
maintenance records kepi at vour dealership
should include compression readings for each
maintenance service.

Compression

Low compression pressure can indicate any of


the following conditioils:
Excessivelv worn cylinder wall
Worn-down piston or piston rings
Pi5ton rings stuck in the grooves
* Poor scaling of valves
Ruptured or otherwise defective cylinder
head gasket
Overhaul r he engine in the following case!
I ) compression pressure in any one of th
cylinder5 i s I c ~ s than 7 kgJcrn2. 2 ) he
di Frerencc in con~prcssioti pressure between the highest and lowest measurements
i~ Inore than 2 kg/cm2, and 3 ) cornpre~sion
pressure in t hc four cylinders each is belaiv
9 kg/cm2 (stanrlard) even when i t measures
more than 7 kg/crnl.
Con~pressiontcst procedure:

NO TE:
I ) R ~ f o rt ~~s t i r l g$lie cornpressio~tqf the
P I Z ~ ~ ~ tnake
J P ,

sure that the iylir~rler

Irpnd r~rrtsand bolls are ~ i g h t e r l ~tod


sprryicatic~n.
2) Wurtn rrp f /re erigirr~heforp re-sting.
1. Remove all spark plugs.
2 . Fit the compression gauge (special tool:
09915-64510) 1
9 in one of the plug holes,
while taking cam that the connection is
tight.
3. Twist the throttle grip full open.
4. Crank the ensinc a few seconds with the
starter. and record the maximum gauge
reading ns the compression of that cylinder.
5. Repent this procedure with the othrcylinders.

TOP END-REMOVAL
CYLINDER HEAD COVER

.-

CHAIN TENSION ADJUSTER


This adjustment can he accomplished by first
loosening lock nut ,T>and tightening screw C?;
and then by removing three mounting bol ts {% .

NO TE:
Tiglrrerzing screw @
locks
I rfie s p r i n ~

ENGINE
CAM CHAIN IDLER
Remove the four bolts, and remove the cam
chain idler from the cylinder head.
NOTE:
The idler assernbly is composed of
several pieces, and cure should be raken
when removing ir not lo drop an-y pieces
into the engine.

CYLINDER HEAD
Remove spark plugs
Rernove 2-6mm bolts next to # I c% #4
spark plug positions. I - h m m boIt a1 the
front of timing chain area.
Remove 12-10mmnuts. working from #I2
to #I (numbers are cast on head next to
nuts).
@

TACHOMETER DRIVE GEAR


Remove tachometer drive Rear from head b y
pulling the assemblv out after removina its
stopper (sccurcd by n. hex/phillips screw)

-.

,W-

-,.-

Fig. 7-26
Remove the tappets, cornplcte with shims.
and identify each.

CAMSI-IAFT
To remove the camshafts, loosen the
benring cap bolts one turn at a time in a
cross pzttern until all valve rpring prmsure
nn the shafts is relieved. Cams can thcn he
lifted out.
-

NO T E
Damage the cylinder head and/or cam
bearing c a p ma-y be cawsed by [he
cnrnslt~f~
Shrusl shoirlders if you fail ro
observe I he above procedrdre.

ENGINE

Exercise caution ill w ~ n o v i t ~and


g srorirtg
t a p p t s so as not io ?lick r h e ~ n .

3. Take out the valve spring retainer, inner


spring and outer spring.

VALVE GUIDE SERVICE


VALVE REMOVAL
Remove each valve in Ihc follo\ving manner:
1 . U s i n g the valve lifter, comprers the
spring.
Valvc lifter:

09916-14510

-_

4. From the other side, pull out the valve.

'2.

Fig. 7-3 1

2 . Take off the two cotter halves from the


valve stem. using forceps.

V A L V E GUIDE REPIAACEMENT
Drive the valve guide out toward cylinder
head side: use the valve guide remover.

Forceps

Valve guide remover:

09916-44510

NOTE:
Discard ?/re removed valve ~ u i d estrh-

VALVE GUTDE HOLE REAMING


Re-finish the valve guide holes in cylinder
head with a 12.2 rnm reamer 9.
12.2 rnm reamer:

099 16-34530

Failrtrt> ir) oil ill(. ~)ali)r


gtrirl~hole hrfort.
driving the new gui& inro place many
r ~ s z r l rirt Q durnug~dg r r i d ~or h ~ r ~ d .

VALVE GUIDE
Fit a ring to each valve guide. Be sure to use
new rings and valve guides. Use of rings
a n d valve guides removed during
disassernbIy is prohibited. Remember that
the guide for intake valve ri! differs in
shape from that of lthe exhaust valve 2,.

Fig, 7-34

Oil the stem hole. in each valve guide and


drive the guide into the guide hole using the
valve guide and stem seal installer attachment , 3 . Be sure to use a valve guide
installer attachment handle 19 on the
pushing face of the installer, as shown, to
avoid direct contact between installer and
valve guide.

13Villvr giidc inrtnllcr attachment

Valve guitlc inrlnller h:~ndlr.

VALVE STEM SEAL


1 . Oil each oil seal. and drive them into
position with the valve stem seal installer.
Be sure to use a valve guide and stem seal
installer attachment handle on the pushing
face of the installer.

NOTE:
Do nor use rhe oil seals r ~ r n o v ~ id~ l

W91h--9530
099 1 h-57720

Install valve spring lower seats Ti). Be


careful not to confuse the Power seats with
the spring retainer 3.

a) Valcc stern seal inrlaller aztwhmcnt

OW1 l-L)4530

V a l w stcnr seal inrtallcr hentile

IWUlh.57.32n

14:

ENGINE

Fig. 7-39
VALVES
2. Insert the valves, with their stems coated
with high quality molybdenum disuifide
lubricant (SUZUKI MOLY PASTE) a11
around and along the full stem length
without any break.

VALVE COTTER TO VALVE STEM


4. Put on the upper valve seat and, using the
valve lifter, press down the springs, fit the
cotter pin to the stem end, and release the
lifter to allow the cotter (3 to wedge in
behvcen seat and stem. Be sure that the
roundcd lip 5', o f the cottcr fils snugly into
the groove F i n the c'tern end.

W k e insertirrg
~
racl~v o h ~ take
,
cnrr fro?

Fig. 7-40

VALVE SPRINGS
3. Position valve springs in place, making
them rest on lower spring seat O by their
closed-pitch ends O, Both springs. inner
and outer i*, have varied coil pitches:
the coil pitch progressively becomes shorter
from one end to the other. Large-pitch
portions are indicated as 0 : small-pitch
portions as B.

5. OiI each valve tappet and the bore in which


it slides. Push the tappet into the bore with
your finsertips. Only a light force is required to push it in.

8%

-Fig. 7-41

CYLINDER HEAD INSTALLATION


CYIAIYI)ER I-IEAD
the hcad on the cylinder block as

* Mount

folIows:
Re sirre to replace cvlindcr liead y a ~ k e t
w i t h nenf one tn prevent gas leakage.
Gnsker is insralled with rhe wider side of
meral ring around cylinder opening toward
the cylinder.
Install bmm t~olr:it frolit of tinling chain
casting and lighten to:
T~ghtcningt 0 t . i l 1 1 ~

0,') kg-rn ( h . 7 Ih-1'1)

If-

Install the four crown nuts and copper


washers in the positions ' A 1 (oil passages)
indicated. (Fig.7-42)
With the head snugly seated on the cylinder
block. secure i t bv tightening the twelve 10mrn nuts sequentially in the ascending
order of numbers on head.
Tighten the twelve 10-rnm nuts to
specification with a torque wrench
sequentially in the ascending order of
ntrmbers.
3.7 kg-m
127.0 Ib-it)

After firmly tightening the 12 nuts, insert


two 6-mrn bolts (indicated as GI ) and
tighlen them to the ToIlowing specifics tion.
(Fig. 7-43)
Cylinder hcad bolt ti~htening
torque:

0.9 k ~ - m
(6-5 Ih-ft)

SPROCKETS ON CAMSHAFTS
Exl~austcamch:lft has i t 5 own ymcket, as
docs the intake camshaft, Do not confuse
the two sprockets.

Cylinder head nut tightening


torque:

I t is very important that each sprocket be


positioned angularly on its camshaft as

illustrated. 1ts correct position is determined by arrow mark "3" (on INTAKE
sprocket) or arrow marks "1" and "2" (on
EXHAUST sprocket) located (as xhown) in,
reference to the notch T1 In the camshaft
cnd. (Fig. 7-46)
Apply TI-IREAD LOCK SUPER "1333B'*
(99000-32020) to the tilreads of Allenhead bolts, and tigliterz them to the following specification:
Camshalt sprocket bolt
tightening torque:

The exhaust camshaft can be distinguished


from that of the intake by the embossed
letters "EX" (for exhaust) as against letters
"'IN" (for intake). Similarly. the right end
can be distinguished "R" from the left end
" L of each camshaft.

0.8- 1.1 kg-rn


(h.0-8.0 111-ft)

POSITTONING CAMSHAFT IN PLACE


NO TE:
Just h ~ f o ~rI ~U C ~ I I J1!1c
: cnmshafr orz the
cvlittd~r hmd, p
high quality
mo(rhrJetrum
disuifirle
lubricant
(SUZUKI MOLY PASTE: 99000-25140)
In its jorrrnafs, ji/l(r coarirre each journal
with I ~ ~P I I S ~laP kilt^ care !lot to ieaw
at$!- d n spot. Applv rlzpirw oil to the
jourtt ul henrirr~s.

Fig. 7-47

* Pull slackout of the timing chain, and


rotate the crankshaft in normal running
direction to bring the "'Thmark on Nos. I
and 4 side (of the advance governor) to the
timing mark. Use a 19-mrn wrench to turn
the crankshaft.

CA UTION:
To (urn over the crankshaft, turn nu, O
with a 19-tnm wrench. Never try to
rotole the crankshap by putling a 12mrn wrench ro bolt

a.

Put exhaust cam under chain


With "'T" mark accurately lined up with
the timing mark, hold the crankshaft
steady and lightly pull up the chain to
remove the slack between the crank
sprocket and exhaust sprocket.
Exhaust sprocket bears an arrow mark "1"
indicated as O . Turn over the exhaust
camshaft so that the arrow points flush with
the gasket surfacc of the cylinder head.
Engage the rimin2 chain with this sprocket.
(Fig. 7-52]
\

The other arrow mark "2" is now pointing


straight upward. Put the intake cam in
place and count the chain roiler pins toward
the intake camshaft. starting from the
roller pin directly above this arrow mark
"2" and ending with the 20th roller pin.
Engage the chain with intake sprocket.
locating the 20th pin at and above the arrow1
mark "3"' on the intake sprocket. (Fig. 754)

Fig. 7-54

NO TE:
TI~P
camshafi chain is now ric1li1r.q on all
~ l l r c es p r ~ c k e r sBe
. arefi fir/ not to distttrh
i h craakshaft
~
~rrrril the fotrr cornshuf~
hearing capx are seczt rtjcl.

ENGINE

CAM BEARING CAPS


Each camshaft hearing cap is identified
with a, cast-on letter within a triangle. A
matching cast-on svmhnl appears on the
head, Install each cap at its' matching
letter. with lriangle synlbols pointing the
same way.

CAM CHAIN lDLER


rn

Secure tlie f o l ~ camshaft


r
hearing caps evenl y l y t i g l ~ t r n i n gtlic carnsliaft hearing cap
bolts scq~~rntially.
Try to equalize the prcssurc h y moving the wrench diagonally from
one bolt to another artd from o n e canisliait
hcnring cap to anottres, t o pull shafts down

Instal! the cam chain idler and tighten to


specification. Ef not, t h e damper rubber
could nor serves ar a chain noise absorber,
and thus an excessive chain noise wilI
result.
Chain idler tightening
torque:

0.6-0.8 kg-rn
(4.5-6.0 lb-ft)

cvcnly.

Tighten tlie camshaft bearing cap bolts to


the following torque value:
CA U TION:

The wmmhqff holder bolts are made qf a


special marerial and rnuclr superior in
srren~rhcompared with other type of
h i ~ srren,p!h
h
bolts.
T a k ~special care mi fro use o t h ~ rtype
hrhts insfpad of t k p s p special bolts. TO
icl~nr(f~:?l
rhese bolrs, eczch of t h ~ 1 has
~1 a
f r g u r ~"9" on its head.
Camshaft bearing cap
holt tiyhtening torque:

1.0 kg-rn
(7.0 Ih-ft)

CAM CHAIN TENSJONER ADJUSTER


Removal of the tension adjustor is necessary
during engine disassembly and also due to
removal of c
s. In either case, re-install
the adjustel
cylinder block after the
camshafts have vrrn installed. The procedure
i s as follows:
While turning knurled knob countcrclockwise. push in the pushrod nil the
way. Keep on hirning the knob until i
becomes tight.

ENGINE
Tighten the lock nut.

Wlrprt f i g h t ~ a i n pt h lock
~ nur, r o k ~care

$-

>-

.AI.'- $
,*

---

.&

Fig. 7-58

Tighten the lock screw to lock the pushrod.


so that the pushrod will not push ant.
* Secure the adjuster to the cylinder block.

JL4_
?

.-

TENSIONING ACTTON CHECK


A t t c r instalring the tensioner, check its
tensioning action according to tlic following
3-step procedure:

Fig. 7-59

Back out the lock screw by one-quarter to


half a turn: this separates the tip of the
screw from the pusL--"
++ereby allo~ving
III W U .
the pushrcjd to adva nce und cr spring force
and press the tens! oner ag;%instthe cam- . .
shatt cnarn.
111

CA UTION:
As srclraci pr~viouslv,(lo 1101 ~ t t ~ ~1'0 t p f
ttrr?;over t / i ~ m r l k . ~ h uby
f i 1(.\+ih~
t h p bolt
I
2' ( H ~ J ~ c ' IrI e q l t i r ~ .a~ 12-v?m 119r~nshl:
1
1 ~ u r t trrut $ willr a 19-rnn~wrrnch, irt-

.r~
P II (1.
L

While turning the tensioner knob counterclock\t~ise.slowly rotate the crankshaft in


reverse direction coiancer clnckivise (thus
cau5iny the chain to push back the rensioner). (Fig. 7-62)

ENGINE
Release the knob and sIowly turn back the
crankshaft in normal running direction (to
slacken that portion of the chain extending
along the tensioncr). See if the knob rotates
by itself 3 s the chain becon~esprogressively
slackened: ii i t does. then the pushrod
inside is olrviously moving fornard under
spring force as it should. thus signifying
that the tensioner is in good operable
condition. l l the knob rotates. b u l
sluggishly. i t means that the pushrod or
lock shaft is sticking and. in such a case,
remove tlrc tcnsiones and service the
pushrod a n d lock shaft to make them move
smoolhlv. (See pace 7-25).

TOP ENDINSPECTION
One camshaft is provided for the intake valves
and the other for the exhaust valves. Be sure to
discriminate between the two. The camshafts
shoz~ld be checked for n ~ n o u tand also for
the wear of cams and journals if the engine
has been noted as giving abnormal noise or
vibration or to lack power output. Any of these
conditions may be caused by camshafts
worn down or distorted to the service limit.
T.D.C

lnlel opcn
(H.T n

c.r

Fxhau~tclmed

I n l e ~clored '
(A.R.D.C-.b

Exhaust own

IH H.I) C.I

R DC.

Fig. 7-65

CAMSHAFT WEAR
CA U7'10N:
itrstallir~g I I ~ P t~ttsioner ~ l r r i i
chr~ckirr~
it irr itlilial(i~SF? rorzdition for
nprralion. do not ulterrrpl Fv Itin1 I ~ I P
krloh ifr i ~ i l l ~ edirectinrr
r
7111rilthe rtrxf
APrr

o~*rrhnut.

TAPPET CLEARANCE ADJUSTMENT


I After checking tensioning action. check all
valves for tappet clearance and. as
necessary, ad,just the clearance to the
speci fica ton outlined on page 3-6.

Worn-down cams can be the cause of incorrect valve timing resulting in reduced
power output. The limit of cam wear is
specified for both intake a n d exharrst cams
in terms of cam height
which is 20 be
measured with a micrometer. Replace
carnstlafts if found worn down to the limit.

ENGINE
Cam height
t

',

I n ~ n k ecnmr
Exhaust cam5

sh

CAMSHAFT JotJRNAI, WEAR


Install the camshaft comectly. and using a
Plastigage measure the camshaft j f i l l r n ~ l
clearance.

J - t $ . 7-68

Camshaft hearing cap


bolt tigl~tcning

1 A kg-tn 17.0 Ib-ft)

Camshaft-Journal clearance ( I N

c%

EX)

Standard

L~mi!

0.'37-'.'''5
mfrr
(O.fln15 -0.01126 rn)

0,150 mm ~ O . I X ) ~ Qin)

CAMSHAFT RUNOUT
Measure the ritneut with a dial gaugc. Replace thc. camshaft if thc r t ~ n o u texcccds
tlic limit.

Carnshaft runoirt (IN & EX)


0.1 rnm (0.004 in)

Scrvict. Limit

If the camshaft journal clearance rneasitrecl


exceeds the tinlit. measure the insidc diameter
o l camshaft bear in^ cap and outsicle diameter
o l camshaft. RepIace either thc cylinder head
or the crrrn.;hnfl. whichever thc difference
from specification is greater.

<.

--:

I'c-

c- ,

1
Itcni

S~andnrd

Cam\hait journ:+I 11nlrlc.r 1.1).

22.O1 ?-22.OZ$mrn

(tn h t X )

(0.8666-ll.KbT1 ~ n )

C a r n ~ k i fjournaf
t
0.1).I 8N S: E X )

21 .'N10-2
(,,,

1.475 nim
Hh4h-n.ab52 in)

Fig. 7- 7(3

CAM CHAIN 20 PITCH LENGTH


Pull the chain tiqht to rernovc iiny sli~ck.then
using vernier calipers, measure the 20 pitch
length of cam chain. I f i t 1ne:tsures mol-c t h
limits. replace the can1 chain.

ENGINE

I.

Service Limit

157.80 m m (6.2 13 i n )

Fig. 7-71

VALVE FACE WEAR


Visually inspect each valve for wear of its
seating face. Replace any valve with an
abnormally worn face.
The thickness (3 decreases as the wear of
the face advances, Measure the thickness
and, if the thickness is found to have been
reduced to the limit, replace it.

VALVE HEAD RADIAL RUNOUT


Place the dial gauge at right angles to the
valve seat, and measure the valve head radial
runout. I f it measures more than limit. replace the valvc.

Valve head radial runaut (IN & EX)


Service Limit

1 0.03 rnm (0.001 in)


1

Valve head thickness (IN & EX)

Scrvicc Limit

0.5 m m (0.02 in)

Fig. 7-74

Fix. 7-72
VALVE STEM RUNOUT
Support the valve with "V"' blocks, as
shown, and check its runout with a dial
gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem mnout (IN & EX)
Scrvicc Limit
0.05 mrn (0.002 in)
-

VALVE GUIDE--VALVE STEM


CLEARANCE
1. Using a micrometer, measure the outside
diameter of the valve stem.
2. Using a caliper gauge, measure the inside
diameter of the valve guide.
* If the difference between the
measurements in 1. and 2. above is more
than limits, replace both valve guide and
valve stem.

Valve guide-valve stem clearance

1
Limit

Srnntlxrd

Valve

Intake

valver:

Exhau~i
vaI5.e~:

0.35 mm

155 mrn
,1D22 ~ n )
o.rwo-o.n;.n m m

(I1.1Xllh-O

(0.014 in)

0.35 mm
(O.IE14 in1

IY)28 in)

Valve stem O.D.


Star

274h in)

h.945-6.960 m m (0.2734-0.1'40

in)

Valve guide I.D.


Standard

The ring-like dye impression left on thc


valve face must be continuous-wi thozit any
break-and. i n addition to this rcquircmerit. the width of the dye ring. which is the
visualized seat "\vidthv. must h e within the
following specification:
Valve seat width
Standard

1.0-1.2mm10.04-0.05in)

If either requirement is n o t met. correct the


seat by servicing it as follows:

Fig. 7-73

Fig, 7-76

ALVE SEAT SERVICING

The valve seats for hot11 intake nna exnnust

VALVE SEAT WTDTH MEASUREMENT


Coat the valve seat with Pnissian blue
uniformly. Fit the valve: and tap the coated
seat with the valve face in a rotating
manner. in order to obtain a clear impression of the seating contact. In this
operation. use the valve lapper to hold the
valve head.

valvcs are angled ( 0 present three hcvtlls.


15" (hottorn). 4S0 Inriddle) nncl 75" (top).
To refnce the seat. proceed as folloiv~:
Valve sent cutter set

90 103-35011

ENGINE
I f so. re-cut the seat to the correct width.
4. After the desired war position and width

i5

achieved. use the 45' cuttcr very lightly to

Fig. 7-79

1. F~iscrtwith n qlieht rotation. the solid pilot


Ihnt give5 a snug fil. The shoulcler on t h e
pilot sho~ilclbe about 10 mrn (0.39 in) From
the valve guide.
2. Usit~gthe 4S0 cutter No. 635. dcscale and
cleatlup the sent tf it11 one or 1wo turns.
3. Inspect thc seAt by thc previous seat npidth
measurement procedure. I f t h e seal is
pitted or burned. additional seal conditioning w i t h the 45' cutter is required.

NOTE:
C~rt I ~ P~ ) r i ~ ~ i ? ?~ ~t nro~r (mr t t ~ ~ P C T S S U ?
.fion~11113 s p a t to J T ~ P I ' P fI/IY
~ ~ pr)s.sihilitv qf
I I I P 1 ~ 1 1 * 0S r P n r hpcorniri~too C I U S ~ ~ I ~ P
ruppcr f b r correct 11all-e contarr at?g/e.

clean irp any hurrs cauqecl by the previous


cutling operations. DO NOT use Inpping
compound after the final cut is made. The
finished valve seat shotlld have a velvcly
snlooth finis11 and not a highly polished or
shiny Finish. This will provide a soft sz~rface
for the final seating of the valve which will
occur during the first few seconds of engine
opera tion.
5. Clean and assemble the head and valve
components. Fill the intake and exhaust
ports with gasoline to check For leaks. If any
leaks occur. inspect the valve seat and face
for hurrs or other things that could prevent
t h e valve from sealing.

NOTE:
A/tvu-vL~ rrse

pxlrprne

crrurion

when

handling gusofi~re.

NOTE:
After servicing r l r ~valve spats. he sure to
adjltsr the tappet c f e a r a n c ~after l f r p
c-ylinder head has been r~i~zstalled.
6, I f , by any chance, too much stock has heen
removed from the sent during the refacing
work resulting in loss of the specified lappet
clearance even with the thinnest shim d i ~ c .
then the only remedy is lo grind off the stem
end face of the valve with a valve refacer,
thereby shortening the overall length of the
valve.

I M P 0 R TANT:
This reme+ is p ~ n ~ l i s s i hwhrrr
l ~ the
Iength (7) will not Ar rr~dtlcrclrn Iess
t hart 4.0 m ~ t Jf. t11i.q I~n~Crt/t
h(~rome,r
sJtorres fr'lcrt~ 4.0 rnm (0.l h irlJ. ~ ~ I P I I
F i y . 7-80

I I thc cont:ict urea is loo low. use 35' cuttcr


No. 2 1 0 to mise ;ind narrow thc conrnct nren.
If t h e co1itnc.t :Ire:[ is too hiyh. use 15" cutter
N o . h35 to lon'cr and nxrron. the con tact nrcn.
Aftcr cutting thc 75' nncl l 5 O nngles. i t i s
pc.rssi2,lc th:1l tlie vn1t.e scat (45") is too narrow.

rlre vuh~rrnldst he rr;r~lr~crd.


* Aftpr irrslallil~gI he ~tuhlewhosr stern
w d hns J ~ ~ P Pgrotrnd
I
off as ahovt.,
r h ~ c kthat t h fat-(>
~
@ of v r r h * ~s r P r n
~ j t dis ahnvr tlw c o t l ~pirt
r
3 1 .

CY1,INT)ER HEAD DISTORTTON


Decarbonize the combustion cliarnberq.
Check the gasket surface of the cylinut-1
head for distortion with a straigll tedge ancl
thickness gauge, taking a clearance seadi ng
at several places indicated. If the largest
reading at any position of the straightedge
exceeds the limit, replace the cylindct head.
Cylinder head disrortion
Service Limit

P IR. 7-81

0.2 rnm (0.008 in)

VALVE SPRINGS
* The force of the two coil springs keeps the
valve seats tight. Weakened springs result
in reduced engine power output. and often
account for the chattering noise coming
from the valve mechanism.
* Check the springs for strength by rneasuring their free lengths and also the force required to compress them. I f the limit indicated below is exceeded by the free length
reading or if the measured force does not
fall within the range specified. replace with
a SUZUKI spring.
-IMPO H TANT:
Heploce all clfrhc vrrlve sprirrgs ~t a rime,

f i,r. 7-83
CAM CHAIN TENSION ADJUSTER
The tension acljustcr used in the Model
GS850G is of automatic type in that it adjusts
itself to apply a constant tensioning force to
i f a r 7 j ~ o n ~ 0 ~ 1 f i e . ~ e i s f 0 ~ t w d r t ~ h e I e, . ~ ~ s r lthe
1 o ~chain
~
by compensating for the stretch of
the chain.
In operation. its spring-loaded pushrod keeps
OIF pushing the timing chain. As the chain
stretches. it yields to this push and rcmnins in
tensioned state. Once the ad.i~iusteris set after
installation, there is no need of making any
adfustment.
The pushrod is prevented from backing away.
By this feature, the pushrod effectively
contends with the tendency of the timing chain
to shake or vibrate during rough driving
condition.
F ~ R7-82
.
Valve spring free length

INNER

OUTER

35.3-37.0 rnm
( I .3q- I .4h in)
(1.69-1.70

33.9 mm
II.2.3 in)

in)
Purh n!d

Valve spring tension

Sprlnp

l ~ x - k ccretr

F.

Hanrltc
tuck shafi

h.

Slccl bnll

REASSEMBLING
I . Apply a hish quality molybdenum
disulfide lubricant (SUZUKI MOLY
BASTE: 99000-25140) to the puskrod and
engine .oil to the pushrod guide l~ale.
Match the lock screw to the long groove in
ihe pushrod, as shown, and insert the
pushrod by pushing it to the indicated
position.
Fig. 7-88

4. Apply engine oil l o the lock shaft. Insert


the shaft into the holder and bring the two
into the relative PO!
iicated.

Fig. 7-89
5. I-Iook the spring onto the holder and
handle, twist the spring by one complete
rotation counterclockwise, and Tit !he
handle onto the shaft.
I

F
2.

/he nushrod back and forth with


Fingers lo see if it moves smoothly as it
shoulcl.
llluYc

Fig. 7-90
6 . After tizhtening the lock shaft nut. install
the lock shaft assembly on the adjuster
body. Be sure to adhere to the following
torque specifications:
I

3. With the pushrod inserted, sun in the lock


screw until its tip bears against [he
p u ~ h r o d .From that positior~of the scre1*I
back i t away by one-quar~errotation.

Lock sIiaft nut tightening torque


I

0.8 - 1.0 kg-rn


(6.0-7.0 16-Ct)

3.1 -3.5 kg-m


Shaft assembly lightcn~ngtorqlle 121,5-,'S,j

REMOVE PISTON
* Place a rag beneath the piston to prevent
parts from falljng into tllc crankcase, and
remove the circlip with pliers.

fir?.

CYLINDER, PISTON AND


RINGS
REMOVAL
REMOVE CYLINDER RLOCK
* After removing cylinder head. firmly grip
the cylinder block at both ends, and lift it
straight up. IF the block does not come off,
lightly tap on the finless portions of the
block with a plaslic mallet to shake the
gasketed joint loose.

7-93
Scribe the cylinder No. on the head of the
piston, and draw out the piston pin with the
special tool li: Place the drawn-out pis ton
pin in the same place as that given the
cylinder No. on the head of the piston.

Piston plin puller

09910-34510

NOTE:
Cylinder wrnoval from crankcase is
made easier hv t h use
~
of f J ~ eqllitlder
disassen~hiirtgtoo/. This 1001 curl be used
on rite c v l i r ~ d hpad
~ r roo.

Cylinder disassembling tool

099 12-34510

In order to remove the piston sing, open the


gap far enough for the entire ring to clear
the piston. then push it off.

Fig. 7-95

INSPECTION
CYLINDER BORE
As illustrated in Fig. 7-96, measure the
cylinder bore diameter at six places.
If any one of the measurements exceeds the
limit. overhaul the cylinder and replace the
piston with an oversize, or replace the
cylinder. If one cylinder is worn to the point
that i t needs to go oversize all cylinder should
SO oversize at the same time. Othemise the
imbalance might cause excess vibration.
CvIinder bore
Standard

Limit

(2,711

PISTQN-CYLINDER CLEARANCE
As a result of the above measurement, if the
piston clearance exceeds the limit shown in the
table below, overhaul the cylinder and use an
oversize piston, or replace both cylinder and

piston.
Standard

hmit

mm
(O.(X)?O-0.1X124
in)

0.120 ni m
tO.IXM7 in)

O.OSO-O.Mfl

PISTON RING-GROOVE CLEARANCE


Using a thickness gauge, measure the side
clearances of the 1st and 2nd rings. If any of
the clearances exceeds the limit. replace
both piston and piston rings.

Fig. 7-96

Piston ring-groove clearance


Piston riny:

Standard
0.020-0.055 rnm
(O.WIR-O.IK)Z?

Limit

0.18 rnm
( 0 . 0 7 1 in)

in)

0.020-O.(XIO mn1
Io.MKM-n.W24 in)

0. 15 m m
(0.0059~ n )

Piston ring groove width


Pirlon ring

Standard

1.21-1.23

mrn (O.M?-Q.O4H in)

1.21-1.23

rnm (0.047-0.048 in)


in)

2.51 -2.53 m m (0.099-0.100

PISTON DMMETER
Using a micrometer. measure the piston
nutside diameter at the place shown in Fig. 798. I f the measurement is less than the Iimit,
replace the piston.

Piston ring thickness


Piston rina

lndard

1.175-

2 nd

1.1 70-,.

I (O.fl463-0.OQh9

in)

, , , , , I (0.0461-0.1)4h9 in1

nit

b8
( L , 7 1 + 4 - 2 . '1SlJ In)

J mm

Thickness gauge

09900-20803

Fig. 7-99

PISTON RJNG FREE END GAP AND


PISTON RING END GAP
Before installing piston rings. measure the
free end gap of each ring using vernier
calipers. Next. lit the ring in the cylinder.
and measure each rins enti gap using a
thickness pauge.
Tf any ring has a n excess end gap. replace

Oversize piston rings


The following two types of oversize piston
rings are used. They bear the foIlowing
identification numbers.

1.0 mrn

NIL

NIL

the ring.

Oversize oil rings


The following ovcs sizc piston ring sets
are available.

Piston ring free end gap


Piston ring

Limi~

Slanrlartl

'.? nim
(0.2H in)

0.5 mm over size

PISTON PTN-PIN BORE CLEARANCE


Using a caliper gauge, measlire the piston pin
bore inside diameter. and using a micrometer.
measure the piston pin outside diameter. If
the difference between
these t w o
measurements i s more than the piston pin-topin bore clearance limit. repIace both piston
and pis ton pin.
Piston pin-Pin bore clearance
Piston ring end gap
-

P Iton
~ ring

Standard

Limit

1st & 2nd

0.1-0.3 rnm
(0.NM-0.012 in)

0.7 mrn
(0.03 in)

Thickness gauge

09900-20803

Piston pin bore I.D.


Standard

16.002-16.008 m m (0,630-0.6302 in)

ENGINE
Using a micrometer, measure the piston pin
outside diameter.

Connecting rod small end bore-Piston pin


clearance

Piston pin O.D.


Standard
15.995- 1 6 . 0 0 m m (0.6297-0.6300 in)

* If the difference between the connecting rod


small end bore inside diameter and the
piston pin outside diameter exceeds the
ahovemen tioned Iimi t, replace both connecting rod and piston pin.

INSTALLATION
* Mount the piston ring

in the order of oil


ring, 2nd ring and top ring.
* Three rings should be mounted to the
groove of the oil ring. First, mount the
spacer OI . Then. mount the side rails GJ to
the upper and lower portions of the spacer

0.
NOTES:

*
CONNECTING ROD SMALL END BORE
I.D.
Using a caliper gauge, measure the connecting rod small end diameter.

Mounting should he carried otit as


explained above since the ring g r o o v ~
is so construcred that rlne spacer ma.v
not b4 inserted if the side rail.7 are
rnountedfirst.
Be sure to remove the carhoti I P ~ Iin
the ring groove before mounting the
pision ring.

Connecting rod small end bore 1.D.


Standard
16,006-16.014

mrn (0.6302-0.6305 in)

Fig. 7-105

ENGINE
Then. mount 2nd ring and the top ring to
the piston. Note the follo\ving before
mounting them.
* The letter "R" is stamped on the
respective end surface of 2nd ring and
the top ring. Mount them with the
stamped end surfaces turned upward.

How to discriminate top ring and 2nd


ring. Top ring and middle (2nd) ring
differ according to the shape of ring face.
In addition the face of top ring is
chrotne-plated whereas that of 2nd ring
is not. The color of 2nd ring appears
darker than that of the tap one.

Piston should he n~ountedto the connecting


rod in the following manner
Before mounting the piston, be sure to
remove tthc carbon left on the upper part of
the piston using a soft metal scraper.
Coat the piston pin with engine oil. and
insert the piston pin into the piston by
pushing it by hand. directing the arrow
mark on the top of the piston totvards the
exhaust side.

Place a rag beneat11 the piston. and install


the circlip,
Replace the circlip by a new one. Once
removed, the circlip becomes misshapen
and loses its tension. I t should always be
replaced.
The circlip should be installed in such n
position
that the mating ends of the
circlip do not coincide with the groove
portion of the piston.

Before putting on the cylinder. oil the big


and small ends of cnch connecting sod and
also the sliding surface of each piston.
Check that the "0'"rings 3' and (2) arc
accurately positioned in the groove.

Fig. 7- i 10

ENGINE

POSlTIOTVlNG OF RING GAPS


Position thc gaps of thc thrce rings ns
~ h n i v n .Before inserting each piston into the
cylinder. check that the gap5 arc co l o c ~ t c d .

LOWER END
GENERATOR STATOR
REMOVAL
Remove nvo bolts and starter motor coves.
Place oil pan under generator cover and

remove screw to remove generator cover


and gasket.

IN.

Set tlic ring gaps as shown in Fig. 7-1 12 on


No. 2 and No. 3 pixtons. and then install
picton ring cnnipressor (~pecialtool) in the
manner indicnterl. Some light resistance
must he nvvcrcome to Io~ver the cylinder
block.
With No.2 and N0.3 pistons in place, in-

slall No.1 and No.4 pistons and insert lhern


into the cylinder.

Remove three lead wire clamp screws m


and three stator set screws 2 to remove
s ta tot.

NO Ti?:
Do ?lot overti~Jrf~rr
tlte special too/

h n ~ l d sor !he r y l i n d ~ r su ~ i l lnot admit


t l t ~~ l i , ~ t 0 ? 1 ~ .
To F ~ ) ~ L ? { Pt / z ~ ~ * r a ~ ~ A - s f ~/ ~w tf ,If ! ,~ I Z P
.s/utbk o ~ t tuf ~ I Z P~~(~tr~s/tuj?-cir(~itt
~ ~ i t h
o>rr? I~nrrrlrrrrc/ trtsrr the ~ h u firr
t nor~~~ul
n t t ~ ~ ~ i dirt~rtio~r
trfi
wit11 / h ( ~o t h ~ hutrd.
r
rrsirl~( I IQ-rnrn \tlrrr~rh.

ENGINE
Instat1 the proper rotor remover attachmcnt
@I and the slide hammer assembly into the
shaft and remove rotor while sliding the
remover.
-

INSTALLATION
Apply THREAD LOCK "1342"

(99000
32050) to the stator and lead wire set
screws and tighten them securely.

NO TE:
Do not hit the rotor with a hammer.

Wipe off oil artd grease on screw corn-

Rotor remover set:

Mount the lead wire clamp as shown in the


photo.
RepIace gasket with new one to prevent oil
leakage, and tighten generator cover screw.

09930-30102

*4 ~ & &

4,

Tg, 7-118

Remove roller R , spring r2: and push piece


@ from starter clutch.

GENERATOR ROTOR
REMOVAL

The generator cover is renloved in the same


manner as lor the stator.
Securely fix the rotor with the flywheeI
holder (1) and remove the rotor bolt by
turning it counterclockwise,
Rotor holder:

Fig. 7-119

09930-44910

Clamp the rotor with a vise taking care not


to damage it and separate starter clutch
from the rotor using the T type hexagonal
wrench O .

"T type hexagonal wrench:

-*.,

Fig. 7-120

09914-25811

ENGINE

INSTALLATION

CONTACT BREAKER POINTS

Installation is carried out in the reverse


order of removal.
* Apply THREAD LOCK SUPER "13338"
(99000-3 2020) to Allen bolt.
Thick copper washer
i s mounted with its
notch directed towards crankshaft.

REMOVAL
Remove points cover and gasket.
Remove the mounting screws and points.

Fig. 7- I23

Loosen lead wire mounting n u t and remove


condenser and ignition coil lead wires from
the points.

* Clean the tapered portion of the rotor and

also tlie crankshaft. Use cleaning soIvent to


wipe off oil or grease so t h a t the surfaces
hecome completely dry.
After mounting the rotor, secure it by
tightening the center bolt to the specified
torq u c valuc with applying thread lock
super "1303".

99000-32030

Thread Iock sllper " 1 303"

Uol t tightening
torque:
j>

Fig. 7- 124

9.0- 10.0 kg-rn


IG5.0-72.5 Ib-ftl

Y\\Y
\

6.\A ,,1S
2' L
-.- x V
*

-.

;I

i 7 -

..

t
;,

Installation is carried out in the reverse


order of removal.
The condenser and ignition coil lead wires
are mounted on the outer side of insulated
washer.

CONDENSER
REMOVAL

* Remove point cover and gasket.

*
Fi,c. 7- I22

Replace gasket by new one to prevent oil


leakage.

Remove condenser mounting screws and


then condenser from contact breaker.

ENGINE

I/

Fig. 7-127

INSTALLATION
Installation i s carriea our in tne reverse
order of removal.
Condenser lead wire is mounted on the
outer side of the insulated washer.

AUTOMATIC ADVANCER FOR


CONTACT BREAKER

INSTALLATION
Installation is carried out in the reverse
order of removal.
* Make sure to fit the slot on the back surface
of the automatic advancer over the locating
pin a t the end of crankshaft and the groove
of the crankshaft turning nut.

REMOVAL
Remove points cover and gasket.
Use a wrench to hold the crank hirning nut
while removing automatic advancer
mounting bolt.

Fig. 7-128
Adjust ignition timing (see page 3-9).

Fig. 7-126
Remove mounting- screws L U I C U I I L ~ L L
breaker assembIy and then remove the
assembly and the automatic advancer.

DISMANTLmG OF AUTOMATIC
ADVANCER
Extract cam from the automatic advancer
body and wipe off dirt, etc., completely
from the cam.

ENGINE
ASSEMBLY
WIlerl installing the cam, the notch ii; on
the end face of the catn is aligned with
the notch '2? of the automatic advancer

REMOVAL
Remove the cam lever bolts for clutch cablt
and clutch cover screw.

Tightening torque

Fig. 7-132

Remove clutch cover and gasket.


Remove clutch spring mounting bolts and
remove spring and pressure plate.

Fig. 7-130

CLUTCH
'

..

Remove clutch release rack 0,needlt


bearing (2, and washer @? from pressurt
plate.
t
' ' 4 ~ -

>',

1 . Primary rlrivcn,qcar assy

2 , lVnrlier
3. Spaccr
4 . I3c;irinp

5 . Slcpve 111111
6. Nut
7. Lock w:~sttcr
8. Wnslicr
9. Ilrivc plnrc
10. Driven pl;ilv
1 1 . Prcsqurr plaie
12. Sprinp
13. Rnlt
14. Waslrcr
15. Oil pwnp drivc Fenr
L

<.-

16.
17.
I 8.
19,

Spaccr
tkaring
Clii tcI1 rclcesc rack
1 7 1 n i s t henrinc

20.
3 1.
12.
23.
24.
25,

Wslar

26.
27.
18.
19.
30.

Clutch rclcasc' ijrm

Ctu tell rcleasc pinion


011 seal
\Ifacl~cr
Oil sen1

llcnrin~
Roll
\V;IVC rv:~cltcrwat
1Ysvv mnshcr
Slnppcr rine

Fig. 7-I34

After removal of several clutch driven and


drive plates, firmly secure clutch sleeve hub
to remove mounting n u t with special tool

0.
Fig. 7- 131

Clutch sleeve hub holder:

INSPECTION

DRIVE PLATE THICKNESS


Measure the thickness of each drive plate with
vernier calipers. Replace drive plates found to
have worn down to the limit.
Drive plate thickness
2.4 rnm
(0.094in)

2.7-2.9 m m
(0.106-0.1 14 in)

Remove washer, sleeve hub and the


remaining plates.
Screw 11v5.a 6 m m screws into the primary
driven gear spacer ant1 pull the spacer out.
With the spacer removed. the primary
driven gear (integral with the clutch
houqing) i s free to disengage From the
primary drive gear.

Fig. 7- 138

CLUTCH PLATE DISTORTION


Check driven plate for distortion by placing it
on a surface plate and by inserting a thickness
gauge under the clutch plate at several places.
The distortion limit is as follows:

Driven plate distortion


Scrvicc Limit
Fig. 7-136

* Grip the driven plate with pliers and


remove the piano wire ctip. Next, pull out

the driven plate, spring and spring seat


from the clutch sleeve hub.

Fig. 7-137

7-36

0. I

mill

(0.004 in)

Be sure to replace any plates exceeding this


limit.

ENGINE

INSTALLATION

DRIVE PLATE CLAW WIDTH


Using vernier calipers, measure the drive plate
claw width. If it measures less than the limit,
replace the drive plate.

Fit the projection of oil pump drive gear


into the notch df primary driven gear and
confirm both pasts fit snugly while rotating
primary driven gear left and right.

Fig. 7-141
Fig. 7- I44

Drive plate claw width


11.0 rnm
(0.43 in)

(0.46-0.47 in)

CLUTCH SPRING FREE LENGTH


Measure the free length of each coil spring
with vernier calipers and compare the elastic
strength of each with the specified limit.
Replace any spring not within the limit.
Clutch spring free length

Standard
40.4 mrn
(1.59 in)

Limit
38.8 rnm

(1.53 in)

ENGINE
After installing the oil pump drive gear and
primary driven gear, apply engine oil to
needle bearing and spacer to assemble the
needle bearing and the spacer in the
prescribed order.
Assemble the primary driven gear and then
thrust washer must bc installed wit11 the
grooved side facing in.

F i ~ 7-14-7
.

After tightening the clutch sleeve hub nut,


be sure to lock the nut by firmly bending
the tongue of the washer. Tightening torque
for the nut is specified.
Clutch sleeve hub ntit
tightening torque:

5.0-7.0 kg-m
(36.0-50.5 Ib-ft)

CORRECT

* Insert clutch driven plate

ant1 drive

plate

one hv one into sleeve hub in the prescribed


crrder. Insert clutch rclease rack, hearing
and thrust washer into pressure plate.
making sure that Ihc thrust washer is
between thc b e a r i ~ ~and
g the prcssurc plate,
then f i t pressure platc into sleeve huh.
Tighten clutch spring bolts in the order
shown in the photo.
a

Install rhe spring seat, qpring and driven


plate in the clutch sleeve hub. Check that
these three parts arc positioned correctly as
illustrated below.
While llolding the driven plarc wirh pliers,
install I hc piano wire clip.
NOTE:
A I k v q r tise a neltl piano ~ v i r eclip.

NO TE:
Tighten the clutcJ~sprirrg spr bolls in ihe
manner irirliwted, tigh terlilrg them bv
degwes rirlfil they art ail^ a srrr$krnr

tightness.
Clutch spring bolt
tightening torque:

1.1-1.3 kp-m
(8.0-9.5 11)-ft)

Fig. 7-149

* Replace clutch cover gasket with new one to


prevent oil leakage.
Engage the teeth of clutch release rack with
those of pinion gear at the clutch cover side
and replace clutch cover. Make sure that
the rack and pinion gear engage positjvely.
T o install cover, tap lightly with plastic
hammer and tighten screws.

e
---

- -

SECONDARY BEVEL
GEAR ASSEMBLY
SECONDARY DRIVE GEAR
ASSEMBLY
REMOVAL, AND DISASSEMBLY
Remove the secondan unit cover: remove
drain plug and drain oil: into a pan.
Remove the four mounting bolts and
remove the secondary drive gear housing
from the crankcase.

Fig. 7- 150

t . Secondary drive gear


7. rear in^

3.
4.
5.
6.
7.
8.

Shim
Nut
Drive pear housing
Plug
0r ~ n ~
Bolt

9. Shim

Using a drift, knock the plug 6


1 out of the
housing
Straighten the bent area of the nut. Use
special tool 13to lock the drive gear. and
special tool 3 to remove the nut. (Fig. 7-

1 ~ e c o n d a qdrive

bevel mar holder

@ ( 4 1 mrn sockel wrench

Fig. 7-152

04924-545 11

09910-23710

1
1

Tap the drive gear with a plastic hammer to


remove it from the housing. (Fig. 7- I 54).

INSPECTION AND REASSEMBLY


NOTE:
Refire reas.~emblv, ck~an nlf ports

ill

It will he helpful to have a seledion of alf


shims ort har~dhefore h p g i n t ~ i nheasitiff
~
preload adjustment.
Use special tool O to install the outer
bearing races into the drive sear housing.
(Fig. 7-156)

Remove the shims from the drive gear


shaft. Do not discard.
Use special tool '3, to remove the inner
bearing race from drive gear. (Fig. 7- 1 54)
Bearing inner race
remover:

Bearing instalIer set:

09924-84510

W941-84510

Use special tool 2;, to install the inner


hearing race on the drive gear shaft. (Fig. 7t 57)
Bearing instailer:

and 6: to remove the


Use special tools
hearing ov ter races from the housing. (Fig.
7- 15 5 )
!4;#
5

Bearing outer race remover


Bearing inrtaller

09Wl-,W~11
09913-84-510

09913-84510

7
CA U TI ON:
If wplrruitrg the sccoucjant drive gear. h~
sztrr to seplucr s ~ c o r ~ ddrivep~
~ y wur
also, as tlrqv micst be r ~ p l a c e dtogether.

ENGINE
Install all the shims, removed during
disassembly. on the drive gear shaft. (Fig.

BEARING PRELOAD ADJUSTMENT


* After tightening the nut to specification
rotate the drive gear several turns in both
directions to seat the bearings.
Use special tools
through 'dl to measure
the torque necessary to turn the gear. Thi!
is the bearing preload. (Fig. 7-1 59)

Preload:

3-5 kg-crn
(2.60-4.35 lb-in)

Install the drive gear into the housing and


install the other inner bearing race and nut.
Oil the bearings with Hypoid gear oil.
Use special: tool 3 to lock the gear, and
special tool 4? to tighten nut to
specifics tion.
'2:

Seconrlau drive

(4)

41 m m socket u

holder

09924-545 1

09910-23710

If the bearing preIoad is not within


specification, the shims between the bearings
must he changed. Refer to the chart below and
make appropriate adjustments. repeating the
preload checking procedure as necessary.

NO TE:
Each rime the p r ~ f o a dis checked after a
shim chatzge. the gear must be rotated in
both directions to sear the hearings after
the rrut is retorqued fo specvicarion.

NOTE:
AIwqvs l t s a
~ w w nut.

Nut tightening
torque:

12-15 kg-m
(87.0- 108.5 Ib-ft)

Prelwad
Under 3 kg-crn

Adjustment by shim
Decrease shim thickness

3-5 kg-cm
I

(2.60-4.35 Ib-in)

Over 5 kg-crn

Correct
Increase shim thick-

ness

ENGINE
List of shims

SECONDARY DRIVEN GEAR


ASSEMBLY
REMOVAL AND DISASSEMBLY
Remove drive unit cover and drain
secondary gear oil into a pan.
Remove the four secondary drivcn gear
housing bolts and remove the assembly
from the crankcase.

7 8

* After the bearing preload has been adjusted


to within specification. remove the drive

gear nut, clean and degrease the threads on


the drive gear shaft, install the nut. and
torque to specification.
Nut tightening torque

12-1 5 kg-rn
(87.0-108.5 ft-lb)

13

1
1

* Bend the collar of the nut over into the

notch in the drive gear shaft.


Press a new plug into the secondary drive
gear housing so that it is 1.5mrn below the
housing shoulder. (Fig. 7-160)

1. Secondary driven gear


2. Renrinp
3. Bearing
4. Spacer
5. Shim
6. Univerul joint flanpc
7. Washer
8. Nut
9. Drivefigear liousin~
10. Oil seal
1 1 . Oring
I ? . Shim
13. Bolt

Fig. 7-161
-

Secure the propeller shaft flange in a vise


and straighten the bent portion of the
driven gear nut. Remove the nut. (Fig. 7162)

The secondary drive gear assembly is now


ready for installation into the crankcase.
For backlash ant-! tooth contact adjustments. see section (7-46).

Fig. 7- 162

ENGINE

* Remove the flange from the driven gear.

Tap the driven gear with a plastic hammer


to remove it from the housing.
To remove the oil seal from the housing. use
special tools T and 2 . (Fig. 7-163)

@-

Benring and oil real remover

W941-64510

-@

Rotor remover shafl set

09930-,30102

INSPECTION AND REASSEMBLY


.

* ,,I

- 3-

-\

(2',

,'

Before reassernb!\), clean all parts


solvent.

ill

NOTE
Remove the spacer and shims from the
driven gear shaft. Do not discard them.
* Use special tool 3' to remove the inner
hearing race from the driven gear. (Fig. 7 164)
Bearing inner race

It will he helpful to Jtave a selectio?l of all


shims a~gailahle for hearing preload

Use special tool @ to install the outer


bearing races into the secondary driven gear
housing. (Fig. 7-1 66)

W941-84510
Bearing installer
set:

09924-84510

Fig. 7-164

Fig. 7- I66
Use special tool I& to remove Ihe outer
hearing races from the housing. (Fig. 7165)
Bearing outer race
remover:

0994 1-,M9 11

to install the inner


Use special tool
bearing race onto the driven gear. (Fig. 7-

167)

CA UTTON:
If replacing the s ~ c o ~ r d aclrjvm
nf
Rear,
h~ suw also to replacr. flte secondary
drill, gear, as ihqr~ musf h~ r e p l r c ~ d
togetJter.

ENGINE

Drive pinion race


instalIer:

09913-80112

Fig. 7-168

Fig. 7-167

4.0-7.0 kg-crn
(3.45-6.0s lb-in)

Preload:

Install the spacer and shims, removed


during disa5sernbly. onto the driven gear
shaft.
Lubricate the bearings with Hypoid gear oil
and install the secondary driven gear and
bearings into the housing.

* I f the bearing preload is

not within
specification, the shims between the
bearings must be changed. Refer to the
chart below to make appropriate adjustments, repeating thc preload checking
procedure as necessaq.

NOTE:
No oil seal is insra/ti%i ar i/lis poittt. Oil
.real i.9 irtstallr.d aftrr hcaarirlr pwlnad is
Correct.

Install the propeller shaft flange, washer.


and nut on the driven gear. and tighten the
nut to specification.

E ~ c i trime I / E E PTPIT)CICI ix c l ~ ~ r after


k ~ da
shim clronge, / I I E p a r rnlrst hp rotatpd irr
hoth disecriorrs ro seat tJlr hearings after
rhe trrtt i s rrrorqrted to spacific-urinn.
Preloacl
4-7 kg-cm
(3.45-6.05 Ih-in)

Nut tightening torque:

9.0- 1 1.0 ken1


(65.0-79.5 Ib-ft)

REARING PRELOAD ADJUSTMENT


* After the nut is tightened to specificat~on,
turn the gear several turns in both directions to seat the bearings.
Use special tools :Tj and 128 and a socket to
measure the torque necessary to turn the
gear. This i s the bearing preload. (Fig. 7168)

a Torque wrench 0-15


@ Adapter

kg-rm

099131)-21107

socket 12.7x6.3 rnm

09915-24550

List of shims

correct

ENGINE
After the bearing preload has been adjusted
to within specifics tion, remove the driven
gear nut. washer. and propeller shaft
flange.
Install a new oil seal into the secondary
driven gear housing, making it flush with
housing shoulder.
* Clean and degease the driven gear shaft
threads, apply a small amount of SUZUKI
THREAD LOCK SUPER "136 1 A" to the
threads, and install the propeller shaft
flange, washer, and nut.
Tighten the nut to specification.

