Professional Documents
Culture Documents
GROUP INDEX
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.
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
Right side
,-
Left side
GENERAL INFORMATION
CONTENTS
IDENTIFICATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
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.
DOT 3,
DOT 4
??-
$;
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.
~
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:
- -
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:
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
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
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
TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary seduction
Gear ratios, Low
2nd
3rd
4th
TOP
SECONDARY DRIVE
TY
Secondary reduction
Final reduction
Shaft drive
1.062 ( I 7/16)
3,090 (34/11)
CHASSIS
Front suspension
Steering angle
Caster
Trait
62" 00
1 I3 nrn (4.45in)
Rear suspension
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
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)
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
.
.
.
SERVICE SPECIFICATIONS
ENGINE TOP END
VALVES -t GUIDES
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)
0.0374.065
(0.00154.0026)
22.012-22.025
(0.8664-0.867 I )
INlEX
Limit
2 1.960-2 1.975
(0.8646-0.8652)
Camshaft Deflection
0.150
(0.0059)
157.80
(6.2 13)
+ RING + CYLINDER
16.002-16.008
(0.6300-0.6302)
15.995-16.000
(0.6297-0.6300)
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)
-
16.006-16.014
15.995-16.000
(0.6297-0.6300)
I .O
(0.039)
0.10-0.55
(0.004-0.026)
0.08
(0.003)
Crankshaft Runout
0.05
(0.001)
LUBRICATION SYSTEM
OIL PUMP
Unit: m m (in)
Standard
Item
I
(7.1 psi) at
Tip Clearance
Side Clearance
CLUTCH
1tern
Unit:
Stnndnrd
2.7-1.9
7 .O
(0.08)
-
Limit
2.4
(0.094)
-
0.1
(o.004)
40.4
(1-59)
(0.43)
38.8
( 1 .S3)
rnm (in)
TRANSMISSION
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
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
Unit:
Limit
Standard
0.08-0.13
(0.003-0.005)
0.03-0.64
.(o.oei -0.025)
mrn (in)
CARBURETOR
'ilot Air J
ELECTRICAL
BRAKE + WHEEL
FrontlRear
Front
Rear
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)
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
Limit
Standard
Unit: mm (in)
42 1
(16.6)
416
(16-4)
140
(5.5)
TORQUE TABLE
ENGINE
Thread
dia.
Camshaft holder holt
6
10
Crankcase holt
Crankcase hol t
Starter n ~ o t o bolt
r
Oil pan nut
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)
.
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
Thread
dia.
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
Conventional Bolt
PERIODIC MA INTENA K E
PERIODIC MAINTENANCE
CONTENTS
.
TIRES ............................................................
STEERING ........................................................
FRONTFORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSlS NUTS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3-17
3-17
3-18
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.
Brakc
I
~
Tire
Stwring
Froni fork
I
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
1. CYLINDER HEAD
Remove [he fuel t a n k .
Tighten the tweIve 10 m m
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)
1 . 3
O.cl- - 2 kptn
((1.5-X.5 Ih-ft)
PERIODIC M A INTENANCE
Nnn-fIammnhlc
Cleaning rolvcnl
Motor nil
1
CA UTJON:
Before
TAPPET CLEARANCE
1 000 6 000 12 000 18 000 24
600 4 000
000 km
Fig. 3-6
Fig. 3-7
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
PERIODIC MAINTENANCE
Fig. 3-12
i securely.
I appe t depressor
--
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
Thickne~s(mm)
Parr No.
2.15
12892-45000
2.20
12892-45W1
2.25
1 2842-45002
2.30
12R92-dJ003
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+
FUEL LINE
(Replace every two years)
SPARK PLUGS
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
!
I
NORMAL
WCIIIN
73
I
7
-
Dl R T Y
- Fig. 3-18
IGNITION TIMING
-
0.6-0.8 m m
Gap (0.024-0.031
Point gap
Spark plug gap
Ignition timing
Fig. 3-16
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 .
Timing terter
s - w
/"-{At.
-2-22
cylinders.
advanced.
F ~ E3-26
.
ENGINE OIL
Initial 3 000 krn ( 2 000 mi) and thereafter
Change Every 3 000 km ( 2 000 mi)
'2), and
rcmove
the
cover.
3 ,
replace w i ~ hnew
one.
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
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.
PERIODIC MAINTENANCE
Fin. 3-33
At the same intervals, adjust the throttle
cable play in the following manner:
CLUTCH
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 .
PERIODIC MAINTENANCE
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: .
NOTE:
The amotinr qf oil ro be replaced is
Fig. 3-38
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
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
R R A K F SQUEAKING
I ) Carhon adhesion on pad ~ u r f a c c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7) Silted pad
................................................
<andpaper
CI Worn
pad<.
...............................................
Rcplacc
................................
Di~as~emble
and cIcan m a w r cyEindcr
Blccd a ~ r
.........-......
............................ .
.
.
.. . . ... . . . .
2) Cracked how
3) Worn p i ~ t n nand/or cup
Replace
....................................
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.
TIRES
-
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.
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
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
0.6- 1 - 2 kg/cm2
(8.5- 17 psi)
.II
;-;
1 . 1 y . .?-
- f s -
-=,:: :.
-,
I/
tc
CA UTION:
adjust
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).
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.)
- 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.
..........
3 pcs
3 pcs
3 pcs
3 pcs
4 pcs
3 pcs
? pcs
4 pcs
.........
K SUPER "1333B"
SPECIAL M A TERJALS
PART
SEE PAGE
7-60
8-1 5
8-1 6
11-31
I1-32
S U Z W SILICONE CREASE
99000-25 100
* Valve stem
* Can1 slrafi journal
L.
7-25
7-56
7-56
7-56
Outcrcounterslaaft
Input cam dog
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
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-?'
-..-
'
- 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)
?
a
4-
4iY'.'-
Ill
I
PInd
rernovcr
SPECIAL TOOLS
Mi\?
--3gr\r.
\/
Rrarlng lnrtaller
109924.745303
Cinsl a ~ s cr p ~ n
e d l e hearint lnvtallrr
lll'MZ4-045101 -
bye
Q,
qf#j4
-
Pilnl
109014-74540)
~3
- *
7- 1
-%
1.;$/
9 ,
34
SPECIAL TOOLS
Carbumlor bahnccc
F m t tork = m m M l n g loot
#nrhrntnl 'D-
SPECIAL TOOLS
SPECIAL TOOLS
@
-..
69
@J
,I
."
p41.
?
- r-.-7
LJ
- .
(99103-45011)
cila,
VJve
acn camrsrt
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
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.
Engine stalls
easily.
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.
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.
Replace.
Replace.
Replace.
Replacc.
Replace.
TROUBLE SHOOTING
Slipping clutch
Adjust.
Rep1acc.
Replace.
Replace.
Dragging clutch
Transmission will
not shill
Transmission
jumps out of
gear.
Engine idles
poorly.
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
Cmplaini
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.
Replace.
R epl act.
Adjusl.
Replace.
Adjust.
Replace.
Repair.
Adjust.
Adjust.
Repair.
Clean.
TROUBLE SIJOQTJNG
Cmplabt
..
Engine overheats.
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.
Refill
2 . Excessive backlash
Adju51
3. 'Improper 100thcontacl
Adjust
4. Damage to bearings
Replace
loow.
Retighten
Replace
3. Cnwfficicnt lubricant
Refill
No power
Replace
I~nsrnittedfrom
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.
Replace.
Repair or replace.
Secnndary h v e l gear
and final hevel gear
1
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.
Replace.
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
Complaint
1
8
Replace.
Refill.
Retighten.
Noisy 60nl
suspension
Wobbly rear
too soft
Rear suspension
too stiff
Noisy rear
suspension
Pmr haking
(FRONT or REAR)
1. Weakened springs.
1 2. Rear <uspension adj~istorsimproperly sel.
1
;
1 Replscc.
Replace.
Replace.
I Replace.
Adjust.
Adjust.
1I
I Retighten.
I
ELECTRICAL
Cmplaint
Bemedy
No sparking or
Replace.
pmr spnrking
Replace.
