Suzuki GV1400 Cavalcade Service Manual

Table of contents :
GV1400 SERVICE MANUAL
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
ENGINE
SHAFT DRIVE
COOLING SYSTEM
FUEL AND LUBRICATION SYSTEM
EMISSION CONTROL INFORMATIONS
ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMATION
GV1400GCG ('86-MODEL)
GV1400GCH/GDH ('87-MODEL)
GV1400GCJ/GDJ/GCL/GDL ('88, '90-MODELS)

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1:1

SUZUKI

SERVICE MANUAL

99500-39053-03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN OCTOBER, '90@

(~)

FOREWORD The SUZUKI GV1400GD and GV1400GT have been developed as a new generation motorcycle to the G V-models. It is packed with highly advanced design concepts including a V4 engine, a liquid cooling system, a new highly efficient combustion system (TSCC), a fully transistorized ignition system and a shaft drive mechanism. Combined with precise control and easy handling the GV1400GD and GV1400GT provides excellent performance and outstanding riding comfort. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-ityourself mechanics, will also find this manual an extremely useful repair guide. This manual contains the most up-to-date information at the time of publication. The rights are reserved to update or make corrections to this manual at any time.

IMPORTANT All street-legal Suzuki motorcycles with engine displacement of 50cc or greater are subject to Environmental Protection Agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service the GV1400GD and GV1400GT in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed.

Further information concerning the EPA emission regulations and U.S. Suzuki's emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN.

SUZUKI MOTOR CORPORATION Overseas Service Department

©COPYRIGHT SUZUKI MOTOR CORPORATION 1990

V1400 G I K U Z SU V I E W OF

L E F T S ID

E

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE SHAFT DRIVE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM EMISSION CONTROL INFORMATION ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION GV1400GCG('86-MODEL) GV1400GCH/GDH('87-MODEL) GV1400GCJ/GDJ/GCUGDL('BB, '90-MODELS)

GENERAL INFORMATION

~----------------CONTENTS----------------~

SERIAL NUMBER LOCATION ................................................... 7_ 1 FUEL, OIL AND COOLANT RECOMMENDATION ...... ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 1 BREAKING-IN PROCEDURES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 2 CYLINDER IDENTIFICATION ................................................... 1- 2 SPECIAL MATERIALS · · · · .... · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · .. · · · · · · · · · · 1- 3 PRECAUTIONS AND GENERAL INSTRUCTIONS ············· .. ······1- 5 SPEC/FICA TIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1- 6

1·1 GENERAL INFORMATION

SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle ldenti· fication Number) CD is stamped on the steering head pipe. The engine serial number ® is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

rating is SAE 10W/40. If anSAE 10W/40 motor oil is not available, select an alternate according to the following chart.

SAE 40 30 20W/50 lOW/50

-

lOW/30 20W lOW Temp.

oc

-20 -10 0 10 20 30 40 OF -4 14 32 50 68 86 104

I

\ I I

GEAR OIL (SECONDARY AND FINAL DRIVE) Use SAE 90 hypoid gear oil which is rated GL-5 under API classification system. If you operate the motorcycle where ambient temperature is below 0°C (32° F), use SAE 80 hypoid gear oil.

BRAKE FLUID Specification and classification

FUEL, OIL AND COOLANT RECOMMENDATION FUEL Use only unleaded or low-lead type gasoline of at

R; M

method) or 89 least 85 - 95 pump octane ( octane or higher rated by the Research method.

WARNING: * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix differ· ent types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored for a long period.

ENGINE OIL SUZUKI recommends the use of SUZUKI PER· FORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the API (American Petroleum Institute) classification system. The viscosity

DOT3& DOT4

FRONT FORK OIL Use fork oil # 15.

GENERAL INFORMATION 1-2

BREAKING-IN PROCEDURES COOLANT Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distilled water only.

WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/COOLANT The coolant performs as corrosion and rust inhibitor as well as anti-freeze. Therefore, the coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard, but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. • Keep to these breaking-in engine speed limits: 800 km ( 500mi)

Below 3 500 r/min

Up to 1 600 km (1 000 mi)

Below 5 000 r/min

Over 1 600 km (1 000 mi)

Below 7 000 r/min

Initial

SUZUKI recommends the use of SUZUKI GOLDEN CRUISER 1 200 anti-freeze/coolant. If this is not avai fable, use an equivalent which is compatible with an aluminum radiator.

