Suzuki GS550 Manuals

Manuals and User Guides for Suzuki GS550. We have 1 Suzuki GS550 manual available for free PDF download: Service Manual

Suzuki GS550 Service Manual (353 pages)

Brand: Suzuki | Category: Motorcycle | Size: 54.32 MB

Foreword
3
View of Suzuki GS550E
4
Right Side
4
Left Side
4
View of Suzuki GS550ES
5
Group Index
7
General Information
9
Contents
9
Serial Number Location
10
Fuel and Oil Recommendations
10
Brake Fluid
10
Breaking-In
11
Cylinder Identification
11
Blowby Gas Recycling
11
Break-In Procedures
11
Special Features
11
TSCC (Twin Swirl Combustion Chamber)
12
Fully-Transistorized Ignition System with Electronic Advance
16
Description
16
Ignition System Diagram and Operation
16
Anti-Dive Front Fork
19
Anti-Dive Device
19
Anti-Dive System
20
The Anti-Dive System Is Inactive, While the Front Brake Is Inactive
21
When the Anti-Dive System Is Activated
21
What Happens When the Motorcycle Receives a Jolt from the Road, While the Anti-Dive Device Is Active?
22
Full-Floating Suspension System
23
Special Materials
24
Precautions and General Instructions
26
Use of Genuine Suzuki Parts
26
Specifications
27
Periodic Maintenance and Tune-Up Procedures
29
Periodic Maintenance Schedule
30
Maintenance and Tune-Up Procedures
31
Battery
31
Cylinder Head Nuts and Exhaust Pipe Bolts
32
Air Cleaner
33
Valve Clearance
34
Spark Plug
36
Fuel Line
37
Engine Oil and Oil Filter
37
Carburetor Idle RPM
38
Idling Adjustment
38
Throttle Cable Play
38
Clutch
39
Drive Chain
39
Checking
39
Adjusting
40
Cleaning and Lubricating
40
Brake Fluid Level
41
Brake Pads
41
Brake Pedal Height
42
Brake Light Switch
42
Air Bleeding from Brake Fluid Circuit
43
Front Brake Air Bleeding
43
Tire Tread Condition
44
Tire Pressure
45
Steering
45
Front Fork
46
Chassis Bolts and Nuts
47
Servicing Engine
51
Compression Check
52
Compression Test Procedure
52
Engine Components Removable with Engine in Place
53
Engine Left Side
53
Engine Center
53
Engine Right Side
53
Engine Removal and Reinstallation
54
Engine Reinstallation
60
Engine Disassembly
64
Engine Components Inspection and Servicing
77
Cylinder Head Servicing
77
Cylinder Head Distortion
78
Valve Stem Runout
78
Valve Head Radial Runout
78
Valve Face Wear
78
Valve Guide-Valve Stem Clearance
79
Valve Stem Wear
79
Valve Guide Servicing
79
Valve Seat Width
81
Valve Seat Servicing
82
Valve Springs
84
Valve Spring Tension
85
Reassembly
85
Camshaft
86
Cam Wear
86
Cam Height
86
Camshaft Journal Wear
87
Camshaft Runout
88
Cam Sprocket Reassembly
88
Cam Chain Tensioner Disassembly
89
Inspection
89
Reassembling
90
Cam Chain 20-Pitch Length
91
Cam Chain Guide
92
Cylinder Distortion
92
Cylinder Bore
92
Piston Diameter
93
Piston-Cylinder Clearance
93
Piston Ring-Groove Clearance
93
Piston Ring Thickness
93
Piston Ring Free Eng Gap and Piston Ring End Gap
94
Oversize Piston Rings
94
Oversize Oil Rings
94
Oversize Side Rail
94
Piston Pin and Pin Bore
95
Connecting Rod Small End I.D.
95
Connecting Rod Big End Thrust Clearance
95
Connecting Rod-Crank Pin Bearing Selection
96
Bearing Selection Table
97
Crank Pin Bearing Oil Clearance
97
Connecting Rod I.D. Specification
97
Crank Pin O.D. Specification
98
Bearing Thickness
98
Bearing Assembly
98
Crankcase-Crankshaft Bearing Selection
99
Crank Journal Bearing Oil Clearance
100
Crankcase I.D. Specification
101
Crankshaft Journal O.D. Specification
101
Bearing Thickness Specification
101
Crankshaft Thrust Clearance
102
Right-Side Thrust Bearing Thickness
102
Thrust Bearing Selection Table
103
Crankshaft Runout
103
Clutch Drive Plates and Driven Plates
104
Clutch Spring Free Length
104
Clutch Bearings
105
Sleeve Hub Spring Washer
105
Starter Clutch Removal
105
Oil Pump
106
Transmission
107
Shift Fork-Groove Clearance
107
Shift Fork Groove Width
108
Shift Fork Thickness
108
Countershaft Disassembly
108
Driveshaft Disassembly
109
Countershaft and Driveshaft Reassembly
110
Shim Selection Table
110
Engine Reassembly
111
Fuel and Lubrication System
135
Fuel System
136
Fuel Cock
137
Carburetor Construction
138
I.D. No. Location
139
Diaphragm and Piston Operation