Fig. 7- 169

SWZUKI THREAD LOCK


SUPER "1 333B"
99000-32020
Nut Tightening
Torque

9.0-1 1.0 kg-rn


(65.0-79.5 it-lb)

Bend the collar of the nut over into the


notch in the driven gear shaft.
The secondary driven gear assembly is nowf
ready for installation into the crankcase for
backlash and tooth contact adjustments see
section (7-46).

SECONDARY GEAR SET


CLEARANCING OPERATIONS
RACKLASH
Install the housing 5hirns removed during
disassemldy anto secondary drive genr
housing and secondary driven gear housing.

Attach a dial gauge as shown to the


secondary driven genr flange and measure
the backlash by turning the flange in each
direction until it stops. (Fig. 7-171)
Secondary Driven
Gear Backlnsl~

0.08-0.13 mm
(0.003-0.005 in)

NOTE:

No o-rings arp rrs~dat this stage.


TnstaII drive and driven gear housing into
crankcase and tighten four bolts on each to
specification. (Fig. 7-169. 7-170)
CA U TION:
Srlcondaq) drive and driven gear
kottsirtgs r n t ~ s t he i?zsialSed with letrers
"trp "facing ~Ipwardas s I r o w ~in~ Fig. 7169, 7-1 70.

5 kg-m

Bolt tightening
tntque:

j.0 Ib-ft)

If the backlash is not within specification.


the shim between the seconday driven gear
housing and crankcase must be changed
and the backlash rechecked until carrect.
Refer lo the tahle below for appropriate
changes.

ENGINE
Blac klash

Shim adjust ment


Increase shim thick-

Under 0.08 mm

ness

0.08-0.13 rnm
(0.003 1 -0.005 I in)

Correct
Dccrcase shim thick-

Over 0.13 m m

ness

List of Shims
Part No.

Shin1 thickness

24945-45100
2494

0.35 mrn
0

24945-45 103

0.3~mm

24945-45 104

0.60 mm

TOOTH CONTACT CHECKING

After bringing the backlash within


spccifica tion by changing the shi rn between
the secondary driven gear housing ancl
crankcase. i t will he necessary to check
tooth contact.
Remove the four holts and remove the
secondary driven gear housing from the
crankcase.
Clean and degrease the seconday driven
gear teeth, and apply n coating of
machinist's layout dye or paste to several

Fig, 7-1 73
I

wcondar?, driven pear


correct shim. into the
and torque the bolts to

--

NOTE: No o-rirrg is used ai f1li.s stage.

CONTACT A T TOOTH TOP

teeth
Reinstall the
housing, with

crankcase.
specifica t"ion.

Shift the engine gearbox into 1st gear to


provide load. and turn thc secondary driven
gear flange several turns in bath directions.
Remove the secondary driven gear housing
from the crankcase. and observe the tooth
contact pattern made in the dye or paste.
Compare the tooth contact pattern to the
examples in Figs, 7-172, 7-173,7-174.

CONTACT

AT TOOTH ROOI'

Fig. 7-174
If tooth contact is found to be correct. go
the Final As.iembly sub-section, ant!
complete.
If tooth contact is found to he incnrrect. the
shin1 between the secondary drive gear
housing a n d crankcase must he changed,
and tooth contact rechecked, until correct.
Tooth contact
Contact at tooth top

Contact at tooth roof

Shim tllickness
Decrease shim thick-

Increase shim thickness

ENGINE
List of shims
Part No.
249

Shim thickness

0.35 m m

249

0.40 mrn

24935.45103

0.45 rnm

24935-45 104

0.50 mm

CA IJTIOIV:
A , f m IIZP frnorlt cor~tucr adiristrnent is
rnodu, IJIP hacklush mlrsi be sech~cked,
a s it ,nay r h a r z ~ Rcft~r
~.
to the hacklash
c - I I P c ~ ~ /sI~~~ I ~ s ( ~ c t (i oI ?Iz ,readjust
~
until
hot11 i~acklns11rrrrd ~ n o t h contacf arc

Fill the gear cavitv to specified capacity.


340-400 ml (11.5-13.5 US 071 with
Hypoid gear oil.
Reinstall swing arm with propeller shalt
and rear wheel see section (11-39 and 1 1-43)
Keimtall secondary drive gear outer cover.

cnrrecl.

FINAL ASSEMBLY
After hot11 gear backlash and tooth contact
arc correct. remwe the seconday drive
gcar housing and secondavj driven zear
llousing from the crankcase.
Clean off nnv machinist's dye or past from
the gear teetl~.and lubricate the teeth with
Hypoid gear oil.
Install new O-rings on the secondary drive
and driven gear housings. Lightly grease

EXTERNAL MECHANISM
FOR GEAR SHIFT
REMOVAL
Remove gear shift lever.
Remove clutch cover and primary driven

gear (see page 7-35).


Extract gear shift shaft from crankcase.

INSTALLATION
InstafIation is carried out in the reverse
order of removal.
Install the gearshift shafts, with the center
of the gear on shaft side aligned the center
of gearshift cam driven gear.

tlie O-rings.

Install Ihc secondary drive and driven gear


Ilou5ings in to the crankcase.

NOTE:
Sr~ct>rrriny d r i v ~ and driven gear
h o ~ r s i t ~nwrsi
~ . ~ he irrsralied with the
f(~rters"UP"focirtg n~pward,as shown in
F i ~ s 7-169,
.
7-1 70.

Use SUZWKI

THREAD LOCK " 1342" on

Fig. 7

the threads of the housing bolts, and torque to specifics tion.


I

Thrc
-

"'1 342"

Bolt I lgnrenlng
Torque

99000-32050

2.0-2.6 kg-m
( 1 4.5-1 9.0 lb-ft)

Reinstall secondary gear drain plug and


torque to specification.

Drain Plug Torque

2.0-3.0 kg-rn
(14.5-21.5 lb-ft)

Install clutch driven gear and clutch cover.


Replace gasket with a new one to prevent
oil leakage.

ENGINE LUBRICATION
SYSTEM

om PUMP
REMOVAL
Remove clutch cover and primary driven
gear (see page 7-35) .
Remove oil pump drive gear, needle
bearing and spacer.
Remove the circlip of oil pump gear and
then the gear.
Remove three oil pump mounting bolts and
remove oil pump body from crankcase.
* Remove one screw fastening oil pump body
and ex tract pin securing the lower case and
the upper case.

r
Fig. 7-177

-r
,2

7\
s

ENGINE
INSPECTION
OUTER R O T O R CLEARANCE I N THE
BODY
Use a thickness gauge,
Outer rotor clearance
Service Limit

0.25 rnm 10.010 in)


I

INSTALLATION

TIP CLEARANCE
This is the clearance between inner rotor and
outer rotor. Use a thickness gauge.

Tip clearance

Service Limit

0.20 rnm (0.008 i n )

Installation is carried out in the reverse


order of removal,
Thoroughly wash the oil pump, inner and
outer rotors and oil pump case with solvent
and apply engine oil to them before inserting them into case.
Since there are no identification marks for
the upper or lower portions of the inner
rotor and outer rotor, the rotor can be
inserted irrespective of these portions.
RepEace circlip with new one.
Apply THREAD LOCK "1 342" (99000320511) to one screw fastening oil pump
body. Wipe off oil completely.

Fig. 7-281

SIDE CLEARANCE
Put a straightedge to Zhe pump and measure
the clearance under the straightedge, as
shown. C Fig. 7- 180)
Side clearance
'I

Service Lirnit

0.1 5 mrn (0.006 in)

ENGINE
Be sure to place two ''0" rings, mounted on
t h e crankcase side. into "0" ring groove.
I t is advisable to apply grease to "O" ring
to prevent it from falling off.

Apply TI-IREAD LOCK " 1363C" 199 111432050)to three screws and secure oil pump
body (wipe oil off completely).
At this time make sure that oil pump gear
rotates srnoathly.

Fig. 7-183
Reinstall primary driven gear, c l u ~ c h ,

clutch cover, etc.

OIL PUMP PRESSURE TEST

Start $he engine and check i f the oil pump


pressure indicator light is turned on. I f i t
keep$ on Lighting, check the oil pump
pressure indicator tight circuit. E f i t is i n good
condition, check t h e oil p u m p pressurc i n [he
ToIlowing manner:
Install the oil pressure gauge ri'. in rlic
position shown in thc figure.
* W a r m up [he engine as f o ! l o w ~
Summer 10 min. or so at 2 000 r/min
Winter 20 min. or so at 2 000 r/rnin
* After warming up operation, increase the
engine speed to 3 000 r/min, and read the
oi S pressure gauge.
The oil p u m p pressure i s specified below:

Above 0.1 kgJcm2 ( 1 A psr), Relow 0.5


kg/cmz (7.1 p s ~ a) t 3 000 rlmin

09915-74510

If the pressure is too low, it means that the oil


pump is internally warn or otherwise defective
and needs to be overhauled. I f inner parts are
found to be worn down to or beyond the limit,
replace the complete. oil pump unit.

OIL FILTER
REMOVAL
Replace the oil filter with a new one in the
follnwing manner.
* Place an oil pan under the engine.
Remove three nuts
securing the Filter
cap 2 ; .
Take off the cap '2'8, pull out the old
element.

ENGINE

Fig. 7- 18~v
* Remove three screws and then sump filter.

INSTALLATION
Oil filter installation
This package contains a rubber seal ring in
addition to the oil filter. When replacing
the oil filter. be sure to also replace the seal
ring to ensure oil-tightness.
In fitting the real ring to the filter chamber
cap. lightly apply grease on the seal ring
groove to avoid any chance of dropping or

rnislacating the ring during thc installation


work.

Fig. 7-189

INSTALLATION
Thorclughlp wash the sump filter with
solvent and fasten it with three screws.

1.

Filter chamber Cap

2. Rr~btwrscnl ring

Put on the cap [T and secure it tightly


Install ail drain plug.

i , i p . 7-190

SUMP FILTER
REMOVAL
Remove screws of oil pan 7? and remove
the oil pan from crankcase.

Install oil pan and tighten screws.


Replace gasket with a new one to prevent
oil leakage.
Tightening torque:

0.6-0.9 kg-rn
(4.5-6.5 Ib-ft)

Potrr ahnut 3.6 L (3.8 US qt) ofeng.ine oil


irjtn oil pan on!v whrr~changitrg oil attd
replacing oilfilter at the same time.

ENGINE

CRANKCASE
REMOVAL
w

Remove two bolts, and lightly hammer the


head of starter motor gear with plastic
hammer to remove starter motor.

Fig. 7-191

Remove the secondary drive bevel gear


assembly from the crankcase. (See page 739).
Remove the secondary driven bevel gear
assembly from the crankcase. (See page 742).
Gear shift cam guide screw Ci)
. . . . . . . . . . . 2 pcs. (overall length 12 mm)
Gear shift pawl screw @
. . . . . . . . . . - 2 pcs. (overall length 12 m m )
Counter shaft B/g retainer screw
. . . . . . . . . . . 3 pcs. (overarl length 16 m m )
Drive shaft plate screw
. . . . . . . . . . . 4 pcs. (overall length 16 mm)
3il pump gallev plate screu
. . . . . . . . . . . 3 pcs. (overall length 16 m m )

Pull out the spring guide (i! mounted on


the kick starter shaft, and remove the
spring O

Fig. 7-194

* Remove the gear shifting shaft and then


cam driven gear shifting pawls No.1 and

Fig. 7-192

* Remove two bolts and then oil seal holder.


* Remove two screws and then gear shifting
switch body.

No,2.
Remove oil pump (See page 7-48).
Remove upper crankcase tightening bolts.
6 mrn boIt. . . . . . . . . . . . . . . . . . . . 12 pcs.
8 mmbolr.. .................. 4pcs.

\
&-@

T? li

0o.m
I. Gear shining swltch

I . Sumrlchcontact
3. Sprinp
4.

"0"ring

Fig. 7-195

ENGINE

Next turn engine upside down to remove oil


pan from lower crankcase (see page 7-5 1) .
After removal of oil pan, remove lower
crankcase tightening bolts.
6 m m bolt. . . . . . . . . . . . . . . . . . . . 11 pcs.
8 rnrn bolt. ................... 13 pcs.

Remove cam stopper holder to remove cam


stopper and spring.

Fig. 7-196

Make sure that bolts are removed. Lightly


hammer the lower crankcase side with a
plastic hammer lo separate the upper and
lower crankcase halves and then lift the
latter,
Remove the crankshaft sub-assembly,
counter shaft gear and drive shaft gear
which are all mounted on the upper crank
case.
At [his time be careful not to drop "C"
rings and the like.

Fig. 7-197

Hold gear shifting forks by hand to extract


gear shifting fork shafts from the lower
crankcase.

Fi8. 7-199
Fxtract gear shifting cam to the right side.

ENGINE

CRAMSEZAlT
INSPECTION
Big end side clearance
Measure the big end side clearance of the
connecting rod with a thickness gauge as
shown. Replace the crankshaft if the clearance
exceeds the limit.

Crankshaft runout
Support the crankshaft with "V"' blocks as
shown. with the two end bearings resting on
the blocks. Rig up the dial gauge, as shown,
and rotate the crankshaft slowly to read the
runout.
RepIace the crankshaft if ~thr:runout is greater
than the limit.

Big end side clearance

Crankshaft runout

Standard

26 in)

Thickness gauge:

Service Limit
1

in)

09900-20803

Fig. 7-202

Connecting rod big end wear


Support the crankshaft at both ends with Vblocks, and measure the amount of wear on
the connecting rod big end. If worn more than
specification, replace the crankshaft.

Connecting rod big end wear


Service Limit

Fig. 7-20]

0.08 m m (0.003 in)

0.05 rnm 10.002 in)

ENGINE
INSTALLATION

TRANSMISSION
*

Counter shaft gear assembly

NOTE:
* Before install in^ the shafts arid gears,
wash them in a cleaning solvent.
Before mounting the gears on the
outer shaft, apply the engine oil to rhe
gear bore.
For gear installation, refer to Fig. 7-203.
(Be sure that the gears and spacers are
correctly mounted facing in the correct
direction.)
Always use new circlips.
Align the oil hole in the spacer GO with that
in the outer counter shaft, and mount the
spacer on the shaft.
1, Inner counterrhsft
2. Outer cnunter~haft
3. 2nd drive gear
5. 5th drive

ear

16. Oil seat


17. Output cam dog
18. 011 seal

21). Input cam dog

8. Lock washer
9. 3rd drive Rear

Fig. 7-203

REMOVAL
Remove the bearing and spacer, compress
the spring with the special tool 0 ,and
remove two stoppers @

Dog cam stopper


set tool:

rn
Fig. 7-204

Install the locating washes to the spacer


dogs.
Take special care so that the circlip is
correctly installed, fit i t to the side where
the thrust is as shown in the figure.

0992444s 1 1

Fig. 7-206

ENGINE
Spline the 3rd drive gear to the outer shaft
so that the oil hoIe in the shift fork groove
is aligned with the oil hole in the outer
shaft.

NOTE:
Mounr the 2nd drive gear on the outer
counter shaft, appfy SUZUKI MOLY
PASTE (99000-25240) to both surfaces of the washer sparin&,
and
install the washer.

Fig. 7-207

Before mounting the 5th drive gear on the


outer shaft. align the oil hole in the spacer
O with that in the outer shaft.
I
S W Z W MOL Y
PASTE (99000-251401 to the area of
t h otrter
~
coulrter shaft bore, 20 to .7(1
mm (0.8 - 1.2 in) fkom each end of
the shaft. Oil bearing stirfaces on
Sparingly

inner counfershafi.
Now install inner shaft inlo outer shaft.

*
a

When installing the 5th drive gear spacer


on the outer shaft, he sure that the spacer
faces in the correct direction.

Fig. 7-209

Mount the output cam dog on the outer


counter shaft.
Align the cut on the cam dog with the oil
hole in the counter shaft.

.,

Next. apply SUZUKI MOLY PASTE


(99000-25140)to the splines of the input
cam dog. and mount it on the inner count
shaft.

Mount the spring, spring guide, and sliding


stopper on t h e inner counter shaft, and
compress the spring with the special tool 03,
and install the hvo stoppers.
1

Dog cam stopper


set tool:

INSTALLATION
* See the above drawing with respect to the
assembly of each gear (pay attention to the
gear's direction).
Always use new circlips.

09924445 1 1

NOTE:
of spacer CO ,
washer I: b , circIip
, 3rd driven gear
I%, lock washer O , and washer (67,.
Order of

mounw

Mount the circlip rii, and washer (Ti3 on


the drive shaft, in that order.
Temporarily position the circlip beyond the
groove.
Align the hole in the spacer @
with
l the
oil hole in the drive shaft, and install the
3rd driven gear.

D W E SHAFT GEAR
ASSEMBLY

* Mount the lock washer B


Ib
I

"

i
19

($:

'
20

1. Circlip

2. Rear~nr
3. \Vasl~er
4 2nd driven pear
5. 5th driven pear
6. Washer
7. Luck wasl~er
8. 3rd drivcn gear
9. Ru5h1ng
10. IV3rlier

and washer
on the drive shaft, in that order, and by
turning the washer in or out, align the lmk
washer tongue with the cut on the washer.

I I. Circlip
I?. 4th driven gear
13. CircLip
14. Washer
15. I st driven g a r
1 6. Drive shaft
17. Washer
18. Bearing
19. Spacer
20. Oil seal

Fig. 7-215
* Fit the circlip in the groove on the drive
shaft, using the special tool m. (Fig. 7-2 B 6)
Snap ring pliers:

0990-06106

ENGINE

ra

F
r

i+ d

IINSPECRON
Shift fork-Groove clearance
* Using a thickness gauge, measure the fork
groove clearance. I f i t exceeds the limit,
check the amount of wear on both gear and
shift fork using vernier calipers, and
replace either one that has greater wear.
Sllift fork..Groove clearance

Take special care so that the circlip is


correctly installed.

Fit i t to the side where the thrust is as


shown in the figure.

Shift fork groove width

Standard:

5.45-5.55 m m
(0.215-0.219 in)

Shift fork thickness


Standard:

There is an oil hole in the shift fork groove


for the 5th driven gear. When installing the
5th driven gear, this oil hole must be
aligned with the oil hole in the drive shaft.
The 5 t h driven gear is subjected to special
surface treatment for better wear resistance
and thus i t is colored black.

4.95-5.05 rnm
(0.195-0.199 in)

ENGINE

NOTES ON INSTALLATION OF
TRANSMISSION GEARS AND
C W K S H A J T IN CRANKCASE

KICK SHAFT

Thoroughly wash the upper crankcase and


the lower crankcase with solvent to remove
any sealing compound.
* Firmly insert crankshaft locating '"pins"
3 , transmission gear locating "C" sings
for bearings on both sides and locating
pin @.

4;--4.

1.
1.
3.
4.
5.
6.

Kick starter levcr


Oil ccal
Bolt
Spnng guide
Spring
Dowel pin
7. Bushing
8. R ~ c krtarter ~ l ~ n f f
9. Kick @,tasterdr~vegear

10. Washer
I I . CircIip
12. Kick vtarter
13. Spr~n_e
14. Starter guide
15. Screw
16. Dowel pin
17. Plate
18. Bushing

Fig. 7-220

* For installation. refer to the illustration

Fig. 7-222
Mount crankshaft and transmission shaft
assemblies on the upper case. A t this time
firrnIy fit the bearing races onto the locating
pins with punch mark stamped on the circumference of the bearings directed upwards.

above.
Align the punch mark on the kick starter
with that on the kick starter shaft, and
install the kick starter.

Punch mark

Fig. 7-223

Use the "C" rings and bearing stopper pins


to position the bearings as shown in the
photo.

Apply engine oil to gear shifting fork and


gear shifting cam,
Insert gear shifting cam into the lower
crankcase. Confirm the neutral position of
gear shifting cam, mount cam stopper,
spring and cam stopper holder and fasten
the cam stopper holder.

Insert gear shifting fork shaft from the right


side and mount gear shifting fork and cam
stopper as shown in the photo.
A t this time, pay attention to the direction
of the gear shifting fork.

O Gear shifting fork for 3rd drive gear.


C? Gear shifting forks for 4th and 5th driven
gears.
9Cam stopper.

Completely wipe off oil on the mating


surface of lower crankcase and apply
sealing compound (SUZUKI BOND NO.
1207B; 991 04-3 1 1401 uniformly to the
mating surface.
D o not forget "0"ring Q

* Place the lower crankcase on the upper


crankcase housing the transmission gears
and crankshaft. Align shift forks into gears.
Fasten together the upper and lower
crankcase halves using the crankcase
fastening bolts.

The lower crankcase fastening bolts must be


tightened securely in the order of the numbers
embossed on the crankcase.
6 m m bolt. . . . . . . . . . . . . . . . . . . . 11 pcs.
8 mrn bolt. . . . . . . . . . . . . . . . . . . . 13 pcs.
Tightening torque tor 8-mm hnlts
1.0 kg-m

7-60

ENGINE

Fig. 7-228
Turn the crankcase over so that the cylinder
studs are up and tighten the upper
.
crankcase bolts.
6 mrn bolt. . . . . . . . . . . . . . . . . . . . 12 pcs.
8mrnbolt. . . . . . . . . . . . . . . . . . . . 4pcs.

N 0 TE:
* When the secondoty bevel Rear is
installed, the offser or the mating
s u d ~ c e s of rhr crankcase halves,
upper altd lower, shozrld be 0.I mrn or

less.
ThoroughJy wipe off arl-v overflow of
the sealing compound applied to the
matirtg surfaces of crankcase before
installing the s e c o a d a ~bevel gear
assern hlies.
Take special carp not to scratch inner
surfaces of the crankcase.
The s h a p ~of each gear s h v f i n g pawl is
different. Motrrrt the otre with the
tzarrower width on t J r ~gear shifting
cam side.

Fig. 7-229

SHAFT DRIVE

SHAFT DRIVE
CONTENTS
FINAL DRI
'EL GEAR ASS
.............................. 8 - 4
FINAL GEAR CASE BREATHER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
REMOVAL AND D
.MBLY ..................................... 8 - 7
INSPECTION AND REASSEMBLY ................................... 8. 9
FINAL DRIVE GEAR PRELOAD ADJUSTMENT ........................ 8. 10
ElNAL DRIVEN GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
FINAL GEAR BEARING COVER SHIM ADJUSTMENT .................. 8-13
BACKLASH MEASUREMI
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
TOOTH CONTACT ADJUS 1 M ~ N ...................................
T
8-14
FINAL ASSEMBLY ................................................
8.15
INSTALLATION OF PROPELLER SHAFT AND
FINAL DRIVE GEAR ASSEM BLY ................................8-16

SHAFT DRIVE

SHAFT DRIVE

SHAFT DRIVE

7.0 kg-cm (3.45 - 6.05 Ih-in.)

Clearance 0.05 - 0. I5 m m
(0.002 - 0.006 in.)

Fig. 8-2

SHAFT DRIVE

Fig. 8-3

SHAFT DRIVE

Part No.

Part No.

Shim thickness

Shim thickness
Shim thickness

27327-45100

0.35 m m

SHAFT DRIVE

FINAL GEAR CASE BREATHER CIRCUR


AJR A N D GEAR OIL FLOW IN FINAL GEAR CASE BREATHER CIRCUIT
Breather circuit
'Stre GS850G final gear case breather circuit
(passage) consists of the final gear case and final
gear bearing case, and airJoil mixed gas flows
through the following routes:
Breather
gear bearing case

Final gear case.

Chamber
(C)

Fig, 8-5

Passage

(R:)

Chamber
(Dl
-

Air passage
When the air pressure in the final gear case becomcs higher than atmospheric pressure both air and
oil flow in the following passages.

Air flows from hole (A) to chamber (B)and passes through the gap between rib (RI)
and bearing case
to the atmosphere through the breather hole IF).

Oil passage
When the finJ gear case pressure rises abruptly or when the gear case oil level changes during cornering,
the gear oil may sometime flows out into the air passage.

In this

case, the gear oil. which

has flown into hole (A), goes into chamber (B), where the oil is

separated from the air.


Then, the air flows through the gap between rib (RI)and bearing case and goes out through the
breather.
On the other hand, the gear oil, when the gear case pressure is higher than atmospheric pressure, flows
through the gaps between ribs, (RI), (Rz)and (R3)and bearing case and returns to the gear case from
gear oil return port (El.

FINAL DRIVE BEVEL GEAR


ASSEMBLY
REMOVAL AND DISASSEMBLY

NOTE:
Re sirre to retain all adjusting shims f o r
reassem hlv.

Place an oil pan under the final drive bevel


gear assembly, remove the drain plug and
drain the oil.
Remove the rear wheel assembly (See page
1 1-39)
Remove three nuts attaching the Final drive
housing to the swing arm, and move the
housing to the rear to detach it from the
swing arm.
Remove ten final gear bearing case bolts.
(Fig. 8-6)

---

Fig. 8-8

Using special tool O , remove the ball


bearing from the driven gear. [Fig. 8-91
Final driven gear bearing
installer and remover

09m-74570

* To remove

the final gear bearing cover


from thc housing, use two 6 rnm screws;
screw them into the holes provided and
draw the cover off evenly. (Fig. 8-7)

Fig. 8-9

Remove the three screws and bearing


retainer, and shims from the final gear
case, {Fig. 8-10)

Fig. 8-7

* Using special tools @ and @ , rernove the


oil seal from the final gear bearing case.
(Fig, 8-8)

SHAFT DRIVE
.*

Remove the final drive gear housing from


the finaI gear case.
Remove the oil seal 6 , cirdig @
,I
propeller shaft coupling @ , and spring O
from the final drive gear coupling. (Fig. 8-

shims and spacer on the final drive gear


shaft. (Fig. 8-13)

11)
@

Snap ring plier

09900-06108

NOTE:
To remove the circfip O , it will be
necessary to push the propeller shaft
coupling. in wards, ro remove spring
pressure from Ihe circfip.

Fig. 8-13

* To

remove the inner bearing race from


gear shaft, use special tool O . (Fig. 8- 14 )

rn

Bearing inner race


remover

09941.84510

r- -

Straighten the bent portion of the final


drive gear nut. Use special toat O to hold
the coupling, and remove the nut. FFis. 812)
Final drive gear
coupling holder

09924-645 I0

Fig. 8-14

To remove the oil seal from the housing,


use special tools O and @ (Fig. 8- 15)

Bearing and oil seal

remover
Rotor remover shaft

* Remove the washer and coupling, and tap


the drive gear shaft with a plastic hammer
to remove it from housing. Do not lose the

Fig. 8-15

0994 1-645 10
Q909430-30102

SHAFT DRIVE

To remove the outer bearing races from the


housing, use special tools Q and @ and a
hammer. (Fig, 8-16)

To remove the final gear case oil seal, use


special tools O and @
(Fig.
I 8-193

Fig. 8-I 9

If replacing the final gear case, remove the


three drive housing studs, and shock
absorber mounting stud.
Fig. 8-16

To remove the two needle roller bearings


from the final gear case, use special tools
and @I
. (Fig.8-17, 8-18)

Bearing and oil


seal remover
Rocor remover shaft

0994 1-645 10

INSPECTION AND REASSEMBLY

NOTE:
Before reassembly, thoroughly clean all

09930-30102

It will be h e l ~ f u llo have a selection of


all shims avoiluble .for clenrancinp
operations.

To install the outer bearing races into the


drive gear housing, use special tool
.
(Fig. 8-20)

Fig. 8-20

* To

install the inner bearing race onto the


final drive gear shaft, use special tool @ .
(Fig. 8-2 1$

SHAFT DRIVE

Nut tightening torque

When replacing the final drive gear,


replaw [he driven gear also, as they
must be replaced t o ~f her.
e
@ Bearing 111stalEer

Final drive gear


coupling holder

9.0-1 1.0 kg-m


(65 .O-79.5 Fb-ft)
09924-645 10

099 13-845 I 0

Fig. 8-2 I

Install the spacer and shims removed from


the old final drive gear on the newheear.
Install gear into housing (Fig. 8-22)

FINAL DRIVE GEAR PRELOAD


ADJUSTMENT
After tightening the final drive gear nut to
specification, measure the bearing preIoad
using special tool O with a 'A" x '/do adapter
Socket. (Fig. 8-24)

NOTE:
Rofate the gear several /urns in both

Preload torque

Install the other inner bearing race, the


washer and final drive gear nut, and
tighten to specification, using special tool

Q Torque wrench

NOTE:
Always use a new nut.

NOTE:

r
Coal /he bearings wifhHypoid pear oil.

NOTE:
No oil seal is insratled at [his point. Oil
seal is installed afier bearing preload is
correct.

4.0-8.0 kg-cm
(3.4--6.9 Ib-in)
09900-21 107

SHAFT DRIVE

I f the preload measured is not correct.


(4.0-8.0kg-cm)remove the final drive gear
and change the shims according to the
following chart:
Preload
Under 4 kg-cm
4.0-8.0 kg-cm

(3.4-6.9 lb-in)
Over 8 kg-cm

Shim
Decrease shim
thickness
-

Correct

Increase shim thickness

* Re-torque the final drive gear nut

* LiberaIly coat the

bearings with Hypoid


gear oil and reinstaII the final drive gear
into the housing.

Make sure the final drive gear threads are


free of oil. Put a small amount of SUZUKI
THREAD LOCK SUPER "1 333B" on the
threads, install the drive gear coupling,
washer and nut, and torque to
specification. (Fig. 8-26)
Thread Lock Super "1333BW

to

specification, and re-check the preload


measurement until it is correct.

'

Final drive gear coupling


holder

99000-32020

09924.645

9.0- 1 1.0 kg-m


(65 -0-79.5 R-lbs)

Nut tightening torque

List o f Shims

Fig. 8-26
Once the bearing preload is correct,
remove the nut, washer and coupling, and
remove the final drive gear from the
housing. Using special tools 3 and 8 ,
install a new oil seal into the housing. (Fig.
8-2 5 )
Bearing and oil seal
Final drive bevel g a r
housing oil seal installer

09924-545 10

* After tightening the

nut to specification,
bend the collar of the nut over into the

notch in the final drive gear shaft.

FINAL DRlVEN GEAR ASSEMRLY


To install the final gear case oil seal. use
special tooIs O and @ (Fig. 8-27)

Oil Seal Installer

04924-54540

@ I
-

@ Handle

09924-74550

09924-745 10

The seal is correctly installed when the


lip spring is on rhe driven gear side.
NOTE:
A /ways use a new seat.

SHAFT DRIVE

Fig. 8-29

Fig. 8-2 7

Use special tools @


andI @ to install the
needle bearing for the driven gear. (Fig. 8-

Install the driven gear needIe bearing


retainer plate. Use SUZUKI THREAD
LOCK " 1342 " on the screws, and ti&ten
to specification.

281

The bearing case has a stamped mark on


one end, which must face inside.

Bearing installer

099 1 3-8451 0

Final Gcnr Cnse Rearing


Installer

09924-94510

Thread Lock "1342"

Screw tightening
torque

99000-32050

0.8-1.0 kg-rn
Ib-ft)

(6.0-7.5

lnstall the ball bearing onto the final


driven gear, usin2 specid tool O . { F i g . 8303

"'

Final driven gear bearing


insta1ler

09924.74570

Fig. ((9-28
Install the needle sc
ring for the
f i n d drive gear into
~ a lgear case
using special tools O , z51 ar~d8 . (Fig. 829s

'

Bearing & oil seal installer


handle

09124-745

izl

Bearing installer

09924-74530

(3 Pilot

09924-74540

Fig. 5-30

Place the final driven gear shims on the


driven gear needle bearing, oil the bearing
with Hypoid gear oil, and instaIl the driven
gear complete into the final gear case. (Fig.
8-3 1)
Place two lOmm nuts on each stud ( t o
prevent the nuts from bottoming on the
vnthreaded portion of the studs) and
tighten the nuts to the following torque.

SHAFT DRIVE

Tightening Torque

2.0-3.0 kg-rn
(14.5-21.5 Ib-ft)

Fk. 8-32

Oil the final driven gear ball bearing with


Wypoid gear oil, place the shims removed
during disassembly on the bearing, and
install the final driven gear bearing cover,
without oil seal. Install the ten bolts and
tighten to specification.
Final Gear Bearing Cpver
Bolt Torque

2.0-2.6 kg-m
(14.5-1 9.0 Ib-ft)

BACKLASH MEASUREMENT
Using t h e shims removed during
disassembly, install the final drive gear
housing, witl-fout o-ring, into the final gear
case and remove the final gear bearing case
oil seal. Tighten the nuts a n d bolts to
specification.

Install the backlash measuring tool on the


drive gear coupling, and set-up a dial gauge
as shown in Fig. 8-33).

FINAL GEAR BEARING COVER SHlM


ADJUSTMENT

Using a thickness gauge, measure the


clearance between the shims and the
bearing cover. I f not within specfffication,
the shims must be changed. (Fig. 8-32)

Final gear bearing cover


sl~irnclearance

0.05 - 0.15 m m
10.002 - 0.006 in )

List of Shims
P:~rtNumber

Thickness

27327- 45100

0.35 mm

-45102
- 45 103
-45IQ4

0.40
0.50
0.60

Fig. 8--33
Backlash Measuring Tool

Adjust the dial gauge so that it touches the


backlash measuring tool arm at the mark;
hold the final driven gear securely, and
turn the final drive gear coupling slightly in
each direction. reading the total backlash
on the dial gauge.
*

Final Gear Backlash

0.03 - 0.64 mrn


(0.001 - 0.025 in)

C
I
SHAFT DRIVE

specificn!ion, adjust the shim thickness

Remove shims from final gear cover and


final gear case, and measure total

thickness.
In order not to change the clearance
between the final gear cover and final
driven gear bearing, the totaI thickness of
the shims installed after a change is made
must equal the original total thickness of

List of Shims - Final Gear to Case


Part Number

Thickness

27326-45 104
45 100
45101
-45103
45102

1.35 mm
1.25

1.20
1.10

8 .OS

List of Shims - FinaI Gear Covet to Bearing

shims.
I f backlash is too large:

a) install a thinner shim pack between Final


driven gear and final gear case.
b) Increase thickness of shims between
final gear cover and bearing by an
amount equal to the decrease above.
Jf backlash is too small:
a) Install a thicker shim pack between final
driven gear and final gear case.
b) Decrease thickness of shims between
final gear cover and bearing by a n
amount equal to the increase above.
EXAMPLE:
Final gear to case shims:
1.3Smrn -I-1.05rnm = 2.40rnm
Final ;gear cover to bearing shims:
0.SOrnm t.0.40mm = 0.90mm
Original total measurement = 3.30mrn
Backlash ton large:

Final gear to case shiins:


I .30mrn + 1.05mm = 2.35mrn
Final gear cover to bearing shims;
0.601-11m+ 0.35rnm = 0.95mm

3.30mm
Backlash too small:
Final gear to case shims;
1.40mrn + 1.05rnrn = 2.45mrn
Final gear cover to bearing shims;
0.50mrn +0.35rnm = 0.85mm

3.30mm

TOOTH CONTACT ADJUSTMENT


* After backlash adjustment is carried out,
the tooth contact must be checked.
Remove the 10 baits from the final gear
cover, and remove the cover, using the
screws from the contact breaker cover (sce
page 8 - 7). Do not misplacc the shims.
Remove the driven gear.
w Clean and de-erease several teeth on the
final driven gear. Coat these teeth with
machinist's dye (usually available from
parts houses) or paste, preferably qf st light
color.
Re-install the driven gear with shims in
place, positioning the coated teeth so they
are centered on the final drive gear.
Re-instail the final gear cover and bolts,
and tighten to specification.
7

Final Gear Cover Bolt


Tightening Torque

2 .0-2.6 kg-rn
(14.5-1 9.0 Ih-ft)

Using a socket and handle on the final


drive gear coupling nut, rotate the final
drive gear several turns in each direction,
while loading the final driven gear. This
wilI provide a contact pattern on the coated
teeth of the driven gear.
* Remove the final gear cover and final gear,
and inspect the coated teeth of the driven
gear. The contact patch should be as
shown below:

SHAFT DR I YE

* If

the tooth contact pattern is correct, as


shown in (A), go to the Final Assembly
section.

I f the tooth contact pattern i s incorrect, as


shown in (B), a thinner shim is needed
between the final drive gear housing and
fina! gear case.
* If the tooth contact pattern is incorrect, as
shown in (C),a thicker rhirn is needed
between the final drive gear housing and
final gear case.
I f the tooth contact pattern is incorrect for
either reason, the appropriate shim must
be instaIled. and the tooth contact pattern
re-checked by repeating the tooth coating
procedure above.

NOTE:
If if is necessary to ndjlrsi the shim
thickness between .final drive gear
housing and final gear case, the final
gear backlash may change, and shotcld
be re-checked according f o [he
procedure ourlined under the Backlash
Measurement sub-section. Both adjusrments may need to be cltanged until
both backlash and loo!Jr contact are
correct.
List of Shims - final Drive Gear Housing to
Final Gear Case
Part No.
Shim thickness
27445-45
I
0
0
27445-45 101

27445-45 102
27445-45 103

0.35mm
0.40 mm

FINAL ASSEMBLY
After adjusting the backlash toot 11 conract
and clearance between the bearing covet
and the bearing, remove the final gear
cover, clean the m a r i n g surfaces
thoroughly, and apply SUZUKI BOND
No. 12Q7B to the area indicated below.
(Fig. 8-37)

urroiv

CA
Tlrflro~rgJ~1y clean tnatr'ng strrfac~s qf
final geur ruse arrd heorir~grase.
Take rare trot to upp1,v SUZUKJ BOND
NO.12137i3 to ribs [;s' or trot allow it to
flow on to ribs.

Fig. 8-35{BI.

Fig, 8-3'6 (C)

Fig. 19-37

8-1 5

SHAFT DRIVE

* Use special tools O and @

install a new
oiI seal into the final gear bearing cover.
(Fig. 8-38)
to

Using special tool O , instal1 a new oil seal


into the propelIes shaft coupling.

Lip of seal with spring goes to ward final

Install a new o-ring on final drive gear


housing, lubricate it lightly with Hypoid
gear oil, and install the housing into the
final gear case.
Fig. 8-38
Install the final gear bearing cover and
tighten the 10 bolts to specification. Take
care not to damase r he scal lip.
Tightening Torque

2 -0-2 b kg-nt
(14.5-19.0 Ih-ft)

* Remove the final drive gear

housing from

the final gear case.


Liberally coat the final drive gear coupling
splines with Liihiurn Rar;e Molybdenum
Grease (NLGT #2). and install the
propeller shaft coupling spring and
propeller shaTt coupling.
Push the coupling in against the spring and
install the circlip. (Fig. 8-39)

Snap Ring Pliers

INSTAL1,ATIOY OF PROPEL1,ER
SHAFT A FINAL IIRIVE GEAR
ASSEMRLY
For in~tallation,reverse the procedure for
removal.
Apply SUZU Kl BOND NO.1 207B (99 1 043 1 140) to the end of the swing am.
Coat propeller shaft splines with Lithium
Base Molybdenum Grease (NLGI #2),
Install the final driven gear assembly,
making sure the propeller $haft splines are
aligned into the coupling.
* Torque the attachment nuts t o
specifications.
Ti-ghtening torque

09900-06108

3.5 - 4.5kg-m
(25.5 - 32.5 Ib-ft)

* Tighten the final gear case drain plug.


Tightening torque

2.0 - 3.0 kg-m


- 21 .S Ib-ft)

(14.5

Add Hypoid gear oil through filler hole


until level is equal to filler hole opening
level.

FUEL SYSTEM R CARRURETORS

FUEL SYSTEM & CARBURETORS

FUELCOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUELTANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . . . . . . . . . . .
STARTERUNET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTTNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9- 2
9- 2

9- 3
.9-12

FUEL SYSTEM 8 CARBURETORS

FUEL SYSTEM &


CARBURETORS
FUEL COCK
Thc construction of the diaphra_pm type auto
cock is shown below. When t h e ensine is not
running with the lever in the ON or RES
position, the valve i q kept in the closed
position by applying pressure utilizing a
spring so thar no fuel will flew to the carburetors. When tlic c r ~ ~ i n is
e started, a
negative pressure
generared in [he
diaphragm chamber through the vacuum
(negative pre~sure)pipc which is connected to
the carburetors, and builds u p a negative
pressure which EF iiipher than t l ~ e spring
presrure so that I he diaphrazrn is forced to
open the valve and thus atlow the fuel to flow
to tile carburelors. When [lie lever i s set at the
PRI (which stands for priming ro supply the
fuel to the carburetors of an internal combustion engines) position, the fuel Slows to
the carburetors not via the diaphragm unit
hut directly l h r o t ~ g hthc RES (reserve) pipe.

when fillins the fuel tank for the first time, or


when the motorcycle has been left unused for
a long time, or when the carburetors have
been disassembled and repaired. Shift the
lever to the ON position when the engine
begins to run smoothly.
--

Cleaning
The fuel cock filter will collect impurities,
and therefore must be periodically checked
and cleaned.

FUEL TANK
The fuel tank has a cap with an air vent which
is necessary for the smooth flow of the fuel to
the carburetors. The fuel will not now if the
air vent is clogged. If this occurs, clean the air
vent with compressed air.
Install the t a n k filter cap with tlic arrow mark
facing toward the front.

ON:
RES:

PRE:

Normally used. Func~ionq as auto


cock.
Rcserve fttel i q used. Function? as
auto cock.
F~rcl is dircc~ly supplied. Does not

ft~r~ctiori
as auto cock.
The PRI position is used when the carburetors have little or no fuel, for example,

Cleaning

Clean the fuel tank with flushing oil at the


same time the fuel cock filter is being cleaned.

FUEL SYSTEM & CARBURETORS

CARBURETORS
IMPORTANT:

The GSMOG carburetors have been


rnanuf~crured and adjusred ro special
precise tolerunc~s lo meet [he EPA
emission levels. Before attempting to
servic~ or repair the carburelor
assemblies, thoroughly read und undersfand the following inslrucrions
canrain~d in this chapter, and also
careful/v review rhe informalion con-

toined in /he ernission conrrol sysrems


and regulorions chapter. IF contains very
imporfan, and spec rfic information on
/he carbureror components.

DO NOT ADJUST THE AIR SCREW AND

PlLOT SCREW. Both of these components


are pse-set at the factory using very
specialized equipment. They can not be reset
to the exact setting determined by the factory.
Refer to the emission control systems and
regulation chapter for further information.
Descxipt ion

Thir motorcycle has four carburetors, each of


which must be so adjusted properly to assure
engine performance.
The link a r m is moved hy the two throttle
cables that are connected to the throttle grip
to open or close all carburetor throttle valves
a t the same time.

Each carburetor has four units for regulating


and supplying fuel. There is the starter unit
for supplying a rich fuel-air mixture when
starting the engine, a pilot unit for supplying
fuel when the engine is idling, a main unit for
supplying Fuel when the engine is running at
medium-or high-speed, and a float unit for
maintaining a constant carburetor fuel level.
The carburetors mix gasoline with air. and
regulate the mixture. Carburetor malfunctioning or trouble generally occurs due to a
bad mixing ratio, which is the result of
wearing, biocking by foreign matter, or an
improper fuel level. The following are some
of the symptoms of a Faulty carburetor.
Fuel-air mixture too lean
1. The engine becomes overheated.
2. The engine runs well when the starter is
opened further,
3. Poor acceleration.
4. The ?park plugs become overheated.
5 . Engine speed is irregular
6. Exhaust gas is light.
Fuel-air mixture too rich
1. The engine is sluggish, and does not run
smoothly.
2. The engine runs badly when the starter is
opened further.
3, The engine runs badly after being
warmed up.
4. The engine runs well when the air filter
is removed.
5 , The spark plugs gel soiled with carbon.
6 . Exhaust gas is blackish in color.

STARTER UNIT
The starter unit is a starting aid device which
st~pplics a highly colicen tra tcd fuel-air
rnixttire to a cold engine at initial starting. I t
ctsnsiqts of a starter jel 0,
starter pipe @ ,
and starter plunger 3 . Refer io Fig. 9-5. Tc
activate the starter unit closc the throttle
valve. open the starter plungers fully by
pulling out choke knob. and activate the
starter or kick, Then the engine will generate
negative pressure to draw the fuel tllrough the
fuel injection ports.
The fuel is metered by [he starter jet, is mixed
witl.1 the air coming from the float cl~arnberin
the starter pipe, sucked i n t o the starter

F U r L .5 YSTEM & CA RBUHETORS


plun_eer cliamber, where i t is mixed with the
starter's primary air, and then drawn out into
the main bores From the injection ports as a
well-atomized and concentrated fuel vcry
suitable for starting purposes. This fuel-air
mixture is added to the fuel-air mixture being
supplied by tlie pilot circuit in tllc car-

This negative pressure allows a hiyhly


concentrated gas mixtiire to be drawn up
from the pilot outlet. The metered fuel arid
air arc mixed together prior going to the pilot
fuel-air outlets.

buretors.
When using the starter, the throtrle valve
must he completely closed. If the throttle
valve i s opened, the negative pressure falls
and will not build u p at injection ports and
the enyine wilt not bc able ro draw sufficient
fuel. The starrer plunger has a necdle-like tip,
which closes the starter ~ ~ n i rfuel
' s pasqa_ge. I f
the starter knoh is not pullcd all the way up,
thc fucI passage w i l l not open to let !he
gasoline flow. 1 f the starter pipe's blccd hole
is clogged, the fuel will not he atomi~ed
properly.

MAIN CIRCUIT
The main circuit consists o f t h e main jet GI,
bleed pipe 3 , jet needle GI , needle jet @ ,
throttle valve
ancl air jet @ . Refer to Fig.
9-7. I t starts operation when the throttle
opening is about 1/4.
Gasoline flows from the float chamber
through the main jet, and it is metered by the
air jet. The gasoline is then mixed with air
that is regulated hy the air jet. This mixing
occures in the bleed pipe after which the
mixhire glows into the carburetor bore
through the needle jet.
When the throttle opening is in the range
From 1/4 to 3/4, gasoline is metered by the
clearance between the needle jet and jet
needle. When the throttle opening exceeds
3J4, the clearance between the needlc jet and
jet needle becomes larger than the main jet
hole and therefore. sasoline is metered by the
main jet.
The throttle valve has a cutaway on its intake
side to decrease the suction on the needlc j e t
by means of vacuum nrhen the rlirotrlc
opening is about 1/4, and thus the flow o f
gasoline can be regulated.
I f the main circuit rnalfsrnctions, power toss
will result in h i y l ~ speed operation. I f [lie

m.

PI1,OT CIRCUIT
The pilot circuit consists of a pilot air screw
0) , pilot jet @) , pilot screw @! , and pilot
outlet 'i&. Rcfcr to Fig. 9-6.
The purpose o f the pilot circuit is to supply
the fuel ro the engine ur~til il reaches low
idling speed. The passage around the needle
jet which serves as [he main unit's fuel injection port is wide and little gasoline can he
drawn out through the needle jet. T h e
passage is narrower near the pilot outlet and
this is where the negative pressure builds up.

niain jet clogs up, the fuel-air mixture


become? Ican. On tlie conrrary, iT the air jet
or bleeder pipe's bleeder hole clogs ~ t p .the

mixture will become rich. A worn needle jet


or jer needie. or a l o o ~ cmaiti jct, bleeder
pipe, or needle j e ~will also causc a rich
mixi ure.

fuel level falls as the gasoline is consumed,


the float and needle will fall t o allow gasoline
to flow in.
C:

Fuel

,I'

i I

r-

1
1
1 .I

'I.

Fig. 9-8

Fig. 9-7
FLOAT U N I T
Thc floar u n i ~ consists of a float
and
needle valve ,3. etc. Refer to Fi8. 9-8. The
flnnt tlnil regulate? the fuel level in the carburetors to ensure uniform fuel mixing. If the
fuel lcvel i s ton 101~.it i s diffictijf lo dmw the
gasoline and the mixed gas will hecnrne lean.
On ihe other hand. if thc fuel level is too high.
it is too easy to draw the e:is and the mixed gas
will he rich.
Fuei level means the distance from the center
of the carburetor's main bore to the surface
of the gasoline in the float chamber. I t is kept
regulated by the opening or closing of the
fIoat. valve. When the gasoline flows in
through the float valve, t h e fuel level of the
float chamber rises and the float goes up at
the same time to push the needle up.
When the gasoline reaches the required level,
the needle contacts close to the seat cornplctcty ctopping thc Ilow oi gns;oline. When

NEEDLE V A L V E
I f foreign matter is caught between the valve
seat and the needle, the gasoline will continue
flowing and overflow. I f the seat and needle
arc warn beyond the permissible limits,
similar troubles will occur. Conversely. i f the
needle sticks, the gasoline will not flow into
the float chamber.
To service and inspect, remove the carburcrnrs, Float chnmberl; and floats, and
clean thc float chambers and float parts with
gasoline. I T the needle i s worn as ~ h o w n
below, replace i! toyether will? a valve seat.
Clean the fuel passage of the mixing chamber
with cornprewed air.

FUEL SYSTEM& CA RBUKETORS


Ilisassemhly
Shift the fuel cock lever to the ON or RE5
position.
Disconnect the fuel pipe and negative
pressure pipe from the fuel cock.
Open thc seat, remove thc fuel tank
mounting 'bolt, and remove the Fziel tank
from the frame.
Remove the air cleaner body. (See page7-6).
Disconnect the throttle cables and starter
cable from the carburetors. (See page 7-6).
Remove the carburetors. (See page 7-61.
Remove the carburetor top covers From
each carburetor.
At the center portion of the carburetor
assembly, unhook the :hrottle return
spring from the pin.

.=
.. .*;
,4--&

-4;

.P

r:

.I
-:I

.,

.,r

,
I/

*'

8.

\id.

1.

;(

2.-.

:',
,.
.
,

'

,,

i.

;,, Q7
;I '

..

. - .~- *O.&

,,

% \,-..I

..I..

;p8*'

_.

.,

,!

"

.
-,>,i.

, 'k y..; ',

+.;

*'A

*>

,.jl

r 0,

.-

I.
2.

Carhurctor asr).. No. 1

4.

Carburcmr a r w N,I a

5.
h.
7.

Screw

14. Thr$>rrlrr a l t r
40. Gnskcr

I-txk wn<hcr

31.

Floar

4:.

Luck w-nsh?r

4'.

t'np

No. ?
3. C:lrhr~retor irssy. NO. 3
Carhurctor ass?.

R. Floar
9.

pin

Gasket

10. 0 ring

3:.

W:lchcr
Rnlr

33.

I . ~ c l i warhcr

7.6.

SI'ICW

Scnl
45. N~pple
54.

Scrcw
Needle valve

4h,

N~pplr

.If,

Hosc

I f . Gaskc1
14. Necdle jct
15. Ilrr~tlhcr pipc
16. O ring
17. Main jet
I R . Adjuster
19. 0 ring

4s.

Screw

I I.
1.2.

20. Sprinp
2 r. Pilot jcl
22. Needle j e l
23. Nccdle clip
?4.
25.

Spring
Plnlc

26.
23.
28.

King
Plate

29.

Scrtw

Rrackcl

30. Lock washer


3 1.

Spring
Ptn

32.
33. Adjuster
34.

Nut

35.

L m k washer

Fig. 9-10

44.

IIocc

50.
51.

IIOPP

Contrlil ass'!

52.

Sturtcr shaTt

53.

l~i~sllcr

Sprinc
5. Washer

4 .

Sb.

SCTCH.

57.

Lock washer

.tH,
59.
60.
h I.
12.

I'lnle
Tlirottlc return spring
Scrcw

Lock r r a ~ h e r

Throttlc stop ~ d i u s t e r

6 3 . Ttimtllr rclurn \ p r ~ n p
h ~ .Throttle <h;~fi

Choke lcver
Screw
67. Adj~intcr
hR. Nu1
67.

hn.

Remove the five bolts to free the throttle


shaft.

FUEL SYSTEM R CARBURETORS

* Remove the stopper

plate and pull out the

shaft.

Re-assembly
Carburetor identification
Be sure to identify each carburetor for the
cylinder which it serves and to mount each
in the correct position as indicated:

Loosen the four croqs head scrcws and also


the screw in the slot. Draw oul tlic choke
shaft.