Contact pofnts
k n r or pit
prematurely.
Defcctivc condenser.
Replace.
I
1 . Mixture too rich.
2. Idling speed get too high.
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
h ~ i j u scarburetors.
t
Adlust carbure~ors.
C hanee.
Clean.
Repalce by hot type plugs.
become fooled
too soon.
plugs.
Tune up.
Adjust.
Reti~hten.
Adjust carburetors.
connectlons.
2. Shorted. prounded nr open generator coils.
Rcplace.
Repair or replace.
I
I
Generator dues
charge, bul
charging rate i s
Repair, or retighten.
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.
Replace.
Add distilled water
to raise its level.
Replace the battery.
Repair or replace.
Replace.
Replace.
Recharge or replace.
Replace.
Repair nr replace.
Cmplaint
Battery "Sulfation"
Remedy
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
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
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.
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.
Fig. 7-6
10.
ENGINE
Contact point lead wire.
Neutral switch and gear position lead wires.
* Oil pressure gauge lead wire.
Plug cords.
*
*
Remove the four bolts securing the universal joint flange and propeller shaft.
ENGINE
NOTE:
The frame on
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).
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:
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)
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.
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
NO TE:
I ) R ~ f o rt ~~s t i r l g$lie cornpressio~tqf the
P I Z ~ ~ ~ tnake
J P ,
TOP END-REMOVAL
CYLINDER HEAD COVER
.-
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).
@
-.
,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
09916-14510
-_
'2.
Fig. 7-3 1
V A L V E GUIDE REPIAACEMENT
Drive the valve guide out toward cylinder
head side: use the valve guide remover.
Forceps
09916-44510
NOTE:
Discard ?/re removed valve ~ u i d estrh-
099 16-34530
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
NOTE:
Do nor use rhe oil seals r ~ r n o v ~ id~ l
W91h--9530
099 1 h-57720
OW1 l-L)4530
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.
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.
8%
-Fig. 7-41
* 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 ~
If-
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.
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:
Fig. 7-47
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.
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
0.6-0.8 kg-rn
(4.5-6.0 lb-ft)
cvcnly.
1.0 kg-rn
(7.0 Ih-ft)
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
JL4_
?
.-
Fig. 7-59
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
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.
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
J - t $ . 7-68
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.
Scrvict. Limit
<.
--:
I'c-
c- ,
1
Itcni
S~andnrd
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
ENGINE
I.
Service Limit
157.80 m m (6.2 13 i n )
Fig. 7-71
Scrvicc Limit
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)
-
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)
274h in)
h.945-6.960 m m (0.2734-0.1'40
in)
1.0-1.2mm10.04-0.05in)
Fig. 7-73
Fig, 7-76
90 103-35011
ENGINE
I f so. re-cut the seat to the correct width.
4. After the desired war position and width
i5
Fig. 7-79
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.
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
P IR. 7-81
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
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
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.
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
REMOVE PISTON
* Place a rag beneath the piston to prevent
parts from falljng into tllc crankcase, and
remove the circlip with pliers.
fir?.
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.
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.
099 12-34510
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
Fig. 7-96
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 )
Standard
1.21-1.23
1.21-1.23
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.
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
1.0 mrn
NIL
NIL
the ring.
Limi~
Slanrlartl
'.? nim
(0.2H in)
P Iton
~ ring
Standard
Limit
0.1-0.3 rnm
(0.NM-0.012 in)
0.7 mrn
(0.03 in)
Thickness gauge
09900-20803
ENGINE
Using a micrometer, measure the piston pin
outside diameter.
INSTALLATION
* Mount the piston ring
0.
NOTES:
*
CONNECTING ROD SMALL END BORE
I.D.
Using a caliper gauge, measure the connecting rod small end diameter.
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.
Fig. 7- i 10
ENGINE
LOWER END
GENERATOR STATOR
REMOVAL
Remove nvo bolts and starter motor coves.
Place oil pan under generator cover and
IN.
NO Ti?:
Do ?lot overti~Jrf~rr
tlte special too/
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.
09930-30102
*4 ~ & &
4,
Tg, 7-118
GENERATOR ROTOR
REMOVAL
Fig. 7-119
09930-44910
-*.,
Fig. 7-120
09914-25811
ENGINE
INSTALLATION
REMOVAL
Remove points cover and gasket.
Remove the mounting screws and points.
Fig. 7- I23
99000-32030
Uol t tightening
torque:
j>
Fig. 7- 124
Y\\Y
\
6.\A ,,1S
2' L
-.- x V
*
-.
;I
i 7 -
..
t
;,
CONDENSER
REMOVAL
*
Fi,c. 7- I22
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.
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
Fig. 7-130
CLUTCH
'
..
>',
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.
llcnrin~
Roll
\V;IVC rv:~cltcrwat
1Ysvv mnshcr
Slnppcr rine
Fig. 7-I34
0.
Fig. 7- 131
INSPECTION
2.7-2.9 m m
(0.106-0.1 14 in)
Fig. 7- 138
Fig. 7-137
7-36
0. I
mill
(0.004 in)
ENGINE
INSTALLATION
Fig. 7-141
Fig. 7- I44
(0.46-0.47 in)
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
.
5.0-7.0 kg-m
(36.0-50.5 Ib-ft)
CORRECT
ant1 drive
plate
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
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
3.
4.
5.
6.
7.
8.
Shim
Nut
Drive pear housing
Plug
0r ~ n ~
Bolt
9. Shim
1 ~ e c o n d a qdrive
Fig. 7-152
04924-545 11
09910-23710
1
1
ill
09924-84510
W941-84510
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.
Preload:
3-5 kg-crn
(2.60-4.35 lb-in)
Seconrlau drive
(4)
41 m m socket u
holder
09924-545 1
09910-23710
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
7 8
12-1 5 kg-rn
(87.0-108.5 ft-lb)
13
1
1
Fig. 7-161
-
Fig. 7- 162
ENGINE
@-
W941-64510
-@
09930-,30102
* ,,I
- 3-
-\
(2',
,'
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
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
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
09913-80112
Fig. 7-168
Fig. 7-167
4.0-7.0 kg-crn
(3.45-6.0s lb-in)
Preload:
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.
kg-rm
099131)-21107
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
0.08-0.13 mm
(0.003-0.005 in)
NOTE:
5 kg-m
Bolt tightening
tntque:
j.0 Ib-ft)
ENGINE
Blac klash
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
Fig, 7-1 73
I
--
teeth
Reinstall the
housing, with
crankcase.
specifica t"ion.
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
Shim tllickness
Decrease shim thick-
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
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
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.
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
Fig. 7
Thrc
-
"'1 342"
Bolt I lgnrenlng
Torque
99000-32050
2.0-2.6 kg-m
( 1 4.5-1 9.0 lb-ft)
2.0-3.0 kg-rn
(14.5-21.5 lb-ft)
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
INSTALLATION
TIP CLEARANCE
This is the clearance between inner rotor and
outer rotor. Use a thickness gauge.
Tip clearance
Service Limit
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
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 ,
09915-74510
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
Fig. 7-189
INSTALLATION
Thorclughlp wash the sump filter with
solvent and fasten it with three screws.
1.
2. Rr~btwrscnl ring
i , i p . 7-190
SUMP FILTER
REMOVAL
Remove screws of oil pan 7? and remove
the oil pan from crankcase.
0.6-0.9 kg-rn
(4.5-6.5 Ib-ft)
ENGINE
CRANKCASE
REMOVAL
w
Fig. 7-191
Fig. 7-194
Fig. 7-192
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
Fig. 7-196
Fig. 7-197
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.
Crankshaft runout
Standard
26 in)
Thickness gauge:
Service Limit
1
in)
09900-20803
Fig. 7-202
Fig. 7-20]
ENGINE
INSTALLATION
TRANSMISSION
*
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
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 @
rn
Fig. 7-204
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
inner counfershafi.
Now install inner shaft inlo outer shaft.
*
a
Fig. 7-209
.,
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
D W E SHAFT GEAR
ASSEMBLY
"
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
Standard:
5.45-5.55 m m
(0.215-0.219 in)
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
4;--4.
1.
1.
