What to do if my Suzuki Madura GV700GL Motorcycle engine stalls easily?
If your Suzuki Motorcycle engine stalls easily, the issue might stem from several causes. Fouled spark plugs need cleaning. A defective signal generator or ignitor unit, a clogged fuel pipe, or a defective fuel pump/fuel pump relay should be replaced. Clogged jets in carburetors require cleaning, and a defective lash-adjuster needs replacement.
How to fix a noisy Suzuki Madura GV700GL Motorcycle engine?
A noisy Suzuki Motorcycle engine can arise from various issues. Excessive valve chatter needs air bleeding. Weakened or broken valve springs, a worn and burnt camshaft journal, or noises coming from the pistons, piston pins/bores, piston rings/grooves all necessitate replacement. Combustion chambers fouled with carbon require cleaning. Noises from the timing chain, worn sprockets, or a non-working tension adjuster all require replacement. If the noise seems to come from the clutch, worn splines of the countershaft or hub, worn teeth or distorted clutch plates, or a worn/damaged clutch push rod bearing each requires replacement.
General| Manufacturer | Suzuki |
|---|---|
| Model | Madura GV700GL |
| Category | Motorcycle |
| Displacement | 699 cc |
| Fuel System | Carburetor |
| Transmission | 5-speed |
| Final Drive | Shaft |
| Front Suspension | Telescopic fork |
| Front Brakes | Dual disc |
| Rear Brakes | Drum |
| Rear Tire | 140/90-15 |
| Ignition | Electronic ignition |
| Rear Suspension | Swingarm |
| Power | 70 hp (52 kW) @ 9, 500 rpm |
Location and importance of frame and engine serial numbers for registration and parts ordering.
Recommendations for fuel, engine oil, gear oil, brake fluid, and front fork oil types.
Guidelines for using antifreeze and coolant compatible with aluminum radiators and distilled water.
General rules for breaking in the engine to ensure reliability and performance.
Identification of engine cylinders numbered from left rear to right front.
List of special materials needed for maintenance work on the GV700GL.
Essential items to observe during servicing, disassembling, and reassembling the motorcycle.
Importance of using genuine Suzuki parts for optimal performance and to avoid mechanical troubles.
Key physical dimensions, engine, transmission, chassis, electrical, and capacity specifications.
Recommended intervals for periodic service work to maintain peak performance and emission levels.
Detailed procedures for servicing each item of periodic maintenance requirements.
Procedures for inspecting and maintaining the motorcycle's battery.
Instructions for cleaning and replacing the air cleaner element.
Information on cleaning and replacing spark plugs, including gap specifications.
Inspection and replacement intervals for fuel lines.
Procedures for changing engine oil and replacing the oil filter.
Adjusting idle RPM, throttle cable play, and choke cable.
Checking clutch fluid level and bleeding air from the clutch fluid circuit.
Procedures for draining, flushing, and refilling the cooling system.
Procedures for changing secondary and final gear oil.
Checking front brake fluid level, brake pads, and bleeding air from the system.
Checking tire tread condition, pressure, and replacement recommendations.
Inspection and adjustment procedures for the steering system.
Inspection and adjustment procedures for the front fork, including air pressure.
Torque specifications for important chassis bolts and nuts.
Procedure and specifications for checking engine cylinder compression.
List of parts that can be removed/reinstalled without engine removal from the frame.
Step-by-step guide for removing and reinstalling the engine from the motorcycle frame.
General cautions and steps for disassembling engine components.
General procedures for inspecting and servicing engine components.
Steps for disassembling the cylinder head and its related parts.
Checking the cylinder head gasket surface for distortion and the service limit.
Inspecting and servicing lash adjusters and cam followers.
Inspecting valve faces for wear and measuring the thickness service limit.
Checking valve stem runout with a dial gauge.
Measuring valve head radial runout and replacement criteria.
Measuring clearance between valve guide and stem, and replacement procedures.
Inspecting valve stem for wear using a micrometer.
Procedures for removing and installing valve guides.
Checking valve seat width and contact pattern.
Machining procedures for valve seats at specific angles.