* Grease the throltle shaft, and install it in


[he carburetor. Leave the throttle shaft
screw loose.

Fig. 9-1 7
Remove the plate. A total of 8 screws must
be removed to free this plate for remove].

Tlir iorcgoit~gprocedure permits each carhusetor ,~sscmbEicsto be disassembled Further


in the usual manner

Secure the plate by tightening the 8 screws.


Be sure to apply THREAD LOCK
CEMENT (99000-32040) to these screws
before tightening them.

Fig. 9-18
9- 7

T i ~ h t e nbolt

to this torque value:

Ti~bieningtorque

0.35 kg-m (2.5 lb-ft)

Fig. 9-22

Adjusting full-open a n d full-closed


poqitions of throttle valve%and halance the
carburelor?.
FULL-CLOSED POSITION
Run back throttle stop screw fi) to produce a
clearance between the screw and pulley.

Loosen the locknuts and turn I he adjusting


screws '3so tlial the four carburetor throttle
valves are aligned with the bottom end of the
rnairl bore.
Move the throttle valves up and down 2 or 3
times to make sure that the four rt~rottle
valves are positioned evenly, and tighten the
locknuts O .

FULL-OPEN POSITION
Adjust Full-throttle stopper 7 ' in such a way
that, when the throttle valve is turned to its
full-open position, the valve will come to the
position indicated.

Fig. 9-24
Checking fuel level in tach fIoaz clnamher
1 . Leave fuel cock lever in "ON" or
"RES" position.
2. Placc machine on ccnrer stancl.
3 . Remove Float chamber screw and install

the special tool.


4. Move fuel cock lever to "PRI" posirinr~
lo admit fuel into float cliarnhc
u-x

FUEL SYSTEM & CAKRURETC3R.T


5. With the floal chamber filled with fuel,
turn the cock lever back to "ONv'
position, and ?tar1 up tlre engine.
6. R u n the engine at l l ~ eidling speed (9501 150 r/min), and measurc distance {A:
with the middle line o f the level gau_ge
a l i ~ n e dwith the mating surface o f the
float howl as shown in the photo. A
should he within h e range specified
here.
Distance A

Fuel lcvcl gauye

3 -0-5.0 m m
(0.1 1-0.19 in)

NO TE:
When checking (he fuel level, place the
machitte on rJw center ~ r a r ~ dThe
. firel
level shotrld he 20 m m 10.8 in) above rhr
rear end of the float clrarnhar.

Fuel level adjust ment


If distance A is not within the specified
range, it means that float height H is off
the specification. To adjust this height,
proceed as follows:
Remove the float bowl, and bend the float
arm to increase or decrease the height to
this value:

09913-14510
Float height

73-25 m m
(0.90-0.98 in)

Fin?,
9-25

Fuel level

rneasurcltlrnlr

IMPORTANT:
Be sure to remove the gasket before
measuring fhe height.
Moving the arm upward toward A raises
the level; moving it downward toward 8
lowers the level (in the inverted condition
of the carburetor).

Fig. 9-26

Fig, 9-28

FUEL SYSTEM d CARBURETORS


Balancing f he carburetors
The four carburetors must be balanced after
disassembling the engine or the carburetors.
As a first step, calibrate the carburetor
balancer gauge @ (special tool) as follows:
1. Remove the vacuum inlet screw (Allen
bolt) on No. 4 carburetor or No. I casburetor intake pipe using a 4 rnm hexagon
wrench (special tool), and install the
adaptor @ (special 2001) in the screw hole.
Hexagon wrench
4 rnm

0991 1-70130

2. Connect one of the four rubber hoses of


the balance gauge to this adaptor,
3. Start up the engine, and keep i t running at
1500-2000 r/min.
Carburetor balancer
set

Fig. 9-31
5 . After finishing with one hose, connect the
adapter to the next hose and, by adjusting
the next air screw, bring the steel ball in
that tube to the center line.

Repeat the process on the third and fourth


tubes. The balancer gauge is now ready for
use in balancing the carburetors.

09913-13121

Fig. 9-31
Fig. 9-30
4. Turn the air screw of the gauge so that the
vacuum acting on the tube of that hose will
bring the steel ball in the tube to the center.

Remove the respective vacuum inlet screws


and insert the adaptcrs in the holes. Connect
the balances gauge hoses to these adaplors,
one hose to one adapter, and balance the four
carburetors as follows:

FUEL S I'STEM & CA RRURETORS


Start up the engine, and keep it running at
1 500-2000 r/rnin.
The four steel balls in the carburetor
balancer should line up, indicating that the
four carburetors are we11 balanced.

NOTE:
If adjusrmen t is required, ir is suggesled
!hat rhe fuel rank and the carburefors
top covers be r ~ m o v beforehand.
~d

Fig. 9- ' L

* Install

the top covers on the carburetors


which have been adjusted.
Remove the adapters from the intake
manifolds and install the vacuum inlet

screws.

Throttle cahk adjustment


* See page 3-13 for throttle cable acljustment.

If the steel balls are not in the correct


positions as shown in the above diagram,
remove the carburetor top cover, and
correctly sdjust the throttle valve adjusting
screw with special tool IT .
P

Throttle valve adjusr


wrench

04913-14520

After this adjustment, adjust the idling


speed to somewhere between 950 and 1 150
r/min with throttle stop adjusting screw

If e e ~ i n eis run w i f hfuel tnnk removed,


be sure m plug Ike percock vacuum line.

FUEL SYSTEM& CARBURETORS

TROUBLE SHOOTING
Before adjusting the carburetors. be sure to check that there is nothing wrong with the engine's compression, ignition timing, and ignition spark performance.
Complaint

Symptom and posrible causes

Remedy

2. Starter pipe is clogged.


3. Air leaking from a joint between

4. Air leaking from carburetor's joint or


vacuum gauge joint.
I
5 . Starter plunger is not operating

gged or

Medium- nr

high-speed

troi~hle

I . Clean.
2. Clean.
3 . Check starter body and carburetor
for tightness, adjust and replace
gasket.
4. Check and adjust.

5. Check and adjusr.

1 . Check and clean.

2. Check and adjusr.

2. Air leaking from carburetor's joint.


vacuum gauge joint, or starter.
3 . Pilot outlet or bypass is clog&.
4. Starter plunger is not fully closed.

3. Check and clcan.


4. Check and adjust.

1 . Main jet or main air jcl is ctosgcd.


2. Needle jet is dogged.
3. Fuel leaking due to a broken O-ring

I . Check and clean.


2. Check and clean.
3. Replace O-ring.

in needle jet.

Ovcrflaw and
frlel level
flurtuatickna

4. Throttle vaIve is not operating

4. Check throtile valve for operation.

properly.
5. Filter is clogged.

5. Check and clean.

E . Needle valve is worn or damaged.


2 . Spring in needle valvc is broken.
3. Float is not working properly.
4. Foreign matter has adhered to needle

1. Replace.
2. Replace.

3.Check and adju~t.


4. Clean.

valve.

5. Fuel [eve! is too high or !ow,

1I 5 . See page 9-9 .

This section gives service data and servicing procedures which differ those o f the GS85QGZ/GLZ and describes the new features o f the GS85OGD/GLD . Refer to the sections '
through 7 8 except for the items described in this section.

CONTENTS

I.

VIEW OF SUZUKl GS850GD. . . . . . . . . . . . . . . . . . . . . . . . . .


SPECJHCA TIONS. ...................................

PERIODIC MAINTENANCE. ...........................


W/R/NGDIAGRAM...................................

WIREAND CABLE ROUTING ..........................


T/GHTENING TORQUE ...............................

SER VICEDA TA .....................................

I1

VIEW OF SUZUKl GS850GLD.........................

SPECIF/CA T/ONS....................................
PERIODJC MAJNTENANCE............................

/GMT/ON S YS TEA4 ..................................


WIRING LTIA GRAM...................................
WIREAND CABLE ROU T/NG..........................

TIGHTENING TORQWE ...............................


SER V/C DA JA

.....................................

I. VIEW OF SUZUKl GSSSOGD

. ,

LEFT SIDE

L -

18

E MPO RTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also enhance the reliability and performance of the motorcycle.
-

- -

NOTE:
Vehicles operated under severe conditions may require more frequent servicing.

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and t o maintain proper emission levels. Mileages are
expressed in terms of kilometers, miles and time for your convenience.

RER'IODIC MAINTENANCE SCHEDULE

INTERVAL:
THIS INTERVAL SHOULD B E JUDGED
BY ODOMETER READING OR
MONPMSWHICHEVERCOMESFIRST

Mile

km
Month

600

4 000

7 500

11 000

15 000

1000

6000

12000

18000

24000

12

24

36

I
T
C
I

I
T

-C

Battery (specific gravity of electrolyte)

- I

cylinderhead
nuts and
-. exhaust-p- i p e b o l t s p -Air cleaner element
_
I
Tappet clearance

Spark plug
Fuel line

Engine oil and oil filter

f ngine idle speed


Clutch
Secondary and Final gear oil

C
1

stem
-Steering
Chassis bolts and nuts
Front forks

NOTE:

r = T i n h * ~1 = Inspect, R = Replace, C = Clean

48
l
T

R
C
I
I
I
I
'
Replace
every four years
R
R
R
R
R
I
I
I
1
I
I
1
I
Change oln ar ~nitial600 miles 11 000 km) 1
every 7 SO0 mites (12 000 km)
1
E
I
I
I
Rewlat:e
--every four years
le every two years
I
I
I
1
I
I
1
I
I
I
I
I
1
I
I
T
T
T
f
T
I
I
Check air pressure every 6 months.

Tires

R
I

(;,s(j8.7 OGfj;(;

L !I

WIRING DIAGRAM

WIRE AND CABLE ROUTING


Body ground
/

Clarnn

Clamps

Turn signal relay

clamps
A

Rear N r n signal

clamp

Rear rurn signal

Clamp

Clamp

motor

Throttle c

Clutch cahfe

Clutch cable

TIGHTENING TORQUE
ENGINE

ITEM

Ib-ft

kg-m

Cylinder head cover bc~ l t

N.m
6 - 113

0.6- 7.0

4.5 - 7.0

Cylinder head bolt

7 - 11

0.7-

5.0 - 8.13

1.1

p
p
p

Cylindler head nut

35

CamsFlaft bear ing cap bolt

24 - 26

Camshaft sprocket bolt

3.5 - 4.0

25.5 - 29.0

1.2

6.0- 8.5

2.4 - 2.6

17.5 - 19.0

0.8

Cam chain idler bolt

6 - 10

0.6 - '1.0

4.5 - 7.0

Cam chain guide No. 2 bolt

4-

0.4 - 0.7

3.0 - 5.0

Generator rotor bolt

60 - 70

6.0- 7.0

43.5 - 50.5

Signal mtor bolt

25 - 35

2.5 - 3.5

18.0 - 25-5

0.4 - 0.7

3.0 - 5.0

15- 20

1.5 - 2.0

Clutch sleeve hub nut

50 - 70

5.0 - 7.0

Clutch spring bolt

11 - 1 3

1.1 - 1.3

6-10

0.6 - 1.0

4-

Startelr motor bolt


-

6 - 10

0.6 - 1.O

11.0- 14.5
36.0 - 50.5
8.0- 9.5
4.5 - 7.0
4.5 - 7.0

Gear shifting cam stopper spring holder bolt

18 - 28

1.8- 2.8

13.0 - 20.0

Gear shift arm stopper bolt

15 - 23

1.5 - 2.3

11.0 - 16.5

0.6 - 1.O

4.5 - 7.0

Startei

LIULLII

bolt

Clutch release arm bolt


-

P
P
P
P

Oil strainer screw

Crankcase bolt (6m m )

Crankcase bolt (8 mm)

18

Engine mounting nut (10 mm)

25 - 45

2.2
2.5 - 4.5

(12mm)

45 - 70

4.5

Engine mounting nut

Exhaust pipe bolt


Muffler bolt
Gear shift lever bolt

Secondary drive gear nut

9 - 14
18-28

13 - 23
120 - 150

Secondary driule housir~gbolt

90-110

20 - 26

18.0 - 32.5

7.0

0.9 -- 1.4

6.5 - 10.0

1.8-

2.8

13.0 - 20.0

1.3-

2.3

2.0 - 2.6

I
I

Secondary drive~l11uusingbolt

TO - 26

2.0 - 2.6

32.5 - 50.5

--

9.5-16.5
--

9.0-11.0

Secondary driven gear nut

13.0 - 16.0

1.8-

87.0 - 108.5
--

>

65.0-79.5
14.5

- 19.0

14.5 - 19.0

GS850GDJGLD

CHASSIS

It
clamp b

nt fork

rnt and r

e oil bledd e r boll

nountin!F bolt
3r brake

~ a gear
l
t

TlGHfENlNG TORQUE CHART


For other bolts and nuts not listed on previous pages, refer to this chart:

