Suzuki GS1000 - Diaphragm and Piston Operation

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Product View4
Group Index6
General Information: Contents8
Identification Table9
Serial Number Location9
Fuel, Oils and Breaking-In Procedure9
Orientation10
Braking-In Procedure10
Location of Parts10
Cylinder Identification10
Service Specifications11
Service Specifications: Contents14
Engine Top End Specifications15
Engine Lower End/Lubrication System/Clutch Specifications17
Transmission/Fuel System Specifications18
Ignition System/Charging System Specifications19
Lamp Wattage, Brakes and Wheels Specifications20
Tire Pressure, Suspension, Frame, Steering Specifications21
Torque Table: Engine, Chassis22
Tightening Torque Chart23
Periodic Maintenance: Contents24
Periodic Maintenance Schedule25
Periodic Maintenance Procedures26
Battery26
Cylinder Head Nuts and Exhaust Pipe Bolts26
Air Cleaner Element27
Checking and Adjusting the Tappet Clearance28
Tappet Clearance Adjustment29
Shim Selection Chart31
Spark Plug32
Contact Breaker Points32
Ignition Timing32
Fuel Line32
Timing Adjustment for Nos 1 and 4 Cylinders/For Nos 2 and 3 Cylinders33
Engine Oil34
Checking the Ignition Timing with the Timing Light34
Engine Oil Filter35
Carburetor Idle RPM35
Throttle Cable Adjustment35
Pulling Cable Play35
Clutch36
Drive Chain36
Clutch Cable Adjustment36
Returning Cable Play36
Chain Cleaning and Oiling38
Tires38
Brake Hoses38
Cleaning by Washing38
Brakes39
Steering39
Front Forks40
Chassis Bolts and Nuts41
Special Materials44
Use of Genuine Suzuki Parts45
Special Tools46
Troubleshooting: Contents50
Engine and Chassis Troubleshooting51
Electrical Troubleshooting54
Engine: Contents56
Engine Removal58
Engine Remounting60
Engine Overview62
Compression Check64
Top End Removal64
Cylinder Head Cover Removal64
Chain Tensioner Adjuster Removal64
Camshaft, Cylinder Head Removal65
Top End Installation67
Valve Guide Hole Reaming67
Valve Guide, Valve Stem Seal67
Valve, Valve Springs68
Installing Valve Cottter to Valve Stem68
Cylinder Head Installation68
Sprockets on Camshafts69
Positioning Camshaft in Place69
Camshaft Holder71
Cam Chain Tensioner Adjuster71
Tensioning Action Check72
Top End - Inspection73
Camshaft Journal Wear, Camshaft Wear73
Camshaft Runout74
Valve Face Wear74
Valve Stem Deflection75
Valve-To-Guide Clearance75
Valve Seat Width Measurement75
Valve Seat Servicing76
Valve Spring77
Cylinder Head Distortion77
Cylinder Removal78
Cam Chain Tensioner Adjuster Reassembling78
Cylinder Installation79
Distribution of Ring Gaps79
Cylinder Wear Inspection80
Piston and Rings Removal80
Piston and Rings Installation81
Piston Wear Determination Inspection82
Piston Ring Clearance in the Groove Inspection82
Lower End83
Piston Ring Gap Inspection83
Generator Stator Removal/Installation83
Generator Rotor Removal/Installation84
Contact Breaker Points Removal/Installation85
Condenser Installation85
Automatic Advancer for Contact Breaker Removal85
Automatic Advancer for Contact Breaker Installation86
Dismantling/Assembly of Automatic Advancer86
Clutch Removal87
Clutch Inspection88
Free Length of Clutch Spring88
Clutch Drive Plate Wear88
Clutch Plate Distortion88
Clutch Installation89
External Mechanism for Gear Shift Removal/Installation90
Engine Lubrication System Overview91
Oil Pump Removal/Installation92
Side, Tip Clearance92
Outer Rotor Clearance in the Body92
Oil Pump Pressure Test93
Oil Filter Removal/Installation94
Sump Filter Removal/Installation94
Crankcase Removal95
Crankshaft96
Crankpin Wear and Big End Side Clearance96
Transmission97
Crankshaft Deflection97
Mounting 2Nd Drive Gear on the Counter Shaft97
Caution in Installation of Transmission Gears and Crankshaft on Crankcase99
Gear Backlash99
Fuel Cock/Fuel Tank Cleaning101
Carburetors101
Carburetors Description102
Starter Unit102
Fuel-Air Mixture too Lean/Too Rich102