• Upon reaching an odometer reading of 1 600 km ( 1 000 mi) you can subject the motorcycle to full throttle operation. However, do not exceed 7 000 r/min at any time.

REQUIRED AMOUNT OF WATER/COOLANT Solution capacity (total): 3 600 ml (3.8 US qt) For coolant mixture information, refer to cooling system section, page 5-3.

CAUTION: Mixing of anti-freeze/coolant should not exceed 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze/coolant mixing ratio is below 50%, the rust inhibit· ing performance is greatly reduced. Be sure to mix the solution at 50%, even though the atmospheric temperature does not go down to freezing point. Every new unit contains Bar's leak.

CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No. 1, No. 2, No.3 and No.4 cylinder, as counted from left rear to right front (as viewed by the rider on the seat).

1-3 GENERAL INFORMATION

SPECIAL MATERIALS The material_s listed below are needed for maintenance work on the GV1400GD and GV1400GT, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. Part

Material

SUZUKI SUPER GREASE "A" 99000-25030

SUZUKI BOND No. 12078 99104-31140

~

Throttle grip Speedometer gearbox Gearshifting link pivot Rear brake link pivot Centerstand pivot Side stand pivot Shaft drive 0-ring

•

Final driven bevel gear coupling Starter motor oil seal

• • • • • • • • •

SUZUKI MOLY PASTE 99000-25140

~

• • • • • • •

• •

Valve stem Conrad big end bearing Countershaft Drive shaft Crankshaft journal bearing Cam shaft journal Starter motor armature end Clutch master cylinder push rod Mating surface of upper and lower crankcase Secondary gearcase bolt

Page 2-2 2·2 2-2 2-2 2-2 2-2 4-14 4-31 4-32 8-10

3-61 3-63 3-64 4-16

Cam chain guide bolt Idler shaft bearing retainer screw

3-37 3-64

Oil pump case screw Generator rotor bolt Secondary driven bevel housing bolt Final drive bevel gear nut Final drive gear bearing retainer screw Final driven gear adjusting lock nut

3-51 3-63 4-15

•

•

~

Wheel bearings Steering stem bearings and races Rear wheel 0-ring Passenger footboard pivot Levelling sensor Swingarm bearing Final gear spline

9-17 9-44 9-57 9-60 9-72 9-73 9-57

9-77

3-78 3-80

•

Page

3-34 3-44 3-53 3-54 3-59 3-73 8-10

Cylinder head cover gasket Mating surface of crankcase and clutch cover, generator cover • Oil pressure switch • Mating surface between inner and outer secondary case

•

• • • • • • •

Part

Mating surface between final • gearcase and bearing case between swingsurface Mating • arm and final gearcase

4-30 4-33

•

Water temperature gauge

5-16

•

Rear wheel driven joint bolt

9-57

3-80 4-14

THREAD LOCK SUPER "13338" 99000-32020

~

f!

THREAD LOCK SUPER "1303" 99000-32030

•

•• • • •

4-24 4-26 4-32

GENERAL INFORMATION 1-4

Part

Page

Generator stator set screw Generator lead wire guide screw Gearshift cam pawl stopper screw • Gearshift cam guide screw • Oil sump filter screw • Countershaft bearing retainer screw

3-51 3-51 3-57

Material • • •

THREAD LOCK "1342" 99000-32050

3-57 3-62 3-65

•

To prevent leakage of cooling solution from small hole.

5-3

•

Disc mounting bolt

9-19 9-57

•

Coolant

•

Carburetor front plate screws Front fork damper rod bolt

SUZUKI BAR's LEAK 99000-24240

THREAD LOCK "1360" 99000-32130

SUZUKI GOLDEN CRUISER 1200 99000-24120

•

THREAD LOCK CEMENT 99000·32040

6-24 9·39

Part • Idler shaft drive chain tensioner bolt • Water pump drive sprocket bolt • Cam chain tensioner bolt • Final gear bearing case bolt • Throttle valve screw • Starter motor housing screw

Page 3-67 3-68 3-71 4-31 6-20 8-11

1·5 GENERAL INFORMATION

PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when servicing, disassembling and reassembling motorcycles. o Do not run engine indoors with little or no ventilation. o Be sure to replace packings, gaskets, circlips, 0 rings and cotter pins with new ones.