TIGHTENING TORQUE
rhread Diameter

"7" Marked Bolt

ntional or "4" Marked Bolt


kg-m
Ib-ft

Imm)
1-

0.1-0.2

0.7-

Nm
1.5

1.5-

kg-m

0.15-0.3

Ibft

1.0-

2.0

4
0.2 - 0.4
0.3 - 0.6
2.0 - 4.5
1.5 - 3.0
3 - 6
5
2~~~-~
6
47
0.4-0.7
3.0- 5.0
8 - 12
0.8 - 1.2
6.08.5
1.8 - 2.8
43.0 - 20.0
1.0 - 7.6
7.0 - 11.5
18 - 28
8
10- t6
4.0 - 6.0 29.0 - 43.5
2.2 - 3.5
16.0 - 25.5
40 - 60
T0
22 - 35
-.
12
35 - 55
40.0
70- 100
7.C
50.5 -.
14
50 - 80
58.0
110 - 160
11.1
79.5-.
16
80 - 130
8.0 - 13.0 58.0 - 94.0 170 - 250
17.0 - 25.0 123.0 - 181.0
~~~18
130 - 190
13.0 - 19.0
94.0 - 137.5 - 200 - 280
20.0 - 28.0 144.5 - 202.5

Conventional Bolt

'Y" Marked Bolt

"7" Marked Bolt

SERVICE DATA
VALVES

+ GUIDES

Unit: mrn ( i n )

Valve diam.

--

- --

36
1.4

IN.

-. .

Valve lift

IN.

II IN. 8( E X . '

0.03-0.08
(

0.001-0.003

0.025-0.055
( 0.0009-0.0022

Valve guide t o valve stem clearance

0.040-0.070
10.0016-0.0028
1
-7.000-7.01 5
(0.2756-0.2762)

E X.
.

Valve guide I.D.

-.

--

'IN"EX'

IN. et E X .

IN. & EX.

- 1

Valve stem O.D.

Valve stem runout

(0.014

IN.
-

-.

Valve head thickness


Valve stem end length

Valve seat width

IN. & EX.

Valve head radial runout

IN. & EX.

1 0.17 1
1

T -0-1.2
0.04-0.05

0.03
( 0.001 )

Valve spring free length

(IN. & EX.)

kg
1 19.62-27.56 Ibs)
at length 31 mm ( 1.22 in 1
22.1-27.1
kg

8.9- 12.5

Valve spring tension


( I N . & EX.]

I
-

OUTER

at length 35 rnm I

1.38 in

CAMSHAFT

+ CYLINDER HEAD

I
I Cam height

ITEM

Unit: mrn (in)

i
IN.

EX.

STANDARD
36.32-36.36

35.77-35.81

1.430-1.432

LIMIT

36.02

( 1.418 )

35.47

1.408-1.410
-

[: 1.397
- )
0.f 50

IN'& EX'

0.037-0.065
0.0015-0.0026

I 0.0059 1

IN. & E X .

Camshaft journal oil clearance


Camshaft journal holder I.D.
Camshaft journal 0.D.
Camshaft runout

Cam chain 20 pitch length

1
I1

157.80

I 6.213
)
--

Cam chain pin (at arrow "3")

Cylinder head distortion

--

:YCINPER

0.2
( 0.008 )

+ PlSTON + PISTON RING


Unit: mrn (in

ITEM
compression pressure

STANDARD

LIMIT

9 - 12 kg/cm2
(128 - 171 psi)

7 kg/cm2
(TOO psi)
2 kg/crn2
428 psi)

Compression pressure difference


Piston to Cylinder clearance

Cylinder bore
Piston diam.

0.050- 0.060
(0.0020- 0.0024)
69.000- 69.01 5
(2.7165 - 2.7171)
68.945 - 68.960
(2.7144 - 2.7150)
Measure a t the 15 mm (0.59in)

0.120

(0.0047)
69.080
(2.71 97)

68.880

(2.7T 18)

from piston skirt end.

Cylinder distortion
Piston ring free end gap

0.2
F0.008)
1st

Approx.

2nd

Approx. 11.5 (0.45)

9.0 10.35)

7.2

(0.28)

9.2

(0.361

0.10 - 0.30
(0.004- 0.01 2)
0.10 - 0.30
(0.004- 0.01 2)

I st

2nd

2nd

(0.0059)

1s t
2nd

oil
Piston ring thicknew

1st
2nd

Piston pin bore I.D.

Piston pin 0.0.

CONROD

0.7

(0.03)
0.18
(0.0071 1
0.15

1st

Piston ring groove width

0.7
(0.03)

'

f .23 - 1.23
(0.047- 0.048)
1.21 - 1.23
(0.047- 0.048)
2.51 - 2-53
(0.099- 0.100)
1175 - 1.190
(0.0463- 0.0469)

1.170- 1.190
(0.0461 - 0.0469)
16.002- 16.008
(0.6300- 0.6302)
15.995 - 16.000
10.6297 - 0.6300)

+ CRANKSHAFT

16.030
(0.631 1)
f 5.980
(0.629 1)

Unit: mrn (in)

LIMIT

STANDARD

- ITEM

Conrod small end 1.0.


-

16.006 - 16.014
( 0.6302-0.6305
)
. .

Conrod deflection

16.
.

( 0.5
( 0.12

0.10-0.65

I
Crankshaft I

3."

1.0

STANDARD

ITEM
Oil pump reduction ratio
I

1.723

Oil pressure (at 6Q56,140"F )

87149

Above
Below

LIMIT

33134

)
I

kg/cm
1.4
psi)
0.25 kg/cm2

0.1

3.6

psi)

at 3000 r/rnin.

CLUTCH

Unit: mm {in)

ITEM

Clutch cable play


(

Drive plate thickness


(

STANDARD
2-3
0.08-0.12
2.7-2.9
0.106-0.114

LIMIT

2.4

1 0.094 I

Drive plate claw width


Driven plate thickness

Driven plate distortion


Clutch spring free length

0.1
( 0.004

38.4
( 1.51

ust$s.rocn/cm

TRANSMISSION

Unit: mrn {in) Except ratio

Unit: mm (in)

ST,
0.1:

ITEM
Secondary bevel gear backlash
- -

Final bevel gear backlash


I

D
3
(0.003- 0.005)
Drive side , 0.03- 0.64 (0.001 - 0.025)
Driven side
0.02 - 0.35(0.001 - 0.044)
3-

Secondary drive bevel gear preload


-

Secondary driven bevel gear preload

Final drive bevel gear preload

(2.60
4 -- r

b-in)
~yaurn

(3.45 - 6.05 Ib-in)


4 - 8 kg-crn
(3.45 - 6.95 Ib-in)

LIMIT

CARBURETOR

Ef EM
Carburetor type

:ATION

BS32SS

Bore size

32 (12 6 ) .

I.D. No.

45161)

Fuel level

5.0 k 0.5 (0.20? 0.02)

Float height

22.4 k 1 .O (0.88k 0.04)

# IIS

Main jet

Unit: mrn Iir

1.7 (0.07)

Main air jet


(J.N.)

5050

Needle jet

(N.J.1

X- 5

Pilot jet

(P.J.1

# 4fl

1.0 (0.041, 0.8 10.03), 0.8 (0.031


Pilot outlet

--0.7 (0.028)

(P.0.)

2.0 (0.08)

Valve seat

I
I

Pilot screw

(P.S.)

Pilot air jet

(P.A.J.1

Throttle cable play


Choke cable play

PR E-SET

I
I

* 180

0.5- 1.0 (0.02- 0.04)


0.5 - 1.0 (0.02 - 0.04)

I
I

ELECTRICAL

Unit: rnm (in)


NOTE

SPECIFICATION
17 " B.T.D.C. Below 1500 k 150 rlmin and
37 " B.T.D.C. Above 2350 ? 150 r/min.

ITEM
Ignition timing

1,2,4,3,

Firing order

Spark plug

NGK : B8ES
N.D. : W24ES-U

TYP~

I Spark performance

Over

Ignition coil resistance

+-

Secondary

More than

Generator no-load voltage


Regulated voltage

3 - 5 SZ
Plug cap - Plug cap
30-40 kfl

80 V (AC) at 5000 r/min.


V a t 5000

14.0- I 5.5

'

Brush length! MlTSUBA

Starter motor

Commutator under cut


--

I Starter relay resistance


1 Battery

6
Limit: ( 0.24
~ i m i t : 0.2

--

Type designation

Capacity
Standard
electrolyte S.

fuse size

r/min.

G.

I
12V50.4kC ( 14Ah)ll OHR
.-

1.28 a t 20DC (68" F )

I
1

Headlight

10

10

Turn signal

GSH5 O CDJGL LI

BRAKE

+ WHEEL

Rear brake pedal height


Brake disc thickness

STANDAR b

ITEM

0.8

0.20

Front
Rear

5.0
6.7
( 0.26

)
4

0.2

0.008
0.2

0.008

4.5
( 0.18

Front

Rear

Brake caliper cylinder bore

Brake caliper piston diam.

0.5512-0.5529

15.827- 15.854
0.6231 -0.6242

38.1 80- 38.256


( 1.5031-1.5061

38.098- 38.148
( 1.4999-1.5019
-- -

38.098-38.1 48
( 1.4999-1.5019
(

0.25
(

-.

- --

Front

3.50H19 4PR

Rear

4.50H17 4PR (Tubeless tire)

Front

2.0
0.08 1
2.0

( 0.08

Front

Tire tread depth

Rear

Tire size

0.30
( 0.012

Axial
Radia I

13,957- 13.984
( 0.5495-0.5506

Rear

Wheel axle runout

0.6248-0.6265
)
.
14.000-14.043

38.1 80- 38.256


( 1.5031-1.5061

Rear
Wheel rim runout

Front

Front

10.24

1 5.870- 1 5.91 3

Front
Rear

6.0

Brake disc runout

Master cylinder piston diam.

LIMIT

20

Master cylinder bore

Unit: rnm (in)

0.010 1

0.25
(
0.010
)
--

;s tire)

1.6

I 0.06 )
.-

2 .O

SUSPENSION
ITEM

Unit: mrn ( i n )
LIMIT

STANDARD

Front fork stroke


I

Front fork spring free length

4 16

1 16.4)
Front fork oil level

140
15.5)
0.6 kg/cm2
(8.5 psi)
110

A
-

Front fork air pressure


Rear wheel travel

(4.33)

FUEL

+ OIL + CAPACITY
ITEM

SPEC1 FlCATlON

Fuel type

Fuel tank including reserve


reserve
Engine
- -oil- -type

Engine oil capacity

Use only uinleaded or low-lead type gasoline of a t least 85 R+M


95
~ c t a n e(
method) or 89 octane or higher
rateo o y rne Research Method.
22 L
(5.8 US gal)
4.2 L
(4.4 US qt)
SAE
1OW/40
-Chanse
3 000 rnl (3.2US qt)

"

F ilter cha ge

3 600 rnl (3.8US qt)


3 800 mt (4.0 US qt)

Overhau l

Front fork oil type

Fork oil # 15

Front fork oil capacity (each leg)

255 ml (8.62 US o t )
Hypoid Gear oil SAE 90, API gracle G L-5

Bevel gear
oil type
-Bevel gear oil capacity

Brake fluid type

Secondary

340 - 400 rnI ( 1 1 . 5 -- 13.5 US oz)

Final

280
DOT:

19.5 - '1 1.2 US 02)


T4
11

TIRE PRESSURE

1
!

1
FRONT
-

NORMAL RIDING

--

REAR

S0iORhD:NG

psi

kPa

kgicm2

psi

175

7.75' 24

175

1.75

24

200

2.00

28

225

2.25

32

kPa

kg/crn2

--

1 ="'"ING

DUAL
.
RIDING
--

.-

CONTINUOUS HIGH SPEED RIDING

COLD INFLATION
TIRE PRESSURE

DUAL R I D I N G

kPa

kg/cm2

200

2.00

28

200

2.00 28

225

2.25

32

280

2.80

kp,

kgicm2

psi

40

WAITAGE
Unit: W Icp)

ITEM

Head!ight

--

HI

LO

SPECI FlCATlON

60

55

8/23 (3/32)

TailJBrake light

License light
-

--- --

Turn signal light


-

Speedometer light
-

Turn signal indicator light


---

High beam indicator light

Neutral indicator light


..

Oil pressure indicator light


Side stand check light

--

- .-

23 (32)
-

- 11-

-.

3.4
--

Tachometer light

- --

3.4
--

--

3.4
-- -

--.k

.-

-r--

- -

.--

3.4
--

--

--

--

3.4
-.

3.4

3.4

--

--

- .--

GSA'SOG DIG LD

11. VIEW OF SUZUKl GS850GLD

RIGHT SIDE

LEFT SIDE

1 9-22

CHASSIS
Front suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telescopic, pneurnatfc/coil spring, oil dampen&


Swinging arm, oil dampened, damper 4-way/spring
5-way adjustable
Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40' (right and left)
Caster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62' 30'
Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 mrn (4.13 in)
Turning radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 rn (8.5 ft)
Front brake, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc brake, w i n
Rear brake.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc brake
Front tire size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100/90-1957H (Tubeless tire)
Rear t ire size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130/90-1667H (Tubelesstire)
Front tire pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 kg/cm2 (24 psi) (Normal solo riding)
Rear tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 kg/cm2 128 psi) (Normla solo riding)

ELECTRICAL
Ignition type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistorized
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17' B.T.D.C. below 1 500 r/min and
37" B.T.D.C. above 2 350 rJmin
.................................
NGK B8ES or NIPPON DENSO W24ES-U
Spark plug.
Spark plug gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.8 mm (0,024 - 0.031 in) both NGK and

NIPPON DENSO
12V 50.4 k c (14 Ah1110 HR
Three-phase A.C. generator

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/10/10/10/15A

CAPACITIES
Fuel tank including reserve.. . . . . . . . . . . . . . . . . . . .
reserve.. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . .
filter change ......................

overhaul . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary bevel gear ail . . . . . . . . . . . . . . . . . . . . . . .
Final bevel gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front fork air pressure . . . . . . . . . . . . . . . . . . . . . . . .
Front fork oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications subject to change without notice.

17 L (4.5 USgalE
4.5 L (4.8 USqt)
3.0 L (3.2 US q t )

3.6 t (3.8US qtl


3.8 L (4.0US qt)
340 - 400 rnl 1'1 1.5 - 13.5 US ozl
280 -330 ml 19.5 - 11.2 USozf
0.8 kglcrn2 (1 1.4 psi)
245 ml (8.27 US oz) in each leg

IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with ERA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also enhance the reliability and performance of the motorcycle.
.-

NOTE:
Vehicles operated under severe conditions may require more frequent servicing.

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and to maintain proper emission levels. Mileages are
expressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE


INTERVAL:
THIS INTERVAL SHOULD B'E JUDGED
BY ODOMETER 'READING OR

600

Mile

7 500

11 000

15 000

6000 112000

18000
--

24000
48
I

36
I
T

4 000

1000

12
i

24
1

Cylinder-head nuts-and
exhaust: pipe-bolts
-.
-

Air cleaner element


Tappet clearance

Spark plug

I
R

I
R

Front forks

NO TE: T = Tighten, / = Inspect, R = Replace,

Chassis bolts a nd nuts

I
T

I
T
I

I:

I
T

Check air pressure every 6 months.

C = Clean

Steeri~
stem
--?g
- --

'

T
I

IGNITION SYSTEM
On the Model GS850GLD, the timing advance characteristics of the ignition timing have been changed
from the hitherto-employed mechanical timing advance system incorporating an advance governor to an
electronic timing advance system The introduction of this new electronic timing advance system has kept
the change in the ignition timing due to time lapse at a minimum level and also has improved the timing
advance performance during high-speed operations,

Srgnal generator

lgnlror

unlr

When the signal rotor is rotated in the system block diagram above, the signal "A" is generated in the
pick-up coil. The thus-generated signal will be convertd to the signal waveform "B" at the inside of the
ignitor unit. Based on this "B" waveform, control i s made by means of the advancing control circuit and
the closing angle control circuit. As a result, the timing advance takes place, as shown in Fig. "Cap.

Slow-speed
revolution

Medium-speed
revolution

Advanced angle 0'


Highspeed
revolution

SIGNAL GENERATOR
Measure the resistance between lead wires. If the
resistance is infinity or less than the specifications,
the signal generator must be replaced.
Pocket tester

STD resistance
Approx. 140 - 180 S2

IGNITOR "NIT
Remove the spark plugs from Nos, 1 and 2 cylinders. Install the respective plug caps and place
spark plug on the cylinder head.
w Remove the frame cover on the left side and disconnect the coupler from the signal generator.
As indicated in Fig. 1, connect the pocket tester
alternately to the terminals provided inside the
coupler. For this test, use the "RXI" range of
the tester and set the ignition switch at the ON
position. If the ignitor unit is functioning
normally, a spark will occur a t rhe spark plug a t
the moment when both of the fester pins @ and
@ are removed from the terminals sirnultaneowsly.

09900 - 25002

Aoc ket tester

NOTE:
This checking presupposes that the ignition
coil used for checking is a good one.

Fig. 7

cs~usoc~/csn
WIRING DIAGRAM

WIRE ANQ CABLE ROUTING


Turn signal control unit

Guide

Horn

prox. 15'

Main wiring harness

To fuse

Starter relay

Cramp
handle SIW ( R 1

Handle SIW ER Cb

Fuel, ignit~onSlVV

lamp

Clnrnp

Headlight housing
Turn signal
Guide

Throttle cable

'.

Cable guide

Starter cab11

Clamo

Clutch cable

TIGHTENING TORQUE

ENGINE

~gcam st

drive gea

" A*erisk

indicates new D model specification.

GSiSSOCD/GLD

CHASSIS

tle shaft

pake mas

lder mou

Front arid rear b

ie union

14.5-21.5

3.5

18.0 - 25.5

2.5

11.0-18.0

Rear brake caliper mounting bolt

2.0- 3.0

Rear brz~ k e c a l i p e r a x l e b o l t ~ 2 5 - 3 5

2.5

Rear bn~ k master


e
cylinder mounting bolt

15 - 25
90- 110
-

Propeller shaft bolt


Final gear bearing case bolt

Final gear case shock mount stud bolt


Final case oil filler plug

1.5-

65.0 - 79.5

35 - 45

9.0- 11.0
3.5 - 4.5

30 - 40

3.0- 4.0

21.5 - 29.0

20 - 26
90- 110

2.0- 2.6

14.5 - 19.0

9.0- 11.0
2.0- 3.0

65.0 - 79.5

20 - 30

25.5

- 32.5

14.5 - 21.5

TIGHTENING TORQUE CHART


For other bolts and nuts not listed on previous pages, refer te this chart:

TIGHTEN1NG f ORQUE
Thread Diameter

Conventional or "4" Marked I

kg-m

N*m

N-m

"7" Marked Bolt


kg-rn

------1-

6.1 - 0.2

0.7 -

7.5

2- 4
0.2-0.4
1.53.0
7 3.05.0
47 - 0 . 4 - 0 ..0- ll.! 3
10- 16
I .6
7.
22-

35

3.5

16.

12

35 - 55

3.5 - 5.5

25.5 - 40.0

74

50 - 80

5.0- 8.0

36.0- 58.0

16

80 - 130

8.0 - 13.0

58.0-

18

130 - 190

t 3.0 - 19.0

Conventional Bolt

"'4" Marked Bolt

1.5-

0.15-

0.3

1.0-

2.0,

3 -

0.3-0.6

2.0-

4.5

6.0-

8.5

-12

- 28
40 - 60
70 - 100
18

0.8-1.2
'

- 2.8
4.0 - 6.0
7.0 - 10.0
1.8

50.5 - 72.51

-160

11.0 -16,O

79.5-115.5

94.0

170 -250

17.0 - 25.0

123.0 - 181.0

94.0 - 137.5

200 - 280

20.0 - 28.0 144.5 - 202.5

110

'7"Marked Bolt

SERVICE DATA
VALVES

+ GUIDES
'Unit: rnm (in)

ITEM

STANDARD

Valve diam.

36

IN.

EX.

IN.

Valve clearance or tappet clearance


(when cold)

--

IN.

I
II

i
I
I

0.03-0.08
0.001 -0.003
0.025-0.055

0.0009-0.0022 1

0.35
1 0.014 1

EX.

Valve guide I.D.

Valve stem 0.
D.

I,

IN.

EX.

Valve stem runout


Valve head thickness

0.05
f 0.002 )

IN. & EX.

0.5

I IN. & EX.

(-0.02-)

4.4

Valve stern end length

Valve seat width

6.945-6.960

0.2734-0.2740 1

1.4

IN. & EX.

Valve guide to valve stem clearance

LIMIT

IN. & EX.

IN. &

OUTER

EX.

Valve head radial runout


Valve spring free length
(IN. & EX.)

Valve spring tension


(IN.& E X . )

I
8.9-12.5

INNER

kg

( 19.62-27.56 tbsl
at length 31 rnm ( 1.22 in )

22.1-27.1
kg
1 48,72-59.74 bs)
at length 35 mm ( '1.38in 1

0.17

CAMSHAFT

+ CYLINDER + HEAD

Unit: rnm {in)

36.32-36.36

35.77-35.81
-- -

.-

Camshaft journal oil clearance


-

0.037-0.065

Camshaft journal holder I.D,

Camshaft journal 0.D.

1
1

IN. & E X .

22.01 2- 22.025
( 0.8666-0.8671

21.960-21.975
(
0.8646-0.8652
-. - .

Camshaft runout

IN. & EX.

-.
- - -- -- Cam chain 20 pitch length
- -

Cam chain pin Iat arrow

'"3")

0.10
(- 0.004-)
157.80
( 6.213
1
--

20 th pin

Cylinder head distortion

PISTON

+ RING f

.-

0.2
0.008 3

CYLINDER
Unit: rnm (in)
I

ITEM
Compression pressure

9- 12
128-171

kg/cm2
psi)
-

7 kg/cm2
(100 psi) -- -- -2 kg/cm2

Compression pressure difference

-- - -

-.

psi)
- -. ( 2 8-

--

1 0.0020-0.0024 )

0.120
( 0.0047 )
-

69.000-69.01 5
{ 2.7165-2.7'171

( 2.7197
-- -

0,050-0.06:

Piston ta cylinder clearance


Cylinder bare
Piston diam.

69.080

68.945- 68.960
( 2.7144-2.7150

Measure a t the 15 ( 0.59 ) from skirt end.

Cylinder distortion

Piston ring free end gap

lst

t lMIT

STANDARD

9.0
APP~OX.

1 0.35

Piston ring end gap

1s t

-2 nd

Piston ring to groove clearance

,
!

0.10-0.30

1 0.004-0.012
-(

0.18
0.0071 1
0.15
( 0.0059

2nd

1st

2nd
Oil

1st

2nd
Piston pin bore 1.D-

Piston pin 0.D.

0.03 1 -

1st

Piston ring groove width

Piston ring thickness

0.10-0.30
0.004-0.01 2

0.7
0.03
0.7

E
1

1.21 -1.23
0.047-0.048
I
1r21- 1.23
0.047-0.048
)
2.51 -2.53
0.099-0.100
1
1.175-1.190
0.0463-0.0469 1
1.170-1 .I90
0.0461 -0.8469 )

16.002 - 16.008
( 0.6300-0.6302
75.995- 16.000
( 0.6297-0.6300

16.030
( 0.631 1

15.980

0.6291 )

CRANKSHAFT
ITEM

STANDARD
f 6.006 - 16.014

Conrod small end I.D.

Conrod deflection

LIMIT
16.040

3.0

1 0.12
-

Conrod big end side clearance


(

0.10-0.65
0.004-0.026

1.0

1 0.039 1

Crankshaft runout

0.05
( 0.002 1

OIL PUMP
-r

STANDARD

ITEM
Oil pump reduction ratio

1.723

Oil pressure { a t 60C, 140" F )

87/49

Above
Below

LIMIT

33/34

0.1 kg/cm2
(

1.4

psi1

0.25 kg/cm2
3.6 psi)
a t 3000 rlrnin.

CLUTCH
Unit: mrn tin\

ITEM

Clutch cable play

LIMIT

2-3
(

Drive plate thickness


-

Drive plate claw width


-

STANDARD

Driven plate thickness

0.08-0.12

2.7-2.9
0.106-0.1 14

1 0.094 1

1 1 -8-12.0
0.46-0.47

'
-1

2.4

11.0

0.43

2.0 t 0.06
0.08 0.002
-

Driven plate distortion


( 0.004 )

Clutch spring free length

1.51 1

TRANSMISSION

Unit: mm (in) Except ratio

ITEM

STANDARD

LIMIT

Primary reduction ratio

1.775

87/49

Secondary reduction ratio

1.062 (

17/16

Final reduction ratio

3.090 (

3411 1

--

Gear ratios

Shift fork to groove clearance

5.45- 5.55
0.21 5-0.219

4.95- 5.05
0.195-0.1 99

Shift fork groove width

-Shift fork thickness

SHAFT DRIVE

Jnit: m rn (in\

ITEM

STANDARD
0.08-0.1 3

Secondary bevel gear backlash

0.003-0.005 1

Final bevel gear backlash


Secondary drive bevel gear preload
Secondary driven bevel gear preload

3.45-6.05
4-8

Final drive bevel gear preload


(

3.45-6.95

kg-cm
Ib-in)
kg-cm
Ib-in)

LIMIT

GS8SOGDICLD

CARBURETOR

Unit: mm (in)

Pilot c
Valve seat
starter jet

(G.S.)

# 32.5

Pilot screw

(P.S.)

PRE-SET

Pilot air jet

(P.A.J.)

Throttle cable play

# 180
0.5 - 1.0 (0.02- 0-04)

ELECTRICAL
Unit: mrn (in)

I f EM

SPEC1FlCATlON
1 7 " B.T.D.C. Below 1500i:150 r/rnin and
37 " B.T. D.C. Above 2 3 5 0 1 50 r/rnin.

lgnition timing

[~irin
order
~

NOTE

1,2,4,3
--

.-

--.

NGK: B8ES
N.D.: W24ES-U

Spark plug

Over 8 (0.3)
at 1 atm.
..-

--

Signal coil resistance


-

--

.-

Ignition coil resistance

- - --

Primary

Generator no-load voltage

More than
1-

Regulated voltage

Starter motor

El-Y,G-B
.-

.-

- - .- -- . -

* @ tap - @ tap
3-5 n
Plug cap- Plug cap
30-- 40-.kC2
-.
80 V (ACJat 5000 rlrnin.

- .

* 140- 180R

Secondary

- -

14.0-1 5.5 V a t

rimin.

5000

---

. -

Brush length

I
L
1
-

Commutator under

Starter relay resistance

--

3-4

- -

YB14L-A2

Battery

Capacity

-- -

--

j?

2~ 50.4k~(
1 4 ~ h )OHR
/l

-.-. --

Fuse size

10 A
-

10 A

Main

15A

Output terminal

10 A

* Asterisk indicates new D model specifications.

.-

10 A

Ignition

.a

BRAKE

+ WHEEL

Unit: mrn Iinl

STANDARD

ITEM
Rear brake pedal height

15

Front

Rear

0.6
5.0

Brake disc thickness

LIMIT

Brake disc runovt

0.2
0.2i0.008 I
6.7 5 0-2
0.26 0.008

4.5
10.18 }
6.0

( 0.6248-0.6265

Rear

Master cylinder piston diam.

Front

Rear

Brake caliper cylinder bore

a
Brake caliper piston diam.

Front

Rear

Front

Rear

Wheel rim runout

14.000- 14.043
0.5512-0.5529 )
1 5.827 - 1 5.854
0.6231-0.6242 1
13.957- 13.984
0.5495-0.5506 I
38.180- 38.256
1.5031-7.5061 )
38.180- 38.256
1.5031-1.5061 1
38.098- 38.148
1.4999-1.5019 )
38.098- 38.148
1.4999-1.5019 1
-

Axial

- -

--

2 .O

I 0.08 1
--

- - A

--

Front

Radial
Wheel axle runout

2.0
( 0.08 1

Front

Rear

Tire tread depth

'

Rear

0.010 )
---

0.06 1
2.0

100190-19 57H (Tubeless tire!


1 30190-1 6 67H [Tubeless tire]

1.6

Front
,-

0.25
0.010 3

0.25

Rear

Tire size

1 0.012 1

T 5.870- 15.913

Front

0.24

0.30

- --

Master cylinder bore

--

- -

I 0.08 1

SUSPENSIO'N

Unit: mrn (in)

LIMIT

STANDARD

I f EM

NOTE

'I 60

Front fork stroke

1 6.3)
51 6

Front fork spring free length

20.3
2 60
(-- 10.2 1
0.8 kg/crn2

Front fork ail level


-

- -

Front fork air pressure

Psi)

(11.4

Rear wheel travel

FUEL

3.9

.-

+ OIL
SPEC! FlCATlON

ITEM

NOTE

Use only unleaded or low-lead type gasoline


of at least 85 - 95 pump octane
method) or 89 octane or higher rated by the
Research Method.--T
17
L
4.513.7- - -US/lrnp gal)
-I

Fuel type

dy-

1
Fuel tank including reserve

reserve
-

--

-.-

L~?

Filter
change-

L.-.

.--

--

245
(

. .

LlSllmp
- -- qt)
ml
USllmp
qt)
--

-a-

m!

3800
Fork oil

-.

ml

- --

Front fork ail capacity leach leg)

* 15
ml

-ii

8.2818.63
USltrnp o r )
--

--

Hypoid Gear oil SAE 90,API grade GL-5

Bevel gear oil type

--

--

--

--

--

340-400
S e c o n d a r y ~1.5/12.0-13.5/14.1
~
US/lmp-o r ).-----

Bevel gear oil capacity

Brake fluid type

---

--

3.212.6
3600
3.8132
-

Overhaul
Front fork oil type

1
I

3000

Engine oil capacity

USilrnp qtl

SAE 10W/40

L
4.E.0

Engine oil type


-

280-330
ml
( 9.519.9- 1 1.211 1.6 USilrnp or)
p
p

. --DOT3 or DOT4

- --

--

--

TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
TIRE PRESSURE

CONTlNUOUS HIGH SPEED RlDlNG

SOLO 'RIDING
DUAL RIDING
SOLO RIDING
DUAL RIDING
kPa

kglcrn2

psi

FRONT

kPa

kglcrn2

psi

kPa

175

1.75

24

200

250

2.50

36

225

kg/crnz

psi

kPa

kglcrn2

psi

2.00

28

225

2.25

32

2.25

32

280

2.80

40

'

REAR

200

2.00

28

Unit: W (cpl

ITEM

SPEC! FIGATION
H1

Headlight

--

TaillBrake light
--

--

Lo

60

55
8/2313/32]

--

8123( 3132

RunninglFront turn signal light

- --

- -- -

23 132)
3.4

3.4

1.7
Turn signal indicator light
>-

3.4

- .-

High beam indicator light


--

--

3.4
-

Neutral indicator light

3.4

Oil pressure indicator light

3.4

Side stand check light

3.4

Prepared by

SUZUKI MOTOR CU,,LTD.


Motorcycle Tecl~nicalSentice Department
6 t h Ed. June. 1983
Ed. January, 1979

1st

Manual No. 99500-38002-03E


Printed in Japan

EMISSlON CONTH OL R REG [TI. A 7'10NS

EMISSION CONTROL & REGULATIONS


CONTENTS
REGULATION ...................................................
EMISSION CONTROL CARBURETOR COMPONENTS ...................
GENERAL EMISSION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10- 2
3 0- 3
1 0- 4

EMISSION CONTROL AND REGULATIONS


REGULATION
On February 4, 1977 Federal Emission Regulations for motorcycles took affect. All motorcycles
produced after January 1, 1978 must meet specific emission limits. This act establishes three
categories of motorcycles and an emission level far each category. The categaries are a s folIows:
50 cc- 170 cc
17 1 CC-749 cc
740 cc-Larger
The emission limits for motorcycles produced d u r i n g I978 and I979 are as follows:
1978-1979 EMISSTON LIMITS
Categories

Carbon Monoxide (CO)

H ~ ~ d r o c a ri bs o(HC)
~

50 CC-

I70 cc

1-71 cc-749cc

5.0 Grams/Kilo~
(R.0Grams/Mile)
*5.0- 14.0 Grarns/Kilometcr

(8.0-22.5

Ciram~JMile)

17 GramsJKilornc~er
(23.4 GrarnsJMire)

17 GramsJKilomctcr
(27.4 Grams/Mile)

17 Grams/Kilometer

750 cc-1-arges

(27.4 Grams/Mile)

* Dependent upon displaccrnen t .


The emission limits for 1980 are more restrictive tnan the prevlous two model years.
are as follows:

1 hese

limits

1980 EMISSION LIMITS


Categories

Hydrocarbons (HC)

All motorcycles
50 cc- Larger

5.0 Gram$/Kilon~eser
(8.0Grarn~JMiIe)

Carbon Monoxide (C0)

12 Grams/Kilomcter
(19.3 GramrJMile)

This reguIation affects all motorcycles licensable for highway operation. This definition of
highway-approved motorcycles covers motorcycles equipped with a headlight, taillight and stop light
and which have an engine displacement larger t l ~ a nSO cc.
All testing and certification of emission-controlled motorcycles will be performed 'by Suzuki Motor
Company in compliance with the E.B.A. testing- regulations.
Motorcycle dealers are not r e ~ u i r e dto
.
certify emission levels on any mo~orcycle.
This regulation provides for fines of up to $10,000 per motorcycle far individuals who alter, render
inoperative or improperly service emission-controlled motorcycles. I t is essential that the individual
serv.icing this emission-cont rolled motorcycle review thoroughly the correct service procedures
discussed in this manual. Under n o circumstances should the service procedures be deviated from
nor adjustments made which are not in accordance with the factory specifications.

EMISSION CONTROL & REGULATIONS

EMISSION CONTROL CARBURETOR COMPONENTS


The GS850G is a n ernisxion control tvpe model as i t was introduced after January 1. 1978. This
model utilizes a specially manufactured carburetor to limit emissions. Emission type carburetors
require different components and other special adjustments if they are to perform properly.
There are seven (7) carburetor mixture control components in each carburetor assembly. Three (3)
of these components are machined to much closer tolerances than standard carburetor jets. These
three (3) jets, MAIN JET, NEEDLE JET, PILOT JET, must not be replaced by standard jets. To
aid identification of these three (3) jets a different style letter and number are used. Tf replacement
of these close tolerance jets becomes necessary, be sure to replace them with the same type of close
tolerance jet marked in the same manner as the examples shown below.
CanvcntionaI Figure?
Used On Standard Tolerance
.kt Compc~nents

1 2 3 4 5 6 7 8 9 0

Emis~innTypc Figure<
Uscd On Closc t olcrance
.let components

1 2 3 4 5 6 7 8 9 a

The throttle Slide and the Jet Needles are not special tolerance components. Either o f these two
parts may be replaced by standard tolerance parts provided that they are the same size. The carburetor specifications for the emission-controlled GS850G are as follows.
Carburetor
I.D.No.

Main

Needle

let

Jet

Jet
Needle

Cut Alvqv

45100

f102.5

5DL36-2

Pilor

Air
Screw

Pilot
Screw

PRE-SET

PRE-SET

1.5

DO NOT ADJUST
DO NOT ADJUST THE AIR SCREW AND PILOT SCREW. Adjusting, interfering with,
replacing, or resetting of either of these adjustable metering components may affect the carburetor
performance adversely and cause the machine to exceed the emission levels. Tampering with either
of these two adjustments may also subject the person to fines under the federal emission
regulations and also the state regulations regarding tampering. The air screw and pilot screw are
pre-set by the factory using specialized testing and adjusting procedures. It is not possible to
duplicate these adjustments. If persons, who are unaware of these special adjustments or the antftampering laws, have tampered with the carburetor adjustments the Suzuki dealer should contact
the disributor's representative for further technical information and assistance.

- -

EMfLYSIONCONTROL R HEGULATJONS

GENERAL EMISSION INFORMATION


There are three different types of emissions. They are:
Hydrocarbons (HC)
Carbon Monoxide (GO)
Oxides of Nitrogen (NOx)

Automobiles must meet specific emission standards for all three of these pollutants. Motorcycles
must only meet the requirements for the following:
Hydrocarbons (HC)
Carbon Monoxide (C0)

HC exhaust emissions ate basically unburned fuel vapors which have passed through the engine
and escaped the combustion process.

CO exhaust emissions are formed during an incomplete combustion cycle as

a result

of a rich air

fuel mixture. The only way thal CO can be produced is by the combustion cycle.

Total NOx emissions from all motorcycles is considered negligible. The EPA states that total NOx
emission from motorcycles by 1990 will only amount to approximately 0.5%. NOx is formed
during the combustion process at high combustion chamber temperatures.

CARBON MONOXIDE
Carbon monoxide is a product of an incomplete combustion cycle. CO is measured in grams per
mile or kilometer and also in percentage (Vn)

r h e most common causc oF CO is rich carburetion. As the mixture is richened excessively. the CO
amount increases proportionntcly. Engine oil i5 also a hyrlrocnrhon. so engine prohlenls which lead
to oil tlurning increasc carhon monoxide.
CARRURETION MALFUNCTION
1. Air Cleaner-Dirty or over oiletl.
2. Idle Mixture-Adjusted incorrectly.
3. Idle Speed-Too high or low.
4. Fuel Level-Sticking float. leaking needle. incorrect setting.
5. Choke-leaking o r linkage sticking.
6. Svnchronization- I mpropcr halance of mu1ti cylinders.

ENGINE MALFUNCTIONS
1. Valve Seals-Leaking or torn.
2. Valve Guide-Worn and leaking excessive oil.
3. Gaskets-Leaking oiI into combustion chamber.

EMISSION CONTROL 8-REGIILA 7'10N.Y

HYDROCARBONS
Hydrocarbons are unburnt gasoline vapors and can he measured in two differenct ways. The first is
to measure the weight of the pollutants over a specific distance such as grams per mile or grams per
kilometer. The second method is to measure the concentration of HC in the exhaust gas in parts per
million (PPM).

The most common cause of high HC emissions are ignition system problems. Tf the ignition system
fails to ignite the fuel mixture properly, then raw gasoline vapors will pass through the engine into
the exhaust system. Listed are the most common ignition problems which occur and which can
affect HC emission output.

1GNITlON SYSTEM MALFUNCTIONS


1 . Spark plugs-Fouled, dirty, improper type or improperly gapped.
2. Contact Points-improperly adjusted, pitted, worn or sticking,
3. Ignition Timing-Advanced or Retarded.
4, Timing advance-Too fast or too slow an advance rate.

5. Battery-Low

charge or faulty.

Carburetion can also lead to high HC emissions if the mixture is either excessively rich or excessively lean.

MIXTURE-RELATED MALFUNCTIONS
1. Air CIeaner-Dirty, over oiled or tern.
2. Jets-Clogged, constricted or incorrect size.
3. Float Level-Level too low (lean) or too high (rich).
4. Choke-Leaking choke plunger or sticking linkage.
5 . Air Leaks-Intake manifolds, engine gaskets and other sealing surfaces.
6. Synchroniza tion-Unbalanced on mu1ti-cylinder machines.
7 . Exhaust System-Restricted flow or improper exhaust system.

Engine wear or damage can also cause high HC emission,


1 . Rings-Low compression, leakage into crankcase.
2. Valves-Improper adjustment, bent stem or burnt.
3. Gaskets-Leaking, loss of compression.
4. Crank seals-leaking.
5 . Oil Consumption-Worn valve guides, worn rings, clogged crankcase breather.
6 . Oil-lmproper engine oil.

CHASSIS
CONTENTS
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I F.2
CLUTCH CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F I. 3
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l f . 3
CHOKE CABLE ................................................... 1 1. 5
SPEEDOMETER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1 . 5
TACHOMETER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. 5
SPEEDOMETER AND TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- (1
HEADLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 IIGNlTlONSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. 7
FRONTFORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I 1. 9
STEERINGSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
STEERJNGSTEM BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-20
REMOVALOFTUBEANDTIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-25
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E 1.25,
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.30
REARBRAKECALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
REAR MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-11-35
REARWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3H
REARSWINGlNGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-43
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -45

CHASSIS

I-IANDLEBARS

Remove throttle grip and throttle wire

REMOVAL
Remove the left and right rear view
mirrors.
Shift the clutch cover boot towards the
cable side.
Loosen lock nut Oof clutch Iever portion
to fully tighten adjuster GI.
Align the grooves of the adjuster and lock
nut with that of the clutch lever t o remove
cIutch cable from the clutch lever.

together from the handlehars.


Rernnve the Flandlehars clamping holts and
remove handle holders.

To remove the clutch lever from the handle


bar, take off the handle grip before
loosening the clutch lever bolts.

Remove vinyl bands from t h e left and right


of the handlebars.
Remove screws for mounting the left
handlebars switc11 to separa tr: the iippcr
and lower portions of the switch.
Remove screws for mounting the right
handlebars switch to separate the upper
and lower portions of the switch.
Remove themaster cylinder clamp bolts.
Remove the four screws, two each on both
right and left sides, and remove the
handlebars pad.

MOUNTING
Pass both the throttle grip and the throttle
wire t h r o t ~ g ht11c handlelrars from the right
side.
Alipn punch mark on t h c handlebars with
the upper end of t h e steering upper bracket
and rnor~nt the handlebars. At tliis time tlie
front and rear holder bolts must be
tightened with the same clearance 3 ) .

bolts tightening
torque:

1.2-2.0
(8.5-14.5

kg-m
Ih-ft)

Motlilt t h o right and left handlebars


switchcs securely on the handlebars fastenin? them with the screws.

Mount the master cylinder securely on the


handlebars. (see page 1 1-26')
Fix the lead wire from the left and right
switch or t h e I~andlebarswith a vinyl band.
Mount the left and right rear view mirrors.
Adjust the dutch play. (Sec page 3- 13)

CLUTCH CABLE
REMOVAL
* Removethe fuel tank.
See Fig. 11-1 for removal procedure of the
clu tcli cahlo on the hancltebars sidc.
Remove cam lever bolt $on [he clutch
side, loosen the adjuster lock nut and
remove the adjuster.
Remove the clutch cable from the
motorcycle frame.

MOUNTING
Route the clutch cable between carburetors
Nos. 1 and 2. Next, as shown in the
drawing below, route i t along the upper
left portion of the ignition coil below the
upper steering bracket to the IeFt side of the
ignition switch through the tachornetesspeedometer mounting brackets.

Mount the clutch cable an the clutch lever.


Mount adjuster bolts on the clrrtch cover
side and fasten the cam Iever with the cam
lever bolts.
Adjust the clutch lever play (see page 3-13).

THROTTLE CABLE
REMOVAL
Remove the fuel tank.
Loosen the lock nuts on both cables on the
throttle grip portion and firmly tighten
both cable adjusting nuts to provide
sufficient cable play.
Remove cable adjusters @from the bracket
at the opening and closing ports on the
carburetor side and remove the inner cable
from the lever.

CHASSIS

A clamp fixing the throttle wise is located


in front of the ignition coil. Draw out the
throttle wire over the bent clamp.
Remove the right I~andlebarsswitch screws
and separate the upper and lower portions
of the handle switch.
Screw back cable adjusting nut at the
closing side and remove it from the throttle
cable guide. Loosen the cable guide lock
nut and remove cable guidemfrom the
handlebars switch.

Mount the throttle inner cables at the


opening and closing sides respectively on
the front and rear hoIes in the throttle grip.
* Fix the riglat handlebar switch en thc
handlebar.
Route both cables through the space
between the tachometer and ignition switch
and then between the steering head pipe
and the right front fork.
* Fix the throttle wire with the clamp on the
front of the igniton coil.
throttle inner cablemat the
closing side from the throttle grip and
remove the cable.
Loosen the cable guide lock nut at the
opening side and remove the cable guide
from the handlebars switch.
Remove tIlrottle inner cable Tz? a t the
opening side from the throttle grip and
remove the cable.

Remove

Mount the inner cable a1 the opening side


on the lever at the rear side. Mount the
cable adjuster on the bracket and fix it with
the upper and lower nuts.
Mount the inner cable at the closing side on
the lever at the front side. Mount the cable
adjuster on t h e bracket and fix i t with the

MOUNTING
Mount throttle cable guide @ at the
opening side and throttle cable guide(?, at
the closing side on frc handlebars switch
and lightly tighten the lock nuts.

upper and lower nuts.


If it is difficult to mount the inner cable on
the lever, turn the throttle grip te the full
open position and then mount the inner

cabIe.
Adjust the throttle cable (see page 3-13).
Mount the fuel tank.

CHASSlS

* Install the cable adjuster on the bracket

CHOKE CABLE

REMOVAL
* Remove the fuel tank.
* Loosen the lock nut o n the carburetor side
and remove both inner and outer cabIes
from the carburetor. (See page 9-6.)
0
Remove the handlebars pad. (See page
2.1
,Loosen the choke knob lock n u t 1:, turn
the choke knob counterclockwise. remove
tlie choke knob from the steering head
pipe, and rctnove the choke cable.
* Release the clamp holding the starter cable
at the rear of the ignition coil.

and install thc inncr cable. Adjust for 0.51.0 rnrn (0.02-0.04 in) free play. Secure
the cable adjuster with the locknut.
Install the starter knob on the steering head
pipe and secure the knob with the locknut.
Enstall the handlebars pad.
Mount the fuel tank.

SPEEDOMETER CABLE
REMOVAL

* Remove both ends of the speedometer


cable with pliers and remove the cable

from the
7 7 -

Fig. 11-J2

INSTALLATION
Pass t h e choke cable through the head
pipe and route i t under the ignition coil.

speedometer gear housing and


speedometer from the front hub.

MOUNTING
Route the speedometer cable to the brake
oil hose joint portion and through the
cable guide. Mount the cable nut of the
upper end on the speedometer and tighten
i t with pliers.
Route the cable in hetween the lower triple
clamp and the front fork cover.
Mount the lower end of the cable on the
speedometer gear housing. Then rotate the
wheel so that the groove at the end of the
inner cable meshes with the projection of
the speedometer pinion and tighten the
cable nut.

The choke cabte shorlld he ilrreaded


through the wire harness, not through

TACHOMETER CABLE
REMOVAL
Remove the tachometer cable from the
tachometer side and the cylinder head side
with pliers,
MOUNTING
Route the tachometer cable from the rear
portion of the tachometer between the
steering head pipe and right front fork and
mount it on the cylinder head cover.
At this time make sure that the inner cable
engages the tachometer gear, and tighten
the cable nut.

SPEEDOMETER AND
TACHOMETER

HEADLIGHT

14,

REMOVAL

-1315

1.

REMOVAL
Remove the hvo instrument bracket
retaining bolts.
Remove the fuel tank.
Rernove the headlight.
Remove connection coupler connected to
the main wire harness on the tower portion
of tank for the meter lead wire over the
fixed clamp.
I . H e ; ~ d I i ~ass'y
l~l

2. Rim
3 . Mountine

riny

4. Ring
5. Unit
6 . Scrcw

7 . Screw
8 . Lock washer

13. Scscw
14. Lock W . ~ F ~ I C ~

9. Nu!

E. Spacer

1 0 . /\dju<rcr rcrus

1 1 . Spring
' - . Nut

16. I-lcndliph~

IIO\I\~IIC

F ~ E/I-15
.

Rernove three screws ii? securing the


headlight.
Disconnect thelieadlight leadcoupler.

MOUNTING
Route the lead wire of the meter between
the steering head pipe and the right front
fork and clamp i t to the fixed clamp on the
frame side.
* Fasten the meter with two baits. Fasten the
right side of the meter together with the
brake hose guide.
Mount the speedometer a n d the
tachometer.
Mount the headlight.
Mount the rue1 tank.

Remove adjusting screw l o .


Remove two screws (3 and remove the
rim.
Remove three screws (Q and remove the
headlight unit.
CA LITION

*
*
*

W l t ~ nI'YIsIoEII*FI~ tb P actjzl~titt,qScrPw.
ills~i-ra wasl~erberwpcv~the # ~ p r iatzd
n~
brack~~r.
Wlren motinrir~grJw Ireadligl~turlir the

word "TOP" tnrrsf j ~ c e~ipwards,


After c o t n p l ~ t i oof'
~ ~work. adj~csrthe
horizontal nnd ~~crriral
afrglcs of rha
heod/igizr h~o.nm.
-

ADJUSTMENT OF HORIZONTAL
ANGLE
Turn adjusting screwlTon the headlight
rim to change the direction of the beam.
Turning the screw clockwise directs the
beam to left and turning the screw
countercEockwise directs the beam to the
right.

AD,IUSTMENT OF VERTICAL ANGLE


L ~ o s e ntheleft and right housing bolts.
Manually adjust the vertical beam angle of
the headlight and tighten the right and left
mounting bolts.

IGNIlrION SWITCH
RFMO'VAL
* Remtw e the headlight and then each Iead
wire connected within the headlight
housi ngRemcw e the two headlight housing bolts
and rlemove the housing.
Remtw e the two screws that hold the
igniti on switch with n 5 mrn Allen wrench
and 1-crnove t l i e igrlilion 5wizcPi.

5 rnln "L" type tlcxagan


wrench

0991 1-701 10

MOUNTING
Mount parts in the reverse order to
removal.
* Route the lead wires of the ignition switch,
leFt handlebars switch, front brake switch
and turn signal light through the lower hole
in the headlight housing and fasten the
housing with two bolts.
Connect each lead wire.
Connect the lead wire of the ignition switch
to coupler @on the wise harness side.
Connect the lead wire of ttlc right handlebars switch to coupler I
on the wire
harness side.
The orange and white Iead wires of the
front brake switch are to be connected
respectively to the orange and white ones
on the wire harness side.
The black/white lead wises of the left and
right ground wirc for the front turn signal
arc to be connected respectively to the
bIack/white ones en the wire harness side.
Also connect the black lead wire of the left
turn signal body to the black one on the
wire harness, and connect the sight side
lead wire to the light green one on the wirp
harness side.
Connection of headlight. Connect cor
nection coupler @of the headlight to t h
headlight connection.

CHASSlS

Fig. I l - I Y
Secure the headlight with the three screws.
Adjust the vertical beam angle of the
headlight (see page I 1-7).

CHASSIS

FRONT FORK
0
laincd cnnsianl

a
3

1.

Air v d v c cap

2.

Spring

3. Inncr
4.
5.

tube

Dusl xal
Oil MPI slopper

Fig. 11-20

ring

6
7.
8.

011sen1
Outer tube

011lotk piccc
Bolt

10.

Seui prpc

Fig. 11-21

at

140 mm and charged

CHA S S I S

21

26

>,;,

25-.Gk;

I . fnner t uhe
2.Outcr tube
3.0il sc31
4.Washer
5 , Oi'l seal .;tnpl,er ring
h.Stud Ilnlt
7 . 0 i l lock piccc
8 . Roll
I

B.C:a~ket
10. Rust rc:~l
1 I , Scrctv

1 2. (iasket
1 3.Danipcr rod
14. Da~itperrod ring

When removing the front fork, remove the


caliper mounting bolts and remove the
sight and left calipers.
Hang the caliper from the motorcycle
frame using string, erc., taking care not to
bend the brake hoses.
Pull down the Front fork while rotating it.

*a--9

d-8

MOUNTING
Mount the front fork so that the upper end
of the inner tube in the front fork is Rush
with the upper surface of the stem head.

1 5 . Rcbound sprinr
I h.Sprinp
17. Spriny riiidc
1 8. Spaccr
1 9. Upper cap
20. Valve cap
2 1 .Valve
2 2 . 0 ring
23.0 r i n ~
24. Arle Iiolder
25. Nut
26. Lnck washcr

Upper pinch boll

lightening ~orque

Lower pinch bolt


tightening torque

27. Wasl~er

2.0-3.0 kg-m
(14.5-21.5 Ib-ht)
1.5-2.5

kg-m
( 3 1.0- I R.0 lb-it)

Mount the caliper. The tightening torque


-

REMOVAL
Place a jack below engine,
* Remove the fronr wheel and front fender.
* Remove valve cap !T and hold the valve
with a pointed tool to bleed air.
To remove the fork, it is preferable to
loosen upper pinch bolt 3 .
Loosen front fork tube upper pinch
bolt @and lower pinch bolt GO.

of the caliper mounting bolt is as follows:


Calipcr mounting
bolt tightening
torque

2.5-4.0

kg-rn

( 1 8.0-29.0 tb-Ft)

Mount the Front fender on the front fork.


Mounz the front wheel.

CA U TIOW
Fnsfen the speedomerer gear box at
the position shown in she drawing
below and take care not to bend the
speedometer cable excessively,
* MJ1~etlsecru-ir
on t a-~leholders,
check /Ira/ /J
mces, front and
hock, on eocfl noraer are equal. To
I ~ T Usttrc
~ P I ~ Cthe
I ~t lo leg,$, riphr and
Iqfr, are pcrrulle!, check as follows.
Fbsfen tlte two axle holders fernporurj!v ur~d l o o . ~ ~lIte
n four front
.fender nroltrttirjg hfllrs; rrnd~r this
condition. move the fork trp and
do14)n several titrres lo tnrrke /he two
1 ~ poraJl'el.
~ s
Ti~ltren(he boJts on {he
tfly nftes
o.vJe 17o1ders and fc
his
!??an?
c l ~ e c k i nin~ I

1.5-2.5

( I 1 .o-1s.o

09440-34520

Front fork assembling tool


attachment "D"

09940-34651

Fig. 1 1-25
r

Tightening torque
of front axle

Front fork assembling tool


"TT"handle

kg-rn

lb-ft)

Remove the inner tube from the outer tube.


Remove the cvlinder unit from the inner
tube.
To remove the oil seal from the outer tube,
remove the oil seal stopper sing and the
washer. When removing oil seal stopper
ring, use special tool @.
Snap ring pliers

09900-06 105

Fig. 11-14

DISASSEMBLY OF FRONT FORK


Remove the upper cap bolt and the fork
spring.
Expand and compress the front fork to
drain oil.
Remove dust rail.
Remove Allen bolt mounted on the lower
portion of the front fork using the special
tool 'i'. At this time firmly secure the
cylinder using special tool 3 ; so that the
cylinder does not rotate.
R rnm hexagon wrench

0991 1-71510

* Remove the oil seal, using special tool #if


necessary. If, after two or three impacts
with the hammer the seal does not start to
move, rotate the remover 90, retighten
and strikc again.

NOTE:

When usiitg the oil scol rptnovcr, use lire


sliding hammer wirh if.

Front Fork oil seal remover

09941-645 t O

CHASSIS

Place the washer on the upper surface of


the oil seal and fit the oil seal stopper ring,
using the special tools.
Mount the dust seal.
Use SAE 10WJ20 oil.
Amount of fronr

fork oil

ASSEMBLY
Insert the cylinder unit into the inner tz~be.
Apply screw lock (99000-32040) to t h e
Allen bolt and firmly secure the cylinder so
that i t does not rotate with the front fork
assembling tool "T"handle and front fork
assembling tool attachment "D", and
tighten the Allen bolt.
Allen bolt
Tightening torclize

2.0-2.6 kg-111
( I 4.5- 19.0 Ib-fa)

After removing the oil seal replace i t with a

new one mounting it on the outer tube


using special tools. i.e.
and 2. after
app!ying oil to the outer periphery of t h e
oil seal.
*.

Front fork oil seal


installing tool driver
Fronr fork oil seal
installing tool at-

09940-549 10

09940-54920

25 1 m t on one side
(8.48 US oz)

METHOD OF MEASURING FORK OIL


LEVEL
Carry out the measurement with front fork
damper assembIy removed from the
motorcycle frame.
Carry out the measurement using special
tool 7'with the front fork spring extracted
and the inner tube fully compressed.
Measure fork oil level by securing adjustable clip '27 to the upper end of the inner
tube as shown in the drawing.
Front fork oil level

140 rnm (5.5 in)

I f the oil is found to be over the level after


measurement, drain the oil to the correct
level using the oil pump lever.
I f the oil is below the level, supply oil using
the oil level gauge.
CA UTION:
Exceeding [he specified oil level will lead
to matfwtcfioning of the fork resu/ting
in oil leako~e,br~aknge,efc. A l ways
make sure [har the oil /eve/ is as

specified.

tachment
Fronl fork oil
level gauge

Fig. 11-28

?l-12

09943-74 1 1 0

CHA SSIS

terclockwise until it turns freely. Mount


valve nut @on the air valve of the front
fork and turn it manually clockwise until i t
stops. Next turn valve G?clockwise until i t
locks, Inject air ~ h r o u g h air charging
port musing an air pump (hand pump),
Front fork gauge

Insert the spring into the inner tube with


closely coiled portion upward and mount
the upper cap bolt.

AIIJUSTINC THE A I R FORK


The GS8SOG front fork is mechanical
pneumatic type. The fork tubes contain
compressed air, and coil springs are used to
augment the pneumatic cushioning action.
The air pressure i s adjustable so that you can
obtain a degree of "softness" to suit running
conditions by raising or lowering the

pressure.

AIR PRESSURE GAUGE


Stand the motorcycle erect on the center
stand, and raise the front end slightly by
jacking up the underside of the engine.
Remove the air valve cap.

Inject 2 to 2.5 kg/cm2 of air with the air


pump to adjust the pressure t o the
specified value, carrying out fine adjustment with valve COT).
When the specified pressure is obtaind,
turn valve 6 clockwise until it locks,
100sen valve,Z, and remove the gauge.
Next, loosen valve nut Band remove the
gauge from the front fork. Finally firmly
fasten the valve cap.
CA UTlON:
Inspect and adjusr air prpssure when the
front fork is cold.
Only air w nilro~enshould be used.
Never use oxygen or any orher gas.
Mver ullow the chargecl gas to come
into contact with, or near, fire.
a The spec!fied pressure of rhe charged

'R

7110 ws:

Fig. 11-30

rn

* Before attaching the special tool on the


front fork, turn valve O clockwise until it
locks. Next turn freely valve 2 coun-

SpeciJied pressure

0.6-1.2 kg/cm2
(8.5-1 7 p s i )

H a ~ r e v ~ rit. muv he adjusted within


I ~ range
P
o f 0 . 6 k g / c m 2 [??.Spsi)to 1.2
kg/crn2 (17 psi) according to the
rrrstorner:~reqrdirernents.

* Never use an air compressor to inject


air. Always supply air with
Pump.

hand

Adjtlst the balance of the left and


right pressures ro within 0. I kp/cml.

Before riding. always inspect and if


necessary, adjust (he presslrre to the
reference pre- sure.
The pressure rn rrsl nor exceed the jollo wing valtte.

'~
1

Airpressrise ahnve the max. vnlre ulill


d o m a ~ e the fork leadirfn~ to oil
leakage, b r e s k u ~ e , er c. A lwnys
main fain the pressure ar !he specified
value.

UTA R hrf NG:


Balance he fmnc atrd rcur srtspensjon by

referring to "'MATCHING FRONT


A N D REAR FORKS". Changln,q the air
pressrtre s e f t i n ~of .fronr jbrk r~quires
the s p r i n ~and damper settings of the
sear suspension ro he c h a n ~ e din accordance ~ d r ht he instructions, and vice
verm.
/ I j . ~verv i!nporrunr to h l e ~ d
oxfa// uir
pre,ssurlJ prior lo clratr~irr~the air
presstire. At tlri.~fitne drcrin fhe air
slo ~ l v by
, degrees. Draining the lrir
all rrt o ~ t tnav
c ~ cause hyclmtdic ./7irid
ro Ire mi.ved into the oil.

FNSPECTION
Inspect front fork spring.
Measure the free length of the fork spring.
Replace if with a new one when it is less
tlran the service limir.

Inspect the inner tube.


Visually inspect the sliding surface of the
inner tube. Replace the inner tube with a
new one if any flaws are found.

Inspect the outer tube.


Visually inspect the outer tube to see
whether it is dented or damaged.
Inspection for oil leakage.
Replace the oil seal with a new one if oil
leakage is found, Leakage is caused by
i n t r u ~ i o n of dust or flaws on the inner
tube.

STEERING STEM

Remove the connection coupler at the end


of lead wire.
Before removing the front wheel, loosen
steering stem head center locking nut
and stem head center bolt '2).

:E

1'16C
d

fi-,*.-F!,i
-.

\4

'v'

1 . Sleertn!: Flc~nhe:id

2. Sleer~ng~ t c n l
3. Lowcr hcnrin~
4. !VPCIIP~
5. llendlipht l1r;urket R1 I
6 . He:ldlirlit hr:lcker Ll4
7. C ~ ~ ~ l i i o n
8. Wa5hcr
9. Nu1
t 0. Rol t
1 1 , Nul
12. Lock washer
13. \Va\hcr
14. Dolt
15. Washer
16. Lrxk wdsller
17. Nut

1 R. Rolt
19. Lock w c h e r
20.
?I.

'2.

Hnndlehar upper clamp


Hnlt
Lock wsqher

13. Stccrin: rtcm nut


24. Dearin:!
25. D u ~ ~t e a l
26. front fork cnvcr
1 7 . rmhlem
28. Hdndlebar pad
19. rmhlcrn
30. Nut
31. Screw
32 Lock wacher
33. IVa~her

Remove the Tour caliper mounting bolts


and remove the caliper assern bties from the
ricght and left front fork.
Then suspend the removed calipers from
the motorcycle frame with scring so ac not
to bend I he oi I hoses.

--I

-7

Fig. I 1-33

REMOVAL
* Remove the fuel tank.
Rcmove the three headlight retaining
screws, draw out the socket connected to
the headli~htand remove the headlight.
Remove the lead wires connected to the
interior of the headlight.
Remove the two bolts fastening the
headlight housing and remove the housing
from headlight bracket.
Remove the tachometer cable and
speedometer cable on the meter side.
Rernove handlebar pad.
Remove the two bolts fastening the metes
and remove the meter assembly.

IS-

Remove the front wheel.


Remove the front fender.
* Loosen the left and rieht upper pinch bolts
and lower pinch holts securing the front
forks.
Draw out the front fork while rotating it.
While removing each front fork, hold the