3.
4.
5.
6.
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
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
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
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
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
has flown into hole (A), goes into chamber (B), where the oil is
NOTE:
Re sirre to retain all adjusting shims f o r
reassem hlv.
---
Fig. 8-8
09m-74570
* To remove
Fig. 8-9
Fig. 8-7
SHAFT DRIVE
.*
11)
@
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
rn
09941.84510
r- -
09924-645 I0
Fig. 8-14
remover
Rotor remover shaft
Fig. 8-15
0994 1-645 10
Q909430-30102
SHAFT DRIVE
Fig. 8-I 9
0994 1-645 10
NOTE:
Before reassembly, thoroughly clean all
09930-30102
Fig. 8-20
* To
SHAFT DRIVE
099 13-845 I 0
Fig. 8-2 I
NOTE:
Rofate the gear several /urns in both
Preload torque
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
(3.4-6.9 lb-in)
Over 8 kg-cm
Shim
Decrease shim
thickness
-
Correct
to
'
99000-32020
09924.645
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
nut to specification,
bend the collar of the nut over into the
04924-54540
@ I
-
@ Handle
09924-74550
09924-745 10
SHAFT DRIVE
Fig. 8-29
Fig. 8-2 7
281
Bearing installer
099 1 3-8451 0
09924-94510
Screw tightening
torque
99000-32050
0.8-1.0 kg-rn
Ib-ft)
(6.0-7.5
"'
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
'
09124-745
izl
Bearing installer
09924-74530
(3 Pilot
09924-74540
Fig. 5-30
SHAFT DRIVE
Tightening Torque
2.0-3.0 kg-rn
(14.5-21.5 Ib-ft)
Fk. 8-32
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.
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
C
I
SHAFT DRIVE
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
Thickness
27326-45 104
45 100
45101
-45103
45102
1.35 mm
1.25
1.20
1.10
8 .OS
shims.
I f backlash is too large:
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
2 .0-2.6 kg-rn
(14.5-1 9.0 Ih-ft)
SHAFT DR I YE
* If
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. 19-37
8-1 5
SHAFT DRIVE
install a new
oiI seal into the final gear bearing cover.
(Fig. 8-38)
to
2 -0-2 b kg-nt
(14.5-19.0 Ih-ft)
housing from
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)
(14.5
FUELCOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUELTANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. . . . . . . . . . . . . .
STARTERUNET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTTNG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9- 2
9- 2
9- 3
.9-12
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:
ft~r~ctiori
as auto cock.
The PRI position is used when the carburetors have little or no fuel, for example,
Cleaning
CARBURETORS
IMPORTANT:
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
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.
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.
.=
.. .*;
,4--&
-4;
.P
r:
.I
-:I
.,
.,r
,
I/
*'
8.
\id.
1.
;(
2.-.
:',
,.
.
,
'
,,
i.
;,, Q7
;I '
..
. - .~- *O.&
,,
% \,-..I
..I..
;p8*'
_.
.,
,!
"
.
-,>,i.
+.;
*'A
*>
,.jl
r 0,
.-
I.
2.
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
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.
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:
Fig. 9-1 7
Remove the plate. A total of 8 screws must
be removed to free this plate for remove].
Fig. 9-18
9- 7
T i ~ h t e nbolt
Ti~bieningtorque
Fig. 9-22
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
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.
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
0991 1-70130
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.
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.
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
screws.
04913-14520
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
Remedy
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.
in needle jet.
Ovcrflaw and
frlel level
flurtuatickna
properly.
5. Filter is clogged.
1. Replace.
2. Replace.
valve.
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.
I1
SPECIF/CA T/ONS....................................
PERIODJC MAJNTENANCE............................
.....................................
. ,
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.
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
- 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
C
1
stem
-Steering
Chassis bolts and nuts
Front forks
NOTE:
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
Clarnn
Clamps
clamps
A
Rear N r n signal
clamp
Clamp
Clamp
motor
Throttle c
Clutch cahfe
Clutch cable
TIGHTENING TORQUE
ENGINE
ITEM
Ib-ft
kg-m
N.m
6 - 113
0.6- 7.0
4.5 - 7.0
7 - 11
0.7-
5.0 - 8.13
1.1
p
p
p
35
24 - 26
3.5 - 4.0
25.5 - 29.0
1.2
6.0- 8.5
2.4 - 2.6
17.5 - 19.0
0.8
6 - 10
0.6 - '1.0
4.5 - 7.0
4-
0.4 - 0.7
3.0 - 5.0
60 - 70
6.0- 7.0
43.5 - 50.5
25 - 35
2.5 - 3.5
18.0 - 25-5
0.4 - 0.7
3.0 - 5.0
15- 20
1.5 - 2.0
50 - 70
5.0 - 7.0
11 - 1 3
1.1 - 1.3
6-10
0.6 - 1.0
4-
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
18 - 28
1.8- 2.8
13.0 - 20.0
15 - 23
1.5 - 2.3
11.0 - 16.5
0.6 - 1.O
4.5 - 7.0
Startei
LIULLII
bolt
P
P
P
P
18
25 - 45
2.2
2.5 - 4.5
(12mm)
45 - 70
4.5
9 - 14
18-28
13 - 23
120 - 150
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
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
nountin!F bolt
3r brake
~ a gear
l
t
TIGHTENING TORQUE
rhread Diameter
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
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
0.040-0.070
10.0016-0.0028
1
-7.000-7.01 5
(0.2756-0.2762)
E X.
.
-.
--
'IN"EX'
IN. et E X .
- 1
(0.014
IN.
-
-.
1 0.17 1
1
T -0-1.2
0.04-0.05
0.03
( 0.001 )
kg
1 19.62-27.56 Ibs)
at length 31 mm ( 1.22 in 1
22.1-27.1
kg
8.9- 12.5
I
-
OUTER
at length 35 rnm I
1.38 in
CAMSHAFT
+ CYLINDER HEAD
I
I Cam height
ITEM
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 .
1
I1
157.80
I 6.213
)
--
--
:YCINPER
0.2
( 0.008 )
ITEM
compression pressure
STANDARD
LIMIT
9 - 12 kg/cm2
(128 - 171 psi)
7 kg/cm2
(TOO psi)
2 kg/crn2
428 psi)
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)
Cylinder distortion
Piston ring free end gap
0.2
F0.008)
1st
Approx.
2nd
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
CONROD
0.7
(0.03)
0.18
(0.0071 1
0.15
1st
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)
LIMIT
STANDARD
- ITEM
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
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
STANDARD
2-3
0.08-0.12
2.7-2.9
0.106-0.114
LIMIT
2.4
1 0.094 I
0.1
( 0.004
38.4
( 1.51
ust$s.rocn/cm
TRANSMISSION
Unit: mm (in)
ST,
0.1:
ITEM
Secondary bevel gear backlash
- -
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-
(2.60
4 -- r
b-in)
~yaurn
LIMIT
CARBURETOR
Ef EM
Carburetor type
:ATION
BS32SS
Bore size
32 (12 6 ) .
I.D. No.
45161)
Fuel level
Float height
# IIS
Main jet
1.7 (0.07)
5050
Needle jet
(N.J.1
X- 5
Pilot jet
(P.J.1
# 4fl
--0.7 (0.028)
(P.0.)
2.0 (0.08)
Valve seat
I
I
Pilot screw
(P.S.)
(P.A.J.1
PR E-SET
I
I
* 180
I
I
ELECTRICAL
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
+-
Secondary
More than
3 - 5 SZ
Plug cap - Plug cap
30-40 kfl
14.0- I 5.5
'
Starter motor
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
.-
I
1
Headlight
10
10
Turn signal
GSH5 O CDJGL LI
BRAKE
+ WHEEL
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
0.5512-0.5529
15.827- 15.854
0.6231 -0.6242
38.098- 38.148
( 1.4999-1.5019
-- -
38.098-38.1 48
( 1.4999-1.5019
(
0.25
(
-.
- --
Front
3.50H19 4PR
Rear
Front
2.0
0.08 1
2.0
( 0.08
Front
Rear
Tire size
0.30
( 0.012
Axial
Radia I
13,957- 13.984
( 0.5495-0.5506
Rear
0.6248-0.6265
)
.