CAUTION: Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. o Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller

diameter, and from inside to out-side diagonally, to the specified tightening torque. o Use special tools where specified. o Use genuine parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After the reassembly, check parts for tightness and operation. o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use

gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING ............ When personal safety of the rider is involved, disregard of the information could result in injury. CAUTION . . . . . . . . . . . . For the protection of the motorcycle, the instruction or rule must be strictly adhered to. NOTE ................ Advice calculated to facilitate the use of the motorcycle is given under this heading.

USE OF GENUINE SUZUKI PARTS To replace any part of the machine, use a genuine SUZUKI replacement part. Imitation parts or parts supplied from any other source than SUZUKI, if used to replace SUZUKI parts can reduce the machine's performance and, even worse, could induce costly mechanical troubles.

GENERAL INFORMATION 1-6

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length

2530 mm (99.6 in)

Steering angle

35° (right & left)

Overall width

935 mm (36.8 in)

Caster

61°

Overall height

1550 mm (61.0 in)

Trail

119 mm (4.7 in)

Wheelbase

1670 mm (65.7 in)

Turning radius

3.3 m (10.8 ft)

Ground clearance

130 mm (5.1 in)

Front brake

Disc brake, twin

Seat height

780 mm (30.8 in)

Rear brake

Disc brake

Dry mass

331 kg (730 lbs) ... GT 349 kg (768 lbs) ... GD

Front tire size

130/90-16 67 H

Rear tire size

150/90-15 74H

Front fork stroke

150 mm (5.9 in)

Rear wheel travel

106 mm (4.2 in)

ENGINE Type

Four-stroke, water-cooled, DOHC, 82-degree V-four

ELECTRICAL

Number of cylinders 4 Bore

81.0 mm (3.189 in)

Ignition type

Transistorized

Stroke

66.0 mm (2.598 in)

Ignition timing

Piston displacement

1360 cm 3 (83.0 cu. in)

Compression ratio

9.5: 1

B.T.D.C. below 1500 r/min and 35° B.T.D.C. above 3000 r/min

Carburetor

MIKUNI BDS 33 SS

Spark plug

N.D.: X22EPR-GL

Air cleaner

Polyester fiber element

Battery

12V 72 kC (20Ah)/10HR

Starter system

Electric

Generator

Lubrication system

Wet sump

Three-phase A.C. generator

Fuse

10/10/10/10/1 OA

Circuit breaker

30A

TRANSMISSION

r

Clutch

Wet multi-plate type

Transmission

5-speed constant mesh

Gearshift pattern

1-down, 4-up

Fuel tank

23 L (6.1 US gal)

Primary reduction

1.756 (72/41)

Engine oil

3.2 L (3.4 US qt)

Front fork oil

482 ml ( 16.3 US oz)

Secondary gear oil

330-350 ml (11.2- 11.8 US oz)

Final gear oil

330-350 ml (11.2- 11.8 US oz)

Coolant including reservoir tank

3600 ml (3.8 US qt)

reservoir tank

600 ml (0.6 US qt)

Secondary reduction 1.000 (19/19) Final reduction

2.666 (32/12)

Gear ratios, Low 2nd 3rd 4th Top

2.750 1.684 1.250 1.000 0.851

Drive system

Shaft drive

(33/12) (32/19) (25/20) (25/25) (23/27)

CAPACITIES

CHASSIS Front suspension

Telescopic, coil spring oil damped

Rear suspension

Swinging arm, pneumatic/ coil spring, oil damped ... GT Swinging arm, pneumatic/ coil spring, oil damped with Suzuki Auto Leveling system ... GD

These specifications are subject to change without notice.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