left and right headlight brackets to prevent
them falling.

CHASSIS

Remove the four clamp bolts securing the


handle bar and remove the handle bar
assembly with grip, cable and handle bar
switch together, and place them on the
upper part ofthe motorcycle frame.
Remove the steering stem head center bolt
and remove steering stem head.
Turn the steering stem nut Ocounterclockwise and remove it using special
tool @ *
At this time hold the steering stem
carefully to prevent it falling.

Remove front fork cover.


* Remove the t w o master cylinder mounting
bolts llii on the handle bar.
At this time rake rare not to bend the oil
hose.

Remove one bolt fastening the oil hose


joint at the lower portion of the steering
stem and remove the oil hose joint from
the lower portion of the steering stem.
The series of parts from the master
cylinder to the caliper assembly can now be
removed.

Fig. 11-38

11-16

Steering nut socket wrench

09940- 14910

Remove the upper dust seal and remove the


steering stem.

4SSEMBLY
Wipe dirt off the upper and lower beating
races with a rag. In addition, thoroughly
wash the bearings with detergent.
Apply a suitable amount of water-resistant
chassis grease to the upper and lower
bearings.

Insert the: steering stem into the head pipe


from below. Place the upper bearing on the
upper portion of the head pipe. place the
upper dusr seal on he bearing and tighten
the srecring nut. Tighten the nut using the
special rorque wrench 9.
Steering nut socket wrench

09940- 149 10

Steering stem nzlt tightening method

NOTE:
Tighten the steering sretn lock nut ro a
ssrfficiea r de~reefor assemblin~.It can
be changed durinl: sli bsequenr readjusrmenr of /he s r e e r i n ~ .

5. Tighten the steering stem side bolt to 1.52.5 kg-m(1 1.0-18.0 Ib-ft).
6. Turn the stem nut back slightly and tightell
the steering stem head center bolt to it's
normal torque of 33.6-5.2 kg (26.0-37.5
lb-ft). When the front fork is moved hack
and forth. it must move freely. If there is
any play in the forks. loosen the center bolt,
tighten the stem nut slightly and retotqrie
the center bolt.
Steering stem head
center bolt:

3.6-5.2 kg-m
(26.0-37.5 Ib-ft)

Steering stem side

1 .S-2.5 kg-m
t i 1.0-1 8,O lb-ft)

bolt:

Install the handle bar using the two clamps


and four bolts.
CAUTION:
The following adjustment procedure applies
when the front fork has already been set.
Follow the steps below for adjusting and
checking the steering stem.
1 . Using the steerin3 nut, socket and a torque
wrench, tightcn ~ h cszem nut to 4.0-5.0
kg-rn (29.0-36.0 lb-ft,)

Tightening torque:

Push the main wire harness O forward


through the left lower portion of the
steering stem. A bolt fastens the oil hose
joint on the lower portion of the steering
stem. The holder is fastened by this bolt
together with other parts. Firmly secure the
wire harness with this holder after
assembling the hose joint.
Route clutch cable GI and lead
wires@ ,t9 of left and right handle bar
switches to the front side of the steering
stem head as shown in the drawing.

2. Move the stecring stem back and forth five


or six times to sea! the bearings.
3. Turn the steering stem nu! back to 0 kg-rn.
Then retighten very lightly so that no play
can be detected in the stem.
4. Install ;the steering stem head and tem-

porarily tighten the steering stern head


center bolt to 2,O-3.0 kg-rn (14.5-21.5

Ib-it).

1.2-2.0 kg-rn
(8.5- 1 4.5 Ib-ft)

Fig. J J -42

Insert the left and right front forks from


the underside of the steering stem and
tighten the front fork upper pinch bolt and
Iower pinch bolt. Then align the end of the
inner tube with the upper end of the stem
head.

Secure the meter assy with the two bolts.


Install tachometer cable @
Now, thread the tachometer cable through
the bottom of the steering stem to the Front
of steering stem head as shown in the
i.

Install [he speedometer cable


mounting the front wheel. See

drawing.

after

Tightening torque:

page 1 1-23.

pinch bolt:

2.0-3.0 kg-rn
(1 4.5-2 1 .S Ih-ft)

Fronl rnrk Power


pinch bolt:

1 -5-2.5 kgm
( I I .Q-18.0 Ib-ft)

Front fork upper

Secure the front caliper assembly to the


right and left f r ~ o tforks with the two
bolts.

I
Tightening torque:

Fig. 1 1-43
Secure the front master cylinders each with
hvo bolts @ . Maintain a clearance @I
between the righl handle bar switch and the
master cvlinder of 2 mltr (0.08 in).
Tightening terquc

0.5-0.8 kg-rn
(3.5-6.0 Ib-Ft)

2.5-4.0 kg-tn

( 1 R.O-79.0 Ib-fi)

Secure the front fender with the four bolts.


Mount the front wheel.
Thread speedometer cable through the

cable guide mounted on the fender and


along the brake hose joint through [he
middle part between the front fork cover
and steering stem and mount it on the
meter side.
* Confirm that the speedometer gear box is
positioned correctly (see page 11- 10).
Remove the jack from under the engine.
Route the main wire harness 6,ignition
switch lead wire @, right handlebar switch

lead wire@, front brake switch lead


wire @] and turn signal light lead
w i r e B t h r o u g h the lower hole of the
headlight housing and fasten them together
using the headlight bracket.
Attach the brake hose joint to the lower
portion of the steering stem with one bolt.
Then tighten the clamp securing the main
wire harness. Suspend the caliper from the
motorcycle frame by string.
Fit rhe headlight brackets into the intermediate portion between the steering
stem head and steering stem without
mistaking the left or right positions. New,
replace the Front fork cover.

Fix. 11-45

* Connect each lead wire (see page 11-7).


S tecring inner race and

Secure the headlight with the three screws.


* Adjust the vertical angle of the headlight
beam (see page 1 1-7).

REMOVAL OF STEERING STEM RACE


Place a jack under the engine.
* Hook special tool :Con the race and use
special tool 2)to remove the upper and
lower races.
'I '

Slccrit~gFlcm inner race


i-~~~~ui'er

W94 1 -5491 1

l r r r ~ c racc
r
:EIICI bearing

09941-74910

staller

1L

dri~mer
-

STEERING STEM REARING


REMOVAL
* Remove bearing using special tool 9.
Use of stwcia! tatnl

MOUNTING
Apply a small amount of motor oil to the
outer periphery of the upper and lower
race? and start [hem into the head pipe by
lapping them tightly with a plastic hammer.
Press in the lower and upper races using
special tool (3,
Using special tool

Two of the four tapered guides set in the


special tool 9are to be used. Place the one
with the larger outer diameter below and
the other with the smaller outer diameter
above and press-fit the race while rotating
it.

Then tighten the nut until i t locks completelg.

Firmly fiit the holder into the roller portion


of slteeriing stem bearing. Next, fit the ring
into the L-l.-l*IIUIU~~
and screw the two shafts
into the upper portion of the holder.
Screw attachmentlTfinto the top of the
steering shaft and remove the bearing while
rotating the handlc.
Rearing inncr race remover

119941-84510
I

CHASS1.S

MOUNTING
* Apply a small amount of motor oil to the
inside of the bearing and press it into the
steering stem shaft using special tool 10.
Lubricate bearing wit t i grease.
Race and bearing driver

0994 1-749 10

REMOVAL
Lift the front wheel off the floor by raising
up the engine, with the center stand resting
firmIy on the ground.
Disconnect the speedometer cable from the
wheel.
* Pull off cotter pin Q from axle nur a:and
loosen the nut. Remove the axle holders,
right and left, and take off the wheel.
CA U TION:
After removing the front wheel, do not
squeeze the front brake lever or the
brake pads will move inside the caliper.
The pads should be left wh~lrethey are at
the time of wheel rerno~~ul
otherwise
dgficulty wiil be encountered in reinstalling.

Fig. 11-49

FRONT WHEEL

i
Fig. Il-3 1

>

1 . Front wheel

1 1. Speedometer gear box

2. Rearing
3. Spacer
4. Front axle

12. Front hrakc disk


13. nolt

5 . Nut
6. Cotter pin
7. Bearing spncer
8. Axtc spacer

9. Washer
10. Dust seal

14.
15.
16,
17.

Washer
Tire
lnncr tube
Balancer

* Unlock

the 6 bolts securing the disk to the


wheel hub after straightening the lock
washers. Remove the bolts and separate
the disk from the wheel.
SimiIarIy remove the disk on the other side.

CHASSIS

Insert an iron bar into the front hub from


the speedometer gear box side and tap the
circumference of the ball bearing inner
race uniformly to remove the bearing.
F

Fig. 11-54
a

* Similarly, insert an iron bas into the front


hub and uniformly tap the periphery of the
ball bearing inner race on the opposite side

Inspect the play of wheel bearing inner race


by hands while fixing it in the wheel hub or
wheel. Rotate the inner race by hands to
inspect whether abnormal noise occurs or
rotating smoothly.
Replace t h e bearing if there is something
unusual.

to remove the bearing.


Play

Play

INSPECTION
Using a micrometer check the disk for
wear. The thickness can be checked with
the disk and wheel in place. The thickness
limit of the disk is specified below:

Front Brake disk Thickness


Standard

(0.23 - 0.14 in)

Limit
Under
5.5 m m (0.22 in)

Using a diaI gauge, check the axle shaft for


runout and replace it if the runout exceeds
the limit.

With the disk mounted on the wheel, check


the disk for face runout with a dial gauge,
as shown.

Front axle runout


Service Limit
I

Front brake disk runout


Service Limit

0.30 m m (0.0 1 2 in)

0.25 rnm (0.010 in)

CHAS S I S

Check the tire pressure, and examine t h e


valve for evidence of air leakage.
Check the wheel for axial and radial
runout. Far the axial runout, apply lie
dial gauge spindle horizontally to he rim;
for the Iatter, point the spindle radially to
the inner surface of the rim.
Support both ends of the shaft to inspect
f the rim with a dial gauge.
n
'ront wheel rim runout

Rvnout

Service Limit

AXIAL

2.0 m m (0.08 in)

RADIAL

2.0 mm (0.OR in)

* Inspect

the tire for wear and damage, and


check the tire tread depth as shown.
Replace a badly worn or damaged tire. A
tire with i t s tread worn down to the limit
(in terms of rrcad depth) must be replaced.

Front tire tread depth


I

Service Limit

1.6 rnm (0.06 in)

Fig. JI-58

Fig. 11-5 7

TIRE WARNING
Check tire pressure and general tire condition
frequently. S~tzukirecommends replacement
only with the specified si7e Dunlop, or I n o ~ ~ e
brand H-rated tire.

Spin the wheel (complete with the brake


disk and tire) to check dynamic balance.
Uqe a 20-gram o r 30-gram balancing piece,
as necessary. Spin rhe wheel sevcraI timec
and make sure that the wheel corncs t o a
natural halt not in a particular nosition but
in random positions each time.
Wheel balancer

30 grams (0.03 tbs)

* TlRE PRESSURE SHOULD BE MEASURED


WHEN T l R E IS COLD.

5541245100

IMPORTANT:
Remember rhar the wheel will not be ,
dynamically balanccd when the tire is
replaced or repaired after a puncrure:
rhe wheel musr be rehalanced eaclt /imp
its muss is altered.

ASSEMBLY
Reassemble and remount the front wheel in
the reverse order to disassembly and
removal in addition to the fo!lowing items:
Use special t o o l m t o install thc wheel
bearings. These bearings are driven into
the hub bore.

NOTE:
When arraching a balance weigh! to the
wheel (rim), use a plastic hammer lo
prevent damaging lo the wheel. Never
use a rneral hammer.

l'ig. I 1-62

* Make

sure that tile brake disk i s

clean and

free from grease. Usc only nor1 pezro-based


cleaner. After sccuring i t in placc by
tightenins the bolts, be sure to lock eacli
bolt by firmly bendins d o w n the lock
washer tongue.

Fig. I/-60

Disk plate tightening


torque

1.5-2.5 kg-n~
l .O- 1 8.0 lb-ft)

(I

Fig. /I-63

Before installing the speedometer gear


b o x @ , grease it and align groover2 (for
fitting the two drive pawls to the hub) with
t h e hub to insert the gear box in the wheel.

REMOVAL OF TUBE AND TIRE


* Mark the position of the tires and

Insert an axle spacer into the front wheel


and insert the front axle. Next, From the
right side, assemble the bearing spacer,
cover, axle spacer, washer and nut in that
order and temporarily tighten the axle nut.
See page 11-10 for the order of assembly.
With the axle shaft mounted. place the
front wheel under the front fork and lower
the jack placed under the engine to the

front fork.
Do not change the position of the
speedometer gear box (see page 11 - 10).

rotational direction of the valve stem with


chalk.
Remove the valve cap and let out the air.
Remove the valve fastening nut and fully
loosen the bead protector nu2.

Fig, 11-65
Step on the tire bead, push it down and as
shown below, install the five wheel rim
protectors (special tools) to the wheel.

Wheel rim protector

* Tighten axle nut.

0994 1-945 10

CA UTION:

To prevent the axle shafi rotating while


tightening the axle nut, insert a round
bar into the head of theshaft on the disk
plote side. Rotation of rhe shaft may
Spud to bending of the speedometer
cohie.

Axle shaft tightening

torque

3.6-5.2 kg-m
(26.0-37.5 Ib-ftj

Mount the axle holder on the lower portion


of the front fork. Maintain a uniform
clearance between the axle holder and the
fork side front and rear (see page 11- 10).
Axle holder
tightening torque

1.5-2.5 kg-m
( I l .O- 1 8.0 lb-ft)

Remove the jack from under the engine.

Fig. 11-66
Using f a t tire levers, work the tire bead
over the rim, starting near tlie valve stem.
CA UTlON:
I . Always use the wheel rim prolecrors.
If nor, the fire rim could be damaged
by the lire lever.
2. The fire lever should be upplied over

the wheel rim protectors.

Remove the tube.


Remove the tire from the whee

Apply soapy water to the tire bead.


Hook the bead protector on the beaa
wortion of the tire.
Fit the rest of the tire using tire levers in a
position well away from the valve.
CA UTION:
I . Avoid inserting rhe tire lever too
deeply into the tube (ro avoid
damaging the rube).
2. As in tire semovol, use rhe wheel rim

MOUNTING
Inflate the tube sufficiently so that the tube
does not Told,
Press the tube irlto the tire.
* Push one side o f the tire hc:ads intc> the
whccl rim. 1
that t l1e embc~ s s e d
--- the
arrow mark U K I i r l r lire faces- .---.
toward
rotar ional direction of the wheel.
Next, install the tube, insert the valve into
the rim, and tighten the valve nu! temporariiv. A n arrow i i
:the rotational direc~ioni s mark
le rear tire.
A yellow mark i s prov1ut.u on the valve
portion to aid checking of the tire balance.

By pushing the tire, confirm that the tube


is not caught between the rim and tire.
Inflate the tire t o the specified pressure (see

*
*

page 11-22).
Tighten the bead protector n u t and then
the valve nut ,
Mount the valve cap.

FRONT BRAKE MASTER


CYLINDER
1f=-Y)
;
. :=
7 -:
',, - 4
>

~4

:?"C "

1 . Piston& cup~et

2 . Diaphragm
3 . Diaphragm plate

4. Cap
5 . Washer

6.

~011

'

7. 0 ring
8. Scretv
9. Reservior

CHA SSlS
-

(P

3,,

CA UTION:
A clearanc~of about 2 mm (0. OcY in) # A
must he provided hetween the ri~hr-lzund
Ilandlehar switch arrd t l ~ r rriusrvr
cvlirr der.

3
.7
''<\WX.
I

'%
* &>

,-

<$

-3
-1
: ?I
Y- !3

I
I

c;

0
Fi,?.11-7-7

I . Masrer cvlinder boo1


2. Union boll
3. Gasket
4. Rrakc N o . I hose
5. Hoacguidc
h. Grommet
7. Brake hose joint

R. Bolt
9. Washer
10. Lock washer

* Refer to the illustration to reconnect the

,,

brake hose to the master cylinder.


II

1 I. Rrake No. 2 hose


12. Union boll
1 3 . Gaskc1
14. 'Union boIt
I S . Gasker

Fig. J 2 - 72

REMOVAL
Remove the headlight.
* Remove the front brake switch lead wire
connected within the headlight housing.
Remove the union bolt.
CA UTION:
Loosening of the union bolr will cause
brake flttid lo flow our. Th~refore,
remove the brake fltrid from the brake
fluid cup beforehand. Completely wipe
off any brake fluid adhering ro any par!
of the motorcycle frame.

MOUNTING
Mount the master cylinder on the handlebar.
11-26

Fig. 1I - 74

Connect the front brake light switch lead

wire within the headlight housing.


Secure the headlight with the three screw

AIR BLEEDING THE RRAKE FLUID


CIRCUIT
Air trapped in the fluid circuit acts like a
cushion to absorb a Patge proportion of the
pressure developed by the master cylinder and
thus interferes with the Full braking performance of the caliper brake. The presence
of air is indicated by "sponginess" of the
brake lever and also by lack of braking force.
Considering the danger to which such trapped
air exposes the machine and rider, i t is
essential that, after remounting the brake and
restoring the brakc system to the normal

C H A SSIS

valve. Repeat this process until the oil


flowing into the receptacle no longer
contains air bubbles.

condition, the brake fluid circuit be purged of


air in the following manner:
* Fill up the master cylinder reservoir to the
'"igh"
level Iine. Replace the reservoir
cap to prevent entry of dirr.

NOTE:
Replenish the brake fluid reservoir as
necessary while bleeding the brake
system. Make sure that there is always
somefluid visible in the reservoir.

Close the bleeder valve, and disconnect the


pipe. Fill the reservoir to the 'Wigig' level
line.

Fig. 11-75

Blecder valve
tiyhtening torqire

0.6-0.9 kg-m
(4.5-6.5Ib-ft)

Attach a pipe to the caliper bleeder valve,


and insert the free end of the pipe into a
receptacle.

Hondie the brake fluid with care: the


fluid reacts chemically with paint,
plastics, rubber materials, erc.

MASTER CYLINDER DISASSEMBLY.

Fig. 11-77

Bleed the left caliper first, and then the


right caliper.
Squeeze and release the brake lever several
times in sapid succession, and squeeze the
lever fully without releasing it. Loosen the
bleeder valve by turning it a quarter of a
turn or so so that the brake fluid runs into
the receptacle; tlis will remove the tension
of the brake lever causing it to touch the
handlebar grip. Then, close the valve,
p u m p and squeeze the lever, and open the

Remove the front brake lever: pull off the


cotter pin and remove the n u t - t o free the
lever for removal.
Remove the boot. Take out the circlip
from the bore of the master cylinder with
special tool 6.

1
NOTE:

Discard the rerno ved boor. Replace with


a new boot when reassembling.

Snap ring pliers

09900-06 I05

INSPECTION OF MASTER CYLINDER


* Check the fit of the reservoir with the
cylinder body. The "0" ring should be
replaced with a new one when the master
cylinder is disassembled.
* Inspect the primary cup for wear and
damage, and replace i t with a new one if
necessary.

Fig. 11-78

Take out the piston, check valve, coil


spring and primary cup from the bore.
NOTE:
Clsing a piece of wood or soft-melal,
push our the check valve coil spring and
primary cup. A void scratch irtg the bore
wall.

Fig* 1 I - 79
Remove two screws (3 securing the
reservoir to the master cylinder body, and
take off the "0" ring from the body.

Fig. 11-81

* Replace the brake hose every two years.

ASSEMBLY
* Reassemble the master cylinder in the
reverse order to disassembly with the
following additional steps:
r Apply brake fluid to the cylinder bore and
all the internal parts to be inserted into the
bore. Do not attempt to insert one part
after another into the bore; assemble the
primary cup, coil spring and check valve
together, and insert this assembly into the
bore, taking care not to allow the check
valve to become cocked or to unseat the
coil: spring as it goes into the bore.

I t is advisable, though not essential, to


replace the primary cup with a new one in

FRONT BRAKE CALIPER

reassembly.

Alu~nysinstall (he circlip with (he sharp


edge a wu.v,front [he spring.

After ritting the circlip, try to turn ir in


place to make sure i t is snugly seated in the
sronve. Replacing the circlip with a new
one advisable instead of re-using the circlip
removed i n disassembly.

1 . Piqton % pad se! 6.


2. Pad set
7.
3. Oring
8.
4. Axlc dust cover
9.
5 . Pistnn scal
10.

Pisfon boo1
1 t . Cap
Caliper holdcr 12. Roll
1 3. Washer
Screw
Caliper axle
14. Lock washer
Bleeder

Fig. 11-86

Recorrnect the brake levcr to the master


cy!inder before rnoiln~ing the master
cylinder on the handlebar. Mount to the
handlebar as described in page 11-2.

REMOVAL
Disconnect brake hose No. 2r3frorn the
caliper, and catch the brake fluid in a
suitable receptacle. Squeeze the brake lever
to push out the fluid.

CA UTION:
Do no6 splash the brake fluid when
removing the caliper assembly.

CALIPER DISASSEMBLY
* Loosen and remove the two caliper axle
bolts.

* Remove two mounting boItsO securing the


caliper to the fork. Take off the caliper
assembly .

Remove screw sq, fastening No. 2 pad


(stationary) ro the caliper body. and take
oul the pad. Separate the caliper holder
from the body.

MOUNTING
Tighten two caliper mounting bolts.

7.5 -4.0 kg-rn


( 1 8.0-29.0 ih-ft)

Tightening torquc
I

Tighten the brake hose union bolt.

Tich tcning torquc

1 .S-2.5 kg-m
l .O- 1 8.0 lb-ft)

(I

Pour brake fluid into the reservoir up to the


"High" level line.
See page I f -26 for air bleeding of the
caliper and brake hoses.

Fig. 1 1-89
Apply compressed air (2.0 kg/cm', 28 psi)
to tlie oil hose connecf ion to pt~slio ~ t tthc
piston.
NOTE:

CALIPER

Remove Che pisfon boot ro facilitate

C H A -5.71.7

After removal of the caliper hoIder, take


out the piston seal, dust seal, piston boot
and "0" ring. Wash the piston seal and
piston boot cIean with fresh brake fluid.
Discard the removed dust seal and 'W"
ring: always use a new seal and "0" ring in
reassembly.

ASSEMBLY
Apply brake fluid to the piston seal 9and
fit it into the caliper body.

CA UTiON:
nor use such a cleaning fluid os
tricld~neor even gasoline to wash rhe
pistorz seal and boo f.

Dn

Fit the caliper holder@, to the body,


taking care not to damage the dust seal.
Apply brake fluid to the piston, and insert
it into the bore.

I NSPECTION
Check brake pads for wear. A pad worn
down no the limit (indicated by the red
groove on the edge) must be replaced.
Fig. 1 1-94

..

2.

Par1 KO.Z
Pod Ua,. I

3,

Rcd crorn

I.

I./,

Apply a thin film of SUZUKT SILICONE


GREASE to the brake pad on the floating
side. Do not apply a thick coat, or never
use any other brand grease. Otherwise, the
grease smears the disk surface, thus causing
the brake to slip.
Do not apply grease
at this portion

Portion requiring
grease

Fig. 1 1-95

I
LLEL

Fig. I 1-99
CA UTION:
As in the case of front-brake caliper
ussemlrl+v, ir is essenriol fhaf rhe air

I M P 0 R TANT:
Mosr gf rhe s t ~ p sin reossemhl-Y elf the
fronr-brake caliper assern hf-v are applicable also to [he rear-brakc caliper
assemb fy.

bleeding operation be carried out afier


restoring the rear brake systenl to the
operaring condition.

Remove the right frame cover.

Remove the reservoir cap and suppty brake

RRAKE PEDAL ADJUSTMENT

fluid.

Adjust the pedal height in the following


manner:

* Bleed air from lie caliper ancE the oil hose.


AIR BLEEDING OF THE RRAKE FLUID
CIRCUIT
a Refer
fa 111e procedure outlincd in
FRONT-BRAKE ASSEMlI3P.Y; he unclcrlyin9 principlec arc riic sntne. Differctlccs, however. due zo rhc h c t thar the
master cylindcr ic. ac~uared a pedal and
that there are ~ w o
hlccder vnlvec. Bleed air
from the inboard valve First. and lllcn from
the out hoard valve,
* Operate thc pedal in the wav the brake lever
i s operated to drive air out. The pedal
depressed will yield and go down as thc
fluid runs in to the scceptacle; in the ca5e of
the front brake, 13ie lcvcr touches the
handlchar. When the pedal is abaul 40 m m
(1.6 in) f r o m I he footrest whet1 deprcsqing,
cloxc tlre bleeder valve and rcleaqe he
pedal. Repeat the process of pumping and
depressing ttic pedal until no air bubbles

Blccdcr valvc
t i ~ l ~ t c n i ntorque
g

0.6-0.9 kg-m
(4.5-6.5113-ft )

Loosen lock nut 1' > . Loosen the return


stopper boIt (21on the brake pedal.
Loosen lock n u t 3 . Rotate t h e
pushrod,3no bring the pedal to a position
20 mrn (0.8 in) below [he top face of rlie
footrest; and secure the pedal rhere by
tightening nut ,3.

* Adjust the clearance

between pedal arm

and return stopper to 0.5 mrn (0.02 in.).


and tighten lock nut 0.

PAD REP1,ACEMENT
The pads can be replaced with the caliper
assembly in place, by removing the pins
supporting the pads and their stop pin? and
springs, but tliix method is not recommended because rtlc piston boots might
also come off and, i t is almost impossible
to accurately refit the boot when the
assembly is in place. Reliable and accurate
replacement is ensured by first removing
the caliper assem hlv.
DISASSEMR1,Y 01:REAR BRAKE
CALIPER

Remove the boot from each piston. Apply


compressed air (2 kg/cm2, 28 psi) to ~ h c
intcrnal fluid passaFe to force each pisron
out of the bores.
-1

I.

2.

Pnrl
l x F r c n l i r r htrlr*

:.

I t r ~ l ~<:~liw:
r
IK1d\

-1.

17i\rnn

C1

Fig. 11-102

* Reniovc t h e pad in~pectioncap.

D r a w out
the two pins 5 supporting each pad ( a stop
pin 173 must he pulled off first from the end
of each pin msi ). A t the samc time. remove
the two springs 3 .

Remove the two bolts fastening tlie two


caliper body halves togcrhcr, and separate
the two halves.

INSPECTION
* Chcck brake pads for wear. Each pad is
stepped at itr edge to present two edge
faces; one is painted red and the other is
1.S m m (0.06 in) T thick. The pad may 17c
kcpi in service until this 1.S m m (0.06 in)
face disappears due to wear.

C H A SSIS

ASSEMBLY
RearsembFe in the reverse order to
disassembly paying attention to the
following points.

Wash the pistons, piston boots, rubber seal


and caliper body halves with fresh brake
fluid just before reassembling each part:
reassemble while washing.

While holding the springs with fingers,


insert the other pin through the shims and
pad into the caliper body.
Set thestop pin into rhepin hole.
Place the inspection cap back on the brake
pads.
Bleed the air from the system as describe4
in page I 1-33.

\
REAR MASTER CYLINDER
T

Fasten the two body halves together,


tightehing the two bolts to the torque
specified below:
Tightening torque

2.5-3.5 kg-m
(18.0-25.5 Ib-ft)

Fit a brake pad shim to the rear of the


brake pac! so that the " h n l ~ " i n the shim
poinrs to [lie ironr.

I. Rear master uyllndcr assy


2. P~ctcin& cup FCI
3.
4.
5.
6.

Fig. 11-108

Insert rhe pin into h e caliper body from


the wheel side.
Run the pin through the shims and pad
into the opposite caliper body.
Hook the two springs onto the lower part
of the pin.

Yoke

PUS^ rod
Nu1
8001

7. Cisclip
S. Dolt
9. Warher
10. Lock wochcr
1 I . R c w r v o ~ rlank ass?
12. Cap

13.
14.
15.
16,
17.
18.
19.
20.
21.

Diapllrag~nplatc
Di;~phragrn
Clozrlp
no11
Lock washcr

Hose
Clamp
Rear hrakc Iiore

Rolr

22. Grommel
23. Union boll
24. Ciaskc~

CHA SSIS

REMOVAL
Pull off split p i n w from the lower end of
pushrod, and disconnect the master
cylinder rod from the brake pedal arm.
Remove the right frame cover.

Remove rhe master cylinder by lifting i t up,

Fig, I J - I 1 0

Remove the union bolt O securing tile


brake hose.

MOUNTING
Fasten the reservoir with one bolt.
Insert the cylinder master rod into the
brake arm.
Fasten the master cylinder with two bolts.
Ti.gIitenin9 Torque

NOTE:
Drain rhe brake fluid from the reservoir
beforehand. Ex~scisecare to prevent the
brake fluid corning in contact wilh [he
motorcycle frurne. Jf any brnke fluid
touches the frame, wipe it off immediately with a rag.
Remove the two bolts @: securing [he
master cylinder to the frame, and lower the

1.5-2.5

kg-rn

( 1 1.0-18.0 Eh-f~)

* Position the master cylinder rod and the


brake arm with the pin and secure them
with a split pin.

Inserf rlte pin fmnr //re Sqft side, i n s w


a washer and connect 6/7e rod (O the arm
through the s ~ ~ lpitr.
ir

cylinder.
o u t air bleeding indicated
previously. (See page I f -33)Adjusr the brake pedal height as indicated
3reviously. (See page 1 1-33).
Carry

* Remove bolt Osecuring

the reservoir and


remove the reservoir from the frame.

CHASSIS

DISASSEMBLY OF MASTER CY LFNQER

NOTE:
Using a piece of wood or soft-metal,
push these internal parts out of the
cylinder bore, taking care not to nick or
scrarch the bore wall. Be cureful, too,
not to damage the parts.

1
2
3
4

INSPECTlON
Inspect the primary cup and boot for wear
and damage and, if necessary, replace
them.

6
I

i
8

I , Check

V ~ V C

3. Master cylinder M v
3. Spring
4. Primary cup
5 . Piston

9 CUP

h e Secondary

7.

Rwt

8.

Push rod

9.

Yokr

Take out the piston, check valve, coil


spring and primary cup from the cylinder.

Fig. 11-113

* Loosen the clip screw on the master

ASSEMBLY
Reassemble the master cylinder in the reverse
order to disassembly with the fallowing
additional steps:
* Be sure to apply brake fluid to the cylinder
bore and all the internal parts to be inserted into the bore.
* Assemble the check valve, coil spring and
primary cup outside the cylinder, and
insert the assembly into the bore, taking
care not to unseat the coil spring off the
check valve. Remember that the spring can
easily come off the valve. Be careful not to
allow the primary cup to cock inside the
bore.

cylinder side and extract the brake hose


from rhe master cylinder.
Take off the boor, and take out the circlip
usirlg special toot
Snap ring plien

09900-06 105
-

It is advisable to replace the primary cup


unless the cup removed in disassembly is in
perfect condition.
C A UTION:
A /ways install the circlip wilh the sharp
edge n way from the s p s i n ~ .

REAR WHEEL

After fitting the cisclip, try to turn it in


place to make sure i t is snugly seated in the
groove. Use of a new circlip is advisable
instead of re-using the one removed in
disassembly.

BRAKE PARTS TO RE PERIODICALLY


REPLACED
Brakes are critical safety components which
must be maintained in peak condition at a11
times. In view of this requirement, the
following brake pasts of the Model GS850G
should all be simuttaneovsEy replaced at
intervals o f t w o years.
The parts named are subject to wear or
deterioration but may continue ta work
satisfactorily beyond the two-year interval.
Experience, however, tells that replacement
after each two years is justified from standpoints of safety and economy. Adherence to
this rule is strongly recornrnenderl

Replacemcnl interval: Two years


Components of master cylinder assembly
(Use Suzuki Genuine parts: Master
cylinder cup set)
Component ofcaliper assembly
(Use Suzuki Genuine parts: Pad and piston
set)

NOTE:
Pad and piston set inclttdes two kinds 01
grease packed in pouch. Grease in rhe
pouch primed "Caliper Axle Grease"
should be used for !he caliper axle and
prinred "Rruke Pod Grease' 'for rhe pad
No. I .
I

Be sure to wash all component paris in


the above sets with clean brake fluid
before installing them into the master
cylinder or caliper.

1. Rear wheel ~ e z
2. Cudlion
3. Bcarinr.. RH
4. be art^. LH
5 Rear~nyspacer
6. Spacer. R tl
7. Spaccr. LH
8. Spacer, R H
9. Rcar axle
10. Nut
I I . Rear caliper bracket
1 7. cotter pin
13. W a ~ h e r

14, Warher, LH
15. Llriven ioint

16. Rolt
17. 0 r ~ n p
18. Nut
19. Washer
20. Bolt
2 1. Rear hrakc d i ~ k
22. Rnlt
23. Wa~her
24. Rear tire
25. lnncr tube
26. Balancer

CHASSIS

REMOVAI,
Place rhe motorcycle on level ground and
place the rnotorcyle on the center stand.

Insert R phillips head screwdriver into the


right side of the center stand pivot to
prevent the motorcycle from Falling off the
center starrrl.

Fig. 11-120

Remove both right and lef[ rear shock

absorbers.
Remove the rear torque link cotter pin,
bolt, nu1 anci support bolt af the brake
hose.
Remove the axle cotter pin and axle nut.

* Remove the upper shock absorber nuts and


pull the top side o f thc shock absorbers
frec from rhe mounting lugs. Thiq will
allow rhc swing arrn/differenriat to be
easi3y moved.

Take care r ~ n r 10 burn yourself if / I I P


Fig. 11-121

Lift the swing arm/differential up by


attachir~gthe 14 rnm wrench to one of the
caliper bolts and use the wrench as a lift
h a n d l e . While lifting t h e s w i n g
arrn/differen tial Insert the socket wrench
handle through the righi mufftcr support
and swing arm hole. This will hold the
swing a r m in the best position for
removing the sear wheel axle-

Remove the axle. while at the same timc


st~pportingI h e caliper assembly. After the
axle is clear of the caliper, hang the caliper
on the upper shock absorber mount stt~cE.

Do no/ allow rhe /?rake hose

to fnucl7 a
hat tnr!~ler.Prorerr ir by wrapping llte

hose in o rClg.

CHA SSIS

Remove the axle from the differential


housing. Remove the wheel from the
splined drive and set the wheel assembly on
the ,wound.

Remove the rear wheel assembly.

Fig* ! I - 1 ;

The front forks niust be compressed in


order !n till the back or the motorcycle u p
so that t l i c tire can be rcrnovcd from the
fender welt area. Depress rhc Trot11 fork
filler vnIvcs to rcmovc all air prc~~iii-v
from
tlie systcm. Remcin her to hleccl prcsairc
off slowly. To compress t h c f'nrks tun1 the
forks to the right Ibrk stopper, Hang the
front fork compressing tool hook I o n the
left fronl tkr~durboss. Hauy wirc lnop 3 ' on
thc left fork stoppcr. Pivot tlic rron( fork
compressing t ~ o lI ~ a ~ i d lto
e compress the
forks, then position Eiook 13 on t h e tool
lever handle to Ilold the forks in the
compressed position.

The brake disk is secured to the wheel hub


by h bolts, each being locked with a washer.
Rend u p the lock washer. remove the bolt?
and s e ~ a r n
te the disk from rlle wheel.
1 6

y7 r
k
.

,.

\4

fX5kA-

Fi,q. 11-126

Straighten the washer Ionzucs bent over


~ h sic
c nutl;, remove the nuts and remove
the driven joint from the wheel.

Remove the six bolts from the bushings.


Remove the bearing.

INSPECTION
Using a micrometer check the disk for
wear. The thickness can be checked with
disk and wheel in place. The thickness limit
of the disk i s specified below:
Rear brake disk ti-iickness
Standard
6.5-6.9 mrn
(0.26-0.77 in)

Using a dial gauge, check the axle shaft for


runout and replace i t if the runout crxceecfq
the limit.
Rear axle runout

0.25 mrn 10.01 0 in)

Service Limit

Service Limit
(0.24 i n )

Fig. 11-130

* Inspect

the tire for wear and damage, and


check the lire tread depth as shown.
Replace a badly worn or damaged tire. A
tire with i t s tread worn down to the limit
(in terms of tread depth) must be replaced.
Rear tire tread depth

Fi,ig. 11-128

Reinstall disk on huh.


2.0-3.0 kg-m
Tightening torque
( 1 4.5-21.5 Ib-ft)

With the disk mounted on the wheel, check


the disk for face runout with a dial gauge.
as shown.

Rear brake disk ninnout


Service Limit

0.3 mrn (0.01 2 in)

Service Limit

2.0 mrn (0.08 in)

Check t h e tire pressure, and examine the


valve for evidence of air leakage.
Check the wheel for axial and radial
runoul. For the former runout, apply the
dial gauge spindle horizonrally to the rim;
for the latter, point rhe spindle radially 10
the inner surface o i the rim.
r While supporting both ends of the shaft
inspect runouc of t h e rim with a dial gauge.
Rear whecl rim r u n o u t

Fig. J 1-133

Service Limit
Runout
-

AXIAL

2.0 mm 10.08 in)

RADIAL

1.0 rnm 10.08 i n )

ASSEMR1,Y
Inserr ~ h crear whccl assen~hlvunder the
7

Spin the wheel (complete with the brake


disk) to check dynamic balance. Use a 20gram or 30-gram balancing piccc, as
necessary. Spin the whcel several timec and
make sure that the wlieel comes to a
natural IiaFt not in a parzictllar posit ion but
in random positions each time.

CA U TI ON:
ri'J1etr reinsraltirl,~the rerrr caliper he
carefir1 not f n ~ M I ~ T1 I1 1 ~hrukr 11ose nr
roll re it itnpro/ler/-v. N e w r ~Jepresstltc
Broke pedal w i ~ h(he rear ~ ~ l r crct~toved
el
as it i - ~
vver?, rfqji'arl~ro +forcetlte hrake
prrds bock into r/re caliper assenlA(v.

Part Nurnber

I~isra!l the rear torque fink in the caliper


awernbly. Rernem bet to reinstall the cotter
pin after tightening the bolt and nut.
Remove thc socket wrench handle a n d
replace tlic shock ab~orbers.Tighten I heir
securing nuts ro specification below.
Removc the screwdriver from the ceriter

20 grams (0.04 Ihs)

5541 1451 00

qtand p i v o ~ .
Tightening torque

30 grams (0.07 Ibs)

5541 2-45 1 00

Wheel h a l a ~ i c e x
--

Weight

JMPORTA NT:
Remember thnr (he wheel will nor be
I

rear fender well area.


Remove the fronr fork comprcssin~tool
from the front fork.
* Fit the whccl awernbl?l hack onto r l ~ c
rplirled engapcrncnl r haft. I nwrt Ilic avIe
through to rhc risht sick o f the swinginy
a r m . Insrnll and tjsIltcn tlic axle riirt
securely. Fit lhc cotter pin in t l l c axlc nur.

balanced whea t f i ~tire i s rrplaced or


repaired after a ptrnctttrr: the lvlreel rntrsr
he r ~ h n l a t l c ~ ~d a c f it i r n ~ its mass is
altered.
P

Rear axlc shaft

11lr1t

Torque link n u t

Rear stlock absorber


nut

8.5- 1 1.5 kg-rn


(6 1.5-83.0 113-R)
2.0-3.0 kg-m
(14.5-21.5 Ih-ft)

2.0-3.0 kg-rn

{F 4.5-21.5 Ib-ft)

CHASS 1.5

REAR SWINGING ARM

GI,
yii

Pull the rear swinging arm rearward and


remove it from the frame.
CA UTION:

When removing the rear swinging arm,


the inner roller b~aringon both right
and left sides could ~asilyfd off the
beuring. Exercise care ro prevent this
happening.

<

I . Rear s w i n ~ i n gam sct

2. Rearing
3.
4.
5.
6.

Pivot thaft
Nut

Drive rhaft boot


Clamp

7. Screw

8. Spring
9. Rear torque link
10. Front bolt
I I . Rear bolt
12. Lock warher
13. Nut
14. Clip

Fig. 11-634

Rcrnove t h e rear wheel (See page 11-39)


Remove the brake hose from the clamp on
the swinging arm, tie the rear brake caliper
with a string and hook i t on to the frame.

Fig. 11-136

MOUNTING

* Install both inner roller bearings,


Be coreful not to bend or twist the brake
h ose.

Remove the final drive gear assembly.


Remove the sing holding the secondary
boot and slide the boot t o the other side.
Remove the rear stop light switch.
Pull or tlle cotter pin from the master
cylinder pushrod.
Remove the rear swinging arm nuts 1% and
loosen the pivot shafts C2! .

to the

rear swinging arm and install the rear


swinging arm on the frame.
Tighten both pivot shafts to specification.

Pivot shaft
tightening torque

0.35-0.45 kg-ITI
(2.5-3.0 Ib-llt)

CA UTlON:

The gaps between rhe frame and rear

I
MOUNTING

Using speciaI tool 2 , force-fit the bearing


outer races, both right and left, into t h e
swinging arm.

and
seal handle

Fig. 11-137

torque

I 1.0- 13.0 kg-m


(7~.5-C14.0Ib-ft)

Install the secondary boot.


Install the final drive bevel gear assembly
(See page 8- 14. )
* Install nhc rrnr stop light switch.
* Mount the rear wheel. (See page I 1-42.)

DESASSEMRI,Y OF SWINGING A R M
BEARINC;
Using special tool 'T , remove the bearing
outer races, boll1 right and left, from the
swinging arm.

,, I

B c n r i n ~and oil
SC:II reillover

OC)94

-r,45

Fig. 11-139

09014-745 10

CHA SSI.7

REAR SHOCK ABSORBER

REAR SHOCK ABSORBERS


The spring and damper settings of the rear
shock absorbers can be varied. Spring
preload can be changed in five steps, and
damper force in four steps. The two settings provide the user with a choice of rear
suspension " s o f t n e s s ' ~ ~suit running
speed and road conditions.
SPRING A DdUSTMENT
* At the bottom of each absorber, turn the
spring seat, as shown i n the photo, to bring
the other notch to the supporting lug. This
alters spring tension. The spring seats of
both absorbers are factory-set at Notch 1
which is the softest spring setting.

DAMPER ADJUSTMENT
Roll u p rubber cap @ at the lop end of each
absorber to reveal damper force adjuster 2 . T o increase or decrease the
damper force, turn this adjuster as shown
in the photo. Numbers, 1 to 4, are
engraved on the adjuster. As the adjuster is
turned, it is arrested with a '"lick" at each
numbered position.

fig. 11-142

Fig. If-140

CHASS1.S

Be sure t o leave the adjuster in a click


position. Position 1 is for the smallest
damper force, and position 4 for the
largest. Position 1 is the factory setting.

COMRINATIONS OF SPRING SETTING


AND DAMPER SETTING
At the factory, both spring and damper i n
the rear shock absorbers are set for the
''softest" suspension, that is, spring in
Norch 1 and damper in Posi~ion1. This
combination is calculated to provide the
best cushioning effect for the average-build
rider of 68 kg (1515 Ibs) for solo riding at
about 60 miles/h (95 km/h) on the
highway, wifihout any accessories attached
to the motorcyde.
Rear shock absorber must be made
"harder" if t w o persons on the motorcycle, if accessories are Fitted to the
motorcycIe, or if the machine is to be
driven over sough terrain. F o r stable
cushioning, both spring and damper must
be set similarly. The following is a list of

recommended combinations:

Spring setting

Damper setting

I ........................... l o r 2

IF ...........................2 or 3
111 ...........................3 or 4
IV ........................... 3 or 4
v ........................... 4

WAR NJNG:
I ) Any other combination than [hose
above is dangerous. For safe riding,
only use f he recornmended setring-T.
2) Be sure to adjust the springs and
dampers of ?hetwo absorbers equally.
Making one absorber harder than the
other disrurbs [he running stability of
the machine.
3) Mulch fronr suspension to rear
suspension for balanced cushioning
and for srab/e and safe riding.
Readjusting the rear shock absorbers
a/une or ihe fronr fork alone is
dangerous. Ser rhe two suspensions
similarly according lo the list helo w.

MATCHING OF FRONT AND REAR


SUSPENSIONS

Spring
setting

Damper

Front fork air prcssurc

I
1
11

..........1 ......... 0.6-0.8


..........2 ......... 0.8-0.9
..........2 ......... 0.8-0.9

I[

..........3 .........
.......... 3 .........

111
111

IV
IV

..........
..........
..........
..........

kg/cm2 (8.5-1 7 psi)


kg/c.rn2 ( I 1 - 13 psi )
kgJcm2 ( 1 1 1 - ! 3 psi)
0.8-0.9 kg/cm2 ( 1 t - I 3 psi)
1.0-1.1 kg[crn2 (14-16 psi)
1.0-1.I kg/cm2 (14-16 psi)
1 -0-1.1 kg[cm2 ( 1 4-1 6 psi)
1 -0-1.1 kg/cm2 ( 1 4-1 6 psi)

4 .........
3 .........
4 .........
4 ......... 1.2 kg/cm2 (17 psi)

REMOVAL OF REAR SHOCK ARSORRER


* Locate the mororcyclc on level ground and
place the motorcycle on thc centcrstand.

I n ~ e r tthe crosshead screwdriver into the


right side of thc cen~crscand pivot to
prevent the motorcycle from tipping off
the centerstand.

Fig. 11-147

Fig. 11-j45

Remove the upper shock absorber nuts and


pull rlic top s i c k of the shock absorbers
Free from [lie mounting lugs. Tlzis will
allow the swing arrn/differential to be
casily movcd.

Take care not to burn yourself if the


rnufffers ark hor.
Remove both right and left rear shock
absorbers.

INSPECTION
lnspect the hydrauIic damper for evidence
of oil leakage.
Check the piston rod for distortion.
Visually inspect all other internal parts for
damage (cracks, dents, galling, etc.).

Lih the swing arrn/difl'erential up hy


allaching the 14 m m wrench to one of !he
caliper bolts and use tlie wrench as a lifL
h a n d l e . W h i l e lifting t h e swing
nrm/differenr ial i n s c r ~the sockel wrench
handle ~ h r o u y htlie righl mr~rflersupport
and swing a r m hole. This will hold the
rwing a r m .

NO TE:
11 is s r r o ~ r g i ~rccornt~rended
~
rhar rha

srt ro insrrr~propcr balonc~berwre?r I ~ f r


aud rig11f trlzirs, urrless rfre ot7i.v one
sJznck ?Teed he r e p l a r d and the operarional rime on rhe rernaitlin~slrock is
minimal.

CHA SSIS

ASSEMBLY
Carry out assembly in the reverse order to
removal.
* Tighten the nuts to the specified torque.
Rear shock ahqorbes
tightening torque

2.0-3.0 kg-rn
(14.5-2 1.5 Ib-f~)

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
CONTENTS
IGNITIONSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARKPLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY .... ..............................................

12-2
12-3
12-5

12-8

. 12-10

. . . . . . . . . . . . . . . . . . . . . . . . 12-14
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . . . . . . . . . . . . . . . . . . . 12-15
TROUBLE SHOOTING
UTILITY SWITCHES AND DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 2-20
WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-78
WIRINGDIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
SELF-CANCELLING TURN SIGNAL SYSTEM

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
IGNITION SYSTEM
There are two ignition coils, two contact breakers and t w o condensers to produce sparking cnergy
for the four spark plugs. No. 1 breaker is for Nos. 1 and 4 spark plugs; and No. 2 breaker is for
Nos. 2 and 3 spark plugs. Each ignition coil is connected to the plugs as shown.

When No. 1 piston is on i t s compression stroke, No. 4 piston is u p on its exhaust stroke. The
sparking occurring at the same time in Nos. 1 and 4 cylinders presents no problem, and the same
applies to Nos. 2 and 3 cylinders. Ignition order is 1-2-4-3, counted from left to right by the rider
mounted the machine. I t should be noted that Nos. 1 and 2 breakers operate 180 degrees apart in
terms o f crank angle.
Schematic Diagram nF Ignilion Syszern

L ----

=
I
I
KC) 1
L- - --- -- -- --J-,

('OUT \( T R R t

,ZKTK

Nr) ?
-----.---

NO 3
NO. 4
I
----- ------J

C P A R K PI.IfC;F

Fig. 12-1
Ignition system data

Spark tesicr pcrl'ormance

Ignifion coils
Usin2 the electro-tester, test each ignition coil
for sparking performance. Test connection is
as indicated. Make sure that the tester gap is
at least 8 rnm (0.3 in).

I
Elcctro te5ler (rpecial

toot)

09900-281 Oh

ELECTRICA L ,T YSTEM

Contact breakers
Check and adjust the contact points 2 s
outlined on page 3-9. Inspeci the contact
points for wear and burning. I f the surfaces
of the points are dirty, wipe them clean with a
clean, dry cloth.

e
a

'ir'

YORMAL

NOT PARALLEL

WORN

a
DIRTY

Fig. 12?-,
Breaker cam

Check the contact breaker cam for wear, rust,


or pits that might cause rapid wear of the
breaker rubbing blocks.
Condensers
Use the electro-tester to check the condition
of each condenser. When doing this, be sure
to lift the condenser off the breaker base plate
by removing the screws securing it to the
base.

f ' i ~ 12-.5
.

SPARK PLUG
Spark ptugs ignite the fuel/air mixture in the
cylinder. For effective ignition at the required
time, the correct plugs should always be used,
and they should be properly adjusted and
cleaned.

NGK

speeds at which the ignition begins to advance


or retard, using the electro-tester (special
tool):

Fgnition timing

17" below 1 500 r/min


37" over 2 500 r/min

Remarks

DENSO

IT the rlandard pliie i~ apt lo ~ c t

B7ES

W22ES

wet. rcplacc wil h I hi< plug. Hor

1YW.

B9ES

Checking advancing action


Upon starting up the engine, check engine

NPPON

U'27ES

I f thr <taltdard plug is api rn


overhc;~~.
replacc n~th
!hl\ pltlg.
Cold r y e .

NGK B8ES or NTPPON DENSO W24ES


listed in the above table should he used as the
standard plug. However thc heat range of the
plug should be selected to meel the
requirements of speed, actual toad, fuel, etc.
If tlie plugs need to be replaced. it is
recommended that ones having a heat range
closest to the standard plug in the above table
be selected.
Remove the plugs a n d inspect the insulalors.
Proper heat range would be indicated if all
four inwlatorr; were light brown in color, If
they are blackened by carbon, they should he
replaced by a hot tvpe NGK B7ES or NIPPON
DENSO W22ES and if baked white. by NGK
R9ES or NIPPON DENSO W27ES.
plugs with high heat range number are used
for high speed running. These plugs are
designed to be sufficiently cooled to prevent
overheating and are called cold type plugs.

EL ECTRICA L S YSTEM

CA UTION:

The plug gap i s adjusted to 0.6-0.8 rnm


(0.023-0.031
in). The gap is correctly
adjusted using a thickness gauge (special
tool). When carbon is deposited on the spark
plug, remove the carbon with a spark plug
cleaning machine or a n y tool with a pointed
end. If electrodes are extremely worn or
burnt, replace the plug. Also replace the plug
if it has a broken insujator, damaged thread,

Confirm the rhread size and reach when


replacing the p l u ~ .If the reach is too
shorl, carbon wilt be deposited on the
screw pwfion q f /he plug hole and the
engine will be dumn,ced.

Fis. 12-9 Normal carbon

condi~ion

etc.

.Thickness gauge

099130-20803
Fie, 12-1 1 We1 fouling

0r pI11g

~ I C It. I2

Carbon Wined

ELECTRTCA L S YSTEM

CHARGING SYSTEM
DESCRIPTION
A three-phase AC generator driven by the
engine is used to supply alternating current
through t h e regulatorlrectifjer t o the hatrery.
Thc altcrn:tting c r ~ r r e tn from the generator is
recti fled in thc regula torlrccti fier and the
rect ifietl current is supplied to tfac battery
wtlcn t l ~ c batrcry voltace drops bclow the
spcci fication.
When the battery is fully charged and the
specified voltage is reached, zener diode
"Ze" conducts, switching SCR (thyristor) on
and the current stops flowing to the battery
and instead. flows to ground. In this way, the
battery is protected from overcharging.

When the battery is discharged and the


voltage becomes lower, the zener diode stops
conducting and SCR is switched off. This
prevents the current from flowing lhrough
the regulator and the current is supplied to
the battery. The above operation is continuously repeated as the battery voltage rises
and falls. In this way, the regulator-rectifier
controls the flow of current to the battery.

IGNITION SWITCH

AC GENERATOR
R

. . . . . .Red

. . . .Yellow
W/E . . . .White with Green tracer
W/R . . . .White w i h Red trwer
Y. .

ELECTRfCAL SYSTEM

CHARGING SYSTEM INSPECTION


AC GENERATOR TEST
Disconnect the three lead wires (Y, W/G and W/B1) from the AC generator terminals.
Start the engine and keep it running at 5 000 r/min. Measure the AC voltage between W/BI and
Y, W / B l and W/G, and W/G and Y, using the Pocket Tester.

Pock.et tester

Engine speea
I

5 000 r/min.

AC line val~age

Electrical condition ofA C generator

75V or over

A C generator i s satisfactory

75V or under

AC generator is faulty

- - - - - - - -- - - -- 7

Yellow
W/nl:

G'

White with Rluc lracer


l+'hE~ewith Grecn ,racer

AC GENERATOR

Fig. 12-14

REGULATORJRECTIFlER TEST
Stop the engine and connect the AC generator lead wires,
Make sure the battery is fully charged by measuring the specific gravity of the battery electrolyte.
I f the specif c gravity is less t h a n 1.26, recharge he battery.
Remove the two 10A fuses from the fuse box and start the engine under no load.
Connect the positive (+) side of Ihe Pocket Tester ro the positive (+) terminal of the battery and
connect the negative (-1 side to the negative I-) terminal. Maintain the engine speed at 5 000
rimin and measure the DC voltage.

ELECTRICA I, SYSTEM

Engine speed
5 000 rJmin

DC line voltage

Electrica! condition of Regulator/Rcct il'ier

14Y-

Regulator/Rectifier is satisfactory

14V t t ~ r u cLII~ I 5.5V over

Regulator/Rectifier is faulty

I f the regulator is found to be faulty, check once again t~ be sure that the circuit connections art
good, and again test the regulator as indicated above before deciding to replace it.

INSPECTION OF CHARGING SYSTEM


COMPONENTS
AC

REGULATORJRECTIFIER

GENERATOR

-.

i
6

I AC generator assv
7. stator
3. Rotor
4. Screw

5. Lock washer
6. nort
7. Lock washer
8. Clump

q- Screw

10. (lamp

Fig. 12-16
Using the Pocket Tester, check continuity
between the three lead wires [yellow, white
with blue tracer, and w h i ~ ewith green
tracer) coming from the stator, and make
sure that the stator core is insulated from
these three lead wires.

The regulator-rectifier is comprised of 2


regulator and a rectifier.
* Check resistance between the lead wise!
using the Pocket Tester.
If the resistance measured is incorrect,
replace the regulator-rectifier.
To make this checkup, refer to the charts
below:

Pocket tester

09900-25002
Unit: S1

II' there is no conrinuity bctwecn tlie lead


wires, replace the stator. Also replace the
stator i f there is continz~i~v
between any
one of the leads and p o u n d .

ELECTRICAL SYSTEM

11.

Rcd

Y:

Ycllnu
Hl;lcL wilh R

W/M:
WJR:

\I1hlkc w ~ t hBluc ~raccr


White with Rcd [racer

~III~
rracer
.

STARTER SYSTEM
The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch
and battery. Depressing the starter button (on the right handlebar grip) energize7 the ~ e l a ycausing
,
the contact points to close wliich connects the ctarter motor to the battery. The motor draws about
80 amperes to start the engine.
STARTER SYSTEM

T)f AGRAM
r----I

A Slam l'uw ( 15.A)

3
I Ignition\aifu)i
C Fu\c(FDA)

S'rAKTf. K
STARTER R F L A Y
1

13 Fnvinc kill q i w ~ c l i

E S t a r ~ c zr w j ~ c h
F S!;ir~erdi\conncct swi~clr
tVounted on t h e clutch lcvcrl

STARTKR CLUTCH A N D GENERATOR ROTOR

I
I Starcur idle Fear

2. Sh:ift
3. \V;i~her
4. Starlcr clutcll xcl
5 . Rthlcr
6. S p r ~ n ~
7. Push piecc
8. Bolt
9 Heurlnp

10. \"vsliur
I I . Slartcr ctu tell sliim
t 2. Gencrntor rotor

See page 7 - 3 2 for removal procedures of the rotor and starter clutch.

lNSPECTlON
Pnspecr the components to confirm that wiring connections are all tight and that the circuit wires
are in good condition. Also make sure that each component is securely grounded.
When the system i s in good condition, the starter relay will make a single chattering sound as the