Inspecting valve stem end face for pitting and wear.
Checking valve spring free length and tension, and replacement criteria.
Checking camshafts for wear on cams and journals.
Measuring cam height to check for wear and replacement criteria.
Measuring running clearance of camshaft journals using plastigauge.
Checking and replacing cam chain tensioner assemblies.
Measuring 20-pitch length of cam chain for wear.
Checking cylinder gasketed surface for distortion.
Measuring cylinder bore diameter and specifications for overhaul.
Measuring piston outside diameter and checking for oversize options.
Measuring clearance between piston and cylinder and overhaul criteria.
Measuring side clearances and groove width of piston rings.
Measuring free end gap and end gap of piston rings before installation.
Measuring connecting rod small end bore inside diameter.
Checking connecting rod big end thrust clearance.
Procedure for selecting connecting rod bearings based on measurements.
Procedure for selecting crankshaft bearings based on oil clearance measurements.
Measuring crankshaft thrust clearance on the left side.
Measuring crankshaft runout with a dial gauge.
Inspecting the starter pinion gear for smooth operation.
Checking clutch plates for wear, distortion, and thickness.
Disassembly and inspection of the clutch cylinder.
Applying thread lock to stator screws and mounting lead wire clamps.
Warning regarding oil pump case securing screws and available replacement units.
Diagram illustrating transmission gears and associated parts.
Procedure for mounting the 2nd drive gear and related notes.
Checking and adjusting gear-shifting fork clearance for smooth operation.
Steps for disassembling the driveshaft gears.
Procedures for reassembling the engine, with notes on applying oil and installing parts.
General procedures for inspecting and servicing engine components.
Procedure for setting camshaft timing for the front cylinders.
Detailed steps for timing the camshafts for the front cylinders.
Steps for timing the camshafts for the rear cylinders.
Exploded view and parts list for the secondary bevel gears.
Steps for removing the secondary gear case and related components.
Procedures for removing the secondary drive bevel gear cover, bearings, and shims.
Steps for removing the secondary driven bevel gear assembly and housing.
Inspecting removed parts for damage or wear in the secondary bevel gears.
Reassembling the secondary bevel gears, paying attention to specific points.
Procedure for measuring and adjusting bearing pre-load using shims.
Adjusting shims for the secondary gear to correct backlash.
Installing secondary drive and driven bevel gears and tightening bolts.
Checking tooth contact pattern after backlash adjustment using dye or paste.
Final assembly steps after backlash and tooth contact adjustments.
Information on shims, tightening torques, and fluid filling for reassembly.
Exploded view of the propeller shaft assembly components.
Steps for removing the propeller shaft and its related parts.
Reassembling and remounting the propeller shaft.
Exploded view and parts list for the final bevel gears.
Description of the breather circuit and air/oil flow within the final gear case.
Steps for removing the final gear case and driven bevel gear components.
Procedures for removing 0-rings, shims, oil seals, and couplings from the drive bevel gear.
Adjusting bearing pre-load for the final drive bevel gear using shims.
Installing shims for the final drive bevel gear and tightening housing nuts.
Measuring and adjusting shim clearance in the final gear bearing case.
Measuring and adjusting backlash for the final gear.
Checking tooth contact pattern of final bevel gears and adjusting shims if necessary.
Final assembly of the final gear case after backlash and tooth contact adjustments.
Overview of the engine cooling system, including components like pump, radiator, and thermostat.
Guidelines for coolant mixture ratio, freezing points, and boiling points.
Procedures for removing the radiator and water hoses.
Testing the cooling system for tightness using a radiator tester.
Inspecting radiator hoses for leaks and kinks.
Steps to remove the thermostat and its cover, and test its operation.
Procedures for removing, disassembling, and inspecting the water pump.
Steps for removing the water pump assembly.
Procedure for removing the water pump impeller.
Reassembling the water pump, including replacing O-rings and using a new gasket.
Checking the thermo-switch and fan motor relay for proper operation.
Testing the engine thermo-switch and its specifications.
Checking the fan motor relay coil and continuity.