~----------------CONTENTS----------------~

PERIODIC MAINTENANCE SCHEDULE···································· 2- 1 PERIODIC MAINTENANCE CHART · ·· ·· ·· ·· ·· ········· ············ · 2- 1 LUBRICATION POINTS ........... ········································ 2- 2 MAINTENANCE AND TUNE-UP PROCEDURES · · · · · · · · · · · ·· ··· ·· · · · · · · 2- 3 BATTERY · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 3 AIR CLEANER ELEMENT·················································· 2- 4 SPARK PLUGS··································································2- 5 FUEL AND VAPOR HOSES················································2- 5 FUEL FILTER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 5 ENGINE OIL AND OIL FILTER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2- 6 CARBURETORS ······· ····· ·· ····· ··· ·· ·· · ·· · ·· · ·· ······ ····· ··· ·· ·· · ·· ····· ··· 2- 7 CRUISE CONTROL····························································2- 8 CLUTCH ···········································································2- 8 COOLING SYSTEM ··························································2- 9 SECONDARY AND FINAL GEAR OIL ································2-11 BRAKES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-12 AIR PUMP·········································································2-15 REAR SUSPENSION SYSTEM ···········································2-15 TIRES ··············································································2-16 STEERING ········································································2-17 FRONT FORK · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-17 CHASSIS BOLTS AND NUTS ··········································2-18

2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

PERIODIC MAINTENANCE SCHEDULE IMPORTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Following these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions, however, it is not necessary for ensuring emission level compliance. The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and to maintain proper emission levels. Mileages are expressed in terms of kilometers, miles and time for your convenience.

PERIODIC MAINTENANCE CHART Interval: This interval should be judged by odometer reading or month, whichever comes first.

1 000

6000

12 000

18 000

24 000

miles

600

4000

7 500

11 000

15 000

month

2

12

24

36

48

-

I

I

I

I

km

Battery (Specific gravity of electrolyte)

Clean every 6 000 km (4 000 miles) and replace every 12 000 km (7 500 miles)

Air cleaner element Spark plugs

-

c

c

R

c

Fuel line

I

I

I

I

I

-------------------------------------------------

Replace every 4 years

Fuel and vapor hoses (California model only) Fuel filter

-

-

-

-

R

Engine oil and oil filter

R

-

R

-

R

Carburetors

I

I

I

I

I

Cruise control (GO model only)

I

I

I

I

I

I

-

I

-

I

Clutch hose

Replace every 4 years Change every 2 years

Clutch fluid Radiator hose

I

-

Brake hose

-

I

Replace every 4 years Change every 2 years

Coolant Secondary and final gear oil

I

R

-

I

-

I

I

I

I

I

I

Replace every 4 years Change every 2 years

Brake fluid Brakes

I

I

I

I

I

Air pump element (GO model only)

-

-

-

c

-

Surge tank (GO model only) Rear suspension system (GO model only)

Drain water every 1 month

I

I

I

I

I

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2·2

Interval: This interval should be judged by odometer reading or month, whichever comes first.

km

1 000

6000

12 000

18 000

24 000

600

4000

7 500

11 000

15 000

miles month

Rear suspension system (GT model only)

2

12

24

36

48

-

-

I

-

I

Inspect the air pressure every 6 months

Tires

I

I

I

I

I

Steering stem

I

I

I

I

I

Front fork

-

-

I

-

I

Chassis bolts and nuts

T

T

T

T

T

NOTE: T= Tighten, I= Inspect, R =Replace, C =Clean

LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below.

~

oo ........

Steering stem bearing

00 Throttle cable

~

\

~Rear

brake link pivots

~ Speedometer gearbox

00 Choke cable Clutch lever holder

~ Side stand pivot 00 Speedometer cable

I

Oil

........ Grease

2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements.

BATTERY J

Inspect Every 6 000 km (4 000 miles)

• Remove the right console box lid and console box. (Refer to page 9-1) • Disconnect the battery level warning switch from the battery. CAUTION: Wipe the electrolyte off the switch and be careful not to spill the electrolyte from battery. • Remove the battery EB and 8 lead wires and take out the battery. • Check electrolyte for level and specific gravity. Add distilled water as necessary to keep the surface of the electrolyte above the MIN. level line, but not above the MAX. level line. • For checking specific gravity, use a hydrometer to determine the charged condition. 09900-28403

Hydrometer

An S.G. reading of 1.22 (at 20°C) or under means that the battery needs recharging. Remove the battery from the machine and charge it with a battery charger. CAUTION: * Never charge a battery while still in the machine as damage may result to the battery or regulator/rectifier. * Be careful not to bend, obstruct, or change the routing of the air vent tube from the battery. Make certain that the vent tube is attached to the battery vent fitting and that the opposite end is always open. WARNING: When installing the battery lead wires, fix the EB lead first and 8 lead last. • Make sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the figure.