Pilot/Main Circuit103
Float Unit104
Needle Valve104
Fuel System Disassembly105
Fuel System Reassembly106
Fuel System Adjustment107
Fuel Level Measurement/Adjustment108
Balancing Carburetors108
Fuel System and Carburetor Troubleshooting111
Emission Control and Regulations: Contents112
Emission Control and Regulations113
Emission Control Carburetor Components114
General Emission Information115
Carbon Monoxide115
Engine/Carburetion Malfunction115
Hydrocarbons116
Mixture-Related/Ignition System Malfunctions116
Chassis: Contents118
Handlebar Removal/Mounting119
Clutch Cable Removal119
Clutch Cable Mounting120
Throttle Cable Removal120
Speedometer/Tachometer Cables Removal, Mounting121
Throttle Cable Mounting121
Headlamp Removal122
Cautions in Mounting: Headlamp122
Adjustment of Headlamp in Horizontal/Vertical Angle122
Ignition Switch Removal, Mounting123
Front Fork124
Front Fork Removal/Mounting125
Disassembly of Front Fork126
Assembly of Front Fork127
Measuring Method of Fork Oil Level127
Handling the Front Fork128
Adjusting the Air Fork128
Inspection of Front Fork129
Steering Stem Removal129
Steering Stem Assembly131
Steering Stem Tightening Method131
Removal/Mounting of Steering Stem Race133
Steering Stem Bearing Removal/Mounting134
Front Wheel134
Front Wheel Removal, Assembly135
Front Wheel Inspection136
Tire Warning137
Removal of Tube and Tire138
Front Wheel Mounting139
Front Brake Master Cylinder Removal/Mounting140
Air Bleeding the Brake Fluid Circuit141
Master Cylinder Disassembly/Assembly142
Inspection of Master Cylinder143
Front Brake Caliper Removal/Mounting144
Caliper144
Caliper Disassembly/Assembly145
Caliper Inspection146
Brake Parts to be Periodically Replaced146
Rear Brake Caliper Removal, Mounting147
Air Bleeding of the Brake Fluid Circuit148
Brake Pedal Adjustment148
Pad Replacement149
Disassembly/Assembly of Rear Brake Caliper149
Pad Inspection150
Rear Master Cylinder Removal151
Rear Master Cylinder Mounting152
Disassembly of Master Cylinder152
Master Cylinder Assembly/Inspection153
Rear Wheel154
Rear Wheel Assembly156
Rear Wheel Inspection, Chain Cleaning and Oiling157
Rear Wheel Mounting158
Checking the Sprockets for Wear158
Adjustment of Wheel Alignment158
Swing Arm Removal/Mounting159
Disassembly of Swing Arm Bearing160
Use of Special Tool160
Swing Arm Mounting161
Rear Shock Absorber162
Spring/Damper Adjustment162
Combination of Spring Setting and Damper Setting163
Suspension Math between Front and Rear163
Removal of Rear Shock Absorber163
Swing Arm Assembly, Inspection164
Electrical System: Contents166
Ignition System: Data, Coils167
Schematic Diagram of Ignition System167
Contact Breakers168
Charging System170
Method of Testing Rectifier, Regulator and Alternator170
Inspection of Charging System Components171
Rectifier, Alternator171
Starter System Inspection172
Regulator172
Starter Clutch and Generator Rotor172
Inspection of Components173
Carbon Brushes173
Armature Coil, Commutator173
Starter Motor Specifications173
Battery Description, Specification174
Relay for Starter Motor174
Initial Changing Method175
Initial Electrolyte Filling, Charging Current/Duration175
Battery Servicing176
Electrolyte Adjustment176
Battery Removal, Installation, Inspection176
Recharging Operation Based on S.G. Reading176
Electrical System Troubleshooting178
Utility Switches and Devices178
Ignition Switch, Front Brake Lamp Switch178
Rear Brake Lamp Switch, Lighting and Dimmer Switches179
Turn Signal179
Left Handle Switch, Kill Switch and Starter Switch179
Horn179
Oil Pressure Switch180
Inspection of Headlamp180
Lamp Wattage Data180
Inspection of Tail Brake Lamps and Turn Signal Lamps180
Rear Combination Lamps181
Fuel Gauge181
Inspection of Speedometer and Tachometer181
Inspection of Fuel Meter and Gauge183
Electrical System: Wiring Diagram187
Electrical System: Cable Routing188
GS1000E: Contents193