140
Slow System
141
Main System
142
Starter System
143
Float System
143
Needle Valve Inspection
147
Float Height Adjustment
148
Fuel Level Inspection
150
Balancing Carburetors
150
Lubrication System Chart
153
Engine Lubrication System
154
Oil Cooler
155
Oil Pressure
156
Oil Sump Filter
156
Emission Control and Regulations
157
Emission Regulations
158
Emission Control Carburetor Components
159
General Emission Information
160
Electrical System
163
Starter System Diagram
164
Starter Motor
164
Starter Motor Removal
165
Starter Motor Inspection
166
Carbon Brushes
166
Commutator
166
Armature Coil
166
Starter Motor Reassembly
167
Brush Holder
167
Housing Top
167
Securing Screws
167
Chain Tensioner
168
Starter Relay Inspection
168
Ignition System
169
Signal Generator
170
Ignitor
170
Ignition Coil
171
Charging System
172
Function of Regulator
172
Charging Output Check
174
AC Generator No-Load Performance
174
Regulator/Rectifier
175
Initial Charging
176
Filling Electrolyte
176
Charging Time
176
Servicing
176
Based on S.g.reading Recharging Operation
177
Service Life
178
Ignition Switch
179
Dimmer Switch
179
Horn Switch
179
Turn Signal Light Switch
179
Engine Kill Switch
180
Starter Interlock Switch
180
Front/Rear Brake Light Switch
180
Side Stand Check Light Switch
181
Gear Position Light Switch
181
Oil Pressure Switch
181
Wire Color
181
Combination Meter
182
Fuel Meter and Fuel Gauge
184
Chassis
185
Fairing
186
Removal
187
Front Wheel
189
Removal and Disassembly
189
Wheel Bearing
191
Tire
191
Axle Shaft
192
Wheel Bearings
192
Brake Disc
193
Caliper
194
Front Axle
194
Tire and Wheel
195
Tire Removal
195
Wheel
198
Valve
198
Valve Installation
199
Tire Mounting
199
Front Fork View
202
Damper Rod Ring
206
Oil Lock Piece
206
Fork Spring
206
Inner/Outer Tube
207
Modulator Plunger Assembly and Valve Assembly
207
Modulator Valve O-Rings
207
Chassis Reassembly
208
Oil Lock Piece and Washer
208
Damper Rod Bolt
208
Outer Tube Metal, Washer and Oil Seal
208
Modulator Valve
209
Fork Oil
209
Inner Tube
209
Frok Air
210
Steering Stem
211
Out Races
216
Bearing
216
Steering Stem Nut
216
Front Brake
219
Brake Pad Replacement
220
Caliper Removal and Disassembly
221
Cylinder
222
Piston
222
Dust Boot and Piston Seal
223
Disc
223
Master Cylinder Removal and Disassembly
225
Master Cylinder Inspection
226
Master Cylinder Reassembly
227
Rear Wheel
228
Rear Wheel and Mounting Drum Bearings
231
Cushion
232
Sprocket
232
Mounting Drum Bearing
234
Rear Sprocket
234
Rear Axle Shaft
234
Rear Brake
235
Master Cylinder Removal
240
Piston and Cup Set
242
Rear Brake Pedal
243
Rear Swing Arm
244
Swing Arm Bearings
247
Spacer and Dust Seal Cover
247
Swing Arm Pivot Shaft
247
Full Floating Suspension
248
Cushion Lever Rod Bearings
252
Rear Shock Absorber
253
Servicing Information
255
Troubleshooting
256
Engine
256
Electrical
259
Brakes
262
Wiring Diagram GS550E
263
Wiring Diagram GS550ES
264
Wire, Cable and Hose Routing
265
Wire Routing: GS550E
265
Wire Routing: GS550ES
266
GS550E and GS550ES
267
Cable Routing
269
Hose Routing
270
Oil Hose Routing
271
Brake Hose Routing
272
Special Tools
273
Tightening Torque
279
Tightening Torque Chart
281
Service Data
282
Valve+Guide
282
Camshaft+Cylinder Head
283
Cylinder+Piston+Piston Ring
284
Conrod+Crankshaft
285
Transmission+Drive Chain
286
Carburetor
287
Brake+Wheel
289
Suspension
290
Fuel+Oil
290
Wattage
291
Gs550L
293
View of Suzuki GS550L
294
Dimensions and Dry Mass
295
Capacities
296
Inner Tube and Outer Tube
320
Inner Tube Metal
321
Stopper Ring
322
Fork Air
323
Rear Wheel and Brake
328
Rear Sprocket Mounting Drum
331
Rear Brake Drum
332
Brake Shoe
332
Wheel and Mounting Drum Bearings
332
Brake Camshaft
334
Wiring Diagram
336
Wire, Cable and Hose Routing GS550L
337
Wire Routing GS550L
337
Cable Routing GS550L
340
Hose Routing GS550L
341
Oil Hose Routing GS550L
342
Brake Hose Routing GS550L
343
Diagram 1985 GS550E
345
Diagram 1985 GS550L
347

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Suzuki GS550 Service Manual (353 pages)

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