/

-

~

r

w I --

·-···-·-

- ~~

--I

Standard specific gravity ~

v

1.28 at 20° C (68° F)

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2·4

AIR CLEANER ELEMENT Clean Every 6 000 km (4 000 miles), and Replace Every 12 000 km (7 500 miles) • • • •

Remove the audio cover (Refer to page 9-2). Remove the two wingnuts and air cleaner cover. Remove the air cleaner element. Carefully use an air hose to blow the dust from the cleaner element inside. CAUTION: Always use air pressure on the inside of the cleaner element. If air pressure is used on the outside, dirt will be forced into the pores of the cleaner element thus restricting air flow through the cleaner element.

• Reinstall the cleaned or new cleaner element in the reverse order of removal. • When installing the air cleaner element in the cleaner case, make sure that the element is correctly positioned, as shown in the photograph. CAUTION: If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to run the engine without the element or to use a ruptured element. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component!

2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

SPARK PLUGS Clean Every 6 000 km (4 000 miles) and Replace Every 18 000 km (11 000 miles) • Remove the right and left side covers and frame covers (Refer to page 9-3). The plug gap is adjusted to 0.6- 0.7 mm (0.0240.028 in). The gap is correctly adjusted using a thickness gauge. When carbon is deposited on the spark plug, remove the carbon with a tool with a pointed end. If electrodes are extremely worn or burnt, replace the plug. Also replace the plug if it has a broken insulator, damaged thread, etc.

NOTE: To check the spark plugs, first make sure that the fuel tank contains unleaded gasoline, and after a test ride if the plugs are either sooty with carbon or burnt white, replace them all together. NOTE: Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the screw portion of the plug hole and engine damage may result.

NIPPON DENSO X22EPR-G L listed in the table should be used as the standard plug. However, the heat range of the plug should be selected to meet the requirements of speed, actual load, fuel, etc. If the plugs need to be replaced, it is recommended that the standard plugs listed in the table be selected. Remove the plugs and inspect the insulators. Proper heat range would be indicated if all insulators were light brown in color. If they are blackened by carbon, they should be replaced by a hot type NIPPON DENSO X20EPR-G L and if baked white, by NIPPON DENSO X24EPR-GL. Plugs with high heat range number are used for high speed running. These plugs are designed to be sufficiently cooled to prevent overheating and are called cold type plugs.

FUEL AND VAPOR HOSES Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) Replace Every 4 years

FUEL FILTER

I

Replace Every 24 000 km (15 000 miles)

-

tT----cr=~_.!_+ Gap 0.6 -

0. 7 mm

~~ (0.024- 0.028 in)

NIPPON DEN SO

REMARKS

X20EPR-GL

If the standard plug is apt to get wet, replace with this plug. Hot type.

X22EPR-GL

Standard

X24EPR-GL

If the standard plug is apt to overheat, replace with this plug. Cold type.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6

• Remove the right frame cover (Refer to page 9-3). • Turn the fuel cock to "0 F F" position. • Remove the inlet and outlet fuel hose from the fuel fi Iter. • Remove the fuel filter, then install the new one. WARNING: Gasoline is very explosive. Extreme care must be taken.

ENGINE OIL AND OIL FILTER Replace at Initially 1 000 km (600 miles) and Every 12 000 km (7 500 miles) The oil should be changed while the engine is hot. Oil filter replacement at the above intervals should be done together with engine oil change. • Keep the motorcycle upright, supported on the center stand. • Place an oil pan below the engine and drain the oil by removing the drain plug CD and filler cap

®. • Remove the oil filter®. • Apply engine oil lightly to the gasket of the new filter before installation. • Install the new filter turning it by hand until you feel the filter gasket contacts the mounting surface. Then tighten 5/6 turn using the oil filter wrench. 09915-4 7320

Oil filter wrench

• Fit drain plug CD securely, and install fresh oil through the filler. The engine will hold about 3. 7 L (3.9 US qt) of oi I. Use API classification of SE or SF oil with SAE 10W/40 viscosity. • Start up the engine and allow it to run for several seconds at idling speed. • Check for oil leakage around the oil filter. • Turn off the engine and wait about one minute, then check the oil level through the inspection window@. If the level is below mark "F", supply oil to that level. NECESSARY AMOUNT OF ENGINE OIL Oil change

3.2 L (3.4 US qt)

Filter change

3. 7 L (3.9 US qt)

Overhaul engine

4.2 L (4.4 US qt)

2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

CARBURETORS IDLE RPM Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) NOTE: Make this adjustment when the engine is hot. • Start up the engine and set its speed at anywhere between 850 and 1 050r/min by turning throttle stop screw CD. Engine idle speed

950 ± 100 r/min

CAUTION: No adjustment except the procedure mentioned above is necessary because calibration is performed by carburetor manufacturer.