14.000-14.043
Rear
Wheel rim runout
Front
Front
10.24
1 5.870- 1 5.91 3
Front
Rear
6.0
LIMIT
20
0.010 1
0.25
(
0.010
)
--
;s tire)
1.6
I 0.06 )
.-
2 .O
SUSPENSION
ITEM
Unit: mrn ( i n )
LIMIT
STANDARD
4 16
1 16.4)
Front fork oil level
140
15.5)
0.6 kg/cm2
(8.5 psi)
110
A
-
(4.33)
FUEL
+ OIL + CAPACITY
ITEM
SPEC1 FlCATlON
Fuel type
"
F ilter cha ge
Overhau l
Fork oil # 15
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
Secondary
Final
280
DOT:
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
--
.-
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
-
--- --
Speedometer 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
RIGHT SIDE
LEFT SIDE
1 9-22
CHASSIS
Front suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 L (4.5 USgalE
4.5 L (4.8 USqt)
3.0 L (3.2 US q t )
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.
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
-.
-
Spark plug
I
R
I
R
Front forks
I
T
I
T
I
I:
I
T
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
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
NOTE:
This checking presupposes that the ignition
coil used for checking is a good one.
Fig. 7
cs~usoc~/csn
WIRING DIAGRAM
Guide
Horn
prox. 15'
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
GSiSSOCD/GLD
CHASSIS
tle shaft
pake mas
lder mou
ie union
14.5-21.5
3.5
18.0 - 25.5
2.5
11.0-18.0
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
15 - 25
90- 110
-
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
TIGHTEN1NG f ORQUE
Thread Diameter
kg-m
N*m
N-m
------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
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
110
'7"Marked Bolt
SERVICE DATA
VALVES
+ GUIDES
'Unit: rnm (in)
ITEM
STANDARD
Valve diam.
36
IN.
EX.
IN.
--
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 stem 0.
D.
I,
IN.
EX.
0.05
f 0.002 )
0.5
(-0.02-)
4.4
6.945-6.960
0.2734-0.2740 1
1.4
LIMIT
IN. &
OUTER
EX.
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
36.32-36.36
35.77-35.81
-- -
.-
0.037-0.065
1
1
IN. & E X .
22.01 2- 22.025
( 0.8666-0.8671
21.960-21.975
(
0.8646-0.8652
-. - .
Camshaft runout
-.
- - -- -- Cam chain 20 pitch length
- -
'"3")
0.10
(- 0.004-)
157.80
( 6.213
1
--
20 th pin
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
-- - -
-.
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:
69.080
68.945- 68.960
( 2.7144-2.7150
Cylinder distortion
lst
t lMIT
STANDARD
9.0
APP~OX.
1 0.35
1s t
-2 nd
,
!
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-
0.03 1 -
1st
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 deflection
LIMIT
16.040
3.0
1 0.12
-
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
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
LIMIT
2-3
(
STANDARD
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
-
1.51 1
TRANSMISSION
ITEM
STANDARD
LIMIT
1.775
87/49
1.062 (
17/16
3.090 (
3411 1
--
Gear ratios
5.45- 5.55
0.21 5-0.219
4.95- 5.05
0.195-0.1 99
SHAFT DRIVE
Jnit: m rn (in\
ITEM
STANDARD
0.08-0.1 3
0.003-0.005 1
3.45-6.05
4-8
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
(P.A.J.)
# 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.
..-
--
--
.-
- - --
Primary
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
--
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
.-
10 A
Ignition
.a
BRAKE
+ WHEEL
STANDARD
ITEM
Rear brake pedal height
15
Front
Rear
0.6
5.0
LIMIT
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
Front
Rear
a
Brake caliper piston diam.
Front
Rear
Front
Rear
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
'
Rear
0.010 )
---
0.06 1
2.0
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
- --
--
- -
I 0.08 1
SUSPENSIO'N
LIMIT
STANDARD
I f EM
NOTE
'I 60
1 6.3)
51 6
20.3
2 60
(-- 10.2 1
0.8 kg/crn2
- -
Psi)
(11.4
FUEL
3.9
.-
+ OIL
SPEC! FlCATlON
ITEM
NOTE
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
- --
* 15
ml
-ii
8.2818.63
USltrnp o r )
--
--
--
--
--
--
--
340-400
S e c o n d a r y ~1.5/12.0-13.5/14.1
~
US/lmp-o r ).-----
---
--
3.212.6
3600
3.8132
-
Overhaul
Front fork oil type
1
I
3000
USilrnp qtl
SAE 10W/40
L
4.E.0
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
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
- --
- -- -
23 132)
3.4
3.4
1.7
Turn signal indicator light
>-
3.4
- .-
--
3.4
-
3.4
3.4
3.4
Prepared by
1st
10- 2
3 0- 3
1 0- 4
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)
1 hese
limits
Hydrocarbons (HC)
All motorcycles
50 cc- Larger
5.0 Gram$/Kilon~eser
(8.0Grarn~JMiIe)
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.
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
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.
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.
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.
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.
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
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.
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)
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.
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
Remove
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.
cabIe.
Adjust the throttle cable (see page 3-13).
Mount the fuel tank.
CHASSlS
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
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.
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.
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
.
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.
*
*
*
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
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.
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.
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
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
*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
lightening ~orque
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)
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.
2.5-4.0
kg-rn
( 1 8.0-29.0 tb-Ft)
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
09940-34651
Fig. 1 1-25
r
Tightening torque
of front axle
kg-rn
lb-ft)
09900-06 105
Fig. 11-14
0991 1-71510
NOTE:
09941-645 t O
CHASSIS
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)
09940-549 10
09940-54920
25 1 m t on one side
(8.48 US oz)
specified.
tachment
Fronl fork oil
level gauge
Fig. 11-28
?l-12
09943-74 1 1 0
CHA SSIS
pressure.
'R
7110 ws:
Fig. 11-30
rn
SpeciJied pressure
0.6-1.2 kg/cm2
(8.5-1 7 p s i )
hand
'~
1
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.
STEERING STEM
: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.
--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-
CHASSIS
Fig. 11-38
11-16
09940- 14910
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.
09940- 149 10
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)
1 .S-2.5 kg-m
t i 1.0-1 8,O lb-ft)
bolt:
Tightening torque:
Ib-it).
1.2-2.0 kg-rn
(8.5- 1 4.5 Ib-ft)
Fig. J J -42
drawing.
after
Tightening torque:
page 1 1-23.
pinch bolt:
2.0-3.0 kg-rn
(1 4.5-2 1 .S Ih-ft)
1 -5-2.5 kgm
( I I .Q-18.0 Ib-ft)
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)
Fix. 11-45
W94 1 -5491 1
l r r r ~ c racc
r
:EIICI bearing
09941-74910
staller
1L
dri~mer
-
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
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
2. Rearing
3. Spacer
4. Front axle
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
CHASSIS
Fig. 11-54
a
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:
Limit
Under
5.5 m m (0.22 in)
CHAS S I S
Rvnout
Service Limit
AXIAL
RADIAL
* Inspect
Service Limit
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.
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
clean and
Fig. I/-60
1.5-2.5 kg-n~
l .O- 1 8.0 lb-ft)
(I
Fig. /I-63
front fork.
Do not change the position of the
speedometer gear box (see page 11 - 10).
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.
0994 1-945 10
CA UTION:
torque
3.6-5.2 kg-m
(26.0-37.5 Ib-ftj
1.5-2.5 kg-m
( I l .O- 1 8.0 lb-ft)
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
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.
*
*
page 11-22).
Tighten the bead protector n u t and then
the valve nut ,
Mount the valve cap.
~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
R. Bolt
9. Washer
10. Lock washer
,,
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
C H A SSIS
NOTE:
Replenish the brake fluid reservoir as
necessary while bleeding the brake
system. Make sure that there is always
somefluid visible in the reservoir.
Fig. 11-75
Blecder valve
tiyhtening torqire
0.6-0.9 kg-m
(4.5-6.5Ib-ft)
Fig. 11-77
1
NOTE:
09900-06 I05
Fig. 11-78
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
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.
reassembly.