Testing the cooling fan drive motor current.
Overview of the electrical wiring for the temperature gauge.
Testing the water temperature meter for accuracy using resistors and voltage.
Description of the fuel system components and their operation.
Description of the fuel cock lever positions and their functions.
Testing fuel pump resistance and discharge amount.
Measuring resistance between lead wires to check fuel pump relay condition.
Carburetor construction, specifications, and adjustment procedures.
Explanation of the variable-venturi carburetor's diaphragm and piston operation.
Description of the fuel supply system during low-speed engine operation.
Explanation of the system that maintains fuel/air mixture ratio during sudden throttle changes.
Description of fuel metering by main jet and needle jet during normal operation.
Explanation of how the choke lever and starter jet draw fuel for starting.
Description of the float and needle valve mechanism maintaining fuel level.
Cautions and steps for disassembling the carburetor assembly.
Inspecting the needle valve and seat for wear or foreign matter.
Procedure for checking and adjusting float height using calipers.
Reassembling the carburetor, aligning needle jet groove, and installing float chamber.
Procedure for calibrating and balancing the four carburetors using a balancer gauge.
Measuring fuel level in carburetors using a fuel level gauge.
Checking oil pressure, oil sump filter, and lubrication system chart.
Checking engine oil level and oil pressure specifications.
Instructions for washing and installing the oil sump filter.
Diagram illustrating the flow of oil through the lubrication system.
Federal emission regulations for motorcycles, including 1980 limits for HC and CO.
Special components and specifications for emission-controlled carburetors.
Types of regulated exhaust emissions (HC, CO, NOx) and their sources.
Causes and measurement of carbon monoxide emissions.
Common malfunctions in carburetors affecting emissions.
Engine malfunctions that can affect emissions.
Measurement and causes of hydrocarbon emissions, particularly ignition system issues.
Common ignition system problems affecting HC emissions.
Carburetion issues that can lead to high HC emissions.
Procedures for checking charging output and AC generator no-load performance.
Checking stator lead wire continuity and stator core insulation.
Measuring resistance to check the condition of the regulator/rectifier.
Description of the transistorized ignition system components.
Testing ignition coils for sparking performance using an electro tester.
Testing the ignitor unit by checking spark plug operation.
Testing the ignitor unit using an ignitor checker and spark plugs.
Description of the starter system components and operation.
Steps for removing and disassembling the starter motor.
Inspecting carbon brushes, commutator, and armature coil of the starter motor.
Checking oil seal lip for damage or leakage.
Reassembling the starter motor, including O-rings and housing ends.
Inspecting the starter relay for continuity.
Procedures for removing, disassembling, and inspecting the combination meter and check panel.
Explanation of how the water temperature gauge works based on coil resistance and magnetic fields.
Testing the water temperature meter for accuracy using resistors and voltage.
Wiring diagram and inspection procedures for the fuel level indicator.
Wattage specifications for various motorcycle lamps.
Inspect switches for continuity using a pocket tester.
Continuity check chart for the clutch switch.
Continuity check chart for the front brake switch.
Wire color assignments for the gear position indicator switch.
Continuity check chart for the rear brake switch.
Continuity check chart for the side stand check switch.
Conditions for oil pressure switch continuity.
Specifications, initial charging, and servicing procedures for the battery.
Procedure for filling electrolyte and initial charging of a new battery.
Visual inspection of the battery container and cleaning of terminals.
Procedure for recharging the battery based on electrolyte specific gravity readings.
Construction and disassembly procedures for the front wheel.
Removing brake discs from the wheel.
Procedures for driving out and removing wheel bearings using special tools.
Inspecting wheel bearings for play, noise, and smooth rotation.
Checking axle shaft for runout.
Checking wheel rim runout and adjusting spoke tension.
Tightening spoke nipples as necessary.
Checking tire tread depth and wear limit.
Reassembling the front wheel, including grease application and bearing installation.
Applying thread lock to brake disc bolts and tightening them.
Greasing and aligning the speedometer gearbox before installation.
Procedures for replacing front brake pads.