THROTTLE CABLE PLAY There should be 2- 3 mm (0.08- 0.12 in) play ® on the throttle cable. To adjust the throttle cable play. • Remove the audio cover. (Refer to page 9-3) • Push the throttle cable to check the amount of play. • Loosen the lock nuts ® and slide the adjuster @ upper or lower until the specified play is obtained. • Tighten the lock nuts and re-check cable play. CHOKE CABLE ADJUSTMENT • Loosen the lock nut @ and turn the adjuster @ to adjust the cable play. • Tighten the lock nut and re-check cable play. Choke cable play

@

0.5-1.0 mm (0.02 - 0.04 in)

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2·8

CRUISE CONTROL (GD model only) Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) • • • •

Remove the fairing. (Refer to page 9-4) Remove the radiator reservoir tank. Remove the actuator. Check and adjust the cable play by referring to page 6-45.

CLUTCH Inspect at Initially 1 000 km (600 miles) and Every 12 000 km (7 500 miles) Change fluid Every 2 years Replace hoses Every 4 years CLUTCH FLUID LEVEL • Support the motorcycle on the center stand, and place the handlebars straight. • Check the clutch fluid level in the reservoir. • If the level is found to be below the lower mark, replenish with BRAKE FLUID that meets the following specification. Specification and classification

DOT3 or DOT4

WARNING: The clutch system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone~based and petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for long periods.

2·9 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT The clutch fluid circuit may be purged of air in the following manner. • Fill up the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dirt. • Remove the secondary gearcase cover. • Attach a pipe to the bleeder valve and insert the free end of the pipe into a receptacle. • Squeeze and release the clutch lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the fluid runs into the receptacle; this will remove the tension of the clutch lever causing it to touch the handlebars grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles. • Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the upper end of the inspection window. Bleeder valve tightening torque

6-9 N-m (0.6 - 0.9 kg-m) (4.5 - 6.5 lb-ft)

CAUTION: Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

COOLING SYSTEM Inspect at Initially 1 000 km (600 miles) and Every 12 000 km (7 500 miles) Change coolant Every 2 years Replace hoses Every 4 years • Remove the side cover. (Refer to page 9-3) • Remove the right console box lid and console box. (Refer to page 9-3) • Remove the radiator mounting bolts and slide the radiator.

NOTE: Replenish the clutch fluid reservoir as necessary while bleeding the clutch system. Make sure that there is always some fluid visible in the reservoir.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10

• Remove the radiator cap

CD and drain plug

®.

WARNING: Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. WARNING: Coolant may be harmful if swallowed or if it comes in contact with skin or eyes. If coolant gets into the eyes or in contact with the skin, it should be flushed thoroughly with plenty of water. If swallowed, induce vomitting and call physician immediately! • Flush the radiator with fresh water if necessary. • Tighten the drain plug ®securely and install the specified coolant up to the radiator inlet hole. NOTE: For coolant information, refer to "COOLING SYSTEM". • Close the radiator cap securely. • Fill the reservoir tank to the "HIGH" level with coolant. • After warming up and cooling down the engine, check the coolant level of the reservoir tank and install the coolant to the "HIGH"@ level if the level is below "LOW" @. 3 600 ml (7 .61 US qt) including reservoir tank 600 ml (1.27 qt) reservoir tank • Add 2 packs of anti-leakage material (Bar's leaks) in the coolant. 99000-24240

Bar's leak

2·11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

SECONDARY AND FINAL GEAR OIL Replace at Initially 1 000 km (600 miles) Inspect Every 12 000 km (7 500 miles) To change the secondary and final gear oil, locate the motorcycle on level ground, place it on the center stand and carry out the following steps. Use SAE # 90 hypoid gear oil with GL-5 under API classification. SECONDARY GEAR 01 L • Remove the secondary gearcase cover CD. • Drain oil by removing the filler cap ® and drain plug @. • Refit the drain plug @, remove the oil level screw @and pour the specified oil in through the filler hole until it runs out from the oil level hole. • Refit the oil level screw @, filler cap ®and secondary cover CD. NOTE: The amount of oil to be replaced is 330 350 ml (11.2 -11.8 US oz).