starter button is depressed and the motor will immediately crank the engine. If this chattering noise
is not heard or i f the starter motor fails ro turn the engine over this means that either the relay is not
being properly energized due t o a run-down battery, or the relay coil is open.
I f the relay "chatters" but the motor will not crank, then it is likely that the relay contact points are
defective or the motor i s internally open-circuited.

1. Arma~ure

2. Brush holdcr
3. Brush set
4. Shim sel

.-

.-..
"- .
..-.

.:

,-$.

,A'*

5:-

I.. .
4

-,/

--

5. Bolt ser
6. Orinp
7. RoIt

8. 0 ring
9. Nut

:v
I!

10. I-wk washcr

Fig. 12-22

Starter motor specifications


The motor is mounted on top of the
crankcase behind the cylinder block, and
drives the crankshaft through a series of gears
and a one-way clutch which is mounted on
the alternator rotor.

No-load data

Item

Commutator
Inspect the commutator surface for wear,
"high mica", burns or grooving. T o smooth
the surface, sand it down with sandpaper, as
shown in armature coil. Undercut the mica to
the depth @ specified.
Standard undercut
Limit on undercu~

0.6 rnm (0.023 in)


0.2 rnm (0.00R in)

Locked-rotor dazn

Voltagc
Curren~

1 l volts
50 ampere?or under

5 . 5 volts
280 arnpres or

Tnrquc
S ~ c d

0.35 kg-rn or ovcr

under
4 5Ml r/rn~nor ovcr

INSPECTION OF COMPONENTS
Carbon brushes

When the brushes are worn, the motor will be


unable to produce sufficient current, and the
engine will be difficult to turn over. To
prevent this, periodically, inspect the length
of the brushes, replacing them when they are
too short or chipping.
Brush length specification
Standard
12-13 mrn
(0.24 in )
(0.47-0-51 in )

Fig. 12-24

Armature coil
Using a circuit tester, check the coil for open
and ground by placing probe pins on each
commutator segment and rotor core (to test
for ground) and on any two segments at
various places ( 2 0 test for open), with the

brushes lifted off the commutator surface.


If the coil is found to be open-circuited or
grounded. replace the armature. Continued
use of a defective armature will cause the
starter motor t o suddenly fail.

To confirm thar rhc contacl points are closiny


fully to transmit the hcavy load o f cicrrcnt.
first make sure the battery ha5 an clectrolitc
specific gravity of at teas^ 1.26 then, operate
i t in the usual manner (by depressing the
button on rhe ri_eht handle) to connect thc
battery to the motor and measure the voItngc
between the posizive (+) terminal of the
motor and p o u n d ; and also between I!IP
positivc (+) terminal of t h e battery and
ground. I f the two readings ate equal, i t
means that the relay contact points are
satisfacrosy.
I f the difference between the two is large or i f
no voltage shows up ~n the motor side, the
contact points are faulty and the relay must
be replaced.

Relay fnr starter motor


This relay acts as a solenoid switch a n d , as
such, it i s necessary for the coil, contact
plunger and contact points to be in good
condition. I t should be horne in mind that the
contact points !lave to transmit a large
current 20 t h e starter motor.

BATTERY

Check t h e coil Sot "open",

"ground" and
ohmic resistance. The coil i s in good condition if the resistance i s 3.0-4.0 ohms.

Fig. 12-27
12-I0

DESCRIPTION
Y UASA and FURUKAWA I2N14-3A
vacuum-sealed dry cell batteries are furnished
with every GS850G.
This battery, when properly activated and
initialIy charged, has a capacity of 14 amperehours on a 10-hour sating basis. No skill is
required in activating this battery and
charging it for the first time to place i t in
initial service; all necessary information is
contained in the instructions given under (he
heading of
INITIAL C H A R G I N G
METHOD. The battery's serviceable life
depends mainly both on initial charge and on
the attention it subsequently receives. Each
GS850G user should be reminded of the
importance of giving proper care to their
batteries.

ELECTRICAL SYSTEIW

indicating f o r the day of the month, the


middle part the month, and the last part thc

year.

INITIAL CHARGING METHOD


Each new GS850G motorcycle is deIivered
with the battery in a "vacuum-seaIed dry"
condition. Thc battery can be used after
conducting the four foflowing, steps:
1. lnitial elerlrolytc filling
Takc the battery off ~ h cmotorcycle, and
place i t on a battery servicing bench. Fill each
cell to the upper level will1 cleclrcllyte:
Dilute sulfuric acid solu~ionwith acid concentration of 34.6% by weiglir, having a
spcciric gravity o f 1.26 a1 20C (68F).
Elcc~roly!eternperaturc, ar rhe time of filling,
sliould no1 be higher than 30C (86F).
AFter filling, Icr the battery stand for about
30 minutus. Then, check electrolyte levet in
each cell and, it' thc level i n any cell has fallen
add more elecrsalyte to bring it back to the
upper levct.

2. Initial charging duration


Thc acting materials on [lie cell plates have a
store of energy eqliivalent Lo 75% of the rated
capacity if the batiery is new manufactured
recently. This stored energy, however,
dissipates spontaneously and progressively
with [apse of time, 50 that, after filling i t with
electrolyte, thc charging duration must be
extended i f a period of more than 6 months
has elapsed since the datc of manufacture
(which is indicnred on each battery as s h o w n
in Fig. 12-29). T h e standard initial charging
duration being 20 hours. T h e charging time is
to be delermined according lo the following

Apt nfrlry ha~rery


(crrlcc nisnufacltlre)

Charping limc

l l p to6 monl h~

?O

O r , c r 6 n l o n ~ h sn r
up 1 r ~ nionfllr
9

30 11 ours

Oxcr 9 rnonth5 i111d


up 1 0I ? ~r~onths

40 trotrr\

Ovcr

5 0 ho~ii-.;

~ O I ~ T F

Datc ol' t g i a ~ ~ ~ ~ ~ i iisc tindicated


ure
by a threepart number; Fig. 12-29, [lie leftmost part

Fig. 12-29

i>n.ltc 01' rnanufncturc

3. Inicial charging current


The constant-current method of charging is
recommended for initial charging, and is
carried out in the following manner,
1) Before turning on the charger, to which the
filled battery is connected, remove t h e seal
and cell caps. Make sure that the polarity
marks a r e matched correctly.

F(q. 12-30

(fiscal ( , ~ p 2 I3.1r1 r . r ~ cell cap

2) Start charging, with the charger set for a


charging rate of 1.4 amperes. While
charging, occasianalIy check the electrolyte
S.G. (specific gravity) and also the
charging voltage, particularly towards the
end of the charging time.
33 Towards the end o f the charge, the electrolyte will start releasing gas bubbles and
the voltage and S.G. will be up and
leveling; if not, it i s likely that the vacuum
sea1 was damage during transit or In
storage. Continue charging, even in excess
of the predetermined time, until the
voltage and S.G. stay levet, for one or two
hours, with the battery allowed to continue
releasing gas.

ELECTRICAL SYSTEM

4. Bectrolyfe adjustment
After charging re-check the electrolyte S.G.
to make sure it is 1.280 corrected for 20C
(68F). Add distilled water, if necessary, to
ad just the S.G. of each cell. Replace the caps,
and wash the surfaces of the battery container
with fresh water. Let the battery dry before
mounting it on the motorcycle.

R ATTERY SERVICING
Removal
1. Lift u p the seat and open the too1 hol,,, .
2. Disconnect the lead wires from both
positive and negative plates.
3. Disconnect the breather hose from the
battery.
4. Remove the band remove the battery from
the battery holder.

Inspection

1. Visually inspect the surface of the battery.


If signs of cracking or electrolyte leakage
from the sides o f the battery are noticed,
replace the battery with a new one.
2. I f the battery terminals are found to be
coated with rust or an acidic white
powdery substance, then this can be
cleaned away with sandpaper or hot water,
respectively.
3. Check the electrolyte level and add distilled
water, if necessary, to raise the electrolyte
in each cell to the upper level.

Check t h e Dattery for proper charge by


takirtg an electrolyte S.G. reading. If the
reading is 1.200 or less, corrected Tor 20C
(6HWF),i t means that the battery i s rundown and needs recharging.
Installatian
Before mounting the battery, make sure that
the exterior surface of the battery container is
dry and free from electrolyte. Be careful not
to forget to re-connect the battery breather
hose. The installing procedure is the reverse

Recharging operarinn hased on S.G. reading


To correct on S.G. reading for 20C (6RF),

use this formula:


Sm = St + 0.0007 ( t - 20)= corrected value of S.G. (20C or
6gF),
St = value of S.G. read at temperature

where S,,

t "C,

0.0007 = temperature coefficient of


S.G., and
t = temperature in degrees Centigrade,
at which St was read.
To read the S.G.on the hydromcrer, bring
the electrolyte in the hydrometer to eye level
and read the graduation an the float scale
corresponding to the meniscus (curved

ELECTRICAL S YSTEM

portion of electrolyte surface), as shown in


Fig. 12-34.
Check the reading (corrected for 20C) with
Fig. 1 2-35 to determine tlze recharging rime in
hours by constant-current charging at a charging rate of i -4 amperes (which is a tenth of
the capacity of the present battery).
Do net permit the electrolyte temperature to
exceed 45C (1 13"F), at any time, during the
recharging operation. Interrupt t h e
operation, if necessary, to let the electrolyte
coot down.
The battery is properly recharged if three conditions are met:
Recharging has been carried o u t to the
specification indicated in the graph in Fig.
12-35 Efecrrolvte S.G. has risen to 1.280 or
higher and has remained there for at least one
hour. The battery terminal voltage has risen
to 15-16 volts or higher and has remained
there for at least one hour.
Gas bubbles are being released in every cell.

NOTE:
Cansfant-vof t a ~ echurginfi otherwise
ccrlled "quick" charging, is not
recommended for recharging becaus~i f
may shorfen the lrfe of the battery.

11)

12

Charr~nallmc (hour)

Fig. 12-35

WAR N M :
* Before charging a bartery, remove the
seal cap from each cell.
K w p fire and &wks srway from o
botrery being charged.

14

~h

1s

EL ECTR JCA L S YS TEM

SELF-CANCELLING TURN SIGNAL SYSTEM


CIRCUIT DIAGRAM
R E 4 R TURN SIGNAL LltHf

F R O H I TURN SIGNAL l l 6 t i T

tu!n ragnaq rwllch

Manual cancalllng swbrch-

Turn sqnal telav

S~eedomelerd?srancs senser

IQ
0/W

loghigreen
BlacktVh8re

BrlY
BllA

om
Blue
I Red
v

vrar~ya

B/R

L br
O/G

Brcwn'yrtlow
BluelFled
Oranye Red
BInci RRCT
Laghi blue

OrangstGrte

Fig. J L - ~ o
When the Turn Signal Knob is switched to
LEFT or RIGHT, the turn signal light

starts flashing.
I f the motorcycle speed is Faster than 3 5
kmJh (9.3 rnph), flashing will bc switched
off automatically about 4 sec after the
knob is released.
The timer does not operate when the
rnotorcycle slops or runs at a speed slower
than I5 krn/h.
Only when the motorcycle runs at speeds
faster than IS km/h does the timer operate
to switch the turn signal off automatically
when the total time above that speed exceeds 9 sec.
When the Turn Signal Knob is switched on
again before i t is turned off automatically,
flashing will go off 9 sec after this time at
speed faster than 15 krnJh.
Flashing can be switched off before it goes
off automatically, by pressing the Turn
Signal Knob downward.

REMOVAL
Remove the t u r n signal light switch (See
page 1 1-21
Remove the speedometer (See page 1 1-61
Remove the frame right cover.
Remove the turn signal control unit
coupler from the wiring harness.
Remove the band holding the .turn signal
control unit and remove the unit.

f'iq. 12-.?7

MOUNTING
For mounting, reverse the procedure for
removal.

TROPTRLESHOOTING
RATTERY
S*rnpirtrn

"S~llfarinn", acidlc
~h,hifcprrwdery
\uhxtancc or spots on
\r~rTilcercrf cell plotur.

Rsllcr! runs

1. Not criough elecirolyte

2. Rattcry caqe i~crachcd.


3. haltcry har been left ,I]a run-down
condi~ionI'ur a long lime.
4 . Adr~lterarcdulec~rolytel F o r e i ~ nmellcr
has ctrrrres the batter! and hecome mivcci
ivlth he elecrrolytc.

I. 'Ihe c h a r r j ~ ~merhod
g
i~no1 cnrrccf.

don\.r~quickly.
2 , Ccll plotcc Iiaw lor[ much of rhrir actrrr
material as a r e d l of over-rharying.
1. h \lior3-~ircui~
condirion e x i w wrthrn he
haftcry duc to euceqsive accumulation nl'
qcdiment5 cawed by the Iitgh elec~rolytr
S.G.
4 . E l r c ~ r o l y ~S.G.
e i t roo low.
5 , Adul tcratcd eleclrolyle.
6 . Botrery i s too old.

Rcver~rdbnltcry
prrlar~ty.

Rcmcdr

Probable c a u ~ c

The batwrv has been cmnectcd he kvrnnp


~ a round
y
in the ryrtcm, so that il i~bci~lg
charged in t l ~ crevcrcr directinn.

Add d~stillrdwater. !i
~ h hattcrv
c
I~asno1
becn damaged and "sullation" hnr 1101
advanced loo far. and rcchargc.
Replaccd r l ~ cbarrrry.
Replaced rhe hnltcry.
I F *'\ulfarion" har nor ndvai!ccd too far. lry
l o re5lorc rhc battery by rcplaclng the
rlcc~rolytc,recharginp 11 fullv nil11 lhc halter?
de~achcdCrom t l ~ crnorrlrcyctc and rhcn
ndjuszinp rlectrolytc S.G.
Clieck r he alternator, rcgula~orand circuil
corilrctions, and mnke ncccwar!: adju\trner~t\
10 o b ~ a i n\pecified charping oprralion.
Replace thr hs~tery,and corrccl the charping

<~\tcrn.
Rcplace the battery.

Recharge rhe battery C~rll!: ant! adjust clcc!roly!c S.G.


Replacc rhe clecrsolyrc. recharge ~ h chatlerv
and then adjuqt S.Ci.
Rcplacc the b a u ~ r y .

Replace the ha~tcrvand bc ~ u r cr e connrct


hc ha~reryproperlv.

ELECTRICAL SYSTEM

SELF-CANCELLING TURN SIGNAL


Referring to the Circuit Diagram, check the condition of: 1) the lead connector of the left handle
switch (Turn Signal Knob), 2) t h e lead of the T ~ r Signal
n
Relay, and 3) the lead o f the Speed Sensor
as indicated below.

1. The turn signal lamp docs nol light.

I c Ilicre 13C lo- 14V acrn\c I3f +) and H/\i't - ) when Turn
Signal Knoh i~ . ~ w ~ r c l i rt(1d I !iTT. anr! acrow I.f(-)
and R / W ( - ) rvhetl 1-urn Signal Krioh ir ~rritchetllo RIGHT?

IIC IO- I4V 3CrOlP 1 hl(-t) and R 'Xi'(-1, wltcn


Ttrrn Srpnal Knob

rclearcd?

Is rhc voltnqe acrow B r / Y ( + ) and 8 / \ V ( - ) 0.6-1 .OV?

Befcc~ivcManual Cancel Switch


or rhort circuil in Rr/Y lead to
the t'rarne.

I
Is there niorc than l O V acrors R,'RI(+) and H/U"-)
when Tttrn Signal Knoh ir switched lo LEFT. and acrnsr
LgJB(+) and R/W(-) when Turn Signal Knob
i~
switched tu RIGHT?

I Defective Con~rolUnit

,Dcfcctivc
Signal Relay
or leak in Turn
wire.

ELECTRICAL SYSTEM
5. Flashing goes off before 9

E sec.

Measure the rime after Turn Sisnal Knob ir witched to I . F U or RIGHT. and rclea<ed,
until hlarhing Eoer off.

Is speed Sen~ornormal? (Scc 3-21


(AEso check tighreness of connectors

NO

DeTectirc Speed Sensor.

YES

NO

Replace Jefcctivc component.

1YES
Defective Controt 'Unit.

6 . Flashing does not go ofl at a speed o f 15 krnlll 19.3 mphE or more.

I d * /

Replace delec~iuecornponenl.

le and related components rlormal?


7

I s Speed Sensor normal? ( S e t 3-2)

-I
I

Defecrive Control Unit.

11 -

hln

Defec~iveSpeed Sensor.

ELECTRJCA L SYSTEM

GEAR SHIFTING SWITCH AND GEAR


POSITION INDICATOR

NOTE:
When checking t h ~
continuity of [he
gear indicator (inside the coupler),
connect the positive (I- ) fermind of rhe
Pocket Tester to the ferminnl in rite
coupler, and connecr the negative I-)
termin01 to Ihe orange lead wire.
If there is no continujty, ,he indicaror
l i ~ h bulb
t
is burnt out and if should be
replaced.

. I.

'

1%

-. '\.--/'f-P E A R SHlFllNO W I T C H
i

ih

I f the neutral indicator light and gear position


indicator Eight do not come on, disconnect the
lead wires coming from the gear shifting
switch at the coupler and terminals, and
check continuity between the 0 lead and B1
lead, and also between the W/Y, RJB, G/B1,
Y/BI and Gr/R in the coupler using the
Pocket Tester.

If the above check reveals no irregularity,


remove the gear shifting switch from the
crankcase, and using a lead wire of the
Pocket Tester, ground one of the gear
shifting switch contact points and check the
condition of the pear shifting switch. I f both
neutral and gear position indicator lights turn
on, the switch is in good condition. (To make
this check, the ignition switch should be
turned on with the wiring normal.)

Fig. 12-42

Fig. 12-44

EL ECTR ICA L S YSTEM

UTILITY SWITCHES AND


DEVICES
IGNITION SWITCH
Confirm that ignition switch @ , when
checked with a circuit tester, has internal
continuity as indicated in the chart below,
and replace i t if the condition is not as indicated in the chart.
Ignition switch continuity chart
Terminals

Switch
puhjtlnn

RED

ORANGF

<'I

GRAY'

BROWN
-

OR:
p
p

ON

REAR BRAKE LIGHT SWITCH


This switch is checked in the same way as the
front brake light switch is tested for internal
continuity. Its lead wires are W H I T E 3 and
ORANGE with GREEN tracer@. Press
down on the brake pedal, and continuity
shouId be obtained.

NOTE:
To make the swirch close sooner {urn on
the light by pressing down on the bmke
pedal, and reposition the swirch
body @ upward. Lo wering if retards the
action.

2->

-4:

Fig. 12-4.7

FRONT RRAKE LIGHT SWITCH


To confirm continuity of this light switch,
with the front brake lever squeezed place the
rester probe pins on the WHITECT3and
ORANGE@ lead wires.

NOTE:
To advance of xerard the action of this
swirch change the swirch position by
loosening (he 2 s c r ~ w s securing [he
swirch lo {he body 6 .

LEFT HANDLE SWITCH


This switch operates the lighting, dimmer,
turn signal and horn switches. Circuit canrinuity through each switch component can
be checked by placing the two testing probes
of the circuit tester on the switch Beads (at the
coupler).

1,ICHTING AND DIMMER SWITCHES


The lighting and dimmer switches should
show continuity, when checked with the
circuit tester, according to the chart below.

Dimmer switch

I f abnormally high resistance is noted when


checking continuity, it probably means that
the contact points in the switch are faulty and
need repairing.
Fig. IZ-4h
12-20

ELECTRICAL SYSTEM

HORN AND HORN STYITCH


Check the sound of the horn w ith a 12-volt
-0
SL,
battery and continuity vl
lrlz horn switch
using the circuit tester.
I f t h e volume of the horn is insufficient,
adjust i t by turning the adjusting screw
o n the back of the horn.
Afrer adjusrment, be sure to apply a thin
coat of SUZUKI THREAD LOCK
CEMENT to the adjusting screw.
Make sure that the horn has full volume when
its lead wires are connected to the battery
terminals, if not, replace the horn

Kill switch
ORANGE

ORANGE/WHFTE

Starter switch
Switch
position

YELLOW/GWEN

ORANGENHITE

OIL PRESSURE SWITCH


This switch is located on the discharge side of
the oil pump and turns the warning light on
and off in response to the discharge pressure.

STARTER DISCONNECT SWITCH


Confirm that this switch shows continuity
when the clutch lever is squeezed by placing
the tester probes on the YELLOWJGREEN
and YELLOW /GREEN @ lead wires of
the switch.

Fi!:.

l?-J41

KILL SWITCH AND STARTER SWITCH


These switches are checked in the same way as
the lighting switch.

s
prccqurr. k n ~ r c l l
Fil.,, /2-5/ 'iOil
If the switch is functioning normally, when the
engine is stopped and the switch is turned on
the oil pressure indicator light comes on and
goes out immediately when the engine starts.
This indicates that the oil pump is delivering
enough oil to the engine.
Two possibilities must be taken into consideration when the switch and light do not
operate as stated above. One is that the switch
is faulty due to an open-circuit or grounding
(this can be checked with the circuit tester).

E1,ECTRlCAL SYSTEM
The other is a mechanical malfunction-an
inability of the switch to respond to the
applied pressure which can be checked by
measuring the oil pressure when the engine is
running. If the pressure is low, the oil pump
is malfunctioning; if high, the switch is
mechanically defective and must be replaced.

REAR COMRlNATlON LIGHTS

LIGHT WATTAGE DATA


The lighting system of the Model GS850G
uses lights with the following rated watta2es.

Fig. 12-52

TURN SIGNAL LIGHTS

INSPECTION OF HEADLIGHT
Confirm that the bulb is not burnt out.
* Confirm that the wiring is not damaged
and that there are no poor connections.
Confirm that each connection is tightly
fastened.
Confirm that the beam angle is correct.
See page 11-7 for adjustment proccrllrre of the
beam angle.

Inspection of speedometer and tachometer

* Replace burnt out bulbs after removal of


meters. See
procedures.

page

11-6 for

removal

INSPECTION OF TAILIRRAKE LIGHTS


AN11 TURN SICNAI, LIGHTS
Confirm that the bulb is not 'burnt out.
Confirm that the wiring i s not damaged
and that there are no poor connections.
* Defective grounding or a qhorz-circuit
exists when the front and rear signal lights
continue to stay l i t after the switch has
been turned off.
Confirm that each connection is tightly
fastened. Loose connections can shorten
bulb l i f e due to vibration.
I

Fig. 12-54

ELECTRICAL SYSTEM

FUEL GAUGE
Wiring

3.Construction of
operating meter

I. Puintcr
Main birnctal

2.

The above drawing is a schematic of fuel


gauge wiring. The internal resistance value of
the gauge unit is adapted to vary with the
height of the float. lit is difficult for current
to pass tllrough the circuit when the resistance
value is high, an consequently the swing of
the meter is small (close to point El.
The more current passes through the circuit,
increasing the swing of the pointer (close to
point
when the resistance value is low.
2. The relationships between the amount of
gasoline and meter indications are as
follows:

n,

The meter points to E-2"30


when the
amount of gasoline is between 0 to 2.4
liters. Also the meter points to F +So when
the amount of gasoline in the tank is
between 1 8.7 liters and full.

!.
4.

each

portion

and

Tempcr:~lurcmmpmr:~ring himetal
~
c
~
&
~

* Main operation
Current passing through the heater wire
deflects the main bimetal causing the
pointer to move.

Auxiliary operation
This compensates for variations in temperature and voltage. A temperature
compensating bimetal is provided so that
no indication errors occur due to temperature changes inside the meter:

Fig. 12-57

The passage of current through the heater


wire deflects the bimetal and causes point
separation. This point separation stops the
current until the bimetal begins to cool
which causing the point to connect again.

Fixcd point

Tcmperaturc
cnmpcnsating bimctal

Necdlc

At hlgh temperalure

A large amount of current passes through


the hearer wire whcn the supply voltagc is
high, causing the birneral to deflect
quickly, and the points to separate. This is
illustrated En the following drawing which
shows that the average current is constant.

Main b~mctal

Wilh rcmpernlurc cornpensarion


(conmnr

porition

of needle)

Even i f the temperature rises inside the


meter and causes the main bimetal to
deflect as shown in the above drawing, the
temperature compensating bimetal will
deflect to the same degree as the main
bimetal, in the reverse direction, to keep
the needle position constant.
V e l tage regulator
a

Gaugeunit
The displacement of the float changes the
position of the contact plate which slides
on a wire wound resistor causing the
resistance value to vary.

Wire wound resistor

Float arm

Fig. 12-62

INSPECTION OF FUEL METER AND


GAUGE

The fuel meter is enclosed within the


tachometer assembly.
The f o l l o w i n g table i s used
Tor
troubleshooting.
Fig. 12-60
gasoline I t )

ELECTRICAL SYSTEM
I

Pointer railurc and minus indication


(1)

(2)

Mcler pointer tails to move.


M r t r r has a substantial mtnur indtc;~[tonwhcn kc? I < ~ u r n c don.
J

Checking method

I (L)

Determine whelhcr lrouhle i?wirhin


mcwr or gauBc.
Remove gaupe canneclor l o short-circuit
mclcr stdc 01 samr conneclor Imakc taurrc
reqtrtaalce equal ID zero R), and ob'wrve
mcler ~ n d l c a ~ ~ c l n .

1 rl

PI
b

Meter~Omwr
falls ro m m c

%qctcrrldc defccli\pc

H
Meter potnler swinps to
e'il rcmc p r ~ \ i z i o n

12)

Mclcr check.
Ground meler lerrn~nal of rnerer srde
canncc-lor directlv t o Sramc and obrcrbc
mclcr rndlcatbon.

Meter pornlcr swlngs lo


cxlrcmc p o ~ i l i o n
I xruh u<rmmal

(Conlac1 of connector terminall

Mfasurc rc%i?taticc raluc hcrwcrn two


~crmlnalro f gnupc rtdcconncdnr.

~I-UIIL

1 1 C '3

1 1111111 --

(Mom than I I' R I


lenlmcnl

1;oupc rbrt

:*Crl

Colinec[or cnnract check Iwbrlng


harncrs sidcl.
Strcirprhrn spring prersurc against terminal
a1 w!rrllg hnrntiq qide conncctnr IIO
improve conlac!) and ohqcrvc meter Indication.
(hy normal wrrinp)

(4)

\!

h~tlr

I ~ I B I CIh.hl II~?, h ~ d c i c l l h ~ d r

4
T
b

.lark

1-."

harness vde).
Strcn~thenspring pressure againrt terminal
of 6-polc connecror at afiring harnes s side
[lo improve contact) a nd observe meter
~ndicatton.
W~rqngh m l w .Ide 6-pdc canna.tor
tvrhrck

Gaul..

Wtrine: harneasdelectivc

~crm~rul'

Ciury out check ( 2 ) a1 the same Ilmc.

rkdl

checrt~

EL ECTR ICA L S YSTEM


Mctcr p l n t e r swings ro exrremc posltlon

m d ind~catesplus.
(I) Swinging-up ofpoinlcr.
( I ) Subr[an~ially plur zndiuation
meter.

of

1
Method of checking
(61 Meter sidecheck.
Rcmove gaugc connccior

Mr~erdcfccti\c
(without Con-

ncelinp gauge) and obrervc mcter Indlcation.

Vilh no rncle
8 ,

(Full

( 7 ) Gaugeqide check.
Measure r a i s ~ a n c c value of paugc atcording to(3).

-.Icss 1hsnO.5Q)

4 E m p ~ v+ Icqr than 3 O2R)


I

LI,
Normal resisrancc value b
1
Check ($1

(8)

Metcr sldc chcck (operale voltage


rmulalorl.
Chcck mrtcr vottagc hcrwccn paubc tcrrnlnal (vellow/black lead wircl of mrrcr or
gauge Icrm~nal {as it 1s conncc~cdl or
Lonnector for gaugc and ground

1 I,

1",1;;;y ~ntcrrup\cd

!vic~cr d d e c ~ ~ v e
I

Changt m.Icr
1I

ndicatcr con

tol~agc

19)

Mctcr <idcchcck

Rcmove h - p t j l r nrctcr ride cunncclor and.


mrasute tekrrlance u,ll~rchclwccn
@ terrn~naland ground tctrninill.

Largc rr\lrlancc.

Mcrcr dclcctive

W rre ~

rrtmknh

Z ~ ~ Cdcfcctive
F F

11

(103 Ground connec~orchcck.


Check g r o u n d t n ~ condirron or ground
terminal of 6-pole meter ridc connmor a1
vchiclc side. Measure rccrstnnce valuc
k r w c c n ground lerrnlnal shopn In drawlnp.
(5)and frame proundlng.

Largc rrpris~ance,
nnconductancc

Ground wlrc harness


defecnve

Defective contact
of rnrrer side connector

I
I

(Elen u h c n rncrcr 19 normal, ~nterruptcd


iollagc can lx obtained. Wor\,cvcr, hcrc.
rhc mclcr ES deIcct~%e
b e c a t ~ ~I c~ Cpolnrcr
culner to rrlrcrnc pn*lllon 1

Chcck(1 I )

( 1 1) Coancclorcontac~chcck.
Obrcrvc rncler ind~calionafrcr corrccrvng
wlrc harnetq and connecror (m ~ h cnormal
wlrlnp).

FLII:I. M FTFR

Check rtsis~anccvalucbctwccn terminals


Mercr sidc

Gauge sidc

Full
Empty

1-5 Q
103-1 1 7 ~

Minus meter indication

EL ECTRICA L S YSTEM

S c i r u r c ~metrr
~

is causcd by
defcclh\c w ~ r ~ n g

harncsr

GAUGE

WIRE ROUTING

ELECTRICAL SYSTEM

How to route the high-tension cord.

How to route contact breaker lead wire.

CABLE ROUTING
Thrmrkcahk

REAR BRAKE HOSE ROUTING

Rear Inaster cr llnder

ECTRICA L SYSTEM

IRING DIAGRAM
-r

-1

i-

4I

dZ

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~n
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c
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9
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-.
it;;

g " ; : w : x : ; ~ ~ $ : ~ L :

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c.::
t:L:kiii;<5::
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:..;:?n+i~t~rrc:
~ ~ $ ~ ~ ; ; ~ ~ $ ~ $ j j : :

L?+?~u"'y"E*iu$
rEim:-20c3ci:%<r

FZi:;;
I * z l r :
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:

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AI

IN.'jPECTfO,W A T SETTING-UP

INSPECTION AT SETTING-UP
Inspect the following points at the time of setting up. In addition to this list. please use the "Cer
tification of Vehicle Predeliven, " form giving one copy to the customer and retaining the original i r
your file.

ENGINE AND TRANSMISSION


Spark plug
Contact point
Ignition timing
Thsnttle cable(s)
Idle RPM
Exhaust system
Fuel system connection

(Type, Gap and torque)


(Clean and adjust)
(Check and adjust)
(Check cable play and adjust)
(Check and adjust)
(Lca kage)
(Cisd ip)

CHASSIS
Clutch cable (Check and adjust)

Fronr brake
Cable routing
Rear brake
Brake fluid
The contacts between the brake hose, meter case, etc.
Pedal position
Pedal play
Tire pressure (Check and adjust)
Cast wheel (Check)
Lubrication of all necessary points
Battery (Charge, vent tube location and attachment)
Wiring and cable routing
Wiring connectors
(Cleaned and tight)
Front fork air pressure
Shocks spring preload damping position
Tighten all nuts and bolts (Torque those listed in manual)
Cotter pins (Fasteners check)
Wash and polish

INSPECTION A TSETTlNG-U P

ROAD TEST INSPECTION


Engine starting

Transmission
Clutch
Brake operation
Steering
Suspension operation
Control cables

(Acceleration, smoothness and


noise)
(Operation and noise)
(Operation and noise)
(Operation and noise)
(Stability and tracking)

(Operation and proper return)

Leakage
(Fuel/Oil/Exhaust)
Speedometer and tachometer operation
Digital gear indicator operation

PREDELIVERY CHECKLIST
Brake fluid level
(Front and rear)
Paint and chrome
Electrical system
(Front and rear)
Tail and stop light
Turn signals and indicator light
Headlight beam
(Adjust)
Instrument lights
Oil pressure light
High beam indicator light
Neutral light
Horn
Fuel gauge operation
Kill switch operation

This section gives service data and servicing procedures which differ from those of the
GS850GN and describes the new features of the GS850GT. Refer to the sections 7
through 13 except for the items described in this section.

CONTENTS
VlEWOFGS850GT ............................................
SPECIFICATIONS
SERVICE DATA
TORQUE TABLE ..............................................
SPEClALMAT'ERIALS
'PERIODIC MAINTENANCE
MOD1FICATIONS .............................................
CARBURETOR
ErAZSSION CONT ROL & REGULATIONS
FULL-TRANSISTORIZED IGNITION SYSTEM ......................
FRONT MASTER CYLINDER ....................................
FRONT CALIPER
REAR WHEEL ................................................
WIRE AND CABLE ROUTING ...................................
WIRING DIAGRAM

14-2

............................................. 1 4 - 3
...............................................1 4 - 5

14-16
14-18

.........................................
..................................... 14-20
74-21
14-27
74-41
14-45
14-47
14-5 t
15-55
14-56
14-58

..............................................
...........................
.............................................
............................................

+.-

.-

GTc5'.j0GT

VIEWS OF ES85OGT
The major differences between the GS850G "T" and "Nu models are t h e ignition system,
starter system and carburetors.
That is, the ignition system has been changed to the maintenance-free transistorized ignition
system, the kick starter system is eliminated, and variable-venturi type "BS-type" carburetors
are applied.

Right side

Left side

DIMENSIONS AND DRY MASS


Overa I I I ength
Overall width
Overall heiuht
wheelbase"
Ground clearance
Dry mass
Gross vehicle weight rating

ENG lNE
TYP@
N umber of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

2 230 mm (87.8 in)


865 mm (34.1 in)
1 190 m m (46.9 in)
1 500 mrn (59.1 in)
160 mrn ( 6.3 in)
253 kg (558 Ibs)
455 kg (1 003 Ibs)

Four-stroke, air-cooled, DOHC


4
69.0 m m (2.717 in)
56.4 rnm 22.220 in)
843 cm3 (51.4 cu. in)
8.8 : 1
M I KUN I BS32SS, four
Polyurerhane foam element
Electric
Wet sump

TRANSMISSION
Clutch
Transmission

ear shift pattern


Primary reduction
Gear ratios, Low
2nd
3rd
4th
Top

0
-

Wet multi-plate type


5-speed constant mesh
1-down, 4-up

1.775 187/49)

2.500 (35114)
1.777 132/18)
1.380 (29/21)
1.125 (27124)
0.961 (ZSJ26)

SECONDARY DRIVE
Type

Secondary reduction
Final reduction

Shaft drive
1.062 ( 17/16)
3.090 (34/11)

CHASSIS
'

Front suspension
Rear suspension

Steering angle
Caster
Trail
Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure
Rear tire pressure

ELECTI C A P
Ignition type
Ignition timing
Spark plug
Spark plug gap

Battery
Generator
Fuse

CAPACITIES
Fuel tank including reserve
reserve
Engine oil change
filter change
overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil

" Specifications subject to change without notice.

Telescopic, pneumaticJcoil spring, oil dampened


Swinging arm, oil dampened, damper 4-wayJspring
5-way adjustable
40' (right and left)

62' 00'
f 13 mrn (4.45 in)
2.6 m (8.5 i t )
Disc brake, twin
Disc brake
3.50H19 4PR
4.50H17 4PR
1.75 kg/crn2 (25 psi) (Normal solo riding)
2.00 kg/crn2 (28 psi) (Normal solo riding)

Transistori zed
17" B.T.D.C. below 1 500 rJmin and 37" B.T.D.C.
above 2 350 r/min
NGK B8ES or NIPPON DENSO W24ES-U
0.6 - 0.8 rnm (0.024 - 0.031 in) both NGK and
NIPPON DENSO
12V 50.4 k c (14Ah)/TOH R
Three-phase A.C. generator
10/10/10/10/15A

22 h (5.8 US gal)
4.2 h (1.1 WS gal)
2.8 L (3.0 US qt)
3.6 t (3.8US qt)
3-8 L (4.0 US qtl
340 - 400 rnl ( 1 1.5 - 13.5US ozl
280 -330 ml ( 9.5 - 11.2USoz)
0.6 kg/crn2 (8.5 psi)
251 rnl (8.48 'US os} in each leg

SERVICE DATA

ITEM
Valve Dia.

STARIDA'RD
--

35.9 - 36-1

IN.

(1.41 - 1.42)

29.9 - 30.1
(1.18- 1.19)

EX.

--

Valve liit

8.0
(0.31)

IN.

--

Valve clearance or Tappet


clearance {when cold)

LlMl
l
-

7.5

EX.

--- -(0.30)
0.03 - 0.08
IN.& EX.
IO.001--- 0.003)
-- -, 0.025 - 0.055
I
IN'
(0.0009- 0.0022)
0.040- 0.070
EX,
(0.0016 10.00281-7.000 - 7.01 5
IN.& EX,
40.2756
- 0.2762)
- -.
.

Valve guide to Valve sten


clearance

~
Valve g u i d e r . ~ .
-

Valve stem O.D.

- --*-

IN'

((0.2740
6.960 - 0.2746)
6.975

6.945 6.960
(0.2734 - 0.274(

EX.

Valve stem runout

IN.& EX.

Valve seat width

--

--

T
IN.& EX.

(IN. &spring
Valve
EX.) free length

OUTER

Ie
l l

0.05
(0.0021
0.5
(0.02)

1.0 - 1.2
(0.04- 0.051

IN. & EX.

Valve headradial runout

Valve spring tension


(IN, & EX.)

k!

IN.& EX.

Valve h e a d i c k n e s s

0.35
(0.014)
0.35
(Q.014)

INNER

29.3 - 34.0 kg
(64.59- 74.96 lbs)
at length 23 mrn (0.91 in)

OUTER

50.4 - 58.3 kg
(111.11 - 128.53 1bsl
at length 27 rnm 11.06 in)

0.03

(0.001)

(1.33)
33.9
41.3
(1.63)

CAMSHAFT + CYLINDER

+ HEAD

ITEM

Unit: rnm (in)

Cam height

STANDARD

36.320- 36.360
(1.4299 - 1.4315)

IN.

IN. & EX.

Camshaft journal holder I.D.

lN.&EX.

Camshaft journal O.D.

IN. & EX.

Cahmshaft runout

22-012

- 22.025

Cylinder head distortion

35.470
(1.3965)
0.150

(0.0059)
I

(0,8646 - Q.8652)
0-1
(0.004)

Cam chain 20 pitch length


-chainr(atarrow-

(0.8666- 0.86711
21.960- 21.975

IN. & EX.

36.020
11.4181)

35.770- 35.810
(1.4083 - 1.4098)
0.037- 0.065
(0.0015 - 0.0026)

EX.
Camshaft journal oil clearance

LIMIT

157.80
16.213)
-

20 t h pin

0.2
(0.008)

PISTON + RING

+ CYLINDER

Unit: mrn (in)


STANDARD
9 - 12 kg/crn2
(128 - 171 psi)

Compression pressure
Compression pressure difference

(0.0020- 0.0024)
69.000- 69.015
(2.7165 - 2.7171)
68.945 - 68.960
(2.7144 - 2.7 'I 501
Measure the 15 (0.59)

LIMIT

7 kg/cm2
(100 psi)
12 kg/cm2
(28 psi)
0.120
(0.0047)

69.080
(2.7 197)

6&.880
(2.71 18)

from piston skirt end.

Cylinder distortion
---

Piston ring free end gap

Approx. 9.0 (0.35)


Approx. 9.5 (0.37)

0.10- 0.30
(0.004- 0.012)

Piston ring end gap

0.10 - 0.30
(0.004- 0.012)
Piston ring groove clearance

(0.03)
0.7

(0.03)

2nd

(0.0059)

0.15
1.21 - 1.T3
(0.047- 0.048)
1.21 - 1.23
(0.047- 0.0481
2.51 - 2.53

Oil
Piston ring thickness

Piston pin bore E.D.

7.6

10.30)
0.7

0.18
(0.0071)

- 0.100)
1.175 - 1.190

(0.099

1
2nd

(0.28)

1st

2nd

0.2
IO.008)
7.2

(0.0463 - 0.0469)
1.170 - 1.190
{0.0461 0.0469)

16.002 - 16.008
(0.6300- 0.6302)

16.030
(0,6371)

(0.6297- 0.63001

15.980
(0,6291)

CRANKSHAFT
-

Unit: mrn (in)


-

ITEM
Conrod small end I.D.

STANDARD
-. -.

LIMIT
- -

16.006- 16.014
(0.6302- 0.6305)

1 6.040
(0.6315)

0.10 - 0.65
(0.004- 0.026)

1.O
10.039)

Conrod deflection
-

Conrod big end side clearance


I

Crankshaft runout

0.05
(0.002)
Unit: mrn (in)

OIL PUMP

ITEM
-

STANDARD

LIMIT

1.723 187/49 x 33/34)

Oil pump reduction ratio

Oil pressure ( a t 60" C, 140" F)

Above

Below

0.1 kg/cm2
(1.4 psi)

0.5 kglcm2
(7.1 psi)

at 3 000 rlrnin.
Tip clearance

0.20
(0.008)
0.25
(0.010)
0.15
(0.006)

Outer rotor clearance

Side clearance

CLUTCH

Unit: mm (in)

ITEM
-

STANDARD

--

Clutch cable play

2.7

Drive plate claw width


I

Driven plate distortion


Clutch spring free length
I

--LIMIT

2-3
(0.08
- 0.121

Drive plate thickness

Driven plate thickness

---

- 2.9

(0.106- 0.114)
11.8 - 12.0
I0.46- 0.47)

2.4
(0.094)

1'1.0
(0.43)

2.0 .t. 0.06

(0.138+ 0.002)
0.1
(0.004)

38.5
( 1.52)

GS850GT

TRANSMISS ION

Unit: rnm (in)

ITEM

STAND

Primary reduction
Secondary reduction

l.UW (17 1 1 6 )

3,090 434111)
2.500 (35/ 14)
--

1.380 ( 2 9 1 2 1 )
-

Shift fork to Groove clearance

Shirt fork groove width


Shift fork thickness

0.4 - 0.6
(0.0116 0.024)

0.8
10,0311

5.45 - 5.55
(0.21 5 - 0.219 )
4.95 - 5.05
(0.195 - 0.T 99)

SHAFT DRIVE

Unit: mrn (in)

ITEM
Secondary bevel gear backlash
Final bevel gear backlash
Secondary drive bevel gear preload

STANDARD

0.08- 0.13
(0.003- 0.005)
0.03 - 0.64
(0.001- 0.025)
3 - 5 kg-crn
(2.60 - 4.35 Ib i n 1

4 7 kqcm
(3.45 - 6.05 lb*in)

LIMIT

GSSjOGT

CARBURETOR

It
screw
--

rattle ca ble play

Unit: mrn Ein)

GTSSOCT

ELECTRICAL

Unit: rnm (in)

ITEM

SPEC IF [CATION

Ignition timing

17" B. T. D. C. Below 1 500 f 150 rlmin. and

Firing order

37" 8 . T.D. C. Above 2 350 1 150 rlrnin.


1, 2, 4, 3
NGK : B8ES

Spark plug

Type

IN. D. : W24ES-U

- -

0.6 - 0.8
(0.024 - 0.031)

Gap
Spark performance

Signal coil resistance


Ignition coil resistance

Over

8 10.3) at 1 atm
290-360n

Approx.

OW-W

Primary

Apprex. 3 - 5St
Plug cap - Plug cap
Approx. 31 - 33 kS2

Secondary
Generator No-Load voltage

More than 80 V (ACF a t 5

Brush length

Limit: 6

Commutator under cut

Limit: 0.2
(0,008)
-- -

(0.24)

3-4R

Starter relay resistance


Battery

000 r/min.

14.0 - 15.5 V a t 5 000 rlrnin.

Regulated voltage

Starter motor

31-G

Type designation

Y B3 4h - A2

Capacity

Fuse size

Standard electrolyte S. G.

1.28 a t 20C (68F)

Headlight

10A

Turn signal

T OA

- -

Ignition

10A

Main

1 5A

Output terminal

10A

GSSjOGT

BRAKE +WHEEL
ITEM

Unit: mm (in)

20

Rear brake pedal height

(0.8)
5.0 5 0.2
0.2 + 0.008)
6.7 + 0.2
(0-26 + 0.008)

Brake disc thickness

Master cylinder cylinder bore

15.870-15.913

Front

(0,6248- 0.6265)
14.000 - 14.043
(0.5512 - 0.5529)
15,827 - 15.854
(0.6231 - 0.6242)
13.957 - 13.984
(0.5495 - 0.5506)
38.130- 38.256

Rear
Master cylinder piston dia.

Front
Rear

Brake caliper cylinder bore

Front

Brake caliper piston dia.

38,I 80 - 38.256
(1.5031 - 1.5061)
38.091
48

Front

( 1 -499'

119)

38.098 - 38.148
(7.4999 - 1.5019)

Rear

4.5

(1.5031-1.5061)

Rear

Whppt rim r u n n ~ ~ t

LIMIT

STANDARD

2.0

Axial

l0.081
--

2.0

Radial
-

Wheel a x 6 r u n o u t

Front
Rear

Tire Isize

Tire tread depth

(0.08)
0.25

(0.010)

0.25

10.010)

Front

3.50H 19 4PR

Rear

4.50H17 4PR

Front
Rear

1.6
(0.06)
2.0
10.08)

'I

SUSPENSION

Unit: rnm (in)

-LIMIT
ITEMSTANDARD
Front fork stroke

160
16-31

Front fork spring free length

41 6
I1 6.4)
140

Front fork oil level

(55)

0.6 kg/crn2

Front fork air pressure


I

Rear wheel travel

(8.5 psi)
100
(3.91

CS850GT
FUEL + OIL + CAPACITY

Unit: mrn (in)

SPECIFICATION

ITEM

Use only unleaded or low-lead type gasoline of a t


least 85 - 95 pump octane ( - R P method) or 89
octane or higher rated by the Research Method.

Fuel type

Fuel tank including reserve

22 L
15.8 US gal)

reserve

4.2 t
(4.4 US qt)

Engine oil type

SAE 10W140

Engine oil capacity

Change

Filter change

2 800 ml
(3.0US qt)
3 600 rnl
(3.8 US qt)
-3 800 rnl

(4.0 US st)
SAE 1OWJ20

Front fork oil type


-.

Front fork oil capacity (each leg]


Bevel gear oil type
--

--

--

251 ml
(8.48 US oz)
HypoidGearoilSAE90,APIgradeGL-5
-

Bevel gear oil capacity

Brake fluide type

Secondary

340 - 400 rnl


(11.5 - 13.5US

Final

280 - 330 ~ m l
(9.5- 1 1.2 US 023

OZ)

DOT3 or DOT4

TIRE PRESSURE

COLD INFLATION
TIRE PRESSURE

Unit: W

WATTAGE
SPEC1FlCATlON

ITEM

Headlight
- - -.

HI

60

LO- --

55
.

TaillBsake light
Turn signal light

23 (32 cp)
-

3.4
3.4- -

Speedometer light

Tachometer light
-

--

Turn signal indicator light

3.4

High beam indicator light

3.4

3.4

License light

Neutral indicator light

Oil pressure
indicator
light
--

- -

8/23 /3/32 cp)

-- .- - . --

--

3.4
-

TORQUE TABLE
ENGINE

,r head n

ft bearir
Camsha

<et bolt

Cam ch

bolt

motor b,

ifting cal

CHASSIS

Ib.ft

kg-m

1.2 - 2,O

8.5 - 14,5

Steering stenn upper clamp bolt

1.5 - 2.5

11.0- 18.0

Front fork upper bra~cketbo2t ( R , C )

r
L

14.5 - 21,5

Front fork lower oracket bolt (!?,L)

1.5 - 2.5

11.0 - 18.0

Stee,ring stern head nut

3.5 - 5.0

25.5 - 36.0

1.5-2.5

11.0 18.0

3.6 - 5.2

0.35 - 0.45

26.0 - 37.5
2.5 - 3.0

79.5 - 94.0

Handlebar clamp boE


.-

Front fork axle holder nut

Front axle shaft nut

Swinging arm pivot bolt

--

Swinging arm pivot nut

Rear torque link nut

11

---

14.5 - 21.5

2.0 - 3.0

Rear axle nut

Rear shock absorber nut

LO

.5

2.7 - 4.3

19,5 - 31.0

Front brake caliper mounting bolt

2.5 - 4.0

18.0 - 29.0

Front and rear brake disc plate bolt

1.5 - 2.5

11.0 - 18.0
--

Front brake caliper axle bolt

1.5 - 2.0

11 .O - 14.5

Front brake master cylinder mounting bolt

0.5 - 0.8

Front and rear brake hose union bolt

1.3 - 1.8

- 6.0
9.5 - 13,O

Front and rear brake oil bleede

0.6 - 0.9

4.5 - 6.5

Rear brake caliper mounting bolt

2.0- 3.0

1.5

Rear brake caliper axle bolt

2.5 - 3.5

Rear brake master cylinder mounting bolt

1.5 - 2.5

11.0 - 18.0

Final drive gear nut

9.0 - 11.O

65.0 - 79.5

Final drive gear housing nut

3.5 - 4.5

25,5 - 32.5

Propeller shaft bolt

2.5 - 3.0
2.0 - 2.6
9.0- 1 1 .O
2.0- 3.0

Footrest bolt

Final gear bearing case bolt


Final gear case shock mount stud bolt

Final case oil filter plug

3.5

.,."

14.5 - 19.0
65.0- 79.5
14.5 - 21 -5
18.0 21.5

SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the GS8506, and should be kept on
hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery
cloth and the like. How to use them and where to use them are described in the text of this manual.

"

Oil filter cover nut.

. . . . . . . . . . . . . . . . . . . . . . . . 3 PCS
. . . . . . . . . . . . . . . . . . . . .8 p a

* Camshaft end cap screw


Front fork allen bolt

.......................

2
Carburetor adjuster bracket screw. . . . . . . . . . . . . . . 2
Carburetor plate screw . . . . . . . . . . . . . . . . . . . . . . 8
Carburetor starter shaft screw
4

.................

99000-32040
SUZUKI THREAD LOCK CEMENT

"

pcs
pcs
pa

pcs

. . . . . . . . . . . . . . . . . . . 2 pcs
. . . . . . . . . . . . . . . . . . . . . . . 2 pcs
Counter shaft BIG retainer screw . . . . . . . . . . . . . . . 3 pcs
Drive shaft plate screw . . . . . . . . . . . . . . . . . . . . . . 3 pes
Generator startor screw . . . . . . . . . . . . . . . . . . . . . 3 pes

Gearshift cam guide screw.

* Gearshift pawl screw

...............

99000-32050
SUZUKl THREAD LOCK CEMENT
" 1342'

Generator lead wire guide screw.


3 pa
* Engine oil pump screw . . . . . . . . . . . . . . . . . . . . . . 4 pcs
Oil gallery plate screw . . . . . . . . . . . . . . . . . . . . . . 3 p a
* Secondary drive bevel ge:lr assy set bolt.
. 4 pcs
Secondary driven bevel gear assy se!t bolt . ,
. 4 pcs
Final beve! gear bearing haloer scrt!W. .. ... ..
. 3 pm

..

......

Final bearing case bolt

. . . . . . . . . . . . . . . . . . . . . . I 0 pcs

* Cam sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs

" Thread portion of secondary driven gear


" Thread portion of final drive gear
* Propeller shaft joint bolt. . . . . . . . . . . . . . . . . . . . .

.....................
Cam chain guide bolt . . . . . . . . . . . . . . . . . . . . . . .
Gearshift stopper. . . . . . . . . . . . . . . . . . . . . . . . . .

* Stater clutch allen bolt.

SUZUKI THREAD LOCK CEMENT


SUPER "13338"

4 pcs
3 pcs
3 pcs
1 pc

Material

Part

* Cylinder stud bolt.

.. .. . . . . . . . . . . . . . .. .. . . .

& pcs
(Apply a small quantity to the threads of cylinder stud bolts.}
Cam chain chamber "0"ring (between head and cylinder)
Front

Rear

Mating surfaces of u p p t and lower crank case.


Final gear wse
Joint portion of rear swinging arm and final gear case.

99104.3 114(

SuZUKl BOND No. 1207E


Apply to caliper axle shaft

99000-25100
SUZUKl SltlCUNE GREASE
Cam shaft journal

* Chain tensioner adjuster shaft


Counter shaft washer
Outer counter shaft
* Input cam dog

99000-25140
SUZUKl MOLY PASTE

PERIODIC MAINTENANCE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also enhance the reliability and performance of the motorcycle.

More frequent servicing may be performed on motorcycles that are used under extreme severe
cornditions, however, it i s n o t necessary to ensure emission level compliance.

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating a t peak performance and to maintain proper emission levels. Mileages are
xpressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE

THIS INTERVAL SHOULD B E JUDGED


B Y ODOMETER READING OR
MONTHS WHICHEVER COMES FlRST
Battery (specific gravity of electrolyte}

1000 6 0 0 0
Month

Cylinder head nuts and exhaust pipe bolts


- .-

12000 18000 24000

12

24

3.6

48

3ner eler

Replace every two years

-R--[-~

Engine oil and oil; filter

Engine
idle speed
--.

Clutch

Secondary and final gear oil


-

Replace every t w o years


-

Brake
I

Chassis bolts and nuts

' -. I
I
/

Tires
-

--

Brake hose

Steering stem

I
I
4
Change oil a t initial 600 miles ( 1 000 km)
every 7 500 miles 412 000 km)

--

T I T-

Front forks

"

--

- I 1

1
T

Check air pressure every 6 months.


- -

NOTE: T = Tighten, I = Inspect, R = Replace, C = Clean

14-211

[--R;]
--

ENGINE
On the engine nanor system, the combines electric and kick starter system has been replard by the
electric starter system; t h a t is, the kick starter system is discontinued. As a result, generator has been
replaced by high performance type.

'-4
GS850GN MODEL

GS850GT MODEL

To make the valve timing better suited to the engine, the mounting angles of both intake cam shaft
and intake cam shaft sprocket are partly changed. The result is the following valve timing.

inlet open
Is. T. 0,C.1

T~D. C. Exhaust closed


(A. T. O. C.)

T.~.,-.
I

Exhaust closed
p/A.T.D.G.)

5w
,I

Inlet open
(B.T.D.C.)

,\wp;

Inlet closed (A. 5. D. C.1

.Exhaust open
(B. B. D. C.)

E. 0.C.
GS850GT MODEL

xhaust open
(B.0.D.C.)

(A.B.D.C.1

B.D.c.
GS850GM MODEL

No. 2 and Ma. 3 exhaust pipes are connected by a pre-muffler.

GS850G N MODE L

GS850GT MODE L
FUEL SYSTEM

* The carburetor has been changed from M l KUN l VM26SS to M l KUN l BS32SS.

13 Jet needle
(2)

Needle jet
Main jet
114) Needle valve
i 5;
Throttle valve

(3'

(5) f hrortle valve

GS850GT MODEL

GS850GN MODEL

ELECTRICAL
*The ignition system has been changed from the battery ignition system to the maintenance-free transistorized ignition system.

rrh

I' i '

SIGNAL GENERATOR

BIY

q#"
IGNITOR

1
GS850Gf MODEL

GS850G N MODE L

The l e f t handlebar switch has been changed as shown below:

GS850GT MODE L

GS850GN MODEL

The fuse box and output terminal have been changed from the separate type to the combined type.

GS850GT MODEL

GS850GN MODEL

The headlight bulb has been changed to the halogen type.

GS85OGK MODEL

GS850GN

MODEL

CHASSIS
a The front master cylinder cap has been changed from a screwing-in type to a &screw fastening type.

wtr~c3GTMODE L

GS850GN MODEL

The front and rear brake disc plates are newly provided with holes, and the resultant larger surface
area provided better heat dissipation for improved braking efficiency.

GS850GT MODEL

GS850GN MODEL

CAUTION :
Be careful not t o reverse the right and left front disc plates.

Right front disc plate

Left front disc plate

14-24

GS8SOC T

a As shown below, cable guides are newly added to better hold the clutch cable.

CAUTION:
r Whenever the clutch cable, carburetor and cylinder has been reinstalled in relation ro the routing
of the clutch cable, make sure that the clutch cable is correctly routed through two guides and
between the cylinders.
When reinstalling screw ( A , coat it with THREAD LOCK CEMENT (99000-32040).

GS850GT MODEL

G S 8 5 0 G N MODEL

CARBURETOR

fir' E ring
95, Gasket

(k9 Seat
'17, Needle valve
'1q

O ring

Filter
4lP Plats
~9~
?I

Main jet

?Z

Washer
Needle jet
Plug
Gasket
Pilot jet
Float
Ptn
Throttle valve
Shaft
Lever

'2L

95

36
'21
2fl
139

31,

SPEC! F ICATIONS

32 mm (1.26 in)
'I 050 k 100 r/min
50 + 0.5 mrn
(0.201 0.02 in)

22.4 * 1.0 mrn

(0.88 + 0.04 in)


Jet needle

5050

Pilot outlet
Valve seat

0.7

2.0

Starter jet

# 32.5

Pilot screw

PR E-SET

DIAPHRAGM AND PISTON OPERATION


f he carburetor is of a variable-venturi type, whose venturi cross section area is increased or decreased
automatically by the piston according to the vacuum present an the downstream side of the venturi.
Vacuum is admitted into the diaphragm chamber through an orifice provided in the piston.
Rising vacuum overcomes the spring force, causing the piston to rise to increase the said area and thus
to prevent the air vetocity from increasing. Therefore, air velocity in the venturi passage is kept relatively

constant for improved fuel atomization and for securing an optimum ratio of fuel to air in the mixture.

SCOW SYSTEM
This system supplies fuel during engine operation with throttle valve closed or slightly opened.
The fuel from float chamber is first passed through main jet and metered by pilot jet where it mixes with
air corning in through pilot air jet.
This mixture, rich with fuel, then goes up through pilot pipe to pilot screw. A part of the mixture is discharged into the main bore out of bypass port. The remainder is then metered by pilot screw and sprayed
out into the main bore through pilot outlet.

MAIN SYSTEM
As throttle valve is opened, engine speed rises, and this increases vacuum in the venturi. Consequently the
piston valve moves upward.
Meanwhile, the fuel in float chamber is metered by main jet, and the metered fuel enters needle jet, in
which it mixes with the air admitted through main air jet ;to form an emulsion.
The emulsified fuel then passes through the clearance between needle jet and jet needle and is discharged
into the venturi, in which it meets main air stream drawn by the engine.
Mixture proportioning is accomplished in needle jet; the clearance through which the emulsified fuel
must flow is either large or small depending u'ltirnetely on throttle position.

@ Air
@ FuelIAir
Fuel

Mixture

STARTER SYSTEM
Pulling up the choke knob slides starting plunger
to draw fuel into the starter circuit from the
float chamber through starter jet.
Stal-ter jet meters this fuel, which then flows
into starter pipe and mixes with the air corning
from the float chamber. The mixture, rich in
fuel content, reaches starting plunger and mixes
again with the air coming through a passage
extended from behind the diaphragm.
The two successive mixings of fuel with air are
such that a proper fuellair mixture for starting is
produced when the mixture i s sprayed out
through starter outlet into the main bore.

--------+

i
L .--

--. J

@ FuellAir Mixture

FLOAT SYSTEM
Floats and needle valve are associated with the
same mechanism, so that, as the floats move up
and down, the needle valve too moves likewise.
When fuel level is up in float chamber, floats are
up and needle valve remains pushed up against
valve seat. Under this condition, no fuel enters
into the float chamber.
As the fuel level falls, floats go down and needle
valve unseats itself to admit fuel into the
chamber. In this manner, needle valve admits
and shuts off fuel alternately to maintain a
practically constant fuel Iwel inside the float
chamber

FUEL SYSTEhl
When turning starter motor, negative pressure is
generated in the combustion chamber. This
nagative pressure works on the diaphragm of
fuel cock through passageway provided in the
carburetor main bore and vacuum pipe, and diaphragm builds up a negative pressure which is
higher than the spring pressure. Fuel valve is
forced to open due to diaphragm operation, and
thus allow fuel to flow into carburetor float
chamber.

DISASSEMBLY
Remove two throttle bracket screws (i and
starter bracket screw (2) , and remove bracket,
1

Loosen four screw, and remove starter shaft


13, three levers .di and starter bracket and
lever (';I.
FUEL TANK

VACUUM

CARBURET0

Remove eight screws and remove the plate.

Fuel

Remove four screws and remove float chamber.

a Remove eight screws and remove the plate.

a Separate four carburetors, remove n u t


remove adjuster lever.

and

r Remove three screws, and remove adjuster

bracket.

Remove four screws and remove carburetor


cap,

INSPECTION
FLOAT HEIGHT ADJUSTMENT
To check the float height, invert the carburetor
body. With the float arm kept free, measure the
height
while float arm is just in contact with
needle valve by using the caliper. Bend the
tongue [i, as necessary to bring the height
to
this value.
j

Float height

22.4 -t f ,O rnm
(0.88 k 0.04 in)

NEEDLE VALVE
