Suzuki GS550 - View of Suzuki GS550 E; Right Side; Left Side

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Foreword3
View of Suzuki GS550E4
Right Side4
Left Side4
View of Suzuki GS550ES5
Group Index7
General Information9
Contents9
Serial Number Location10
Fuel and Oil Recommendations10
Brake Fluid10
Breaking-In11
Cylinder Identification11
Blowby Gas Recycling11
Break-In Procedures11
Special Features11
TSCC (Twin Swirl Combustion Chamber)12
Fully-Transistorized Ignition System with Electronic Advance16
Description16
Ignition System Diagram and Operation16
Anti-Dive Front Fork19
Anti-Dive Device19
Anti-Dive System20
The Anti-Dive System Is Inactive, While the Front Brake Is Inactive21
When the Anti-Dive System Is Activated21
What Happens When the Motorcycle Receives a Jolt from the Road, While the Anti-Dive Device Is Active?22
Full-Floating Suspension System23
Special Materials24
Precautions and General Instructions26
Use of Genuine Suzuki Parts26
Specifications27
Periodic Maintenance and Tune-Up Procedures29
Periodic Maintenance Schedule30
Maintenance and Tune-Up Procedures31
Battery31
Cylinder Head Nuts and Exhaust Pipe Bolts32
Air Cleaner33
Valve Clearance34
Spark Plug36
Fuel Line37
Engine Oil and Oil Filter37
Carburetor Idle RPM38
Idling Adjustment38
Throttle Cable Play38
Clutch39
Drive Chain39
Checking39
Adjusting40
Cleaning and Lubricating40
Brake Fluid Level41
Brake Pads41
Brake Pedal Height42
Brake Light Switch42
Air Bleeding from Brake Fluid Circuit43
Front Brake Air Bleeding43
Tire Tread Condition44
Tire Pressure45
Steering45
Front Fork46
Chassis Bolts and Nuts47
Servicing Engine51
Compression Check52
Compression Test Procedure52
Engine Components Removable with Engine in Place53
Engine Left Side53
Engine Center53
Engine Right Side53
Engine Removal and Reinstallation54
Engine Reinstallation60
Engine Disassembly64
Engine Components Inspection and Servicing77
Cylinder Head Servicing77
Cylinder Head Distortion78
Valve Stem Runout78
Valve Head Radial Runout78
Valve Face Wear78
Valve Guide-Valve Stem Clearance79
Valve Stem Wear79
Valve Guide Servicing79
Valve Seat Width81
Valve Seat Servicing82
Valve Springs84
Valve Spring Tension85
Reassembly85
Camshaft86
Cam Wear86
Cam Height86
Camshaft Journal Wear87
Camshaft Runout88
Cam Sprocket Reassembly88
Cam Chain Tensioner Disassembly89
Inspection89
Reassembling90
Cam Chain 20-Pitch Length91
Cam Chain Guide92
Cylinder Distortion92
Cylinder Bore92
Piston Diameter93
Piston-Cylinder Clearance93
Piston Ring-Groove Clearance93
Piston Ring Thickness93
Piston Ring Free Eng Gap and Piston Ring End Gap94
Oversize Piston Rings94
Oversize Oil Rings94
Oversize Side Rail94
Piston Pin and Pin Bore95
Connecting Rod Small End I.D.95
Connecting Rod Big End Thrust Clearance95
Connecting Rod-Crank Pin Bearing Selection96
Bearing Selection Table97
Crank Pin Bearing Oil Clearance97
Connecting Rod I.D. Specification97
Crank Pin O.D. Specification98
Bearing Thickness98
Bearing Assembly98
Crankcase-Crankshaft Bearing Selection99
Crank Journal Bearing Oil Clearance100
Crankcase I.D. Specification101
Crankshaft Journal O.D. Specification101
Bearing Thickness Specification101
Crankshaft Thrust Clearance102
Right-Side Thrust Bearing Thickness102
Thrust Bearing Selection Table103
Crankshaft Runout103
Clutch Drive Plates and Driven Plates104
Clutch Spring Free Length104
Clutch Bearings105
Sleeve Hub Spring Washer105
Starter Clutch Removal105
Oil Pump106
Transmission107
Shift Fork-Groove Clearance107
Shift Fork Groove Width108
Shift Fork Thickness108
Countershaft Disassembly108
Driveshaft Disassembly109
Countershaft and Driveshaft Reassembly110
Shim Selection Table110
Engine Reassembly111
Fuel and Lubrication System135
Fuel System136
Fuel Cock137
Carburetor Construction138
I.D. No. Location139
Diaphragm and Piston Operation140
Slow System141