FINAL GEAR 01 L • Drain oil by removing filler cap @and drain plug@. • Refit drain plug ®and pour the specified oil in through the filler hole until it runs out from the filler hole. • Refit filler cap @. NOTE: The amount of oil to be replaced is 330 350ml (11.2 -11.8 USoz).

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-12

BRAKES Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) Change fluid Every 2 years Replace hoses Every 4 years

BRAKE FLUID LEVEL • Support the motorcycle on the center stand, and place the handlebars straight. • Remove the right frame cover. • Check the brake fluid level in the reservoirs, both front and rear. • If the level is found to be lower than the lower mark, replenish with brake fluid that meets the following specification. )

Specification and classification

DOT 3 or DOT 4

WARNING: The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix differenttypes of fluid such as siliconebased and petroleum-based fluid for refilling the system, otherwise serious damage will be caused. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for long periods. WARNING: Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hoses for cracks and hose joint for leakage before riding. BRAKE PADS • Remove the right side saddle bag. (Refer to page 9-50) • Wearing condition of brake pads can be checked by observing the limit line CD marked on the pad. When the wear exceeds the limit line, replace the pads with new ones. (Refer to page 9-28)

2-13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

BLEEDING AIR FROM THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the caliper brake. The presence of air is indicated by "spongi· ness" of the brake lever and also by lack of braking force. Considering the danger to which such trap· ped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner. • Fill up the master cylinder reservoir to the "HIGH" level line (Rear brake) and to above the "LOWER" level line (Front brake). Replace the reservoir cap to prevent entry of dirt. • Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. Bleeder valve tightening torque

6-9 N·m (0.6 - 0.9 kg-m) (4.5- 6.5 lb·ft)

• Front brake: Bleed the air from the left caliper first, and then the right caliper. • Squeeze and release the brake lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles. NOTE:

Replenish the brake fluid reservoir as neces· sary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir. • Close the bleeder valve, and disconnect the pipe. Fill the reservoir to the "HIGH" level line (Rear brake) and above the "LOWER" level line (Front brake).

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-14

CAUTION: Handle the brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials etc. • Differences between front and rear are that the master cylinder is actuated by a pedal and bleed the air from the in board valve first. BRAKE PEDAL HEIGHT • Remove the right frame cover. • Loosen the lock nut CD, and rotate the stopper bolt ® to locate brake pedal15 mm (0.6 in) ® above the top face of the footrest. • At the same time, loosen the lock nuts@ and turn the push rod @ . • Adjust the angle of the pushrod and lever to the right angle (90°). • Tighten the lock nut CD to secure the stopper bolt®. • Tighten the lock nuts @securely. Brake pedal height

®

15 mm (0.6 in)

BRAKE LIGHT SWITCHES Adjust both brake light switches, front and rear, so that brake light will come on just before a pressure is felt when the brake lever is squeezed, or the brake pedal is depressed.

2·15 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

AIR PUMP (GO model only) Clean the air pump element Every 18 000 km (11 000 miles) Drain water from surge tank Every 1 month Air pump element • Remove the left side fairing (Refer to page 9-4). • Remove the air pump element. • Fill a washing pan of a proper size with cleaning solvent. Immerse the element in the cleaning solvent and wash it clean. • Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands. • After squeezing the cleaning solvent fully, install the element in position. NOTE: Do not twist or wring the element because it will tear or the individual cells of the ele· ment will be damaged. CAUTION: Inspect the element carefully for rips, etc. If any damage is noted, replace the element.

Surge tank • Drain the water from the surge tank by pulling the drain pin.

REAR SUSPENSION SYSTEM (GO model only) Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) Inspect the rear shock absorbers for oil leakage and make sure that the hoses are tightly secured and undamaged, are correctly routed.