I f foreign matter is caught between the valve
seat and the needle, the gasoline will continue
flowing and cause it to overflow. I f the seat and
needle are worn out beyond the permissible
limits, similar trouble will occur. Conversely, if
the needle sticks, the gasoline will not flow into
the float chamber.
Remove the carburetor, float chamber and
floats, and clean the float chamber and float
parts with gasoline. if the needle is worn as
shown below, replace it together with a valve
seat. Clean the fuel passage of the mixing
chamber with compressed air.

m Check following items for any damage or

clogging.

* Pilot jet
* Main jet
* Main air jet
Pilot air jet
Need te jet air bleeding hole and O-ring
* Float
" Needle valve mesh
* Diaphragm
" Gasket
" Throttle valve shaft oil seals
* Drain plug O-ring
* Starter chamber gasket
* Pilot outlet and bypass holes

"

Be sure to remove the gasket before measuring the height.

REASSEMBLY

* Place tongue

CT' of diaphragm to carburetor

body properly.

Connect the carburetors correctly, and


secure top of each carburetor to the plate
with screws.

Tightening torque

0.25 - 0,45 k g m
(1.8 - 3,O Ib-ft)

Secure carburetor cap and float chamber with


screws.
-

Tightening torque

0.25 - 0.45 kg-rn

4 1.8 - 3.0 1bVft)

Secure adjuster bracket to No, 3 carburetor


with two screws.
Before tightening the screws, coat them with

THREAD LOCK CEMENT.


Thread lock cement

Tightening torque

99000-32040

0.25 - 0.45 kg-m


(1,8 - 3.0 tb-ft)

a Secure adjuster lwer with nut.


14-36

Secure bottom of each carburetors to the


plate
with screws. Before tightening the
screws, coat it with THREAD LOCK CEMENT.

Thread lock cement

Tighten Fng torque

99000-32040

0.4 - 0.6kg-m
13.0- 4.5 Ibbfr)

Make sure The throttle shaft lever is installed as shown in photo.

Thread lock cement

Tightening torque

99000-32040
0.06- 0.10 kg-m
(0.4- 0.7 Ibaft)

Pass starter shaft through carburetors and


starter levers, and secure starter lever with
SCTEWS.

Before tightening the screws, coat it with


THREAD LOCK CEMENT.

Secure throttle bracket to No. 3 carburetor,


and secure starter bracket to No. 2 carburetor
cap, using screws.

Align the end of screw with recess in starter


shaft.

Tightening torque

0.25 0.45 kgmm


(1.8 3.0 Ib-ft)

BALANCING FOUR CARBURETORS


Set each throttle valve in such a way that its
top end
meets the foremost bypass @ . This
i s accomplished by turning throttle valve stop
wrew and balance screw.

Fuel level gauge

09913-14511

1((

- 0.22 in)
Distance @:I 4.5 - 5.5 mrn (0,18

FUEL LEVEL MEASUR'EMENT

To check the fuel Iwel, proceed as follows:


Checking fuel level in each float chamber
1. Leave fuel cock lever in "ON" or "RES"
position.
2. Place machine on center stand.
3. Remove float chamber screw and install
the special tool.
4. Move fuel cock lever to ' T R I " position to
admit fuel into float chamber.
5. With the float chamber filled with fuel, turn
the cock lever back to "ON" position, and
start up the engine.
6. Run the engine a t the idling speed (9501 150 r/min), and measure distance
with
the middle line of the level gauge aligned with
the mating surface of the float bowl as shown
in the illustration TAl should be within the
range specified here.

When checking the fuel Iwel, place the


machine an the center stand. The fuel

Fuel level adjustment


If dislance 'A1 is not within thespecified range,
it means that float height is off the specification,
to adjust this height, as shown page 14-35.

BALANCING THE CARBURETORS


When any carburetor has been disassembled or
replaced, check that the negative pressures
(vacuum) in four carburetors are well balanced,
using the carburetor balancer set in the folllowing manner:
1. Place machine on center stand.
2.Afterwarminguptheenginecompletely,remove either No. 1 or No. 4 vacuum inlet
screw, using a 4-rnm hexagon wrench.

3. Insert one of the four carburetor balanct


hoses into vacuum inlet.

4. Start up the engine, and keep it running at


1 500 - 2 000 rlmin.

Carburetor balancer set

5. Turn the air screw of the gauge so that the


vacuum acting on the tube of that hose will
bring the steel ball in the tube to the center.

6. On the three other screws, follow the same


procedure as above.
7. Remove the respective vacuum inlet screws
and insert the adapters in the holes. Connect
the balancer gauge hoses to these adapters,
one hose to one adapter, and balancer the
four carburetors as follows:

8. When the balls in No. 1 and No. 4 carburetor


balancers are on the same level and the other
balls are on the lower position as shown below, all the four carburetors are well balanced.

09913-1312 1
-

If the balls in No. 1 and No. 4 or in No. 2 and


No. 3 carburetor balancers are off more than
the radius of the ball, make an adjustment as
dol8ows:

1. Loosen throttle valve balancing screw lock


nut, and by- turning balancing screw with
special tool, adjust the position of steel ball
in balancer gauge.

09913-14930

3. After this adjustment, adjust the idling speed


to somewhere between 950 and 1 150 r/rnin
with throttle stop adjusting xrew.

Throttle valve adjust


wrench

CAUTION:
This check should be done as quick as possible. If adjustment requires a longer time,
it is advisable to cool the engine by sending
air to prevent engine overheating.

Adjusting order
(&(forNo. 2 carb) -@,Saor

No, 1 ) -El(for No, 4)

THROTTLE CABLE ADJUSTMENT


1. Loosen lock nut
2. Adjust the cable slack by turning adjuster @
in or out to obtain the correct slack 0.5 mm (0.02- 0.04 in].

a).

I
"I 2
L,'

4+

0.5-l.Ornm

lo.02

0.04in)

2. After adjusting, tighten throttle valve balancing screw lock nut.

3. After adjusting the slack, tighten the lock nut,

EMISSION CONTROL & REGULATIONS

EMISSION REGULATIONS

On February 4, 1977, Federal Emission Regulations for motorcycles that may be licensable took effect.
The regulations provided for a gradual, multi-step application of stricter emission limits beginning with
all effected motorcycles manufactured after January 1 , 1978, culminating with the present I980 emission level restrictions. For the 1980 and succeeding years one set of emission limits will be in effer+
They are as follows:

1980 EMISSION LIMITS

CATEGOR l ES

HYDROCARBO N D S ( HC)

CARBON MONOXIDE

All motorcycles
50 cc - 'Larger

5.0 Grarns/K
(8.0G r a m s / ~ ~ r e j

12 GramsJKilometer
4 19.3 GramslMiIe)

Emission-controlled motorcycles which are subject t o the emission regulations are those motorcycles
which are equipped with a headlight, taillight, stop light and which have an engine displacement larger
than SO cc.
Suzuki Motor Company performed all the necessary testing and certification of emission-controlled
models in strict compliance with the E.P.A. testing regulations. Suzuki motorcycle dealers are not
requjredtoeithertestorcertifyemirsionlevelsonanymotorcyclerasSuzukiMotorCompanyislegally
responsible for the entire certification procedure.

E.P.A. regulations also provide fines for individuals who alter, render inoperative or improperly service
emission-controlled motorcycles ranging up t o $30,000.00 per motorcycle. I t is essential that the individual servicing this emission-controlled motorcycle review thoroughly all the service procedures presented in this manual. Under no circumstances should the recommended service procedures be deviated from
nor adjustments made which are not in accordance with the factory specifications or service procedures.

EMISSION CONTROL CARBURETOR CONlPONENfS

GS850G motorcycles are equipped with precision, manufactured carburetors for emission level control.
These carburetors require special mixture control components and other precision adjustments to function properly.
There are several carburetor mixture control components in each carburetor assembly. Three (3) of these
components are machined t o much closer tolerances than standard machined carburetor jets. These three
(3) particular jets - MAIN JET, N E E D L E JET, PILOT JET must not be replaced by standard jets. To
aid in identifying these three (3) jets a different design of letter and number are used. If replacement
of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below.

The jet needle is also of special manufacture. Only one clip position is provided on the jet needle. If
replacement becomes necessary the jet needle may only be replaced with an equivalent performing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for
the best possible performance and durability.
1

Conventional Figures
Used on Standard Tolerance
Jet Components

1 2 3 4 5 6 7 8 9 0
-

Emission Type Figures


Used On Close Tolerance
Jet Components

1 2 3 4 6 78913
1

The carburetor specification for the emission-controlled GS850G are as follows.


Carburetor
l.D, No.

45110

Main
Jet
#

115

Needle
Jet

X-5

Jet
Needle

5050

Pilot
Jet

#YO

,
B

Pilot
Screw

PRE-SET

DO NOT ADJUST

The pilot screw i s pre-set by the factory utilizing specialized testing and adjusting procedures. The pilot
screw is not adjustable as the idle circuit is "sealed" after factory adjustment. Adjusting, interferring
with, improper r?
!nt, or resett ing of any of the carburetor components may adversely affect
carburetor perforr
~d cause the motercycle to exceed the exhaust emission level limits. If persons,
who are unaware or these speciar carburetor servicing requirements tamper with the carburetors the
Suzuki dealer should rest4ore the carbu retors t o their original condition or if unable to effect repairs,
contact the distributors re13resentallive for f urther technical information and assistance.

GENERAL EMISSION INFORMATION

There are three different types of regulated exhaust emissions. They are:
Hydrocarbons (HC)
Carbon Monoxide (CO)
Oxides ef Nitrogen (NOx)

Automobiles must meet specific emission standards for all three of these pollutants, MotorcycSes must
only meet the requirements for the following:
Hydrocarbons (HC)
Carbon Monoxide (CO)

HC exhaust emissions are basically unburned fuel vapors which have passed through the engine and escaped the combustion process.

CO exhaust emissions are formed during an incomplete combustion cycle as a result of a rich airJfuel
mixture. The only way that CO can be produced is by the combustion cycle.
Total NOx emissions from all motorcycles is considered negligible. The EPA states that total NOx emission from motorcycles by 1990 will only amount t o approximately 0.5%. NOx is formed during the
combustion process a t high combustion chamber temperatures.

CARBON MONOXIDE
Carbon monoxide i s a product of an incomplete combustion cycle. CO i s measured in grams per mile or
kilometer and also in percentage (%)
The most common cause o f CO i s rich carburetion. As the mixture is richened excessively, the CO
amount increases proportionately. Engine oil i s also a hydrocarbon, so engine problems which lead to 031
burning increase carbon monoxide,

CARBURETION MALFUNCTION
1. Air Cleaner Dirty or over oiled.
2. IdleMixture-Adjusted incorrectly,
3. Idle Speed - Too high or low.
4. Fuel Level - Sticking float, leaking needle, incorrect setting.
5. Choke- Leaking or linkagesticking.
6. Synchronization - Improper balance on multi cylinders.

ENGINE MALFUNCTIONS
1. Valve Seals - Leaking or torn.
2. Valve Guide - Worn and leaking excess oil.
3. Gaskets - Leaking ail into combustion chamber.

HYDROCARBONS
Hydrocarbons are unburnt gasoline vapors and can be measured in two different ways. The first i s t o
measure the weight of the pollutants over a specific distance such as grams per mile or grams per kilometer. The second method is to measure the concentration of HC in the exhaust gas in parts per million
(PPM).
The most common cause of high HC emissions are ignition system problems. If the ignition system fails
to ignite the fuel mixture properly, then raw gasoline vapors will pass through the engine into the exhaust system. Listed are the most common ignition problems which occur and which can affect HC
emission output.
IGNITION SYSTETvl MALFUNCTIONS
1. Spark Plugs- Fouled, dirty, Impropertypeor improperly gapped.
2. Ignition timing Advanced or Retarded.
3. Timing Advance - Too fast or too slow an advance rate.
4. Battery - Low charge or faulty.

Carburetion can also lead to high t4C emissions i f the mixture i s either excessively rich or excessively
lean.

MIXTURE-RELATED MALFUNCTIONS
1. Air Cleaner - Dirty, over oiled or torn.
2. Jets - Clogged, restricted or incorrect size.
3. Float Level - Level too low (lean) or too high (rich).
4. Choke - Leaking choke plunger or sticking linkage.
5. Air Leaks - Intake manifolds, engine gaskets and other sealing surfaces.
6. Synchronization - Unbalanced on multi-cylinder machines.
7. Exhaust System - Restricted flow or improper exhaust system.
Engine wear or damage can also cause high HC emissions,

7.
2.
3.
4,
5.
6.

Rings - Low compression, leakage into crankcase.


Valves - Improper adjustment, bent stem or burnt.
Gaskets - Leaking, loss of compression.
Crank Seals - Leaking.
Oil Consumption - Worn valve guides, worn rings, clogged crankcase breather.
Oil - Improper engine oil.

FULL-TRANSISTORIZED IGNITION SYSTEM

A fully transistorized ignition system is now employed on the GS850G. I t s primary advantages are:
* Trouble free operation due t o ~liminaiionof contart breaker points which can become contaminat~d.
* Ignition timing is maintained properly at at! times and require no maintenance.
* Free from arcing and provides the ignition coil with stable secondary voltage.
* Excellent vibration and moisture resistance.
Transistor functions can be divided into four main, functions:
1. amplification
3. oscillation
2. switching
4. modulation
These functions are utilized in the ignition system employed on the GS8SOG.
Transistors are divided into two groups, those being of the NPN and PNP types, and the transiston used
in the GS850G model is of the NPN type only, works an amplifier and switching device.

El : BASE
C : COLLECTOR
E : EMlTTE R

Each transistor has three terminals identified as t h e Base (B),Collector (C), and Emitter (E), and operation is as follows:
On a NPN type the base is the controling terminal of the transistor operation. On this type, the base
utilizes on!y a positive or incoming signal to do the "ON", or "0FF'"itching.
The collector is the
terminal where voltage is supplied to the transistor and the emitter i s the terminal for passing this current
for usage when the base has the proper "signal". 'Usually the voltage applied across the collector to the
emitter i s much larger than that needed at the base. This allows a relatively low voltage a t the base to
control large working voltages across the collector t o the emitter.
The transistor ignition system used on the GS850G is (the Nippon Denso brand and) consists of a signal
generator, which ernploysa rator and two pick-up coils, the transistor unit, ignition coils, and spark plugs.

SIGNAL GENERATOR:
The signal generator is mounted on the right
hand side of the engine in the area commonly
used for the contact breaker points. It is comprised of an iron rotor attached t o a mechanical
advance mechanism and two pick-up coils, with
magnets at their bases, affixed to a plate. Each
pick-up coil consists of a coil or wire and a yoke
or coil and is mounted 180" apart on the plate.
As the rotor tip is turned past the coils, AC
current is produced and used for switching within the transistor unit.
The transistor unit controls power to the ignition coils and causes the spark plugs t o fire at
the proper time.

ow

O N
FUSE

SIGNAL

GENERATOR

B
3

W
COIL

Remove the frame cover on the left side and


disconnect the lead wire from t h e signal generator.
Turning the ignition switch to the ON positior

SIGNAL GENERATOR
Measure t h e resismnce betvveen lead wires.
If the resistance noted to show infinity or t o o
low a resistance value must be replaced.

09900-25002

Pocket tester

STD resistance

BL-G

Now connect @ pin of SWZUKI Pocket Teste


( X 1 n range) with Blue lead wire on the ignftc
side and a p i n with Green lead wire. The ignitc
is in good condition if the following is observed
The moment t h e test pins are connected t h
spark plug of No. 1 cylinder sparks and th
moment the tester pins are disconnected t h
spark plug of No. 2 cylinder sparks.

250 - 360St

N_r
I

lGN ITOR
Remove each spark plug of Nos. T and 2 cyl
inders, fit it to respective plug cap and place it
on the cylinder head,

This checking presupposes that the ignition


coil used for checking is a good one.

FRONT MASTER CYLINDER

!711 Reservoir cap


(2; Diaphragm
<3 Reservoir
j3.

:4: 0 rine
5 Spring
161 Prrmary cup
' 7 1 Piston

Tightening torque

MASTER CYLINDER REMOVAL AND DISASSEMBLY


Take off front brake liqht switch.

Remove master cylinder ass'y after removing


two fitting bolts.

s Remove front brake lever.

a Remove filler cap and drain brake fluid.

Place a rag underneath the union bolt on the


master cylinder to catch spilled drops of
brake fluid. Unscrew the union bolt and disconnect the brake hosehaster cylinder joint.

CAUTION:
Completely wipe off any brake fluid
adhering to any part of motorcycle. The
fluid reacts chemically with paints, plastics,
rubber materials, etc.

GSh'fOCT

a Pull out the reservoier and 0 ring.

Draw out dust seal boot.

m Remove circlip by using special tool.

09900-06108

Snap ring pliers

a Pull out piston, primary cup and sprin!

MASTER CYLINDER INSPECTION


Inspect the cylinder bore wall for any scratch
or other damage.

MASTER CYLINDER REASSEMBLY


Reassemble the master cylinder in the reverse
orders of disassembly and by taking the following steps:
CAUTION:
Wash the master cylinder components with
fresh brake fluid before reassembly. Never
use cleaning solvent or gasoline to wash
them.
Apply brake fluid to the cylinder bore and
all the internals to be inserted into the bore.

When

remount the master cylinder to the


handlebars, first tighten the clamp bolt for
upside as shown.

rn lnspect the piston surface for scratch or other


damage.

Maser cytinder

Handlebar

-4I-I t

Cle rance

Inspect the primary cup, secondary cup and


dust seal boot for damage.

CAUf ION:
Adjust the front brake light switch after
installation.
Bleed the air after reassembling master
cylinder. (See page 1 1-30]

FRONT CALIPER

i
2

3
'4

5
16

P~stonset
Piston seal
Plston boot
Pad set
Pad shim
Caliper holder
Pad spring

7'
' N Pad quide

* 5 )Caliper

axle No. 1

rlu Caliper axle No. 2


'11

Awle boot

Tightening torque

112 Bolt
113 Bleeder
14

cap

'1.5 - 2.0

15 Cover

16 Bolt

2.5

- 4.0

11.0- 14.5

BRAKE BAD REPLACEMENT


c Remove two bolts and take off caliper.

Do not operate the brake lever while removing the caliper.

Push in the piston all the way to the


caliper when remount the caliper.

rn Pull out brake pads with pad shim.

Replace the brake pad with a set, otherwise


braking performance will be adversely
affected.

Tighten the caliper axle bolts with specified


torque.

Tightening torque

Do not apply pad grease, when installing


the brake pads.

1.5 2.0 kg-rn


(11.0 14.5 Ib.ft)

CALIPER REMOVAL AND DISASSEMBLY


9 Disconnect brake hose and catch the brake
fluidinaruitablereceptacle.

Remove caliper bracket and draw out caliper


axles.

m Remove caliper axle bolts and take off


cal iper,

m Remove piston boot and piston seal,

Place a rag over the piston to prevent popping


up. Draw out the piston by using air gun.

Do not use high pressure air for preventing


piston damage.

CALIPER AND DISC INSPECTION


Inspect the cylinder bore wall for nick,
scmtch or other damage.

CALIPER REASSEMBLY
Reassemble the caliper in the reverse orders of
disassembly and by taking the following steps:
CAUTION:
Wash the caliper components with fresh
brake fluid before reassembly.
Never use cleaning solvent or gasoline t o
wash them.
Apply brake fluid to the caliper bore and
piston to be inserted into the bore.

r Apply grease t o the caliper axles.


r

99000-25100

SUZUKl Sl LlCONE GREASE

Inspect the piston surface for any flow or


other damage.

Tighten the caliper alxie nuts and caliper


mounting bolts with spt?cifiedt()rque.

rpp
Inspect the each rubber parts fox damage or
wear.

'

Tightening torque

Caliper axle bolt

1.5 - 2.0 k g m
(1 1.0- 14.5 Ib-ft)

Caliper bolt

2.5 - 4.0 kg-m


(78.0- 29.0 Ib-ft)

GSfY.70G T

REAR WHEEL

Insert driven joint into wheel bushing.

REAR WHEEL REMOVAL AND


DISASSEMBLY
The rear wheel can be removed from the machine in the same manner as in the GS850GM
model. Therefore, we discuss the subsequent
operations. (See page 1 1-42)
m Bend up the lock washer, remove the bolts
and separate the driven joint from the wheel.

m Place three washers in the groove around the


driven joint and tighten six bolts. Then bend
washers to lock the bolts,

a Remove the bushings from the wheel.

REAR WHEEL REASSEMBLY


Drive bushings into the wheel.

5.5- 6.5 mm
0.26 in)

In the same manner as in GS850GN, install


disc plate on the wheel, and install rear
wheel on the machine. (See page 11-45)

GScYSOGT

WIRE AND CABLE ROUTING

a,

rn

2
0

-2E
-m
C

',

Clamp

Clutch cable

able

GSA'SOGT

WIRING DIAGRAM

This section gives service data and items which differ from those of the GS855GNIGT and
describes the new features of GS850GLT. Refer t o the sections 1 through 14 except for the
items described in this section.

VIEWSOFGS850GLT

....................................
....... 15- 2

.. . . . . .. . . . . . . . . .. .. . . .. .. . ... . . . . . .. . .. . . .. . . 15- 3
SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
SPEClFlCATlONS

FUELCOCK

...................................................
15- 7

WIRE AND CABLE ROUT lNG


WlRlNGD1AI;RAM

. . . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . . .. .

15- 8

.............................................
75-10

tight sidl

Left side

15-2

SPECIFICATIONS

DIMENSIONS AND DRY MASS


Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry mass
Gross vehicle weight rating

2 280 mrn 190.0in)


900 mm (35.4 in)
1 230 rnm (48.4 in)
1 510 mm 159.4 in)
"0 mrn ( 5.9 in)
245 kg (540 IbsJ
455 kg ( 1 003 Ibs)

ENGINE
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

Four-stroke, air-cooled, DOHC


4
69.0 m m (2.717 in)
56.4 mrn (2.2213 in)
843 cm3 (51.4 cu. in3
8.8: 1
MI KCTN I BS32SS, four
Polyurethane foam element
Electric
Wet sump

Transmission
Gearshift pattern
Primary reduction
Gear ratios, Cow
2nd

Wet multi-plate type


5-speed constant mesh
I-down 4 u p
1.775 (87/49 3
2.500 (35/14)
1.777 (32118 )

3rd
4th
TOP

1.380 ( 2 9 / T f )
1.125 (27/24)
0.96 1 (25126)

SECONDARY DRIVE
Secondary reduction
Final reduction

Shaft drive
1.062 ( t J J 1 6 )
3.090 ( 3 4 11 1

CHASSIS
Front suspension
Rear suspension
Steering angle
Caster
Tra iA
Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure
Rear tire pressurl

ELCTRICAL
Ignition type
Ignition timing
Spark plug
Spark plug gap

Battery
Generan
Fuse

CAPACITIES
Fuel tank
Engine oil change
filter change
overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil

Specifications subject to change without notice,

Telescopic, pnevmatic/coil spring, oil dampened


Swinging arm, oil dampened, damper CwayJsprEng
5-way adjustable
40' (right and left)

6T0 40'
105 rnm (4.13 in)
2.6 m (8.5 ft)
Disc brake, twin
Disc brake
3.50H 19 4PR
4.50H19 4PR
1-75 kg/crn2 I25 psi) (Normal solo riding)
2.00 kg/crnz (28 psi) (Normal solo riding)

Transistorized
17' B.T.D.C. below 1 500 rlmin and
37" B.T.D.C. above 2 350 rlmin
NGK B8ES or N l PPON DENS0 W24ES-U
0.6 - 0.8 rnm (0.024- 0.031 in) both NG K and
NIPPON DENS0
12V 50.4 kC (14Ah)/1OHR
Three-phase A.C. generatc

10/10/10/10/15A

13 L (3.4 US gal)
2.8 L (3.0US qtl
3.6 L (3.8 US st)
3.8 L (4.0 'US qt)
3 4 0 - 4 0 0 m l E11.5- 13.5USoz)
280-330rnl ( 9.5- 11.2CISoz)
0,6kg-rn (8.5 psi)
302 rnl (10.20 US 02) in each leg

SERVICE DATA
-

Please refer to the service data of GS850GT except for the service data shown below.
Unit: rnm

(in)
1

ITEM

STANDARD

LIMIT

160

Front fork stroke

1 6.3 1
Front fork spring free length

Front fork oil lwel

160

0.6kg/crn
1 8.5 psi )

Rear wheel travel

I00
3.9 )

FUEL + OIL CAPACITY

Fuel type

Use only unleaded or low-lead type lfasoline of a t least 85 - 95 pump


octane ( JzF method) or 89 octane or higher rated by the Research
2
Method.

13 t
(3.4 US gal)

Engine oil type

SAE 10WJ40

Front fork oil type

SAE 1OWJ20

Front fork oil capacity (each leg)

302 ml
(10.20 US 02)

Bevel gear oil capacity

Hypoid Gear Oil SAE 90, API Grade GL-5


Secondary

Final

i
Brake fluid type

SPECIFICATION

Fuel tank

Bevel gear oil type

Unit: mrn (in)

l T fM

16.8 )

( 6.3

Front fork air pressure

426
(

340 - 400 mE
(11.5-13.5 US 02)

280 - 330 ml
(9.5-1 1.2 US OZ)
DOT3 or DOT4

Unit: W

ITEM
Headlight

SPEC1FI'CATION

HI

60

LO

55

Tail/Brake light

8/23 (3/32cp)

Turn signal
light
--

23 (32cp)

Speedometer light

3.4

3.4

Turn signal indicator light

3.4

High beam indicator light

3.4

Neutral indicator light

3.4

Oil pressure indicator light

3-4

Fuel gauge indicator light

3.4

FUEL COCK

$2 Fuel valve
(42 Spring
(& Fuel flow

O-ring
13? Diaphragm
: 5 : One way valve
Bt Vacuum
[z?

When the engine is not running with the valve in


the ON position, the fuel valve i s kept in the
closed position by applying pressure utilizing a
spring so that no fuel will flow to the carbure.
tars. When the engine is engaged, a negative
pressure is generated in the diaphragm chamber
through the vacuum (negative pressure)
pipe which is connected to the carburetors, and
builds up a negative pressure which i s higher
than the spring pressure so that the diaphragm is
forced to open the fuel valve and thus allow the
fuel t o flow to the carburetors.
On the other hand, setting the valve in the ON
position keeps the air return orifice open.
Negative pressure does not accumulate on the
diaphragm a t the time of engine stopping, and
then the spring pressure actuates the diaphragm
to move back t o its original posirion and closes
the fuel valve.
However, setting the valve in PRI position with
a screwdriver causes the air return orifice to
close, resulting in negative pressure in the
chamber
under the diaphragm. This negative pressure doesn't allow the fuel valve to
close and therefore the fuel keeps flowing to the
carburetors,

PRI

When starting the engine at PRI position,


be sure to change the valve from PRI

WIRE AND CABLE ROUTING

P
T~ghtenwlrlng harness together with clutch cable

WlRllNG DIAGRAM

This section gives service data and servicing procedures which differ those o f the
GS85QG T/G L T and describes the new features of the GS850GX/G LX. Refer to the sections 7 through 15 except for the items described in this section

CONTENTS
1

VIEW OF S U f U Kl GS850GX ................................. 1 6 - 2


SPECIFICATIONS
16. 3
SERVICE DATA ........................................... 1 6 - 5
TORQUE TABLE .......................................... 16-15
SPECIALMATERIALS
16-18
PERIODIC MAINTENANCE
16-20
CAMSHAFT. SPROCKET AND BOLT
16-21
DRIVEN GEAR SHIFT FORK
76-22
GEAR SHIFTING SPRING
3 6-22
UNIVERSAL JOINT FLANGE AND PROPELLER SHAFT .......... 16-23
TURN SIGNAL LIGHT
16-24
WIRE AND CABLE ROUTING
16-25
WIRINGDIAGRAM
16-27

..........................................

......................................
..................................

..........................
................................
...................................

......................................
................................
........................................
VIEWOFSUZUKI GS85OGLX ................................
16-28

..........................................
76-29
...........................................
16-31
..................................................
16-33
..............................................
16-34
.............................................
16-35
................................16-44
........................................
16-46

SPECIFICATIONS
SERVICE DATA
OILJET
FUELCOCK
FRONT FORK
WIRE AND CABLE ROUTING
WIRING DIAGRAM

Right sic

Left sidf

DIMENSIONS AND DRY MASS


Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry mass

865 rnm 134.1 in)


1 190 rnm (46.9 in)
1 500 mrn 159.1 in)
160 mrn 1 6.3 in)
830 mrn (32.7in)
253 kg (558 Ibs)

Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

Four-stroke, air-cooled, DOHC


4
69.0mm (2.717in)
56.4 mm (2.220in)
843 cm3 (51.4 cu. in)
8.8 : 1
MI KUN! BS32SS, four
Polyurethane foam element
E lectric
Wet sump

Seat height

TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary reduction
Gear ratios, Low
2nd

Wet multi-plate type


5-speed constant mesh
1-down, 4-up
1.775 (87/49)
2.500 (35/14)
1.777 (32/183

4th

1.380(29121)
1.I 25 (271241

Top

0.96t (251261

3rd

2 230 mrn 187.8 in)

SECONDARY DRIVE
TYpe
Secondaw reduction
Final reduction

Shaft drive
1.062 (17116)
3.090 134'1 11

CHASSIS
Front suspension
Rear suspension
Steering angle
Caster
Trail
Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure
Rear tire pressure

ELECTRICAL
Ignition type
Ignition timing
Spark plug
Spark plug gap
Battery
Generator
Fuse

CAPAC lT l ES
Ftrel tank including reserve
reserve
Engine oil change
filter change

overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil

" Specifications subject to change without notice.

Telescopic, pneumatic/coil spring, oil dampened


Swinging arm, oil dampened, damper 4-waylspring
5-way adjustable
40" (right and left)

62" 30"
113 mm (4.45 in)
2.6 m (8.5 ft)
Disc brake, twin
Disc brake

3.50H194PR

4.50H174PR
1.75 kg/cm2 (25 psi) (Normal solo riding)
2.00 kg/cm2 (28 psi) {Normal solo riding)

Transistorized
17" B.T.D.C. below 1 500 rlmin and 37' B.T.D.C.
above 2 350 rimin
NGK B8ES or NIPPON DENS0 W24ES-U
0.6 - 0.8 rnm (0.024 - 0.031 in) both NGK and
NlPPON DENSO
12V 50.4 k c (14 Ah)/lO HR
Three-phase A.C. generator

10/10/10/10/15A

22 L (5.8 US gal)
4.2 C (4.4 US qt)
2.8 C (3.0US qt)
3.6 L (3.8 US qt)
3.8 L (4.0 US qt)
340 - 400 ml (11.5 33.5 US QZ)
280 - 330 ml ( 9.5 11.2 US or)
0.6 kg/crn2 (8.5 psi)
251 ml (8.48 US oz) in each leg

SERVICE DATA

VALVES

* GUIDES

Unit: mrn (in)

ITEM

Valve diam,

IN.
EX.

LIMIT

36.0

IN.

(1.42)

30.0

EX.
Valve lift

STANDARD

.-

(1.78)

Valve clearance or Tappet


clearance {when cold)

Valve guide t o Valve stem


clearance

Valve guide I.D.


Valve stem O.D.

Valve stem runeut


Valve head thickness

IN.

IN.&

EX.

I
1

0.5
(0.02)

IN.& E X .

Valve seat width

Valve head radial runout


Valve spring free length

(IN. & EX.)

IN.& EX.

INNER

OUTER
Valve spring tension
(IN, & EX.)

1
I
I

INNER

29.3 - 34.0kg
(64.59 - 74.96 Ibs)
a t length 23 mm (0.91 in)

OUTER

50.4 - 58.3 kg
( 1 11.1 1 - 128.53 tbs)
a t length 27 rnm (1.06 in)

GSSSOGX/CLX
CAMSHAFT + CYLINDER

+ HEAD

Unit: mrn {in)

LIMIT

STANDARD

ITEM

36,320- 36.360

Camshaft journal oil clearance

IN. & EX.


IN. & EX.

Camshaft journal

O.D.

IN. & EX.

(1.4299

- 1.43151
35.770 - 35.810

( I -4181 1

(1.4083 - 1.4098)

(1.3965)

0.037 - 0.065
(0.0075 - 0.0026)
22.01 2 - 22.025
(0.8666- 0.857 1)
21.960- 21.975
(0.8646 - 0.8652)

0.150
10.0059)

Camshaft aunout

36.020
35.470

0.1

I IN. & E X .

10.004)

Cam chain 20 pitch length

157.80

(6.2131
Cam chain pin (at arrow "3")
I

Cylinder head distortion

20 th pin
0.2
(0.0081

PISTON + RING + CYLINDER

Unit: m m (in)

ITEM

LIMIT
7 kg/cm2

STANDARD
9 - 12kg/crn2
1128 - 17 1 psi)

Compression pressure

(I00psi)
2 kglcrn2
(28 psi)

Compression pressure difference

Piston t o Cylinder clearance

--

Piston diam.

0.050 - 0.060
(0.0020- 0.0024)
69.000- 69.01 5
(2.7165 - 2.7171)
-.
. 68.945 - 68.960
(2.7144 - 2.7150)

0.120
(0.0047)

Measure the 15 10.59)


from
piston
skirt end.
--

(2.71 18)

Cylinder distortion

69.080
(2.7197)

68.880

0.2
(0.008)
7.2

-I
Piston ring free end gap

Piston ring end gap

1st

Approx. 9.0 10.35)

2nd

Approx. 9.5

(0.28)

7.6
(0.30)

(0.37)

0.3 0 - 0.30

Ist

(0.004- 0.072)
0.10 - 0.30
(0.004- 0.01 2)

2nd
Piston ring groove clearance

0.7
1

(0.03)
0.7
(0.031
0.18
(0.0071)

0.15

(0.0059)
Piston ring groove width

a
Piston ring thickness

1.21 - 1.23

I st
2nd

1.21 - 1.23
10.047 - 0.048)

Oil

2.51 - 2.53
10.099 - 0.100)

Piston pin bore 1.D.


Piston pin 0.0.

- 1.190
- 0.0469)

1s t

1.175
(0,0463

2nd

1.170 - 1.190
(0,0461 - 0.0469)

.-

(0.047
- 0.048)
-

3 6.002- 16.008
(0.6300- 0.6302)

1 5.995

- 16.000

(0.6297- 0.6300)

16.030
(0.631 1)

15.980
(0.629I )

CRANKSHAFT

Unit: mm (in)

ITEM

STANDARD
16.006 - 16.014
(0.6302 0.6305)

Cenrod small end I.D.

16.040
(0.6315)

0.10- 0.65

3.0
F0.12)
I .O

Conrod deflection
-

Conrod big end side clearance

LIMIT

(0.004- 0.026)

(0.039)
0.05

Crankshaft runout

(0.002)
d

OIL PUMP

STANDARD

ITEM

LIMIT

1.723(87/49 x 33/34]

Oil pump reduction ratio


Oil pressure (at 60' C, 140" FJ

Above
Below

0.1 kg/cm2
11.4 psi)
0.5 kg/cm2

(7.1 psi)
at 3 000 rlmin

CLUTCH

Unit: rnm (in}

lTEM

STANDARD
2-3

Clutch cable play


Drive plate thickness
Drive plate claw width
Driven plate thickness
Driven plate distortion

Clutch spring free length

LIMIT

(0.08
- 0.12)
2.7 - 2.9

l-I

(0.106 -0.114)
11.8 - 12.0
40.46 - 0.47)

2.4
(0.094)
11.0

(0.43)

2.0 + 0.06
(0.08+ 0.0023
0.1
10.004)

38.5
(1.52)

TRANSMISSION

Unit: rnm (in)

(87 / 49)

1.775
Secondary reduction

1.062 (17 /I61

Final reduction

3.090 (34 / 1 1)

Gear ratios

2nd

3rd
--

4th
Top

Shift fork to Groove clearance

1
I

I
Shift fork groove width

Shift fork thickness

; / 14)
! 1 181

2. t

Low

--

1.;

--

1.380 I29 $21)


1.125 (27 / 2 4 )

0.961 125 / 26)

0.4- 0.6
(0.016 - 0.024)

0.8

(0.031)

5.55

0.219)
4.95 - 5.05
(0.195 - 0.199)

I
SHAFT DRIVE

Unit:

ITEM

STANDARD
-- -

LIMIT

Secondary bevel gear backlash

0,08- 0,13
(0.003- 0.0053

Final bevel gear backlash

0.03 - 0.64
(0.001 - 0.025)
3 - 5 kg-cm

Secondaw drive bevel gear preload

mrn [in)

(2.61) - 4.35 b i n )
Secondary driven bevel gear preload

4 - 7 kg-crn
13.45 - 6.05 Ib-in)

final drive bevel gear preload

4 - 8 kg.crn
(3.45 - 6.95 Ibain)

CARBURETOR

Pilot air jet

Throttle cable play

Unit: mrn (in)

(P. A. .I-1

# 190
0.5 - 1.0 (0.02- 0.04)

ELECTR ICA h

Unit: mm (in)

- No-Loa
l voltage

a t 5 OOC

dard e l e ~

GS8SOGX/GLX

BRAKE + WHEEL

Unit: mm (in)

ITEM
Rear brake pedal height
I

LIMIT

STANDARD

20
(0.8)

Brake disc thickness

Front

5.0 ? 0.2
(0.2* 0.0081
6.7 + 0.2

Rear

(0.26

0.0081

Brake disc runout


L

Master cylinder cylinder bore

Master cylinder piston diam.

Front

ieTr

Front

15.870 - 15.913
10.6248
- 0.62651
-

I
I

1
1

4.5
(0,181

6.0

(0.24)
0.30
(0.012,

14.000 - 14.043
(0.551 2 - 0.5529)
-

t 5.827 - f 5.854
(0.6231 - 0.62421

~---f
f 3.957- 13.984
(0.5495 - 0.5506)

Brake caliper cylinder bore

Front

38.180- 38.256

(1.5031

- 7.5061)

38.180 - 38,256
(1.5031 - 1.50611

38.098 - 38.148
(1.4999 - 1.5019)

38.098 - 38.148
(1.4999 - T.51119)
2.0

Wheel rim runout

(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)

Wheel axle runout

Front
Rear

Tire size

Tire tread depth

Front

3.50H 19 4PR

Rear

4.50H17 4PR

Front

1.6
(0.06)

Rear

2.0
(0.08)

SUSPENSION

l TIE-M

STANDARD
-.

LIMIT

160
(63)

Front fork stroke


Front fork spring free length

41 6
( I 6.4)

140

Front fork oil level

( 5.5)

0.6 kg/cm2
(8.5 psi)

Front fork air pressure


Rear wheel travel

1 00

(3.91

FUEL t OIL + CAPACITY


SPEC I I=lCATlQN

--

Use only unleaded or tow-lead type gasoline of a t


least 85 -- 95 purnp octane (-R+fl
method) or 89
octane or nlgner rated by the Research Method.

Fuel type

.".

Fuel tank including reserve

22 L
(5.8US gal)

reserve

4-27
(4.4 US qt)

Engine oil type

SAE 1OWJ4Q

Engine oil capacity

Change

-4-

Filter change

Overhaul

-front fork oil type

2 800 ml
(3.0US qt)
3 600 rnl
(3.8 US qt)

3 800 ml
(4.0 US gt)
Fork oil # I 5

- --

Front fork ojl capacity (each leg)

Bevel gear oil type


--

-+-.

251 rnl
(8.48 US 02)
Hypoid Gear oil SAE 90,API grade G L-5

Bevel gear oil capacity

Brake fluid zype

Secondary

30 rnl
( 1 1.5 - 13.5US OZ)

Final

28Q - 330 rnl


(9.5 - 11.2 US 0 2 )

DOT3 or DOT4

TIRE PRESSURE

GOLD INFLATION
I R E PRESSURE

e
Unit: W (cp)

WATTAGE
SPEC1FICATION

ITEM

Headlight

60

HI

LO

55

--

8/23(3132)

faiI/Btake light
Turn signal light

- - - -

23 132)
3.4

Tachometer light

3.4

Turn signal indicator light

3.4

-- .---- ..--

High beam indicator light

---

Neutral indicator light


,sure inc

---I

3.4
3.4
3.4

TORQUE TABLE
ENGINE

chain gi~ i d eNo.


tor bolt
ernor bo

r bolt
ter clutcl

1st pipe

?r bolt
- shift letrer bolt
Secondary drlve gear nut

12.0- f 5.0

Secondary driven gear nut

9.0 - 11.0

Secondary drive housing bolt

GS85OGX/GLX

CHASSIS

Rear tor

Rear ax!

Propell e ~shaft bolt

3.0 - 4.0

21.5 - 29.0
14.5 - 19.0

Final gez

65.0- 79.5
Final case oil filler plug

2,0 - 3.0

14.5 - 21.5

TIGHTENING TORQUE CHART

For ether bolts and nuts not listed on previous pages, refer to this chart:

TIGHTENING TORQUE
I

f hread Diameter
(mm)

4
5

6
8
10
12
14
16
18

Conventional or "4" Marked Bolt

kg-m
0.1

Ib-ft

0.2

0.2 - 0.4
10.4 - 0.7
1.0- 1.6
2.2 - 3.5
3.5 - 5.5
5.0 - 8.0
8.0 - 13-10
13.0 - T 9.0

Conventional Bolt

"4" Marked Bolt

0.71.5
1.5 - 3.0
3.05.0
7.0- 11.5
16.0 - 25.5
25.5 - 40.0
36.0 - 58.0
58.0 - 94.0
94.0 - 137.5

"7" Marked Bolt


kg-m

0.15

0.3
0.3 - 0.6
0.8 - 1.2
1.8 - 2.8
4.0 - 6.0

7.0 - 1Q.O
11.0 -16.0

17.0

- 25.0

20.0 - 28.0

"7" Marked Bolt

Ib-ft

1.02.0 -

2.0

4.5
6.0 - 8.5
13.0 - 20.0
29.0 - 43.5

72.5
79.5- 115.5
123.0 - 187 .O
144.5 - 202.5
50.5

SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the GS850G, and should be kept on
hand for ready use, They supplement such standard materials as cleaning fluids, lubricants, emery
cloth and the like. How to use them and where to use tl?em are described in the text of this manual.

Cablr?s (Speedcmeter and tachometer)


CIutc:h release mechanism

" Whee!I

bearings

........ 3. . . . . . . . 8-

Oil filtercovernUt.. . .
* Camshaft end cap screw
* Front fork allen bolt . .

........2

. . . . . . . . . . . . . . 2p a
. . . . . . . . . . . . . . . . . . . . . .8 ~ C S
. . . . . . . . . . . . . . . . . 4 PCS

Carburetor adjuster bracket screw.


* Carburetor plate screw
Carburetor starter shah screw

JIG retainer screw


Driveshaft plal:e screw

. . .

Generator starrer screw . . . . . .


* Generator lead wire guide screw.
Engine ail pump screw.
Oil gallery plate screw
Secondary dri\te bevel gt:ar assy se!t bolt.
t
Secondary dri\fen bevel gear assy 1~ e bolt.
L
holder
s
c
~
rew.
* Final bevel gear oearlnq

............... 3p
..................... 4 p a
...................... 3
. ,. . . . . . . . . 4pcs

..-.-

THREAD LOCK "'1342"'

"

Final bearing case bolt

.......

.................... 4
. . . . . . . . . . . . . . . . . . . . . 3 pcr
. ..................... 3......................... I p c

* Propeller shaft joint bolt.

*
"
"

......... 4-

. . . ......... 3 p a

Stater clutch allen bolt.


Cam chain guide bolt.
Gearshift stopper.

(Apply a small quantity t o the threads of cylinder stud bolts.)


Cam chain chamber "0"ring {between head and cylinder)

"

Mating surfaces of upper and lower crank case.

Joint portion of rear swinging arm and final gear case.

* Apply to caliper axle shaft

Counter shaft washer


Outer counter shaft

PERIODIC MAINTENANCE
IMPORTANT: T h e periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions wil! ensure that the motorcycle will not
exceed emission standards and it will also enhance the reliability and performance of the motorcycle.

NOTE:
More frequent servicing may be performed on motorcycles that are used under extreme severe
comditions, however, it i s not necessary to ensure emission level compliance.

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating a.t peak performance and to maintain proper emission levels, Mileages are
expressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE

'p 1

INTERVAL:
THIS INTERVAL SHOULD BE JUDGED
B Y ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST

7500
- ll000

15000

38 000

24 000

24

36

48

6004000

1 Month

Battery (specific gravity of electrolyte)


Cylinder head nuts and exhaust pipe bolts

1 1 2
I

Ij

'1

-.

Air cleaner element


Tappet clearance

- I C

Spark plug

Replace every two years


I
R
R
R

Fuel line
Engine oil and oil filter

---

Engine idle speed

- -

- - -

Clutch

--

- -

I
I
--

I
I

- -

Chassis bolts and nuts

Front forks

RrO JE: T = Jigh ten, I = inspec s, R = Replace, C = Clean

_ -

Replace every Iw o years


---

Steering stem

1 -7

I
-

Change oil at initial 600 miles (1 000 km)


every 7 5510 miles I112 000 km)

Brake
Tires

j.

Secondary and Final gear oil

Brake hose

.-

CAMSHAFT SPROCKET AND BOLT

As illustrated, the sprocket tightening bolt and


method has been changed from (@ to @, to
Therefore, tightening torque should be absenred.

a.

Part Name
6 rnm Allen bolt +
Thread lock Super

0.8 - 1,2 kg-rn


(6.0- 8.5 Ib-bt)

Type

!ning tor
washer + Thread lock
Super "1303"

Part
Name

Bolt

1.5 - 2.0 kg-m


(11.0- 14.5 Ib-ft)

Type
Part Number

@ Type
Part Number

O Type
Part Number

09106 - 06024

09111 - 06033
12747 - 44000

09103 - 07001

12741 -45111
12711 -45117
1 275 1 45002
1272 1 - 49001

Lock washer

I N, Cam sprocket
I N, Camshaft
EX, Cam sprocket
EX, Camshaft

12741 -45110
1271 1 - 451 10
12750 - 45041
12721 - 49000

Both @type and @) type have an interchangeability by exchanging bolt for lock washer + bolt.
Howeverotype has screw thread diameter of 7 mm, and bore diameters of the sprocket and the camshaft
are also 7 mm, so there is no interchangeability with neither (.. type nor @type.
lh-21

DRIVEN GEAR SHIFT FORK


For sure gear shifting, the shape of the driven gear shift fork has been changed as shown below:

EAR hY

GEAR SHIFTING SPRING


The shape of the gear shifting spring {when it is
can be shifted with less effort.

A: Shape of the spring (when it is set free)


B: Shape o-f the spring (when it is installed)

set free)

has been changed as shown below so that gears

UNIVERSAL JOINT FLANGE AND PROPELLER SHAFT


The shape of the joint area of the universal joint
flange with the propeller shaft, along with the
pitch, has been changed, and a t the same time, the
bolt has been modified.

asls

46.7 mrn
(1.84 in)

42.U mrn

17.0 mm
(0.67in)

16.10 mrn

11-65 in)

(0.63in)

When the universal flange bolt i s reused, it should


be coated with Thread Lock Super "'1361A" and
tightened to specification.

99000 - 32020

Tightening torque

Thread Lock Super


I1

3.0 - 4.0 kg-m


(21.5 - 29.0 Ib-ft)

GS(QSOGX/CLX

TURN SIGNAL LIGHT

(Front and Rear)

CAUTION:
Do not overtighten the lens fitting screws.

WIRE AND CABLE ROUTING

Clamp

Clutch cable

Throttle cable

Make sure that the clutch

Viewed from direction A


Main wiring harness

Pass the stater cabke through interior side of clip

. ...
Bt . , . . . Blue
Br . . . . Brown
G . . . . .Green
Gr . . . . Gray
Lbl . . . . Light blue
Lg . . . . L g h t green
O . . . . .Orange
P . . . . .Pink

WIRE COLOR
IB ,
Black

W l U R N S I C N h t LlORT IRI

..
. .. .
.. . .
.. .
...
. .
. ..
. ..

R.....Red
W ..
.White
Y
. Yellow
BIB1
Black with Blue tracer
B/R
. . Black with Red tracer
Bi'W
Black w ~ t h
White tracer
81Y
Black with Yellow tracer
I/R
. Blue with Red tracer
BllW
Blue with White trecer
B1IY
Blue with Yellow tracer

---

a t ~ - t uSWIM

- .

'---3

G/R . . . Green with Red tracer

3rlR
BrlW .
Br/Y
GIS .
GrlB
h g / ~.
LgR
QIG .
GIBl

. . . Brown with Red tracer


. . Brown wlth White tracer
. . . Brown with Yellow tracer
. . u r e e r with Black tracer
. . . Grav with Black tracer
. . Light green with Black traclsr
. . . Light.green with Red tracer
. . Orancre with Green tracer
. . .Green wttn. -.trlue tracer

TUAY S l G N A I L l G H t SmlCH

w-

. . . Grren with White tracer


. . . Green with Yellow tracer
. . . Orange with Red tracer
OW . . . Orange with Whits tracer
RIB . . . Red with Black tracer
RIB1 . . . Red with Blue tracer
RIG . . . Red w ~ t hGreen tracer
RIY . . . Red w ~ t hYellow tracer
WIB . . .White with Black tracer
W I B l . . .White w ~ t h
Blue tracer
EM
GIY
OIR

YIG
Y IR
YMI

WJR
WlY
VlS
YIBI

WIG

5 1 A A r t 9 YUTOU
4 C SFt4ERAIOP

. . .White with Red tracer


. . .White w i t h Yellow tracer
. . . Yellow w t h Black tracer
. . . Yellow with Blue tracer
. . .Yellow w i t h Green tracer
. . .Yellow with Red tracer
. . .Yellow w ~ t hWhite tracer

. . . Whfte with Green tracer

~ nuo~~r t

RElillL,llOn'RECTIFIER

: STAPl*,l 1IEtAY

m ' FUSE A l l *
I : 1llR)l blCR4L AELAV
: TIJPs
~ lCnltL~u

I
T

REUA TURN 510NAL I I G M l 1 R 1

GS8SOGX/GLX

n VIEW OF SUtUKl GS850GLX

Right side

-.

di,
%

Left side

SPECIFICATIONS
DlMENSlONS AND DRY MASS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Seat height
Dry mass

TYPE
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

TRANSMlSSlDN
Clutch
Transmission
Gearshift pattern
Primary reduction
Gear ratios, Low
2nd
3 rd
4th
Top
SECONDARY DRIVE
TYPE
Secondary reduction
Final reduction

2 250 mrn (88.6 in)


855 mm (33.7 in)
1 130 rnm (44.5 in)
1 510 mm (59.4 in)
145 mm ( 5.7 in)
750 rnm (29.5 in)
243 kg (536 Ibs)

Four-stroke, air-cooled,

DOMC

4
69.0 mrn 12-777 in3
56.4 mrn (2.220 in)
843 cm3 (51.4cu. in)
8.8 : 1
M l KUN l BS32SS, four
Polyurethane foam element
f lectric
Wet sump

Wet multi-plate type

5-speed constant mesh


1-down, 4-up
1.775 f87/49)
2.500 (35/143
1.722 (31118)
1.380 /29/21F
1.1 25 (27/24)

0.923 1241263

Shaft drive
T ,062 ( 17/16)
3.090 (34117 1

CHASSIS
Front suspension
Rear suspension
Steering angle
Caster
Trail
Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
F rant tire pressure
Rear tire pressure

ELECTR1CAL
Ignition type
Ignition timing
Spark plug
Spark plug gap

Battery

Generator
Fuse

CAPACITIES
Fuel tank including r e s e w
reserve
Engine oil change
filter change
overhaul
Secondary bevel gear oil
Finat bevel gear oil
Front fork air pressure
Front fork oil

* Specifications subject to change without notice.

Telescopic, pneumatic/coil spring, oil dampened


Swinging arm, oil dampened, damper Qwayjspring
5-way adjustable
40" (right and left)

62' 30'
105 rnm (4.73in)
2.6 m (8.5 ft)
Disc brake, twin
Disc brake
100190-19 57H (Tubeless tire)
130190-16 67 H (Tubeless tire)
1.75 kg/cm2 (25 psi) (Normal solo riding)
2.00 kg/cm2 (28 psi) (Normal solo riding)

Transistorized
'17" B.T.D.C. below 1 500 rlmin and
37" B.T.D.C. above 2 350 rimin
NG K 08ES or N IPPON DENS0 W24ES-U
0.6 - 0.8mrn 10.024 - 0.031 in) both NGK and
NIPPON DENSO
I 2 V 50.4 kC (14 Ah)/10 HR
Three-phase A.C. generator
lQ/lO/lQ/lO/15A

17 C (4.5US gal)
4.5 L 14.8 US qt)
3.0 L (3.2 US qt)
3.6 L (3.8 US qt)
3.8 L (4.0 US st)
340 - 400 ml ( 11.5 - 13.5 US ozl
280 - 330 ml (9.5 - 11.2 US 071
0.8 kg/crn2 (1 1-4 psi 1
245 ml (8.27 US oz) in each leg

SERVICE DATA

TRANSMISSION

Please refer to the service data of GS850GX except for the service data shown below.

STANDARD

ITEM

1.722 (311181

2nd

Gear ratios

BRAKE +WHEEL

Unit: mrn (in)

STANDARD

ITEM

15 (0.61

- Rear brake pedal height


Tire size

LIMIT

Front

100/90-19 57H Tubeless tire

SUSPENSION

Unit: rnm (in)

LIMIT

STANDARD

ITEM

516 120.3)
-

Front fork spring free length

260 (10.2)

Front fork oil level

0.8kg/cm2 (11.4 psi)


110 (4.3)

Front fork air pressure


Rear wheel travel

FUEL + OIL + CAPACITY


SPEC1FICATIIOM

ITEM

17 L

Fuel tank including reserve

Front fork oil capacity (each leg)

a!)

4.5 L 1

reserve
Engine oil capacity

(1

Change

3 uvu r n 13.2
~
CIS qt)
245 ml 1
t oz)

TIRE PRESSURE

COLD INFLATION
T I R E PRESSURE

Unit:

WATTAGE

(cp)

SPEC1FICATFON

ITEM
Headlight

HI

60

LO

55

8/23 (3/32)

TaEllSrake tight
-

Turn signal light

--

23 (323

Speedometer light

3.4

Tachometer light

3.4

furn signal indicator light

3.4

'
-

High beam indicator light


Neutral indicator light

Oil pressure indicator ight

3.4

OIL JET
A # 110 oil jet is added to the clutch cover as shown in Fig.

FUEL COCK

"'ON"
@ Fuel valve
Spring
@ Vaccurn

@ O-ring

Diaphragm

@ One way valve


Fuel flow

This fuel cock is provided three position, ON


RESand PRI.
When the engine is not running and the lever i s in
the ON or RES position, the fuel valve is kept in
the closed position by applying pressure utilizing
a spring so that no fuel will flow to the carburetors.
When the engine is engaged, a negative pressure is
generated in the diaphragm chamber "C" through
the vacuum (negative pressure) pipe which is
connected to the carburetors, and builds up a
negative pressure which i s stronger than the spring
pressure so that the disphragm is forced to open
the fuel valve and thus allow the fuel to flow to the
carburetors.

"RES"

When the lever is set to PR I position, the protrusion


located on the lever end pushes back the fuel
valve mechanically against the spring force and it
allows fuel to flow t o the carburetors directly,
whether the engine is running or not through the
RES side fuel fiitre and fuel valve clearanoe,

FRONT FORK

O Outer tube
Cylinder
:37 Oil lock piece
Dust seal
(5) Snap ring
(GI Oil seat
c71 Enner tube
I& Slide metal
(3) Spring
1'1$ Spring guide
IiJ Spacer
@ O-ring
(2)

t l l Cap
fir) O-ring

REMOVAL AND DISASSEMBLY


Support the machine by the centerstand and a
jack,

a Remove right and left calipers and speedometer

cable guide.

I
NOTE:
Do not operate the brake lever after the
caliper i s removal.

Pull off cotter pin O and remove axle nut


Loosen axle pinch bolt (3)

Draw out axle shaft and take off front wheel.

(53 .

Remove four bolts and front fender.

Remove valve cap and push in the air valve t o


relieve the air pressure completely.

Loosen the steering stern upper and lower


clamp bolts.

Slightly loosen the front fork cap bolt to


facilitate later disassembly after loosening

Pull down right and left front fork: assemblies.

Remove front fork cap bolt and draw out


spacer, spring guide and spring.

m Invert the fork and stroke

it several times to
remove the oil inside.
Under the condition (inverted condition), hold
the fork for a few minutes.

Draw out dust seal and snap ring.

m Remove damper rod secur.ing bolt by using


special tools.

09940-34520

"T'?mddle

09940-34580

Attachment "F"

m Draw out damper rod and rebound spring.

a Pull out inner tub

Remove the oil seal by using special tool.

09913-50121

Oil seal remover

The removed outer tube metal, inner tube


metal and oil seal should be replaced.

INSPECTION

PAMPER ROD R I N G
Inspect damper rod ring for wear and damage.

FORK SPRING
Measure the fork spring free length. If it is
shorter than service limit, replace it.
Service Limit

516 mrn (20.3in)

INNER TUBE
Inspect inner tubeouter surface for any scuffing.

OUTER TUBE
a Inspect outer tube inner surface for any scuffing.

REASSEMBLY
m Reassemble and remount the front fork in the
reverse order of disassembly and removal, and
also carry out the following steps.

INNER TUBE METAL

a Install the metal by hand as shown.

'Use special care to prevent damage to the


Tef Ion coated surface of the anti-friction

DAMPER ROD BOLT


Apply Suzu ki Bond No. l207B (T, and Thread
Lack Cement 9' to the damper rod bolt and
tighten with specified torque.
99104-31 140

99000 - 32040

Suzuki Bond No. 12078

09940-34520

09940-34580
-

Thread Lock Cement

Thread Lock Cement

"T" handle
Attachment "F"

2.0 - 2.6 kg-m


I14.5 - 19.0 Ib-ft)

Tightening torque

OUTER TUBE METAL AND 01t SEAL


Mounting outer tube metal and oil seal by uisng
special toot as shown.
I

CAUTION:
Use special care to prevent damage ta the
Teflon coated surface of the anti-friction
metal when mounting it.

09940 - 50111

Front fork oil seal installer

UZUKl BOND No. 12078

FO'RK OIL
m For the fork oil, be sure to use a fork oil whose
viscocity rating meets specifications below.
Fork oil

245 rnl (8.27US 0s)

Capacity

Hold the front fork vertical and adjust the fork


oil level with a special tool.

When adjusting oil level, remove the fork


spring and compress the inner tube fully.

09943 - 741 1 1
Oil level

Fork oil level gauge


I

260 rnn

nl

FORK SPRING

- When installing the fork spring as shown in Fig.

B
1

Upper

Lower

INNER TUBE
m Install the front fork assembly, align engraved
line
on the inner tube to the upper surface
O of the steering stem upper bracket.

u Tighten the upper and lower clamp bolts.

I lower)

1.5 - 2.5 kg-rn

FORK AIR
Lift up the tront wheel by jack.

Connect the air pressure gauge t o the valve @ ,


and turn the valve handle :P clockwise. Connect the hand pump t o the valve 5) , turn the
valve handle G'l clockwise, and pump The air.
Let the air out by loosening the handle @ till
the specified air pressure is left inside. Loosen
the valve handle 0 , and remove the a i r pressure gauge.

CAUTION:
During the air filling procedure do not exceed
more than 2.50 kg/cmZ (35 psi). Balance the
air pressure of both right and left forks
within specif icatien.
Do not use a high pressure air source to fiH
the fork tube. Seal damagt? may re:

STD Air pressure

0.8 kg/cm2
( 1 1.4 psi)

GS850GXJGLX

WllRE AND CABLE ROUTING

Assemble the clutch cable

Throttle cable

e
e

wlth clutch cable

it sure that the clutch cable


oes not coma tn contact with
cly~nderhead at this point.

Route guide and clutch

Spring

WIRING DIAGRAM

L a l

k,&"

c m