Pisfon boo1
1 t . Cap
Caliper holdcr 12. Roll
1 3. Washer
Screw
Caliper axle
14. Lock washer
Bleeder
Fig. 11-86
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.
MOUNTING
Tighten two caliper mounting bolts.
Tightening torquc
I
1 .S-2.5 kg-m
l .O- 1 8.0 lb-ft)
(I
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
C H A -5.71.7
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
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./,
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.
fluid.
Blccdcr valvc
t i ~ l ~ t c n i ntorque
g
0.6-0.9 kg-m
(4.5-6.5113-ft )
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
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
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 .
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.
\
REAR MASTER CYLINDER
T
2.5-3.5 kg-m
(18.0-25.5 Ib-ft)
Fig. 11-108
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.
Fig, I J - I 1 0
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~)
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
CHASSIS
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
Fig. 11-113
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.
09900-06 105
-
REAR WHEEL
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
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.
Fig. 11-120
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.
to fnucl7 a
hat tnr!~ler.Prorerr ir by wrapping llte
hose in o rClg.
CHA SSIS
Fig* ! I - 1 ;
y7 r
k
.
,.
\4
fX5kA-
Fi,q. 11-126
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)
Service Limit
Service Limit
(0.24 i n )
Fig. 11-130
* Inspect
Fi,ig. 11-128
Service Limit
Fig. J 1-133
Service Limit
Runout
-
AXIAL
RADIAL
ASSEMR1,Y
Inserr ~ h crear whccl assen~hlvunder the
7
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
5541 1451 00
qtand p i v o ~ .
Tightening torque
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
11lr1t
Torque link n u t
2.0-3.0 kg-rn
{F 4.5-21.5 Ib-ft)
CHASS 1.5
GI,
yii
<
2. Rearing
3.
4.
5.
6.
Pivot thaft
Nut
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
Fig. 11-136
MOUNTING
to the
Pivot shaft
tightening torque
0.35-0.45 kg-ITI
(2.5-3.0 Ib-llt)
CA UTlON:
I
MOUNTING
and
seal handle
Fig. 11-137
torque
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
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
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.
Spring
setting
Damper
I
1
11
I[
..........3 .........
.......... 3 .........
111
111
IV
IV
..........
..........
..........
..........
4 .........
3 .........
4 .........
4 ......... 1.2 kg/cm2 (17 psi)
Fig. 11-147
Fig. 11-j45
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.).
NO TE:
11 is s r r o ~ r g i ~rccornt~rended
~
rhar rha
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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
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
Fgnition timing
Remarks
DENSO
B7ES
W22ES
1YW.
B9ES
NPPON
U'27ES
EL ECTRICA L S YSTEM
CA UTION:
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.
IGNITION SWITCH
AC GENERATOR
R
. . . . . .Red
. . . .Yellow
W/E . . . .White with Green tracer
W/R . . . .White w i h Red trwer
Y. .
ELECTRfCAL SYSTEM
Pock.et tester
Engine speea
I
5 000 r/min.
AC line val~age
75V or over
A C generator i s satisfactory
75V or under
AC generator is faulty
- - - - - - - -- - - -- 7
Yellow
W/nl:
G'
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
14Y-
Regulator/Rectifier is satisfactory
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.
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.
Pocket tester
09900-25002
Unit: S1
ELECTRICAL SYSTEM
11.
Rcd
Y:
Ycllnu
Hl;lcL wilh R
W/M:
WJR:
~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
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
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!
Fig. 12-22
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~
Locked-rotor dazn
Voltagc
Curren~
1 l volts
50 ampere?or under
5 . 5 volts
280 arnpres or
Tnrquc
S ~ c d
under
4 5Ml r/rn~nor ovcr
INSPECTION OF COMPONENTS
Carbon brushes
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
BATTERY
"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
year.
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
40 trotrr\
Ovcr
5 0 ho~ii-.;
~ O I ~ T F
Fig. 12-29
F(q. 12-30
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
where S,,
t "C,
ELECTRICAL S YSTEM
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
F R O H I TURN SIGNAL l l 6 t i T
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
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
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.
ELECTRICAL SYSTEM
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?
rclearcd?
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.
NO
YES
NO
1YES
Defective Controt 'Unit.
I d * /
Replace delec~iuecornponenl.
-I
I
11 -
hln
Defec~iveSpeed Sensor.
ELECTRJCA L SYSTEM
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
Fig. 12-42
Fig. 12-44
Switch
puhjtlnn
RED
ORANGF
<'I
GRAY'
BROWN
-
OR:
p
p
ON
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
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 .
Dimmer switch
ELECTRICAL SYSTEM
Kill switch
ORANGE
ORANGE/WHFTE
Starter switch
Switch
position
YELLOW/GWEN
ORANGENHITE
Fi!:.
l?-J41
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.
Fig. 12-52
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.
page
11-6 for
removal
Fig. 12-54
ELECTRICAL SYSTEM
FUEL GAUGE
Wiring
3.Construction of
operating meter
I. Puintcr
Main birnctal
2.
n,
!.
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
Fixcd point
Tcmperaturc
cnmpcnsating bimctal
Necdlc
At hlgh temperalure
Main b~mctal
porition
of needle)
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.
Float arm
Fig. 12-62
ELECTRICAL SYSTEM
I
(2)
Checking method
I (L)
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.
~I-UIIL
1 1 C '3
1 1111111 --
1;oupc rbrt
:*Crl
(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'
rkdl
checrt~
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-
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)
LI,
Normal resisrancc value b
1
Check ($1
(8)
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
Largc rr\lrlancc.
Mcrcr dclcctive
W rre ~
rrtmknh
Z ~ ~ Cdcfcctive
F F
11
Largc rrpris~ance,
nnconductancc
Defective contact
of rnrrer side connector
I
I
Chcck(1 I )
( 1 1) Coancclorcontac~chcck.
Obrcrvc rncler ind~calionafrcr corrccrvng
wlrc harnetq and connecror (m ~ h cnormal
wlrlnp).
FLII:I. M FTFR
Gauge sidc
Full
Empty
1-5 Q
103-1 1 7 ~
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
CABLE ROUTING
Thrmrkcahk
ECTRICA L SYSTEM
IRING DIAGRAM
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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.
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
Transmission
Clutch
Brake operation
Steering
Suspension operation
Control cables
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
ENG lNE
TYP@
N umber of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
TRANSMISSION
Clutch
Transmission
0
-
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
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.
--
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 g u i d e r . ~ .
-
- --*-
IN'
((0.2740
6.960 - 0.2746)
6.975
6.945 6.960
(0.2734 - 0.274(
EX.
IN.& EX.
--
--
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
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
Cam height
STANDARD
36.320- 36.360
(1.4299 - 1.4315)
IN.
lN.&EX.
Cahmshaft runout
22-012
- 22.025
35.470
(1.3965)
0.150
(0.0059)
I
(0,8646 - Q.8652)
0-1
(0.004)
(0.8666- 0.86711
21.960- 21.975
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
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)
Cylinder distortion
---
0.10- 0.30
(0.004- 0.012)
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
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
-
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
-
Crankshaft runout
0.05
(0.002)
Unit: mrn (in)
OIL PUMP
ITEM
-
STANDARD
LIMIT
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)
Side clearance
CLUTCH
Unit: mm (in)
ITEM
-
STANDARD
--
2.7
--LIMIT
2-3
(0.08
- 0.121
---
- 2.9
(0.106- 0.114)
11.8 - 12.0
I0.46- 0.47)
2.4
(0.094)
1'1.0
(0.43)
(0.138+ 0.002)
0.1
(0.004)
38.5
( 1.52)
GS850GT
TRANSMISS ION
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 )
-
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
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
--
GTSSOCT
ELECTRICAL
ITEM
SPEC IF [CATION
Ignition timing
Firing order
Spark plug
Type
IN. D. : W24ES-U
- -
0.6 - 0.8
(0.024 - 0.031)
Gap
Spark performance
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
Brush length
Limit: 6
Limit: 0.2
(0,008)
-- -
(0.24)
3-4R
000 r/min.