Main System142
Starter System143
Float System143
Needle Valve Inspection147
Float Height Adjustment148
Fuel Level Inspection150
Balancing Carburetors150
Lubrication System Chart153
Engine Lubrication System154
Oil Cooler155
Oil Pressure156
Oil Sump Filter156
Emission Control and Regulations157
Emission Regulations158
Emission Control Carburetor Components159
General Emission Information160
Electrical System163
Starter System Diagram164
Starter Motor164
Starter Motor Removal165
Starter Motor Inspection166
Carbon Brushes166
Commutator166
Armature Coil166
Starter Motor Reassembly167
Brush Holder167
Housing Top167
Securing Screws167
Chain Tensioner168
Starter Relay Inspection168
Ignition System169
Signal Generator170
Ignitor170
Ignition Coil171
Charging System172
Function of Regulator172
Charging Output Check174
AC Generator No-Load Performance174
Regulator/Rectifier175
Initial Charging176
Filling Electrolyte176
Charging Time176
Servicing176
Based on S.g.reading Recharging Operation177
Service Life178
Ignition Switch179
Dimmer Switch179
Horn Switch179
Turn Signal Light Switch179
Engine Kill Switch180
Starter Interlock Switch180
Front/Rear Brake Light Switch180
Side Stand Check Light Switch181
Gear Position Light Switch181
Oil Pressure Switch181
Wire Color181
Combination Meter182
Fuel Meter and Fuel Gauge184
Chassis185
Fairing186
Removal187
Front Wheel189
Removal and Disassembly189
Wheel Bearing191
Tire191
Axle Shaft192
Wheel Bearings192
Brake Disc193
Caliper194
Front Axle194
Tire and Wheel195
Tire Removal195
Wheel198
Valve198
Valve Installation199
Tire Mounting199
Front Fork View202
Damper Rod Ring206
Oil Lock Piece206
Fork Spring206
Inner/Outer Tube207
Modulator Plunger Assembly and Valve Assembly207
Modulator Valve O-Rings207
Chassis Reassembly208
Oil Lock Piece and Washer208
Damper Rod Bolt208
Outer Tube Metal, Washer and Oil Seal208
Modulator Valve209
Fork Oil209
Inner Tube209
Frok Air210
Steering Stem211
Out Races216
Bearing216
Steering Stem Nut216
Front Brake219
Brake Pad Replacement220
Caliper Removal and Disassembly221
Cylinder222
Piston222
Dust Boot and Piston Seal223
Disc223
Master Cylinder Removal and Disassembly225
Master Cylinder Inspection226
Master Cylinder Reassembly227
Rear Wheel228
Rear Wheel and Mounting Drum Bearings231
Cushion232
Sprocket232
Mounting Drum Bearing234
Rear Sprocket234
Rear Axle Shaft234
Rear Brake235
Master Cylinder Removal240
Piston and Cup Set242
Rear Brake Pedal243
Rear Swing Arm244
Swing Arm Bearings247
Spacer and Dust Seal Cover247
Swing Arm Pivot Shaft247
Full Floating Suspension248
Cushion Lever Rod Bearings252
Rear Shock Absorber253
Servicing Information255
Troubleshooting256
Engine256
Electrical259
Brakes262
Wiring Diagram GS550E263
Wiring Diagram GS550ES264
Wire, Cable and Hose Routing265
Wire Routing: GS550E265
Wire Routing: GS550ES266
GS550E and GS550ES267
Cable Routing269
Hose Routing270
Oil Hose Routing271
Brake Hose Routing272
Special Tools273
Tightening Torque279
Tightening Torque Chart281
Service Data282
Valve+Guide282
Camshaft+Cylinder Head283
Cylinder+Piston+Piston Ring284
Conrod+Crankshaft285
Transmission+Drive Chain286
Carburetor287
Brake+Wheel289
Suspension290
Fuel+Oil290
Wattage291
Gs550L293
View of Suzuki GS550L294
Dimensions and Dry Mass295
Capacities296
Inner Tube and Outer Tube320
Inner Tube Metal321
Stopper Ring322
Fork Air323
Rear Wheel and Brake328
Rear Sprocket Mounting Drum331
Rear Brake Drum332
Brake Shoe332
Wheel and Mounting Drum Bearings332
Brake Camshaft334
Wiring Diagram336
Wire, Cable and Hose Routing GS550L337
Wire Routing GS550L337
Cable Routing GS550L340
Hose Routing GS550L341
Oil Hose Routing GS550L342
Brake Hose Routing GS550L343
Diagram 1985 GS550E345
Diagram 1985 GS550L347

Suzuki GS550 - View of Suzuki GS550 E; Right Side; Left Side

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