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GS1000
Service manual
Suzuki GS1000 Service Manual
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Service manual
(255 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Product View
Group Index
General Information: Contents
Identification Table
Serial Number Location
Fuel, Oils and Breaking-In Procedure
Orientation
Braking-In Procedure
Location of Parts
Cylinder Identification
Service Specifications
Service Specifications: Contents
Engine Top End Specifications
Engine Lower End/Lubrication System/Clutch Specifications
Transmission/Fuel System Specifications
Ignition System/Charging System Specifications
Lamp Wattage, Brakes and Wheels Specifications
Tire Pressure, Suspension, Frame, Steering Specifications
Torque Table: Engine, Chassis
Tightening Torque Chart
Periodic Maintenance: Contents
Periodic Maintenance Schedule
Periodic Maintenance Procedures
Battery
Cylinder Head Nuts and Exhaust Pipe Bolts
Air Cleaner Element
Checking and Adjusting the Tappet Clearance
Tappet Clearance Adjustment
Shim Selection Chart
Spark Plug
Contact Breaker Points
Ignition Timing
Fuel Line
Timing Adjustment for Nos 1 and 4 Cylinders/For Nos 2 and 3 Cylinders
Engine Oil
Checking the Ignition Timing with the Timing Light
Engine Oil Filter
Carburetor Idle RPM
Throttle Cable Adjustment
Pulling Cable Play
Clutch
Drive Chain
Clutch Cable Adjustment
Returning Cable Play
Chain Cleaning and Oiling
Tires
Brake Hoses
Cleaning by Washing
Brakes
Steering
Front Forks
Chassis Bolts and Nuts
Special Materials
Use of Genuine Suzuki Parts
Special Tools
Troubleshooting: Contents
Engine and Chassis Troubleshooting
Electrical Troubleshooting
Engine: Contents
Engine Removal
Engine Remounting
Engine Overview
Compression Check
Top End Removal
Cylinder Head Cover Removal
Chain Tensioner Adjuster Removal
Camshaft, Cylinder Head Removal
Top End Installation
Valve Guide Hole Reaming
Valve Guide, Valve Stem Seal
Valve, Valve Springs
Installing Valve Cottter to Valve Stem
Cylinder Head Installation
Sprockets on Camshafts
Positioning Camshaft in Place
Camshaft Holder
Cam Chain Tensioner Adjuster
Tensioning Action Check
Top End - Inspection
Camshaft Journal Wear, Camshaft Wear
Camshaft Runout
Valve Face Wear
Valve Stem Deflection
Valve-To-Guide Clearance
Valve Seat Width Measurement
Valve Seat Servicing
Valve Spring
Cylinder Head Distortion
Cylinder Removal
Cam Chain Tensioner Adjuster Reassembling
Cylinder Installation
Distribution of Ring Gaps
Cylinder Wear Inspection
Piston and Rings Removal
Piston and Rings Installation
Piston Wear Determination Inspection
Piston Ring Clearance in the Groove Inspection
Lower End
Piston Ring Gap Inspection
Generator Stator Removal/Installation
Generator Rotor Removal/Installation
Contact Breaker Points Removal/Installation
Condenser Installation
Automatic Advancer for Contact Breaker Removal
Automatic Advancer for Contact Breaker Installation
Dismantling/Assembly of Automatic Advancer
Clutch Removal
Clutch Inspection
Free Length of Clutch Spring
Clutch Drive Plate Wear
Clutch Plate Distortion
Clutch Installation
External Mechanism for Gear Shift Removal/Installation
Engine Lubrication System Overview
Oil Pump Removal/Installation
Side, Tip Clearance
Outer Rotor Clearance in the Body
Oil Pump Pressure Test
Oil Filter Removal/Installation
Sump Filter Removal/Installation
Crankcase Removal
Crankshaft
Crankpin Wear and Big End Side Clearance
Transmission
Crankshaft Deflection
Mounting 2Nd Drive Gear on the Counter Shaft
Caution in Installation of Transmission Gears and Crankshaft on Crankcase
Gear Backlash
Fuel Cock/Fuel Tank Cleaning
Carburetors
Carburetors Description
Starter Unit
Fuel-Air Mixture too Lean/Too Rich
Pilot/Main Circuit
Float Unit
Needle Valve
Fuel System Disassembly
Fuel System Reassembly
Fuel System Adjustment
Fuel Level Measurement/Adjustment
Balancing Carburetors
Fuel System and Carburetor Troubleshooting
Emission Control and Regulations: Contents
Emission Control and Regulations
Emission Control Carburetor Components
General Emission Information
Carbon Monoxide
Engine/Carburetion Malfunction
Hydrocarbons
Mixture-Related/Ignition System Malfunctions
Chassis: Contents
Handlebar Removal/Mounting
Clutch Cable Removal
Clutch Cable Mounting
Throttle Cable Removal
Speedometer/Tachometer Cables Removal, Mounting