Regulated voltage
Starter motor
31-G
Type designation
Y B3 4h - A2
Capacity
Fuse size
Standard electrolyte S. G.
Headlight
10A
Turn signal
T OA
- -
Ignition
10A
Main
1 5A
Output terminal
10A
GSSjOGT
BRAKE +WHEEL
ITEM
Unit: mm (in)
20
(0.8)
5.0 5 0.2
0.2 + 0.008)
6.7 + 0.2
(0-26 + 0.008)
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
Front
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
(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
-LIMIT
ITEMSTANDARD
Front fork stroke
160
16-31
41 6
I1 6.4)
140
(55)
0.6 kg/crn2
(8.5 psi)
100
(3.91
CS850GT
FUEL + OIL + CAPACITY
SPECIFICATION
ITEM
Fuel type
22 L
15.8 US gal)
reserve
4.2 t
(4.4 US qt)
SAE 10W140
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
--
--
251 ml
(8.48 US oz)
HypoidGearoilSAE90,APIgradeGL-5
-
Secondary
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
-
--
3.4
3.4
3.4
License light
Oil pressure
indicator
light
--
- -
-- .- - . --
--
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
1.5 - 2.5
11.0- 18.0
r
L
14.5 - 21,5
1.5 - 2.5
11.0 - 18.0
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
--
11
---
14.5 - 21.5
2.0 - 3.0
LO
.5
2.7 - 4.3
19,5 - 31.0
2.5 - 4.0
18.0 - 29.0
1.5 - 2.5
11.0 - 18.0
--
1.5 - 2.0
11 .O - 14.5
0.5 - 0.8
1.3 - 1.8
- 6.0
9.5 - 13,O
0.6 - 0.9
4.5 - 6.5
2.0- 3.0
1.5
2.5 - 3.5
1.5 - 2.5
11.0 - 18.0
9.0 - 11.O
65.0 - 79.5
3.5 - 4.5
25,5 - 32.5
2.5 - 3.0
2.0 - 2.6
9.0- 1 1 .O
2.0- 3.0
Footrest bolt
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.
"
. . . . . . . . . . . . . . . . . . . . . . . . 3 PCS
. . . . . . . . . . . . . . . . . . . . .8 p a
.......................
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
...............
99000-32050
SUZUKl THREAD LOCK CEMENT
" 1342'
..
......
. . . . . . . . . . . . . . . . . . . . . . I 0 pcs
.....................
Cam chain guide bolt . . . . . . . . . . . . . . . . . . . . . . .
Gearshift stopper. . . . . . . . . . . . . . . . . . . . . . . . . .
4 pcs
3 pcs
3 pcs
1 pc
Material
Part
.. .. . . . . . . . . . . . . . .. .. . . .
& pcs
(Apply a small quantity to the threads of cylinder stud bolts.}
Cam chain chamber "0"ring (between head and cylinder)
Front
Rear
99104.3 114(
99000-25100
SUZUKl SltlCUNE GREASE
Cam shaft journal
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.
1000 6 0 0 0
Month
12
24
3.6
48
3ner eler
-R--[-~
Engine
idle speed
--.
Clutch
Brake
I
' -. 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
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.~.,-.
I
Exhaust closed
p/A.T.D.G.)
5w
,I
Inlet open
(B.T.D.C.)
,\wp;
.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
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'
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
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
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.
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)
5050
Pilot outlet
Valve seat
0.7
2.0
Starter jet
# 32.5
Pilot screw
PR E-SET
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
VACUUM
CARBURET0
Fuel
and
bracket.
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.
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
"
REASSEMBLY
* Place tongue
body properly.
Tightening torque
0.25 - 0,45 k g m
(1.8 - 3,O Ib-ft)
Tightening torque
Tightening torque
99000-32040
99000-32040
0.4 - 0.6kg-m
13.0- 4.5 Ibbfr)
Tightening torque
99000-32040
0.06- 0.10 kg-m
(0.4- 0.7 Ibaft)
Tightening torque
09913-14511
1((
- 0.22 in)
Distance @:I 4.5 - 5.5 mrn (0,18
09913-1312 1
-
09913-14930
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
a).
I
"I 2
L,'
4+
0.5-l.Ornm
lo.02
0.04in)
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:
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.
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
-
1 2 3 4 6 78913
1
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.
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.
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
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
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,
:4: 0 rine
5 Spring
161 Prrmary cup
' 7 1 Piston
Tightening torque
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
09900-06108
When
Maser cytinder
Handlebar
-4I-I t
Cle rance
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
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
Tightening torque
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.
99000-25100
rpp
Inspect the each rubber parts fox damage or
wear.
'
Tightening torque
1.5 - 2.0 k g m
(1 1.0- 14.5 Ib-ft)
Caliper bolt
GSfY.70G T
REAR WHEEL
5.5- 6.5 mm
0.26 in)
GScYSOGT
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
. . . . . . . . . . . . .. .. . . . . . . . . .. . . . . . . . .. .
15- 8
.............................................
75-10
tight sidl
Left side
15-2
SPECIFICATIONS
ENGINE
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
Transmission
Gearshift pattern
Primary reduction
Gear ratios, Cow
2nd
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
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
1 6.3 1
Front fork spring free length
160
0.6kg/crn
1 8.5 psi )
I00
3.9 )
Fuel type
13 t
(3.4 US gal)
SAE 10WJ40
SAE 1OWJ20
302 ml
(10.20 US 02)
Final
i
Brake fluid type
SPECIFICATION
Fuel tank
l T fM
16.8 )
( 6.3
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
3.4
3.4
3.4
3-4
3.4
FUEL COCK
$2 Fuel valve
(42 Spring
(& Fuel flow
O-ring
13? Diaphragm
: 5 : One way valve
Bt Vacuum
[z?
PRI
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
..........................................
......................................
..................................
..........................
................................
...................................
......................................
................................
........................................
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
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
Seat height
TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary reduction
Gear ratios, Low
2nd
4th
1.380(29121)
1.I 25 (271241
Top
0.96t (251261
3rd
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
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
ITEM
Valve diam,
IN.
EX.
LIMIT
36.0
IN.
(1.42)
30.0
EX.
Valve lift
STANDARD
.-
(1.78)
IN.
IN.&
EX.
I
1
0.5
(0.02)
IN.& E X .
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
LIMIT
STANDARD
ITEM
36,320- 36.360
Camshaft journal
O.D.
(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)
157.80
(6.2131
Cam chain pin (at arrow "3")
I
20 th pin
0.2
(0.0081
Unit: m m (in)
ITEM
LIMIT
7 kg/cm2
STANDARD
9 - 12kg/crn2
1128 - 17 1 psi)
Compression pressure
(I00psi)
2 kglcrn2
(28 psi)
--
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)
(2.71 18)
Cylinder distortion
69.080
(2.7197)
68.880
0.2
(0.008)
7.2
-I
Piston ring free end gap
1st
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)
- 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)
16.040
(0.6315)
0.10- 0.65
3.0
F0.12)
I .O
Conrod deflection
-
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]
Above
Below
0.1 kg/cm2
11.4 psi)
0.5 kg/cm2
(7.1 psi)
at 3 000 rlmin
CLUTCH
lTEM
STANDARD
2-3
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
(87 / 49)
1.775
Secondary reduction
Final reduction
3.090 (34 / 1 1)
Gear ratios
2nd
3rd
--
4th
Top
1
I
I
Shift fork groove width
; / 14)
! 1 181
2. t
Low
--
1.;
--
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
0,08- 0,13
(0.003- 0.0053
0.03 - 0.64
(0.001 - 0.025)
3 - 5 kg-cm
mrn [in)
(2.61) - 4.35 b i n )
Secondary driven bevel gear preload
4 - 7 kg-crn
13.45 - 6.05 Ib-in)
4 - 8 kg.crn
(3.45 - 6.95 Ibain)
CARBURETOR
(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)
Front
5.0 ? 0.2
(0.2* 0.0081
6.7 + 0.2
Rear
(0.26
0.0081
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)
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
(0.08)
2.0
(0.08)
0.25
(0.010)
0.25
(0.010)
Front
Rear
Tire size
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)
41 6
( I 6.4)
140
( 5.5)
0.6 kg/cm2
(8.5 psi)
1 00
(3.91
--
Fuel type
.".