Steps for removing the brake caliper, including disconnecting brake hose.
Inspecting caliper bore, rubber parts, piston surface, and disc wear.
Steps for removing and disassembling the master cylinder.
Inspecting master cylinder bore, piston, cups, and boot.
Reassembling the master cylinder, including washing components and bleeding air.
Removal procedures for the front fork assembly.
Steps for disassembling the front fork, including removing valve cap and bleeding air.
Measuring the free length of the fork spring.
Inspecting inner and outer tubes for scuffing and bends.
Inspecting the damper rod ring for wear and damage.
Reassembling the front fork, including inner tube metal, oil lock piece, and damper rod bolt.
Installing outer tube metal, oil seal retainer, oil seal, and dust seal.
Specifications for front fork oil type and capacity, and adjusting oil level.
Installing the front fork assembly, aligning inner tube with steering stem bracket.
Procedure for checking and charging front fork air pressure.
Construction and disassembly procedures for the steering stem.
Steps for disassembling the steering stem, including removing front wheel, fork, and brake hose.
Setting handlebars and securing clamp bolts to equalize clearance.
Construction and removal procedures for the rear wheel and brake.
Checking brake shoe wear indicator and replacing brake shoes if necessary.
Measuring brake drum I.D. for wear and inspecting for scratches.
Reassembling the rear wheel, including wheel bearing installation.
Steps for removing the rear wheel, seats, and disconnecting electrical harnesses.
Inspecting bearing play in rear shock, cushion lever, or rod.
Inspecting dust seals for damage and replacing if necessary.
Pressing in the bearing outer race for the swingarm.
Installing the bearing to the cushion lever using a special tool.
Applying grease and tightening final gear case joint nuts.
Adjustments required after installing rear suspension and wheel, including rear brake and shock absorber.
Removal, disassembly, inspection, and reassembly of the clutch master cylinder.
Guide for diagnosing and resolving engine, shaft drive, carburetor, and electrical issues.
Troubleshooting guide for noisy shaft drive and oil leaks.
Troubleshooting guide for carburetor issues like starting problems, idling, and fuel level fluctuations.
Troubleshooting for engine overheating or overcooling issues.
Troubleshooting guide for electrical system complaints like no sparking or poor charging.
Troubleshooting for battery sulfation, leaks, and rapid discharge.
Troubleshooting for chassis-related issues like heavy handling, steering oscillation, and suspension problems.
Troubleshooting guide for front and rear brake issues like poor braking, squeaking, and fluid leakage.
Complete wiring diagram of the motorcycle's electrical system.
Diagrams illustrating the correct routing of cables, harnesses, and hoses.
Guidelines for correct routing of front brake hoses, including turning radius and avoiding twists.
Instructions for routing the clutch hose correctly, using guides and protectors.
Diagrams showing the correct routing of radiator and reservoir hoses.
List of special tools required for servicing the motorcycle.
Torque specifications for engine, shaft drive, and chassis components.
Standard and limit specifications for various engine, transmission, and chassis components.
Standard and limit specifications for valve dimensions and clearances.
Standard and limit specifications for camshaft and cylinder head dimensions.
Specifications for cylinder bore, piston diameter, and piston ring clearances.
Specifications for connecting rod and crankshaft dimensions and clearances.
Performance specifications for oil pump, fuel pump, and water pump.
Specifications for clutch plate thickness, springs, and master cylinder components.
Specifications for thermostat, radiator cap, and fan switch.
Ratios for the transmission and final drive.
Specifications for carburetor type, jets, and adjustments.
Specifications for ignition timing, spark plugs, coils, generator, starter, and battery.
Wattage specifications for various motorcycle lamps.
Specifications for brake components and wheel dimensions.
Specifications for front fork, rear wheel travel, and swingarm.
Tire pressure specifications for solo and dual riding.
Specifications for fuel type, tank capacities, engine oil, cooling solution, and gear oils.
Description of the charcoal canister system for controlling HC vapors.
Diagrams showing the correct routing of vapor hoses for the emission control system.
Visual guide to correct routing of hoses, avoiding interference.
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