GS1000E Overview194
GS1000E Service Specifications195
Front Brake197
Master Cylinder Inspection197
Caliper Inspection, Reassembly197
Air Bleeding from Brake Fluid Circuit197
Wheel198
Wheel Disassembly, Inspection and Checking199
Self-Cancelling Turn Signal: Circuit Diagram, Operation200
Self-Cancelling Turn Signal: Troubleshooting201
GS1000E Wiring Diagram204
GS1000S: Contents206
GS1000S: Overview207
Service Data210
Periodic Maintenance217
Choke Cable, Choke Knob Adjustment217
Carburetor Removal217
Fuel System218
Carburetor Disassembly218
Chassis219
Handlebar Removal219
Choke Cable Removal, Installation219
Clutch Cable Installation219
Cowling Removal220
Combination Meter Removal221
Combination Meter Installation222
Tube and Tire Removal222
Tube and Tire Mounting223
Electrical224
Combination Meter Assembly/Disassembly224
Power Source Terminal226
Checking the Thermistor226
GS1000S Wire and Cable Routing227
GS1000S Wiring Diagram229
GS1000L: Contents231
Overviewing GS1000L232
GS1000L Specifications233
Service Data: GS1000L235
Chassis Bolts and Nuts: Maintenance242
Fuel Line, Cock244
Choke Cable/Knob Adjustment244
Carburetor Disassembly (GS1000L)245
Chassis Front Fork246
Front Fork Removal, Mounting247
Front Wheel Removal, Mounting248
Gear Shifting Switch and Gear Position Indicator251
Fuel Gauge Wiring252
GS1000L Wire and Cable Routing257
Wiring Diagram for GS1000L259
GS1000E/ST: Contents264
GS1000ET Overview265
GS1000ET Specifications266
Torque Table278
Fuel System of GS1000E/ST291
Fuel Cock292
Diaphragm and Piston Operation295
Slow System296
Main System297
Starter, Float Systems298
Float Height Adjustment301
Fuel Level Measurement305
Checking Fuel Level in each Float Chamber305
Fuel Level Adjustment305
Balancing the Carburetors306
Fuel-Transistorized Ignition System308
Signal Generator309
Signal Generator Removal/Disassembly310
Ignition Timing Inspection, Specifications311
Signal Generator Resistance312
Igniter312
Charging Output Check315
AC Generator No-Load Performance315
Regulator/Rectifier316
Front Master Cylinder317
Master Cylinder Removal and Disassembly318
Master Cylinder Inspection/Reassembly320
Front Caliper321
Brake Pad Replacement322
Caliper Removal and Disassembly323
Caliper and Disc Inspection324
Caliper Reassembly324
Wire and Cable Routing326
Wiring Diagram of GS1000E/ST328
GS1000ST Overview329
GS1000E/ST Specifications330
GS1000E/ST Service Data332
GS1000E/ST Wire and Cable Routing334
GS1000G/L Contents345
GS1000GT Product View346
GS1000GT Specifications347
Engine Removal and Remounting372
Secondary Bevel Gear Assembly376
Secondary Drive Gear Assembly Removal and Disassembly378
Bearing Preload Adjustment380
Secondary Driven Gear Assembly: Removal and Disassembly381
Secondary Driven Gear Assembly: Inspection and Reassembly382
Secondary Gear Set Clearancing Operations384
Backlash384
Tooth Contact Checking385
Final Assembly386
Clutch Disassembly388
Drive Plate Thickness, Drive Plate Claw Width389
Clutch Spring Free Length390
Crankcase Disassembly392
Shift Fork - Groove Clearance395
Drive Shaft and Gears397
Notes on Installation of Transmission Gears and Crankshaft in Crankcase398
Lubrication System402
Shaft Drive404
Final Drive Bevel Gear Assembly406
Final Gear Case Breather Circuit408
Air and Gear Oil Flow in Final Gear Case Breather Circuit408
Final Drive Gear Preload Adjustment413
Final Driven Gear Assembly415
Final Gear Bearing Cover Shim Adjustment416
Backlash Measurement416
Tooth Contact Adjustment418
Installation of Propeller Shaft and Final Drive Gear Assembly420
Ignition Timing Specifications424
Front Fork Inspection431
Rear Wheel Overview440
Rear Wheel Removal and Disassembly441
Rear Swinging Arm445
Disassembly of Swinging Arm Bearing447
GS100GLT Overview451

Suzuki GS1000 - Diaphragm and Piston Operation

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