22 L
(5.8US gal)
reserve
4-27
(4.4 US qt)
SAE 1OWJ4Q
Change
-4-
Filter change
Overhaul
2 800 ml
(3.0US qt)
3 600 rnl
(3.8 US qt)
3 800 ml
(4.0 US gt)
Fork oil # I 5
- --
-+-.
251 rnl
(8.48 US 02)
Hypoid Gear oil SAE 90,API grade G L-5
Secondary
30 rnl
( 1 1.5 - 13.5US OZ)
Final
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
3.4
-- .---- ..--
---
---I
3.4
3.4
3.4
TORQUE TABLE
ENGINE
r bolt
ter clutcl
1st pipe
?r bolt
- shift letrer bolt
Secondary drlve gear nut
12.0- f 5.0
9.0 - 11.0
GS85OGX/GLX
CHASSIS
Rear tor
Rear ax!
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
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
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
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
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
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.
" Whee!I
bearings
........ 3. . . . . . . . 8-
Oil filtercovernUt.. . .
* Camshaft end cap screw
* Front fork allen bolt . .
........2
. . . . . . . . . . . . . . 2p a
. . . . . . . . . . . . . . . . . . . . . .8 ~ C S
. . . . . . . . . . . . . . . . . 4 PCS
. . .
............... 3p
..................... 4 p a
...................... 3
. ,. . . . . . . . . 4pcs
..-.-
"
.......
.................... 4
. . . . . . . . . . . . . . . . . . . . . 3 pcr
. ..................... 3......................... I p c
*
"
"
......... 4-
. . . ......... 3 p a
"
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.
'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
1 1 2
I
Ij
'1
-.
- I C
Spark plug
Fuel line
Engine oil and oil filter
---
- -
- - -
Clutch
--
- -
I
I
--
I
I
- -
Front forks
_ -
Steering stem
1 -7
I
-
Brake
Tires
j.
Brake hose
.-
a.
Part Name
6 rnm Allen bolt +
Thread lock Super
Type
!ning tor
washer + Thread lock
Super "1303"
Part
Name
Bolt
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
EAR hY
set free)
asls
46.7 mrn
(1.84 in)
42.U mrn
17.0 mm
(0.67in)
16.10 mrn
11-65 in)
(0.63in)
99000 - 32020
Tightening torque
GS(QSOGX/CLX
CAUTION:
Do not overtighten the lens fitting screws.
Clamp
Clutch cable
Throttle cable
. ...
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
3rlR
BrlW .
Br/Y
GIS .
GrlB
h g / ~.
LgR
QIG .
GIBl
TUAY S l G N A I L l G H t SmlCH
w-
YIG
Y IR
YMI
WJR
WlY
VlS
YIBI
WIG
5 1 A A r t 9 YUTOU
4 C SFt4ERAIOP
~ nuo~~r t
RElillL,llOn'RECTIFIER
: STAPl*,l 1IEtAY
m ' FUSE A l l *
I : 1llR)l blCR4L AELAV
: TIJPs
~ lCnltL~u
I
T
GS8SOGX/GLX
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
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
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
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
STANDARD
ITEM
15 (0.61
LIMIT
Front
SUSPENSION
LIMIT
STANDARD
ITEM
516 120.3)
-
260 (10.2)
ITEM
17 L
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
-
--
23 (323
Speedometer light
3.4
Tachometer light
3.4
3.4
'
-
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
"RES"
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
cable guide.
I
NOTE:
Do not operate the brake lever after the
caliper i s removal.
(53 .
it several times to
remove the oil inside.
Under the condition (inverted condition), hold
the fork for a few minutes.
09940-34520
"T'?mddle
09940-34580
Attachment "F"
09913-50121
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
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.
99000 - 32040
09940-34520
09940-34580
-
"T" handle
Attachment "F"
Tightening torque
CAUTION:
Use special care to prevent damage ta the
Teflon coated surface of the anti-friction
metal when mounting it.
09940 - 50111
FO'RK OIL
m For the fork oil, be sure to use a fork oil whose
viscocity rating meets specifications below.
Fork oil
Capacity
09943 - 741 1 1
Oil level
260 rnn
nl
FORK SPRING
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.
I lower)
FORK AIR
Lift up the tront wheel by jack.
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:
0.8 kg/cm2
( 1 1.4 psi)
GS850GXJGLX
Throttle cable
e
e
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
.............................................
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
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
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
*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
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)
SERVICE DATA
VALVES+GUlDES
STANDARD
36.0
IN.
(1.42)
30.0
EX.
(1.1 8)
Valve l i f t
7.5
EX.
(0.301
IN.& E X .
EX.
0.040- 0.070
(0.001
6 - 0.00281
IN.& EX.
I
IN.& E X .
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
INNER
OUTER
50.4 - 58-3kg
(111,11 - 128.53 Ibs)
at length 27 11.06)
LIMIT
--
Cam height
STANDARD
36.320- 36,360
(1.4299 - 1.4315)
LIMIT
I
Camshaft runout
Cam chain 20 pitch length
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
--
36.020
(1.4181)
+-
I0.0059)
1
0.1
I
(0.004)
157.80
(6.213)
---
--
20 th pin
0.2
(0.0081
ITEM
I
Compression pressure
-- -
- -
--
LIMIT
I
7 kg/cm2
(100 psi)
2 kg/crn2
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
.
-
(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
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
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
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)
1.O
(0.039)
Crankshaft runout
0-05
(0.002)
OIL PUMP
I--T f h
STANDARD
LIMIT
Below
0.1 kglcm"
(1.4 psi)
0.25 kglcm'
(3.6 psi)
at 3 000 rimin
-
CLUTCk
STANDARD
LIMIT
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
-
0.1
10.004)
38.5
( 7 -52)
Unit: mm (in)
ITEM - _ _ _
Primary
)R
-
- -
STANDARD
LIMIT
- 1
- -.
1.062 (17 J f 6 )
3.090 134 / 1 1 )
Final reduction
.-
Gear ratios
Low
-I
--
(32/ 18)
1.380
(29 / 21 1
. --
2nd
1.777
3rd
--
4th
1.125 (27 / 2 4 )
TOP
-I . -- -. . -
- ---- ..
0-4 0.6
(0.03 6 - 0.024)
0.8
(0.031)
5.45 - 5.55
(0.215 - 0.219)
4.95 - 5.05
4
(0.195 - 0.1991
SHAFT DRIVE
STANDARD
-
l TEM
- Secondary bevel Igear baclklash
0.08 - 0.73
(0.003- 0.0051
0.03- 0.64
(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
b ureto
e size
rter jet
ELECTRICAL
Unit: mm (in)
SPEC1
F ICATION
-
ITEM
-Ignition timing
--
Firing order
Spark plug
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
~ ~ ~ r o xr-l40-180!2
.
Primary
Secondary
Starter motor
BI-Y,
ON-W
O N - B/Y
Approx. 3 - 5
ptugCap - plug cap
Approx. 30 - 40 k a
'
Limit: 6
Brush length
(0.24)
-Type
--
Fuse size
Standard electroly te S. G.
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)
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)
- -.
Front
Rear
--
>
--
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
I
I
Front
L-
(0.010)
L
Rear
+
I
Front
Rear
Front
I
Rear
0.25
(0.010)
1.6
(0.06)
2.0
(0.08)
I
I
CS8.5 0 GZ
SUSPENSION
LIMIT
1 60
(6.30)
+-
140
(5.5)
--
0.6kg/cm2
(8.5 psi)
"1 10
14.33)
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
22 L
(5.8 US gal)
4.2 L
reserve
(4.4 US qt)
Engine oil type
SA E
Change
Filter change
I!
(3.2US qt)
3 600 ml
(3.8US qt)
11
Over hau l
For~
0 1 1 =F 1 5
--
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
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
- -
-.-.
23 132)
--
3.4
speedometer light
-
Tachometer light
'
-.