Throttle Cable Mounting
Headlamp Removal
Cautions in Mounting: Headlamp
Adjustment of Headlamp in Horizontal/Vertical Angle
Ignition Switch Removal, Mounting
Front Fork
Front Fork Removal/Mounting
Disassembly of Front Fork
Assembly of Front Fork
Measuring Method of Fork Oil Level
Handling the Front Fork
Adjusting the Air Fork
Inspection of Front Fork
Steering Stem Removal
Steering Stem Assembly
Steering Stem Tightening Method
Removal/Mounting of Steering Stem Race
Steering Stem Bearing Removal/Mounting
Front Wheel
Front Wheel Removal, Assembly
Front Wheel Inspection
Tire Warning
Removal of Tube and Tire
Front Wheel Mounting
Front Brake Master Cylinder Removal/Mounting
Air Bleeding the Brake Fluid Circuit
Master Cylinder Disassembly/Assembly
Inspection of Master Cylinder
Front Brake Caliper Removal/Mounting
Caliper
Caliper Disassembly/Assembly
Caliper Inspection
Brake Parts to be Periodically Replaced
Rear Brake Caliper Removal, Mounting
Air Bleeding of the Brake Fluid Circuit
Brake Pedal Adjustment
Pad Replacement
Disassembly/Assembly of Rear Brake Caliper
Pad Inspection
Rear Master Cylinder Removal
Rear Master Cylinder Mounting
Disassembly of Master Cylinder
Master Cylinder Assembly/Inspection
Rear Wheel
Rear Wheel Assembly
Rear Wheel Inspection, Chain Cleaning and Oiling
Rear Wheel Mounting
Checking the Sprockets for Wear
Adjustment of Wheel Alignment
Swing Arm Removal/Mounting
Disassembly of Swing Arm Bearing
Use of Special Tool
Swing Arm Mounting
Rear Shock Absorber
Spring/Damper Adjustment
Combination of Spring Setting and Damper Setting
Suspension Math between Front and Rear
Removal of Rear Shock Absorber
Swing Arm Assembly, Inspection
Electrical System: Contents
Ignition System: Data, Coils
Schematic Diagram of Ignition System
Contact Breakers
Charging System
Method of Testing Rectifier, Regulator and Alternator
Inspection of Charging System Components
Rectifier, Alternator
Starter System Inspection
Regulator
Starter Clutch and Generator Rotor
Inspection of Components
Carbon Brushes
Armature Coil, Commutator
Starter Motor Specifications
Battery Description, Specification
Relay for Starter Motor
Initial Changing Method
Initial Electrolyte Filling, Charging Current/Duration
Battery Servicing
Electrolyte Adjustment
Battery Removal, Installation, Inspection
Recharging Operation Based on S.G. Reading
Electrical System Troubleshooting
Utility Switches and Devices
Ignition Switch, Front Brake Lamp Switch
Rear Brake Lamp Switch, Lighting and Dimmer Switches
Turn Signal
Left Handle Switch, Kill Switch and Starter Switch
Horn
Oil Pressure Switch
Inspection of Headlamp
Lamp Wattage Data
Inspection of Tail Brake Lamps and Turn Signal Lamps
Rear Combination Lamps
Fuel Gauge
Inspection of Speedometer and Tachometer
Inspection of Fuel Meter and Gauge
Electrical System: Wiring Diagram
Electrical System: Cable Routing
GS1000E: Contents
GS1000E Overview
GS1000E Service Specifications
Front Brake
Master Cylinder Inspection
Caliper Inspection, Reassembly
Air Bleeding from Brake Fluid Circuit
Wheel
Wheel Disassembly, Inspection and Checking
Self-Cancelling Turn Signal: Circuit Diagram, Operation
Self-Cancelling Turn Signal: Troubleshooting
GS1000E Wiring Diagram
GS1000S: Contents
GS1000S: Overview
Service Data
Periodic Maintenance
Choke Cable, Choke Knob Adjustment
Carburetor Removal
Fuel System
Carburetor Disassembly
Chassis
Handlebar Removal
Choke Cable Removal, Installation
Clutch Cable Installation
Cowling Removal
Combination Meter Removal
Combination Meter Installation
Tube and Tire Removal
Tube and Tire Mounting
Electrical
Combination Meter Assembly/Disassembly
Power Source Terminal
Checking the Thermistor
GS1000S Wire and Cable Routing
GS1000S Wiring Diagram
GS1000L: Contents
Overviewing GS1000L
GS1000L Specifications
Service Data: GS1000L
Chassis Bolts and Nuts: Maintenance
Fuel Line, Cock
Choke Cable/Knob Adjustment
Carburetor Disassembly (GS1000L)
Chassis Front Fork
Front Fork Removal, Mounting
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Table of Contents
Troubleshooting
Troubleshooting: contents
50
Engine and chassis troubleshooting
51
Electrical troubleshooting
54
Fuel system and carburetor troubleshooting
111
Electrical system troubleshooting
178
Self-cancelling turn signal: troubleshooting
201
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