pU?-.lxg
m

- E x Z F k s

w n r gurn.-- 0
2

m==

5555:5:
- .- , .,

<<

~ " "

g o y u u a

m,-- u u

=s=

V O = m m

* J = Z 2 ! 2 3 2 2 2

rrZ>mmimmmmm

2
I.lr

i
?

i
2

This sectiun gives service data and servicing procedures which deffer those of rhe
GS85OGX and describes the new features of the GS850GL Refer to the sections I
through I G except for the items described in this section.

CONTENTS
.................................... 1 7 - 2

VIEW OF SUZUKl GS850GZ


SPECIFiCATIONS
SERVICE DATA ..............................................
TORQUE TABLE
SPECIAL MATERIALS .........................................
PER IODFC MAINTENANCE
EMISSION CONTROL & R EG'ULATIONS ..........................
COVER TIGHTENING BOLT
OILJET
CY LFNDER HEAD AND HEAD COVER
CAMTIMING ................................................
FUELCOCK
CHOKE LEVER ...............................................
IGNITIONSYSTEM
FRONT MASTER CYLINDER ...................................
WIRE AND CABLE ROUTING
W I R I N G DIAGRAM

.............................................
17-3
.............................................
.....................................

17. 5
17-15
17-18
17-20
17-21
17-25
17-25
17-26
17-26
17-27
17-28
17-29
17-31
17-35
17-37

....................................
.....................................................
...........................

.................................................
...........................................
...................................
...........................................

_;Sh'5OGZ

VIEW OF SUZUKI GS850GZ


4,
I

Right side

Left side

I 7-2

SPECIFICATIONS
DIMENSIONS AND DRY MASS

Overall length
Overall width
Overall height
Wheelbare
Ground clearance
Seat height
Dry mass

Type

Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system

TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary reduction
Gear ratios, Low

2nd
3 rd
4th

TOP
SECONDARY DRIVE
TYpe
Secondary reduction
Final reduction

* Asterisk indicates new Z model specifications.

"2 195 mm (86.4 in)


865 mm (34.1 in)
1 190 mrn (46.9 in)
1 500 mrn 159-1 in)
"1 70 mm ( 6.7 En)
*795 rnm (31.3 in)
"245 kg (540 Ibs)

Four-stroke, air-caoted, DOMC


4

69.0 rnm (2.717 in)


56.4 mrn (2.220 in)
843 cm3 (51.4 cu. in)
8.8 : 1
MI KUN I BS32SS, four
Polyurethane foam element
Electric
Wet sumo

Wet multi-plate type


5-speed constant mesh
1-down, 4-up

1.775 (87/49)
2.500 1351t 43
T -777 /32/T8)
1.380 (29121)
1.125 (27/24)
0.961 (251261

Shaft drive
1.062 117/16)
3.090 (34/11)

CHASSIS
Front suspension
Rear suspension
Steering angle
Caster

Trail
Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure
Rear tire pressllrp

ELECTRICAL
Ignition type
Ignition timing
Spark plug
Spark plug gap

Battery
Generator
Fuse

CAPAClTl ES
Fuel tank including resenre
reserve
Engine oil change
filter change
overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil

Specifications subject to change without notice.


* Asterisk indicates new Z model specifications.

Telescopic, pneumatic/coil spring, oil dampened


Swinging arm, oil dampened, damper 4-waylspring
5-way adjustable
40" (right and left)

*62" 10'
1 13 mm (4.45in)
2.6 m (8.5 ft)
Disc brake, twin
Disc brake
"3,501-1194PR (Tubeless tire)
"4.50H17 4PR (Tubeless tire)
1.75 kg/cm2 (24 psi) FNormal solo riding)
2.00 kg/cm2 128 psi) (Normal solo riding)

Transistorized

17" B.T.D.C. below 1 500 rJmin and 37" B.T.D.C.


above 2 350 rimin
NGK B8ES or NIPPON DENSO W24ES-U
0.6 - 0.8 mm (13.024- 0.031 in) both N G K and
N IPPON DENSO
12V 50,4 kC (14 Ah)/lO HR
Three-phase A.C. generator
1011011 0/10/15 A

22 b (5.8US gal)
4.2 L (4.4US qt)
3 0 L (3.2US qz)
3.6 L 13.8 US qt)
3.8 L (4.0 US st)

340 400 rnl ( T 1.5 - 13.5 US oz)


280 330 rnl ( 9.5 - 11.2 US oz)
0.6 kg/cma (8.5 psi)
"255 ml 18.62 US oz) in each leg

SERVICE DATA

VALVES+GUlDES

Unit: mrn {in)

STANDARD

36.0

IN.

(1.42)

30.0

EX.

(1.1 8)

Valve l i f t
7.5

EX.

Valve clearance or Tappet


clearance (when cold)
Valve guide t o Valve stem
clearance

(0.301

IN.& E X .

EX.

Valve guide 1.D.

0.040- 0.070
(0.001
6 - 0.00281

IN.& EX.
I

Valve stem 0.0.

Valve stem runout

Valve head thickness

IN.& E X .

IN.& EX.

Valve seat width


Valve head radial runouz
-

Valve spring free length


(IN. & EX.)

6.960 - 6.975
(0.2740 - 0.27461

IN.

I
1.0 - f .2
10.04 - 0.05)

IN. & E X .

IN.& EX.

INNER

1
29.3- 34.0 kg

Valve spring tension


(IN. & EX.)

INNER

OUTER

(64.59- 74.96 lbsl


at length 23 10.911

50.4 - 58-3kg
(111,11 - 128.53 Ibs)
at length 27 11.06)

LIMIT

--

CAMSHAFT + CYLINDER HEAD


ITEM

Cam height

Unit: mrn Fin)

STANDARD

36.320- 36,360

(1.4299 - 1.4315)

LIMIT
I

Camshaft journal holder 1 .Q.


-

Camshaft journal O.D.

Camshaft runout
Cam chain 20 pitch length

-- Cam chain pin ( a t arrow "3")


Cy liinder head distortion

IN. & EX.

IN. & EX.

IN. & EX.

0.037 - 0.065
(0.0015 - 0.0026)
22.012 - 22.025
(0.8666 - 0.8671)
- -21.960 - 21.975
(0.8646- 0.8652)

I
-

35.470

/ I .3965)
0.15Q

--

Camshaft journal oil clearance

36.020
(1.4181)

+-

I0.0059)

1
0.1
I

(0.004)
157.80
(6.213)
---

--

20 th pin

0.2

(0.0081

PISTON + RING +CYLINDER

Unit: mrn (in)


STANDARD
9 - 12 kg/crn2
I128 - 171 psi)

ITEM
I

Compression pressure

-- -

- -

--

LIMIT
I

7 kg/cm2
(100 psi)

2 kg/crn2

compression pressure difference


I

Piston to Cylinder clearance


-

C ~ l i n d e rbore
-

128 psi)

- - -- - -- -

0.050 - 0.060
(0.0020
- 0.00241
--69.000 - 69.01 5
(2.7165 - 2.7171)
-

0.1 20
(0.0047)

69.080
12-7197)

68.945 - 68.960
(2.7 144 - 2.7 150)
Measure at the 15mm (0.59in)
from piston skirt end.

Piston diam.

-pa

68.880
12.71 18)

Cylinder distortion

0.2
tO.008)
7.2

.
-

Piston ring free end gap

(0.281
7.6

(0.30)
Piston ring end gap

1s t

0.10 - 0.30
(0.004 - 0.012).

2nd

0.10 - 0.30
(0.004- 0.0121

Piston ring groove width

Piston pin O.D.

0.18
(0.00711

2nd

(0.0059)

0.15

1s t

1 .21 - 1.23
(0.047 - 0.048)

2nd

(0.047 - 0.0481

1st

2nd
Piston pin bore I.D.

0,7
(0.03)

I st

Oil

Piston ring thickness

Piston ring groove clearance

0.7

(0.03)

1.21 - 1.23

t-

.-

2.51 - 2.53

(0.099- 0.1001
1.175- 1.190
(0.0463 0.0469)

1.170 - 1.190
(0.0461- 0.0469)
16.002 - 16.008

(0.6300- 0.6302)

1 6.030
(0.6311 }

(0.6297- 0.6300)

15.980
(0.6291)

GS8.5 0GZ

CONROD + CRANKSHAFT
ITEM
-

STANDARD

C o n r d small end I .D.

16.006 - 16.014
(0.6302 - 0.63135)

3 6.040

(0.631 5)

Conrod deflection

3.0
-

(0.721

--

0.10 - 0.65
(0.004- 0,026)

Conrod big end side cl earance


I

1.O

(0.039)

Crankshaft runout

0-05
(0.002)

OIL PUMP
I--T f h

Oil pump reduction ratio


Oil pressure (at 60" C, 140" F)

STANDARD

LIMIT

1.723 {87/49 x 33/34)


Above

Below

0.1 kglcm"
(1.4 psi)

0.25 kglcm'
(3.6 psi)
at 3 000 rimin
-

CLUTCk

Unit: mrn (in)


ITEM

STANDARD

LIMIT

Clutch cable play


Drive plate thickness
Drive plate claw width

2.4
tQ.106- 0.1 14)

(0.094)

11.8- 12.0
(0.46 - 0.47)

f0.43)

11.0

2.0 2 0.06
(0.085 0.002)
Driven plate distortion
-

Clutch spring free length

0.1
10.004)

38.5
( 7 -52)

Unit: mm (in)

ITEM - _ _ _
Primary

)R
-

Seconda ry red uc:tion


-

- -

STANDARD

LIMIT

- 1
- -.

1.775 187 / 49)


-

1.062 (17 J f 6 )

3.090 134 / 1 1 )

Final reduction
.-

Gear ratios

Low

-I

--

2.500 (35 / 14)

(32/ 18)
1.380
(29 / 21 1
. --

2nd

1.777

3rd

--

4th

1.125 (27 / 2 4 )

TOP

0.961 I25 1261

-I . -- -. . -

- ---- ..

0-4 0.6
(0.03 6 - 0.024)

Shift fork to Groove clearance

0.8
(0.031)

5.45 - 5.55
(0.215 - 0.219)

Shift fork groove width

4.95 - 5.05
4
(0.195 - 0.1991

SHAFT DRIVE
STANDARD
-

l TEM
- Secondary bevel Igear baclklash

Unit: rnm (in)

0.08 - 0.73
(0.003- 0.0051
0.03- 0.64

Final bevel gear backiash


Secondary drive bevel gear preload
I

secondaYy driven bevet gear preload

Final drive bevel gear preload

(0.001- 0.025)
3 - 5 kg-crn
(2.60- 4.35Ib-in)
4 - 7 kg-cm
(3.45- 6.05 Ib-in)
4 - 8 kgcm
(3.45- 6.95 !bin)

CSS.5 0 G Z

CARBURETOR

Unit: mrn (in)

b ureto
e size

rter jet

* Asterisk indicates new Z model specifications.

ELECTRICAL

Unit: mm (in)

SPEC1
F ICATION
-

ITEM
-Ignition timing
--

Firing order
Spark plug

17" 8 . T. D. C. Below 1 500 -t. I50 rlrnin. and


37" B. T. D.-C.
Above 2 350 + 150 r/mEn.
-

1, 2, 4; 3

I-i
NGK : B8ES
N. D. : W24ES-U

0.6- 0.8
(0.024- 0.031 )

Spark performance
Signal coil resistance
Ignition coil resistance

Over 8 10.3) a t 1 atm+

~ ~ ~ r o xr-l40-180!2
.

Primary

Secondary

Starter motor

More than 80 V (AC) a t 5 000 rlrnin.

Generator No-Load voltage


AeguEated voltage

BI-Y,

ON-W
O N - B/Y
Approx. 3 - 5
ptugCap - plug cap
Approx. 30 - 40 k a

14.0- 15.5 V at 5 000 r/rnin.

'

Limit: 6

Brush length

(0.24)

Commutator under cut

Starter relay resistance


.Battery

-Type

--

Fuse size

Standard electroly te S. G.

1.28 a t 20C t 88OF)

Headlight

10A

Ignition

10A

Main

15A

Output terminal

10A

G-8

GS85OGZ

BRAKE + WHEEL

Unit: m m (in)
--

LIMIT

STANDARD

f TE M

1
Rear brake pedal height

20
(0.8)
5.0 ? 0.2
(0.2k 0.008)
6.7 ? 0.2
10.26 + 0.008)

Brake disc thickness

Front
Rear

I
I

4.5
(0.18 )

6.0
(0.24)

0.30
(
I
I
(0.012)
Master cylinder cylinder bore

Front

15.870-15.913
10.6248 - 0.6265)

Rear

14.000- 1 4.043
(0.5512 - 0.5529)

Front

15.827 - 15.854
(0.6231- 0.6242)

--

-b

~ G t e cylinder
r
piston diarn.

-Rear

13.957 - 13.984
(0.5495 - 0.5506)

Front

38.180 - 38.256
(1.5031 - 1.5061)

Brake caliper cylinder bore

- -.

Front
Rear
--

>

Wheel rim runout

--

38.180 - 38.256
(1.5031 - 1.5061)
38.098- 38.1 48
(7.4999 - 1.5019)
38.098- 38.148
(1.4999 - 1.5019)

Rear
Rrake caliper piston diam

--

2.0

Axial

(0.08)

2.0
40.08)
0.25

Radial

Wheel axle runout

I
I

Front

L-

(0.010)
L

Rear

+
I

Tire tread depth

Front

*3.50H19 4PR (Tubeless tire)

Rear

*4.50H17 4PR (Tubeless tire)

Front
I

Rear

* Asterisk indicates new Z model specifications.


f 7-12

0.25
(0.010)

1.6

(0.06)
2.0
(0.08)

I
I

CS8.5 0 GZ

SUSPENSION

Unit: mrn (in)


STAN DAR P

Front fork stroke

LIMIT

1 60
(6.30)

+-

Front fork oil level

140
(5.5)

--

0.6kg/cm2

Front fork air pressure


--

(8.5 psi)

"1 10
14.33)

Rear wheel travel

FUEL +OIL

41 6
16.43

+ CAPACITY
ITEM--

SPEC1FICATION
Use only unlead& or low-lead type gasoline of at
least 85 - 95 pump octane IlLjA4 method) or 89
octane
or higher rated by the Research Method.
-

Fuel type

Fuel tank including reserve

22 L
(5.8 US gal)
4.2 L

reserve

(4.4 US qt)
Engine oil type

SA E

Engine oil capacity

Change

Filter change

I!

(3.2US qt)

3 600 ml
(3.8US qt)
11

Over hau l

Front fork oil type

For~
0 1 1 =F 1 5

--

Front fork oil capacity (each leg)

1
Bevel gear oil type
Bevet gear oil capacity

st)

"255 rnl
(8.62 US or)
Hypoid Gear oil SAE 90, API grade G L-5

340 - 400 ml
( 1 1.5 - 13.5US 02)
Secondar~

Final

Brake fluid type

* Asterisk indicates new Z model specifications.

280 330 ml
(9.5 - 11.2US 02)
DOT3 or DOT4

GS<YSOGZ

TIRE PRESSURE

COLD I N F L A T I O N

TIRE PRESSURE

Unit: W (cp)

WATTAGE
SPEC1FlCAJlON

ITEM

-Headlight

60

51 1
LO

55

.
-

8/23 (3132)

TailIBrake light

License light

Turn signal light


--

- -

-.-.

23 132)

--

3.4

speedometer light
-

Tachometer light

'

-.

.-

3.4
-

- - ..-

3.4

Turn signal indicator tight


-

High blearn indicator light

- -

Neutra I indicator light


--

I-

_ -_

.-

ght

---

light

* Asterisk indicates new Z model specifications.

1 7-1 4

3.4
3.4

-.

Oil pressure inc

- "Side st and chet:k

3.4
3.4

TORQUE TABLE
ENGINE

CHASSIS

Ir clamp
-k upper
Front tork lower
?adbolt
older nu
-k damp1
--

Ee shaft

.-

Front br

3er mow

Front an

union I

Asterisk indicates new Z model specifications,

TIGHTENING TORQUE CHART


For other bolts and nuts not listed on previous pages, refer to this chart:

TIGHTENING TORQUE
Thread Diameter

"7" Marked Bolt

Conventional or 'q4"
Marked Belt

(mm)
4
5
6

1.5 -

3.0

3.0-

7.0-

5.0
11.5

0.3 - 0.6

1.2
1.8 - 2.8

0.8

4.0 - 5.0

10
12
14
16
18

25.5 - 40.0

S t 0 -10.0

36.13 - 58.0
58.0 - 94.0

11.0 -16.0

17.0 - 25.0

I b-fl
1.02.0
2.0 - 4.5
6.0 - 8.5
13.0 - 20.0
29.0 - 43.5

50.5 - 72.5
79.5 - 115.5

123.0 - 181.0
144.5 - 202.5

0
13.0 - 19.0

Conventional Bolt

"4" Marked Bolt

"7'Marked Bolt

SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the GS850G, and should be kept on
hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery
cloth and the like. How t e use them and where to use them are (
j in the text of this manual.

Part

Material

Oil seals
Throttle grip

* Cables (Speedometer and tachometer)


* Clutch release mechanism
Wheel bearings
Swinging arm bearing
Steering stem bearing

S Y f UKl SUPER GREASE "A"

Oil filter cover nut.

99000-32040
THREAD LOCK CEMENT

. . . . . . . . . . . . . . . . . . . . . . . 3. pes

* Camshaft end cap screw . . . . . . . . . . . . . . . . . . . . .8 pcs


* Front fork damper rod bolt. , ................. 2 pcs
ster brack.et serew. . . . . . . . . . . . . . .2 pm
' Carburetor XI~U
Carburetor plat1e screw. .. . . . . . .. . . . . . . . . . . . . .8~
* Carburetor stad:er shaft smcrew . . . . . . . . . . . . . . . . . 4-

. . . . . . . . . . . . . . . . . . .2 p a
. . . . . . . . . . . . . . . . . . . . . . . 2 pcs
. . . . . . . . . . . . . . . 3 pcs

Gearshift cam guide screw.


Gearshift pawl screw
* Countershaf t BIGretainer screw
Driveshaft piate screw
Generator stator screw
Generator lead wire guidtE screw.

...................... 3p d

*
*

99000-32050
THREAD LOCK "1342"

. . . . . . . . . . . . . . . . . . . . 3.
.
........ 3 p
........ 4 p
Engine oil pump screw . . . . . . . .
Oit gallery plate screw . . . . . . . .
........ 3 p a

........... 4 p a
.......... 4 p a

Secondary drive bevel gear assy set bolt


Secondary driven bevel gear assy set bolt
Final bevel gear bearing holder screw.
* Final bearing case bolt

............

3pa

. . . . . . . . . . . . . . . . . . . . ..10 p a

Thread portion o f secondary driven gear


Thread portion of final dlrivs gear
Propeller shaft joint bolt . . . . . . .
Stater clurch allen b o l t ,

.-...... 4

.......
........ 3 p a
" Cam chain guide b o l t . . . . . . . . . . . . . . . . . . . . . . . 3 p a
* Gearshift stopper. . . . . . . . . . . . . . . . . . . . . . . . . . 1 PC
I

99000-32020
THREAD LOCK SUPER
"1333E"

99000-32030
THREAD LOCK SUPER "1303"'

Rear

Maring surfaces of uppCr and lower crankcase.


Final gear case
Jo~ntportion o f rear swtnging arm and final gear ease.

Apply t o callper axle shaft

99000-251 00

Camshaft journal
Chain tensioner adjuster shaft
Counter shaft washer
Outer counter shaft

* Input cam dog

USE OF GENUINE SUZWKI PARTS


To replace any part of the machine, use a genuine
SUZU Kl replacement part. l mitation parts or
partssupplied from any other source than SUZ K I ,
if used t o replace SUZUKl parts can reduce the
machine's perf orrnance and, even worse, cou Id
induce costly mechanical troubles.

PERIODIC MAINTENANCE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will aZso enhance the reliability and performance of the motorcycle.
NOTE:
Vehicles operated under severe conditions may require more frequent servicing.
-

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and TO maintain proper emission levels. Mileages are
expressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE

INTER:VAL:
THIS I NTERV,ALSHOULD B E JUDGED
.-.B Y uuu~vlt
1 k R READING OR
CMEVER COME
m.,

-.. ---

--

c gravity of elect

0
-- miles
e every I

Brake
Tires

NOTE: T = figh fen, 1 = Inspect, R = Repface, C = Clean

Check air pressure every 8 months.

EMISSION CONTROL & REGULATIONS


EMlSSlON REGULATIONS
On February 4, 1977, Federal Emission Regulations for motorcycles that may be licensable took effect.
The regulations provided for a gradual, multi+step application of stricter emission limits beginning with
a l l effected rnotorcyc!es manufactured after January 1, 1978, culminating with the present 1980 ernisrion level restrictions. For the 1980 and succeeding years one set of emission limits will be in effe(
They are as follows:

1980 EMISSION LIMITS


r

CATEGOR
All matorc)
50 cc - Larger

HYDROCARS ONDS I HC)

CARBON MONOXIDE

5.0 GramslK
r
(8.0 Grams/Mile)

12 GramslKilometer
119.3 GrarnslMilel

Emission-controlled motorcycles which are subject to the emission regulations are those motorcycles
which are equipped with a headlight, taillight, stoplight and which have an engine displacement larger
than 50 cc.

Suzuki Motor Company performed all the necessary testing and certification of emission-controlled
models in strict compliance with the E.P.A. testing regulations. Suruki motorcycle dealers are not
required to either test or certify emission levels on any motorcycles as Suzuki Motor Company is legally
responsible for the entire certification procedure.

E,P.A. regulations also provide fines for individuals who alter, render inoperative or improperly service
emission-controlled motorcycles ranging up t o $10,000.00 per motorcycle. I t is essential that the Endividual servicing this emission-controlled motorcycle review thoroughly all the service procedures presented in this manual. Under no circumstances should the recommended service procedures be deviated ftom
nor adjustments made which are not in accordance with the factory specifications or service procedures.

EMISSION CONTROL CARBURETOR COMPONENTS

GS85OG motorcycles are equipped with precision, manufactured carburetors for emission level control.
These carburetors require special mixture control components and other precision adjustments to function properly.
There are several carburetor mixture control components in each carburetor assembly. Three (3) of these
components are machined to much closer tolerances than standard machined carburetor jets. These three
(3) particular jets - MA1N JET, N EEQ LE JET, PI LOT JET - must not be replaced by standard jets. To
aid in identifying these three (3)jets a different des~gnof letter and number are used. I f replacement
of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below.

The jet needle i s also of special manufacture. Only one clip position is provided on the jet needle. If
replacement becomes necessary the jet needle mav only be replaced with an equivalent performing replacement component. Slclzuk i recommends t h a t Genuine Suzuki Parts be utilized whenever possible for
the best possible performance and durability.
Cenventiona I Figures
Used on Standard Tolerance
Jet Components

1 2 3 4 5 6 7 8 9 0

Emission Type Figures


Used On Close Tolerance
Jet Components

1 2 3 Y 5 7 8 9 0

The carburetor specification for the emission-controlled GS850G are as follows.

Carburetor
I.D. No.

Main

45 160

+ 115

Jet

Needle
Jet

X-s

Jet
Needle

Pilot
Jet

Pilot
Screw

51350

-#. Y D

PRE-SET
00 NO3 ADJUST

The pilot screw is pre-set by the factory utilizing specialized testing and adjusting procedures. The pilot
screw is not adjustable as the idle circuit is "seakd" after factory adjustment. Adjusting, interferring
with, improper replacement, or resetting of any o f the carburetor components may adversely affect
carburetor performance and cause the motorcycle to exceed t h e exhaust emission level limits. If persons,
who are unaware of these special carburetor servicing requirements tamper with the carburetors the
Suzuki dealer should restore the carburetors to their original condition or i f unable to effect repairs,
contact the distributors representative for further technical information and assistance.

GENERAL EMISSION INFORMATION


There are three different types of regulated exhaust emissions, They are:
Hydrocarbons l HCF
Carbon Monoxide ICOE
Oxides of Nitrogen (NOx}
Automobiles must meet specific emission standards for all three of these pollutants. Motorcycles must
only meet the requirements for the following:
Hydrocarbons ( HC)
Carbon Monoxide (C01

HC exhaust emissions are basically unburned fuel vapors which have passed through the engine and escaped the combustion process.

CO exhaust emissions are formed during an incomplete ctlrnbustion cycle as a result of a rich airlfuel
mixture. The only way t h a t CO can be produced is by the combustion cycle.
Total NOx emissions from all motorcycles is considered negligible. The EPA states t h a t total NOx emission from motorcycles by 1990 will only amount to approximately 0,5%.NOx is formed during the
combustion process a t high combustion chamber temperatures.

CARBON MONOXIDE
Carbon monoxide is a product of an incomplete combustion cycle. CO is measured in grams per mile or
kilometer and also in percentage (%)
The most common cause of CO is rich carburetion. As the mixture is richened excessively, the CO
amount increases proportionately. Engine oil i s also a hydrocarbon, so engine problems which lead to oil
burning increase carbon monoxide.

CARBURETlON MALFUNCTION
1. Air Cleaner - Dirty or over oiled.
2. ldle Mixture - Adjusted incorrectly.
3. ldle Speed - Too high or low.
4. Fuel Level - Sticking float, leaking needle, incorrect setting.
5 . Choke Leaking or linkage sticking.
6* Synchronization - Improper balance an rnulti cylinders.

ENGINE MALFUNCTIONS
1. Valve Seals - Lea'king or torn.
2. Valve Guide Worn and leaking excess oil.
3. Gaskets - Leaking oil into combustion chamber.

HYDROCARBONS
Hydrocarbons are unburned gasoline vapors and can he measured in two different ways. The first is to
measure the weight of the pollutants over a specific distance such as grams per mile or grams per kilometer. The second method is to measure the concentration of HC in the exhaust gas in parts per million
IPPM).

The most common cause o f high HC emissions are ignition system problems. If the ignition system fails
to ignite the fuel mixture properly, then raw gasoline vapors will pass through the engine into the exhaust system. Listed are the most common ignition problems which occur and which can affect HC
emission output.
IGNITION SYSTEM MALFUNCTIONS
1. Spark Plugs - Fouled, dirty, improper type or improperly gapped.
2. Ignition timing - Advanced or Retarded.
3. Timing Advance - Too fast or too slow an advance rat
4. Battery - Low charge or faulty,
Carburetion can also lead to high HC emissions if the mixture i s either excessively rich or excessively
lean.

MIXTURE-RELATED MALFUNCTIONS
1. Air Cleaner - Dirty, over oiled or torn.
2, Jets - Clogged, restricted or incorrect size.
3. Float Level - Level too low (lean) or too high (rich).
4. Choke - Leaking choke plunger or sticking linkage.
5. Air Leaks - Intake manifolds, engine gaskets and other sealing surfaces
6. Synchronization Unbalanced on multi-cylinder machines.
7. Exhaust System - Restricted flow or improper exhaust system.

Engine wear or damage can also cause high HC emissions.

1. Rings - Low compression, leakage into crankcase.


2. Valves - Improper adjustment, bent stem or burnt.
3. Gaskets - Leaking, loss of compression.
4. Crank Seals - Leaking.
5. Oil Consumption - Worn valve guides, worn rings, clogged crankcase breather.
6. Oil - Improper engine oil.

COVER f IGHTENING BOLTS


The engine case covers fasteners have been changed
from screws to bolts.

Clutch cover
Signal generator cover
Generator cover
Secondary drive unit cover
Starter motor cover

NOTE:
When unscrewing or tightening bolts use an
allen wrench.

OIL JET
A #I10 oil jet is added to the clutch cover as shown below.

CYLlNDER MEAD AND HEAD COVER


The cylinder head and head cover have been modified as illustrated below to improve seating between
cylinder head and head cover.

EFFECTIVE ENGINE NO. : GS850G-755015

EARLY

LATE

CAM TIMING

Align the "T" mark (an Nor. 1 and 4 cylinder ride of the rotor) to the center of pick up coil (Nos. 1
1 and 4 side].

--- --

FUEL COCK

"ON"
01)Fuel valve

spring
I&
Vaccum

This fuel cock is provided three position, ON


RES and PRI,
When the engine is not running and the lever i s in
the ON or RES position, the fuel valve is kept in
the closed position by applying pressure utilizing
a spring sothat no fuel will flow to the carburetors.
When the engine is started, a negative pressure is
generated in the diaphragm chamber "C" through
the vacuum {negative pressure) pipe which is
connected to the carburetors, and builds up a
negative pressure which is stronger than the spring
pressure so that the diaphragm is forced to open
the fuel valve and thus allow the fuel to flow to the
carburetors.
"RES"

When the lever isset to PR I position, the protrusion


@ located on the lever end pushes back the fuel
valve mechanically against the spring force and it
allows fuel to flow to the carburetors directly,
whether the engine is running or not through the
R ES side fuel filtre and fuel valve clearance.

@ O-ring

8One way valve


@ Fuel flow

GSLYSOGZ

CHOKE LEVER
Remove the choke lever and choke cable.

Apply Suzuki Super Grease "A" to the washer


before tighten the screw.

Suzuki Super Grease "A"

99000-25030
I

lGNlTlON SYSTEM

On the Model d5810GZ,t k timing advance characteristics of the ignition timing have been changed from
the hitherto-employed mechanical timing advance system incorporating an advance governor to an electronic timing advance system. The introduction of this new electronic timing advance system has kept the
change in the ignition timing due to time lapse at a minimum level and also has improved the timing
advance performance during high-speed operations.
Signal generator

When the signal rotor is rotated in the system block diagram above, the signal "A" is generated in the
pick-up coil. The thus-generated signal will be converted to the signal waveform "'B" at the inside of the
ignitor unit. Based on this "8" waveform, control is made by means of the advancing control circuit and
the closing angle control circuit. As a result, the timing advance takes place, as shown in Fig. '"C."

Slowspeed
revolution

k--l
I

Advanced angle 8'

Medium-speed
revolution

IHigh-speed
revolution

--

Advanced angle

e0

INSPECTION
SIGNAL GENERATOR
Measure the resistance between lead wires. If the
resistance is infinity or less than the specifications,
the signal generator must be replaced.

09900 - 25002

Pocket tester

I
.,
Generator

Approx. 1 40 - 180 ITt

IGNITOR UNlT
Remove the spark plugs from Nos. 1 and 2 cylinders. Install the respective plug caps and place
spark plus on the cylinder head.

Remove the frame cover on the left side and


disconnect the coupler from the signal generator.
As indicated in Fig. 1, connect the pocket
tester alternately to the terminals provided
inside the coupler. For this test, use the "RX 1"
range of the tester and set the ignition switch a t
the ON position. If the ignitor unit is functioning
normally, a spark will occur a t the spark plug a t
the moment when both of the tester pins @ and
@ are removed from the terminals sirnulatene-

ousry.

09900 - 25002

Pocket tester

NOTE:
This checking presupposes that the ignition
coil used for checking is a good one.
--

1
Fig.

"

FRONT MASTER CYLINDER

0
0

@ Piston and cup set

0 :i

Tightening torque

E:phragrn

~ 4 )Body
( 5 ) Holder

3.5 - 6.0

MASTER CYLINDER REMOVAL AND DISASSEMBLY


a Remove the front brake light switch and front
brake lever.

Place a

rag underneath the union bolt on the

master cylinder to catch spilled drops of brake


fluid. Unscrew the union bolt and disconnect
the brake hoselmaster cylinder joint.

CAUTION:
Immediately and completely, wipe off any
brake fluid contacting any part of the motorcycle. f he fluid reacts chemically with paints,
plastics, rubber materials, etc. and will darnage them severely.

m Remove the master cylinder ass'y after remevlng


two fitting bolts.

a Unscrew two fitting screws and remove the cap


and dia~hraqm.

Pull off dust real boot and remove the circlip


by using special tool.

09900 - 06108

Snap ring pliers

Pul t out piston, primary cup and spring.

MASTER CYLINDER INSPECTION


Inspect t h e cylinder bore wall for any scratch
or other damage.

Inspect the piston surface for scratch or other

damage.
rn Inspect the primary cup, secondary cup and dun
seal boot for damage.

MASTER CYLINDER REASSEMBLY


Reassemble the master cylinder in the reverse
order of disassembly and by taking the following
steps:
CAUTION :
Wash the master cylinder components with
fresh brake fluid before reassembly. Never use
cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all
the internal5
to be inserted into-the
-- -bore.

cvlinder on the
handlebars, first tighten the clamp bolt on t h e
upper side.

a When installing the master

CAUTION:
Bleed the air from the circuit after reassernbling the master cylinder.
Adjust the front brake light switch after
installation.

W I R E AND CABLE ROUTING

Wirlng harness

Turn slgnal
control unlt

Body ground

Wrr~ngharness

Clamp

Clamp

Clamp

Clamp

Clamp

Clamp

WIRING DIAGRAM

This section gives service data and senticing procedures which differ those of the GS850GLX and describes the new features of the GS85QGLZ Refer to rhe sections I through
I6 except for the items described in this section.

VIEW OF SUZUKl GS850GLZ

......................................

18-2

................................................
18-3
SERVICE DATA ..................................................
18-5
TORQUE TABLE .................................................
18-15

SPECIFICATIONS

SPECIALMATERIALS

............................................ 38-18

........................................18-20
EMISSION CONTROL & REGULATIONS .............................. 18-27

PERIODIC MAINTENANCE

COVER TIGHTENING BOLT

STARTER LEVER

....................................... 18-25

................................................
18-25

FRONT MASTER CYLINDER ....................................... 18-26


Wf RE AND CABLE ROUTING

......................................18-30

WIRING DIAGRAM ...............................................

18-32

Right side

Left side

I 8-2

0
@

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Seat height
Dry mass

TYP@
Number of cylinder.
Bore

Stroke
Piston displacemenr
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
TRANSMISSION
Clutch
transmission
Gearshift pattern
Primary reduction
Gear ratios, Low
2nd
3 rd
4th
Top

2 250 mrn (88.6 in)


855 rnm (33.7 in)
1 130 m m (44-5 in)
1 510 m m (59.4 in)
145 m m ( 5.7 in)
"765 rnm (30.1 in)
243 kg (536 Ibs

Four-stroke, air-cooled, DOHC


4
69.0 mrn (2.717 in]
56.4 rnm (2.220 in)
843 cm3 (51.4 cu. in)
8.8 : 'I
MI KUN I BS32SS, four
Polyurethane faam element
Electric
Wet sump

Wet multi-plate type


5-speed constant mesh
1-down, 4-up

1.775 (87149)
2.500 I35/14)
1.722 (31JT8)
1.380 129121)
I . I 25 (271243
0.923 (24126)

SECONDARY DRIVE
Secondary reduction
Final reduction

Shaft drive
1.062 11311 6)
3.090 (34111)

CHASSIS
Front suspension
Rear suspension
Steering angle
Caster
Trail
Turning radius
Front brake
Rear brake
Front tire size
Rear tire sire
Front tire pressure
Rear tire pressure

Teiescopic, pneumaticJcoiS spring, oil dampened


Swinging arm, oil dampened, damper 4-waylspring
5-way adjustable
40" (right and left)
62' 30'
105 rnm (4.13 in)
2.6 m ( 8 . 5 f t )
Disc brake, twin
3isc brake
100190-19 57 H (Tubeless tire)
130190-1667H (Tubeless tire)
1.75 kg/cm2 (24 psi) (Normal solo riding)
2.00 kglcmVE28 psi) (Normal solo riding}

ELECTRICAL

Spark d u g gap

Transistorized
17" B.T.D.C. below 1 500 r/rnin and
37" B.T.D.C. above 2 350 rlmin
NGK B8ES or NIPPON DENSO W24ES-U
0.6 - 0.8mrn (0.024 - 0.037 in} both NGK and

Battery
Generator
Fuse

NlPPON DENSO
12V 50.4 kC (14 Ahl/lO HR
rhree-phase A.C. generati
I OJ10/10/10/15A

Ignition type
Pgnirion timing

Spark plug

CAPACITIES
Fuel tank including reserve
reserve
Engine oil change
filter change
overhaul
Secondary bevel gear oil
Final bevel gear oil
Front fork air pressure
Front fork oil
Specifications subject to change without notice.

* Asterisk indicates new Z model specifications.

17 L (4.5 US gal)
4.5 L (4.8 US qt)
3.0 L 43.2 US q t )
3.6 L (3.8 US qtE
3.8 L (4.0 US qtl
340 - 400 rnl 41 1.5 - 13.5 US oz)
280 - 330 ml 19.5 - 11.2 US oz)
0.8 kg/cm2 ( 3 1.4 psi)
245 rnl (8.27 US oz) in each leg

GS<TSOGLZ

SERVICE DATA

VALVES+GlJIDES

Unit: rnrn (in)

'ITEM

Valve diam.

STANDARD

36.0

IN.

(1.42)

30.0

EX.

Valve lift

Valve clearance or Tappet

clearance (when cold)


Valve guide t o Valve stem
clearance

Valve guide I.D.


Valve stem O.D.

Valve stern r u n o u t
Valve head thickness

Valve seat width


Valve head radial runout

.-

(1.18)

IN.

8.0
(0,311

- - -

EX.

7.5
(0.30)

IN.& EX.

0.03 - 0.08
r0.001 - 0.003)

IN.

0.025 - 0.055
~0.0009- 0.0022)

EX.

0.040
(0.0016

8,

IN.& E X .

7.000 - 7.01 5
(0.2756 - 0.27621

IN.

6.960 - 6.975
(0.2740 - 0.2746)

EX.

6.945 - 6.960
(0.2734 - 13.2740)

IN,& EX.

IN.& E X .

(0.01 4)

0.05
0.5
10.023

1.0 - 1.2
10.04 - 0.053

IN.& E X .

- .

INNER

Valve spring tension


(IN. & EX.)

0.35

(0.014)

/ 0.002)

IN.& EX.

OUTER

.-

0.35

Valve spring free length


(IN. & EX.)

--

0.03
(0.001)
33.9
( 1.33)
41.3
(1.63)

INNER

29.3 - 34.0 kg
(64.59- 74.96 Ibsl
a t length 23 rnrn (0.91 in)

OUTER

50.4 - 58.3kg
(11 1.11 - 128.53 Ibs)
at length 27 rnm (1.06 in]

--

CAMSHAFT +CYLINDER
.

-.

ITEM--

+ HEAD

Unit: mrn (in)

STANDARD

LIMIT

-"

7 3 6 . 3 2 0 - 36.360
E 1.4299 - 1.4315)

36.020

I1.418tl

35.770 - 35.8%

EX.
.

Camshaft journal oil clearance


..*.

--

Camshaft journal holder I .D.

Camshaft journal O.D.

--.

- --

--

-. -

--- --

&

.-

-.. .-

20 th pin

Cam chain pin ( a t arrow "3")

- .-.

-..

0.1
10.0041
-

157.80
(6.2131

--.-

Cam c h a ~ n20 p ~ t c hlength


--

- --+-

10.8646 - 0.8652)

IN. & E X .

- -

0.1 50
(0.00591

r 1 . ~ 6-0 21.975

IN. & EX.

Camshaft runour
-

--

12 - 22.025
56.--0.867 -I.1

IN. & E

- - -

- --

--

0.037 - 0.065
(0.0015 - 0.0026)

IN. & EX.

( 1.4083
- 1.40981-

35.470
(1.3965)
-

.+ ---

-- - -

.-

0.2

Cylinder headdistortion
I

(0.008l

GS85OGLZ

PISTON + RING + CYLINDER

Unit: mrn (in)

9 - 12 kg/cm2
(128 - 171 psi)

compression pressure

Compression pressure difference

7 kg/crn2
(100 psi)

2 kg/cm2

(28 psi)
Piston to Cylinder clearance

0.050 - 0.060
(0.0020 - 0.0024)

0.120
( 0.004 7)

Cylinder I

69.000 - 69.075
(2.7165 - 2.7171)

(2.7 197)

68.945 - 68.960
(2.7144 - 2.7150)
Measure the 15 (0.59)
from piston skirt end.

Piston diar~l.

Cylinder distortion

Piston ring free end gap

Piston ring end gap

1st

Apprex. 9.0 (0.35)

2nd

Approx. 9.5 (0.37)

2nd
Piston ring groove clearance

1st

0.10 - 0.30
(0.004- 0.012)
0. T 0 - 0.30
(0.004 - 0.01 2 )

--

1s t

1.21 - 1.23
(0.047 - 0.048)

2nd

1.21 - 1.23
(0.047 - 0.048)

Oil

69.~80

68.880
(2.71 18)

7.2
(0.281

7.6

(0.30)
0.7
(0.031
0.7

(0.03)
0.18
(0.0071E
0-15
IQ.0059)

2nd
Piston ring groove width

0.2
(0.008)

--

1st

2.51 - 2.53

- 4 0.099- 0.100)
Piston ring thickness

1st

1.175 - 1.190
(0.0463 - 0.0469)

2nd

1.170 - 1.190
(0.0461 - 0.0469)

Piston pin bore I.D.


Piston pin O.D.

16.002 - 16.1008
(0.6300- 0.63023
15,995 - 16.000
(0.6297- 0.6300)

16.030
10.6311 )
15.980
(0.6291)

CRANKSHAFT

Unit: mrn (in)

ITEM
-

16.006 - 16.014
(0.6302 - 0.6305)

Conrod small end 1 .D.

r- .- - -

LIMIT

STANDARD
.-

--

16.040
(0.6315)

Conrod deflection

Conrod big end side clearance

OIL PUMP
-.

ITEM
.-

Oil pump-reduction
ratio
- -- -

-- --

Oil pressure (at 60" C, 140"

1-

--

- -

F)

STANDARD

LIMIT

1.7 23 (87/49 x 33/34)


-

Above

Below
,

0.1 kg/cm2
(1.4 psi)
0.5 kg/cm2
(7.1 psi)
a t 3 000 rJrnin
Unit: mm (in)

CLVf CH
ITEM-

STANDARD

2-3
(0.08 - 0.12)

Clutch cable play


-

Drive plate thickness


- -

Clutch spring free length

2.7 - 2.9
(0.106 - 0.114)
--

-L

Driven plate distortion

11.8 - 12.0
(0.46 0.47)

Drive plate claw w i t h


Driven plate thickness

LIMIT

2.4
(0.094)
11.0

10.43)

2.0 * 0,06
10.08 .t 0.002)
0.1
(0,004)

38.5
(1.52)

GSSSOCLZ

'.

TRANSMISSION

Unit: mrn

(ill,

Shift fork groove width

SHAFT DRIVE

Unit: mrn {in)

S f ANDARD

ITEM
Secondary bevel gear backlash
Finat bevel gear backiash
Secondary drive bevel gear preload
Secondary driven bevel gear preioad

Final drive bevel gear preload

0,08- 0.13
(0.003- 0.005)
0.03 - 0.64
(0.007- 0.025)
3 - 5 kg-cm
(2.60 - 4.35 Ibain)
4 - 7 kgcm
(3.45- 6.05Ib-in1
4 - 8 kg.cm
(3.45- 6.95 Ib.in)

CARBURETOR

Unit: mm (in)

ITEM

Carburetor type

Bore size

Idle rlmin.

SPEC1
FICATION
MlKUNl BS32SS

Fuellevel
a t heighr

Main jet

EM. J.}

Jet needle

(J. N.1

jet

I
i

--

115
-

5D50

Needle jet

LPilot

X-5

I
I

--

Pile

Valve seat

--

32.5

IG. S . )

I
I

pilot screw
Pilot air jet

(P.s.)
(P.A. S.1

2.0

PRE-SET
1

Throttle cable play

* Asterisk indicates new Z model specifications,

" 3 180
0.5 - 1.0 (0.02 - 0.04)

CS850GLZ

*
*

ELECTRICAL

Unit: mrn (in]


ITEM- - -

SPECIF
ICATlOfi
- -

17" B , T. D. C. Below 1 500 + ~ s r~rnin.


u
and
37" B. T. D. C. Above 2 350 + 150 rlrnin.

Ignition timing
- --

Firing order

- -

.--

1, 2, 4, 3

1-

Spark plug

--

NGK : B8ES
N. D. : W24ES-W

TYpe
-

Gap
-

--

Spark performance

-.

Signal coil resistance

Over 8 (0.3) at 1 atm.


Approx.
2901360
BI-G
- R
--- -OW-W
Primary
Approx. 3 - 5R
I
-PI ug cap - PI ug cap
I
Secondary
A p p r o ~ 31
. - 33 k i l
-More than 80
at 5 000 rlmin.
- -- - - 14.0
- 15.5
V at 5
-- -

--

Ignition coil resistance

I--

Generator NO-Load voltage

--

Regulated voltage

- .
-

FAC)
-

Starter motor

Limit: 6

Brush length
.--. .

Starter relay resistance


-

1-

--

--

-.

-,--

Type designation i'&14~

- A2

I 12V 50.4kC (14Ah)/l OH R

-A

1.28 a t 20C (68F)

Headlight

10A

Turn signal

10A

Ignition

L-

--

Standard electrol yte S. G.

-- .
-- - - . -

--

Limit: 0:2 (0.008)

i
:
-I

(0.24)

3 - 4 s2

--

Capacity

Commutator under cut

--

Battery

Fuse size

0.6- 0.8
(0.024 - 0.03T 1

--

10A

--

Main

I 5A

Output terminal

10A

BRAKE +WHEEL

Unit: rnm {in)


LIMIT

Rear brake pedal height

15
I

Brake disc thickness

(0.6)
Front

'

Rear

5.0 ? 0.2
(0.2+ 0.008)

4.5
(0.181

6.7 5 0.2
(0.26 + 0.008)

6.0
(0,241

Brake disc runout


-

Master c~lindercylinder bore

0.30
(0.012)

15.870 - 15.913
(0.6248 - 0.6265)

Front

4
-

Rear
- -

-- --

Master cylinder pistondia&.

(0.5512 - 0.5529)
-

--

Front

15.827 - 15.854
40.6231 - 0.6242)

Rear

13.957 - 13.984
(0.5495-0.5506)

- -.

d --

Brake caliper cyl inderbore

38r180-38.256

Front

(1,5031 - 1.5061)

38.180 --38.256
(1.5031 - 1.5061)

Rear
--

- -

Brake caliper piston diam.

Frant

38.098 - 38.148
(1.4999 - 1.5019)
38,098 - 38.148
(1.4999 - 7.5019)
-

Rear
--.

Wheel rim runoua

--

--

2.0

Axial
I
. -

I
Wheel axle runout

-_

- - -

Radial

- --

_-I

Front
--

.
-

L-

- -

(0.08)
2.0
I0.08)
0-25
(O.Ol0)

Rear

0.25
(0.010)

Tire size

Front

]-La-

100/90-1957H(TubeIesstire)
--

130/90-1667H (Tubeless tire)

--

Tire tread depth

1.6

Front

- - --

(0.06)
2.0
(0.081

CS,:SOGLz

Unit: rnm (in)

ITEM

STANDARD

160
(6.3)

Front fork stroke


I

LIMIT
-

Front fork spring free length

516
(20.31

111260
0.2)
0.8 kg/cm2
(11.4psiF

Front fork air pressure

100

Rear wheel travel

(3.9)

FUEL + 01L

+ CAPACITY
d or low-l
np octane

Bevel gear oil capacity

340 - 400 rnl


( 1 1.5 - 13.5 US 02)

Final

280 - 330 ml
(9.5- 11.2US 0 2 )

GS850GLZ

TIRE PRESSURE
GOLD INFLATION
TIRE PRESSURE

Unit: W (CDI
. ,

TEM
- -.

60

LO- ..-- - - .-

TailJBrake light

- --

55

8/23(3/32)

Turn signal light


-

Speedometer light

23 (32)
3.4

Tachometer light

HI

SPEC1FlCATlON

.-

Headlight

- -

- -

3.4

I---------1
*1.7

Fuelmeter light

Turn signal indicator light


High beam indicator light
-

a l indicator light

3.4
- -

--

U!I pressure indicator light


-.

3.4

- -.

* Side stand check light


Asterisk indicates new 2 model

--

3.4
-

3.4
3 ~ - I Ir u

TORQUE TABLE
ENGINE

llnder nead bolt

gine mot

GS85OCLZ

CHASSIS

ITEM

kg-m

Ib-ft

1.2 - 2.0

8.5 - 14.5

Steering stem upper clamp bolt

1.5 - 2.5

11.0 - 18.0

Front fork upper bracket bolt I R , L)

2.0 - 3-0

14.5 - 21.5

Front fork lower bracket bolt ( R , L)

1.5 - 2.5

11.0 - 18.0

2.0 - 3.0

14.5 - 21.5

Front fork axle holder nut

1.5 - 2.5

Front axle shaft nut

3.6 - 5.2

11.0 - 18.0
26.0 - 37.5

Handlebar clamp bolt


-

*Steering stem head bolt

0.35 - 0.45

Swinging arm pivot bolt


-

-- - - - .

Rear torque link nut

2.0 - 3

14.5 - 21.5

Rear axle nut

5.0

36.0 - 58.0

Rear shock absorber nut

2.0 - 3.0

2.5 - 3.0
79.5 - 94.0

11.0 - 13.0

Swinging arm pivot nut

8
I

14.5 - 21.5

2.7 - 4.3

19.5 - 31.Q

Front and rear brake disc plate bolt

1.5 - 2.5

11.0 - 18.0

Front brake caliper axle bolt

1.5 - 2.0

11.0 - 14.5

Front brake master cylinder mounting bolt

0.5 - 0.8

3.5 - 6.0

Front and rear brake hose union bolt

1.3 - 1.8

9.5 - 13.0

Front brake caliper mounting bolt

.9

4.5 - 6.5

".O

14.5 - 21.5

Rear brake c a l i3er


~ axle Ibolt

2.5 - 3.5

18.0 - 25.5

Rear brake master cylinder mounting bolt

1.5 - 2.5

11.0- 78.0

9.0- 1 T .O

65.0- 79.5

3.5 - 4.5

25.5 - 32.5

3.0 - 4.0

21.5 -

2.0 - 2.6

14.5 -

Rear brake caliper mounting bolt

Finat drive gear housing nut

-I"

Final gear case shock mount stur3 bolt


Final case oil filler plug

* Asterisk indicates new Z model specifications.

9.0- 7 1.0
2.0 - 3.0

65.0 - 79.5
14.5 - 21.5

TIGHTENING TORQUE CHART


For other bolts and nuts not listed on previous pages, refer t o this chart:

TIGHTENING TORQUE
Thread Diameter
(mm)

5
6
8
10
12
14

16
18

ionventilonal or '"4" Marked Bolt

kg-rn
Ib-ft
-0.1 - 0.2
0.7 - 1.5
0.2 - 0.4
1.5 - 3.0
0.4 - 0.7
3.0 - 5.0
-

1.0- 1.6
2.2- 3.5
3.5 - 5.5

5.0 - 8.0
8.0 - 13.0
13.0 - 19.0

Conventional Bolt

"4" Marked Bolt

7.0-

11.5

16.0 - 25.5
25.5 - 40.0

"7"' Marked Bolt


kg-m

0.15- 0.3
0.3 - 0.6
0.8 - 1.2
1.8 - 2.8

36.0 - 58.0
58.0 - 94.0

4.0 - 6.0
7.0 - 10.0
11.0 - 16.0
17.0 - 25.0

94.0

20.0

137.5

- 28.0

"7" Marked Bolt

Ib-ft

1.0 2.0 -

2.0
4.5
8-5

6.013.0 - 20.0
29.0 - 43.5
50.5 - 72.5
79.5 - 1 15.5
123.0- 181.0
744.5 - 202.5

99000-32030
THREAD LOCK SUPER "1303"

Cam chain chamber

"0"ring [between head and cylinder)


Fronr

Mating surfaces of uppkr and lower crankcase.

" final gear case


*

Joint portion of rear swinging arm and final gear case.

SUZUKl BOND No. f 20JB

Camshaft journal
Chain tensionet adjuster shaft
Counter shaft washer
Outer counter shaft
" Input cam dog

USE OF GENUINE SWZUKl PARTS


To replace any part of the machine, use a genuine
SUZUKl replacement part. Imitation parts or
parts supplied from any other source than SUZCIKI,
if used to replace SUZU K l parts can reduce the
machine's performance and, even worse, could
induce cost4y mechanical troubles.

PERIODIC MAINTENANCE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and i t will also enhance the reliability and performance of the motorcycle.

NOTE:
Vehicles operated under severe conditions may require more frequent servicing,

The chart below lisss the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating a t peak perfarrnance and to maintain proper emission levels. Mileages are
expressed in terms of kilometers. miles and time for your convenience.

PERIODIC MAINTENANCE SCHEDULE

INTERVAL:
THIS INTERVAL SHOULD BE JUDGED k m
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST
Month

-A.

'

Battery (specific gravity of electrolyte)


-

Cylinder head nuts and exhaust pipe bolts


.-

--

Air cleaner element


-

- -

Tappet clearance

Spark plug

- -

Fuel line

---

--

- .

Engine oil and oil filter


-

Secondary and Final gear oil


---

Brake hose

Brake

Chassis bolts and nuts

-- - -

--

--

Check air pressure every 6 months.

O TE: T = Tighten, I = Inspect, R = Replace, C = Clean

EMISSION CONTROL & REGULATIONS


EMISSION REGULATIONS
On February 4, 1977, Federal Emission Regulations for motorcycles that rnay be licensable took effect.
The regulations provided for a gradual, multi-step application o f stricter emission timits beginning with
all effected motorcycles manufactured after January 1, f 978, culminating with the present 1980 emission level restrictions. For the 1980 and succeeding years one set of emission limits will be in effect.
Thev are as follows:

CATEGO R I ES
All motorcycles
50 cc - Larger

5.0 Grarns/Kilometer
(8.0 Grams/Mile}

I 2 GramslKilometer
( 19.3 G rarnslMi le)

Emission-controlled motorcycles which are subject to the emission reguiations are those motorcycles
which are equipped with a headlight, tail light, stoplight and which have an engine displacement larger
than 50 cc.

Suzuki Motor Company performed all the necessary testing and certification of emission-controlled
models in Rrict compliance with the E.P.A. resting regularionr. Suzuki mutorcycle dealers are not
requjred to either test or certify emission levels on any motorcycles as Suzuki Motor Company is teqally
responsible for the entire certification procedure.

E.P.A. regulations also provide fines for individuals who alter, render inoperative or improperly service
emission-controlled motorcycles ranging up to S10,000.00 per motorcycle. I t is essential thar the individual servicing this emission-controlled motorcycle review thoroughly all the service procedures presented En this manual. Under no circumstances should the recommended service procedures be deviated from
nor adjustments made which are not in accordance with the factory specifications or service procedures.

EMISSFON CONTROL CARBURETOR COMPONENTS

GS85OG L motorcycles are equipped with precision, rnanufactu red carburetors for emission level control.
These carburetors require special mixture control components and other precision adjustments to function properly.

There are several carburetor mixture control cornllonents in each carburetor assernbty. Three (3) of these
components are machined to rnucll closer tolerances than standard machined carburetor jets. These three
(3) particular jets - MA1N JET, 1\1 EED LE JET, PI LOT JET - must not be replaced by standard jets. To
aid in identifying these three (3)jets a different design of letter and number are used. If replacement
of these close tolerance jets becomes necessary, be sure to replace them with the same type close tolerance jets marked as in the examples shown below.

The jet needle is also of special manufacture. Only one clip position is provided on the jet needle. If
replacement becomes necessary the jet needle may on!y be replaced with an equivalent performing replacement component. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for
the best possible performance and durabi [ity.

Conventional Figures
Used on Standard Tolerance
Jet Components

1 2 3 4 5 6 7 8 9 0

Emission Type Figures


Used On Close Tolerance
Jet Components

1 2 3 Y 5 6 7 8 9 D

The carburetor specification for the emission-conbralled GS850G L are as follows.

I
I

Pi lot
Screw

Carburetor
1.0. No.

45160

'ii5

X-5

5D50

""

RR E-SET

DO NOT ADJUST

'The pilot screw is pre-set by the factory u tilfzing specialized testing and adjusting procedures. The pilot
screw i s not adjustable as the idle circuit is "sealed" after factory adjustment. Adjusting, interferring
with, improper replacement, or resening of any of the carburetor components may adversely affect
carburetor performance and cause the motorcycle to exceed the exhaust emission l'evel limits. If persons,
who are unaware of these special carburetor servicing requirements ramper with the carburetors the
Suzuki dealer should restore the carburetors t o their original condition or if unable to effect repairs,
contact the distributors representative for further technical information and assistance.

GENERAL EMISSION lNFORMATION

There are three different types of regu tated exhaust emissions. They are:
Hydrocarbons IHC)
Carbon Monaxide (CO)
Oxides of Nitrosen (NOx)
Automobiles must meet specific emission standards for all three of theie pollutants. Motorcycles must
only meet the requirements for the following:
Hydrocarbons 4HC)
Carbon Monoxide (CO)

MC exhaust emissions are basically unburned fuel vapors which have passed through the engine and escaped the combustion process.

CO exhaust emissions are formed during an incomplete combustion cycle as a result of a rich airlfvel
mixture. The only way that CO can be produced is by the combustion cycle.
Total MOx emissions from all motorcycles is considered negligible. The PA states that total NOx emission from motorcycles by 1990 will only amount to approximately 0.5%. N0x i s formed during the
combustion process at high corn bustion chamber temperatures.

CARBON MONOXIDE
Carbon monoxide is a product of an incomplete combustion cycle.
kilometer and also in percentase (%I

The most common cause of CO i s rich carburetion. As the mixture i s richened excerrively, the CO
amount increases proportionately. Engine oil is also a hydrocarbon, so engine problems which lead to oil
burning increase carbon monoxide.
CARBURETION MAtFUNCTlON
1. Air Cleaner - Dirty or over oiled.
2. Idle Mixture - Adjusted incorrectly.
3. Idle Speed - Too high or low.
4. Fuel Level - Sticking float, leaking needle, incorrect setting.
5. Choke - Leaking or linkage sticking.
6, Synchronization - Improper balance on multi cylinders.

60 is measured in grams per mile or

ENGINE MALFUNCTIONS
1. Valve Seals - Leaking or torn.
2. Valve Guide - Worn and leaking excess oil.
3. Gaskets - Leaking oil into combustion chamber.

HYDROCARBONS
Hydrocarbons are unburned gasoline vapors and can be measured in two different ways, The first is to
measure the weight of the pollutants over a specific distance such as grams per mile or grams per kitometer. The second method is to measure the concentration of HC in t h e exhaust gas in parts per million
{PPM).
The most common cause of high HC emissions are ignition system problems. If the ignition system f a i l s
to ignite the fuel mixture properly, then raw gasoline vapors will pass through the engine into the exhaust system. Listed are the most common ignition problems which occur and which can affect HC
emission output.

IGNITION SYSTEIvI MALFUNCTIONS


1, Spark Plugs - Fouled, dirty, improper t y p e or improper1y gapped,
2, Ignition timing - Advanced or Retarded.
3. Timing Advance - Too fast or too slow an advance rate.
4. Battery - Low charge or faulty.
Carburetion can also lead to high HC emissions i f the mixture is either excessively rich or excessively
lean.

MIXTURE-RELATED MALFUNCTlONS
1. Air Cleaner - Dirty, over oiled or torn.
2. Jets - Clogged, restricted or incorrect size.
3. Float Level - Level too low (lean) or too h i g h (rich).
4. Choke - Leaking choke plunger or stick Eng linkage.
5. Air Leaks - l ntake manifolds, engine gaskezs and other sealing surfaces.
6. Synchronization - Unbalanced on multi-cylinder machines.
7. Exhaust System - Restricted flow or improper exhaust system
Engine wear or damage can also cause high HC emissions.

1. Rings - Low compression, leakage into crankcase.


2. Valves - Improper acljustment, P~entstem or burnt.
3. Gaskets - Leaking, loss of compression.
4. Crank Seals - Leaking.
5. Oil Consumption - Worn valve guides, worn rings, clogged crankcase breather.
6. Oil - Improper engine oil.

COVER TIGHTENING BOLT


Cover tightening bolts has been changed from
screw t o bolt.
NOTE:
When unscrewing or tightening bolts use an
allen wrench.
- a Clutch cover
Signal generator

Generator coves
Secondary drive unit cover
Starter motor cover

STARTER LEVER
Remove the starter lever and starter cable.

Apply Suzuki Super Grease "A" to the washer


before tighten the screw.
*

99000- 25010

Suzuki Super Grease "A"

FRONT MASTER CYLINDER

@ Piston and cup set

Tightening torque

O Cap
(3) Diaphragm
Body
(5) Holder

0.08

- 0.15

6.6 - 1.1

0.5

- 0.8

3.5 - 6.0

MASTER CYLINDER REMOVAL AND DISASSEMBLY


8 Remove the front brake light switch and front
brake lever.

Place a rag underneath the union bolt on the


master cylinder to catch spilled drops of brake
fluid. Unscrew the union bolt and disconnect
the brake hoselmaster cylinder joint.
CAUTION:
l rnrnediately and completely wipe off any
brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paints,
plastics, rubber materials, etc. and will damage them severely.

Remove the master cylinder ass" after removing


two fitting bolts.

e Unscrew two fitting screws and remove the cap


nrld diaphragm.

Pull off dust seal boot and remove the circlip


by using special tool.

09900 - 06108

Snap ring pliers

Pull out piston, primary cup and spring.

MASTER CYLINDER INSPECTION


m lnspect the cylinder bore wall for any scratch
or other damage.

Inspect the piston surface for scratch or other


damage.
Inspect the primary cup, secondary cup and dust
seat boot for damage.

MASTER CYLINDER REASSEMBLY


Reassemble the master cylinder in the reverse
order of disassembly and by taking the following
steps:
CAUf ION:
Wash the master cylinder components with
fresh brake fluid before reassembly. Never use
cleaning solvent or gasofine to wash them.
Apply brake fluid to the cylinder bore and all
theinternals
to be inserted
into- the
bore.
-- -

When installing the master cy


~n the
handlebars, first tighten the clamp bolt on the
upper side.

CAUTION:
Bleed the air from the circuit after reassembling the master cylinder.
Adjust the front brake light switch after
installation.

WIRE AND CABLE ROUTING


Clamp

Handle SIW IR)

Fuel.

Clamp

J.

Turn s~gnel

Cia

amp position retaining tape

Main wiring harness

Raute guide and clutch cable in

Cylinder inlet No. 1

WIRING DIAGRAM'