.-
3.4
-
- - ..-
3.4
- -
I-
_ -_
.-
ght
---
light
1 7-1 4
3.4
3.4
-.
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
TIGHTENING TORQUE
Thread Diameter
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
"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
99000-32040
THREAD LOCK CEMENT
. . . . . . . . . . . . . . . . . . . . . . . 3. pes
. . . . . . . . . . . . . . . . . . .2 p a
. . . . . . . . . . . . . . . . . . . . . . . 2 pcs
. . . . . . . . . . . . . . . 3 pcs
...................... 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
............
3pa
. . . . . . . . . . . . . . . . . . . . ..10 p a
.-...... 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
99000-251 00
Camshaft journal
Chain tensioner adjuster shaft
Counter shaft washer
Outer counter shaft
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.
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
CATEGOR
All matorc)
50 cc - Larger
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.
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
1 2 3 Y 5 7 8 9 0
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.
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.
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.
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
@ O-ring
GSLYSOGZ
CHOKE LEVER
Remove the choke lever and choke cable.
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
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
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.
ousry.
09900 - 25002
Pocket tester
NOTE:
This checking presupposes that the ignition
coil used for checking is a good one.
--
1
Fig.
"
0
0
0 :i
Tightening torque
E:phragrn
~ 4 )Body
( 5 ) Holder
3.5 - 6.0
Place a
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.
09900 - 06108
damage.
rn Inspect the primary cup, secondary cup and dun
seal boot for damage.
cvlinder on the
handlebars, first tighten the clamp bolt on t h e
upper side.
CAUTION:
Bleed the air from the circuit after reassernbling the master cylinder.
Adjust the front brake light switch after
installation.
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.
......................................
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
STARTER LEVER
....................................... 18-25
................................................
18-25
......................................18-30
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
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
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.
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
'ITEM
Valve diam.
STANDARD
36.0
IN.
(1.42)
30.0
EX.
Valve lift
Valve stern r u n o u t
Valve head thickness
.-
(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
0.35
(0.014)
/ 0.002)
IN.& EX.
OUTER
.-
0.35
--
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
STANDARD
LIMIT
-"
7 3 6 . 3 2 0 - 36.360
E 1.4299 - 1.4315)
36.020
I1.418tl
35.770 - 35.8%
EX.
.
--
--.
- --
--
-. -
--- --
&
.-
-.. .-
20 th pin
- .-.
-..
0.1
10.0041
-
157.80
(6.2131
--.-
- --+-
10.8646 - 0.8652)
IN. & E X .
- -
0.1 50
(0.00591
r 1 . ~ 6-0 21.975
Camshaft runour
-
--
12 - 22.025
56.--0.867 -I.1
IN. & E
- - -
- --
--
0.037 - 0.065
(0.0015 - 0.0026)
( 1.4083
- 1.40981-
35.470
(1.3965)
-
.+ ---
-- - -
.-
0.2
Cylinder headdistortion
I
(0.008l
GS85OGLZ
9 - 12 kg/cm2
(128 - 171 psi)
compression pressure
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
1st
2nd
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)
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
ITEM
-
16.006 - 16.014
(0.6302 - 0.6305)
r- .- - -
LIMIT
STANDARD
.-
--
16.040
(0.6315)
Conrod deflection
OIL PUMP
-.
ITEM
.-
Oil pump-reduction
ratio
- -- -
-- --
1-
--
- -
F)
STANDARD
LIMIT
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)
2.7 - 2.9
(0.106 - 0.114)
--
-L
11.8 - 12.0
(0.46 0.47)
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,
SHAFT DRIVE
S f ANDARD
ITEM
Secondary bevel gear backlash
Finat bevel gear backiash
Secondary drive bevel gear preload
Secondary driven bevel gear preioad
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
" 3 180
0.5 - 1.0 (0.02 - 0.04)
CS850GLZ
*
*
ELECTRICAL
SPECIF
ICATlOfi
- -
Ignition timing
- --
Firing order
- -
.--
1, 2, 4, 3
1-
Spark plug
--
NGK : B8ES
N. D. : W24ES-W
TYpe
-
Gap
-
--
Spark performance
-.
--
I--
--
Regulated voltage
- .
-
FAC)
-
Starter motor
Limit: 6
Brush length
.--. .
1-
--
--
-.
-,--
- A2
-A
Headlight
10A
Turn signal
10A
Ignition
L-
--
-- .
-- - - . -
--
i
:
-I
(0.24)
3 - 4 s2
--
Capacity
--
Battery
Fuse size
0.6- 0.8
(0.024 - 0.03T 1
--
10A
--
Main
I 5A
Output terminal
10A
BRAKE +WHEEL
15
I
(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
0.30
(0.012)
15.870 - 15.913
(0.6248 - 0.6265)
Front
4
-
Rear
- -
-- --
(0.5512 - 0.5529)
-
--
Front
15.827 - 15.854
40.6231 - 0.6242)
Rear
13.957 - 13.984
(0.5495-0.5506)
- -.
d --
38r180-38.256
Front
(1,5031 - 1.5061)
38.180 --38.256
(1.5031 - 1.5061)
Rear
--
- -
Frant
38.098 - 38.148
(1.4999 - 1.5019)
38,098 - 38.148
(1.4999 - 7.5019)
-
Rear
--.
--
--
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)
--
--
1.6
Front
- - --
(0.06)
2.0
(0.081
CS,:SOGLz
ITEM
STANDARD
160
(6.3)
LIMIT
-
516
(20.31
111260
0.2)
0.8 kg/cm2
(11.4psiF
100
(3.9)
FUEL + 01L
+ CAPACITY
d or low-l
np octane
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)
Speedometer light
23 (32)
3.4
Tachometer light
HI
SPEC1FlCATlON
.-
Headlight
- -
- -
3.4
I---------1
*1.7
Fuelmeter light
a l indicator light
3.4
- -
--
3.4
- -.
--
3.4
-
3.4
3 ~ - I Ir u
TORQUE TABLE
ENGINE
gine mot
GS85OCLZ
CHASSIS
ITEM
kg-m
Ib-ft
1.2 - 2.0
8.5 - 14.5
1.5 - 2.5
11.0 - 18.0
2.0 - 3-0
14.5 - 21.5
1.5 - 2.5
11.0 - 18.0
2.0 - 3.0
14.5 - 21.5
1.5 - 2.5
3.6 - 5.2
11.0 - 18.0
26.0 - 37.5
0.35 - 0.45
-- - - - .
2.0 - 3
14.5 - 21.5
5.0
36.0 - 58.0
2.0 - 3.0
2.5 - 3.0
79.5 - 94.0
11.0 - 13.0
8
I
14.5 - 21.5
2.7 - 4.3
19.5 - 31.Q
1.5 - 2.5
11.0 - 18.0
1.5 - 2.0
11.0 - 14.5
0.5 - 0.8
3.5 - 6.0
1.3 - 1.8
9.5 - 13.0
.9
4.5 - 6.5
".O
14.5 - 21.5
2.5 - 3.5
18.0 - 25.5
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 -
-I"
9.0- 7 1.0
2.0 - 3.0
65.0 - 79.5
14.5 - 21.5
TIGHTENING TORQUE
Thread Diameter
(mm)
5
6
8
10
12
14
16
18
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
7.0-
11.5
16.0 - 25.5
25.5 - 40.0
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
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"
Camshaft journal
Chain tensionet adjuster shaft
Counter shaft washer
Outer counter shaft
" Input cam dog
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.
INTERVAL:
THIS INTERVAL SHOULD BE JUDGED k m
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST
Month
-A.
'
--
- -
Tappet clearance
Spark plug
- -
Fuel line
---
--
- .
Brake hose
Brake
-- - -
--
--
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.
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
1 2 3 Y 5 6 7 8 9 D
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.
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.
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.
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.
Generator coves
Secondary drive unit cover
Starter motor cover
STARTER LEVER
Remove the starter lever and starter cable.
99000- 25010
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
09900 - 06108
CAUTION:
Bleed the air from the circuit after reassembling the master cylinder.
Adjust the front brake light switch after
installation.
Fuel.
Clamp
J.
Turn s~gnel
Cia
WIRING DIAGRAM'