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-16

REAR SUSPENSION SYSTEM (GT model only)

Clip

Inspect Every 12 000 km (7 500 miles) and Inspect the air pressure every 6 months

Upper mounting

Inspect the rear shock absorbers for oil leakage and the proper air pressure.

Solo riding Dual riding

Empty saddle bags and travel trunk

Fill saddle bags and travel trunk

c·s-

200-300 kPa

150-200 kPa

e·o-

3.0 kg/cm 2 ) 28-43 psi

kg/cm 2 )

2.0 21 -28 psi

300-350 kPa

e·o -

kg/cm 2 )

3.5 43-50 psi

Shock absorber

350-450 kPa (3.5- 4.5 kg/cm 2) 50-64 psi

TIRES Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a ,dangerous situation. It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specifications. FRONT

REAR

1.6 mm (0.06 in)

2.0 mm (0.08 in)

TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. CAUTION: The standard tire fitted on this motorcycle is 130/90-16 67H for front and 150/90-15 74H for rear. The use of a tire other than the standard may cause instability. It is highly recommended to use a SUZUKI Genuine Tire.

Cold inflation tire pressure is as follows.

FRONT Solo riding Dual riding Maximum load

REAR

kPa

kg/cm2

psi

kPa

kg/cm 2

psi

225 225

2.25 2.25

32 32

280 280

2.80 2.80

40 40

250

2.50

36

280

2.80

40

2-17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

STEERING Inspect at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) Taper roller type bearings are applied on the steering system for better handling. Steering should be adjusted properly for smooth turning of handlebars and safe running. Too stiff steering prevents smooth turning of handlebars, and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground. With wheel straight ahead, grasp lower fork tubes near the axle and pull forward. If play is found, perform steering bearing adjustment as described in page 9-45 of this manual.

FRONT FORK

I

Inspect Every 12 000 km (7 500 miles)

Inspect the front fork for oil leakage, scoring and scratches on the outer surface of the inner tube and replace the defective parts, in necessary. (Refer to page 9-35).

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-18

CHASSIS BOLTS AND NUTS Tighten at Initially 1 000 km (600 miles) and Every 6 000 km (4 000 miles) The nuts and bolts listed below are important safety parts. They must be retightened when necessary to the specified torque with a torque wrench. (Refer to page 2-19 for the location of the following nuts and bolts on the motorcycle.) Item

N-m

kg-m

lb-ft

CD ®

Steering stem head nut

30-40

3.0-4.0

21.5-29.0

Front fork upper clamp bolt

15-25

1.5-2.5

11.0- 18.0

®

Front fork lower clamp bolt

20-25

2.0-2.5

14.5- 18.0

cv

Front fork cap bolt

20-30

2.0-3.0

14.5-21.5

® ®

Front fork damper rod bolt

34-46

3.4-4.6

24.5-33.0

Front axle nut

36-52

3.6-5.2

26.0-37.5

(j)

Front axle clamp bolt

15-25

1.5-2.5

11.0- 18.0

® ® ®

Handlebars clamp bolt

20-30

2.0-3.0

14.5-21.5

Handlebar holder mounting nut

30-40

3.0-4.0

21.5-29.0

Clutch master cylinder mounting bolt

5-8

0.5-0.8

3.5-6.0

@

Front brake master cylinder mounting bolt

5-8

0.5-0.8

3.5-6.0

©

Caliper mounting bolt (Front & Rear)

25-40

2.5-4.0

18.0-29.0

@

Front caliper housing bolt

30-36

3.0-3.6

21.5-26.0

@

Brake and clutch hose union bolt

20-25

2.0-2.5

14.5- 18.0

@

Air bleeder valve

6-9

0.6-0.9

4.5-6.5

@

Disc bolt

15-25

1.5-2.5

11.0- 18.0

@

Swingarm bearing holder bolt

3.5-4.5

0.35-0.45

2.5-3.0

@

Rear shock absorber mounting bolt (Upper & Lower)

20-30

2.0-3.0

14.5-21.5

@

Rear axle clamp bolt

25-35

2.5-3.5

18.0-25.5

® ® ® ® ®

Rear brake master cylinder mounting bolt

15-25

1.5-2.5

11.0- 18.0

Rear torque link nut (Front & Rear)

20-30

2.0-3.0

14.5- 21.5

110-130

11.0- 13.0

79.5-94.0

Rear axle nut

85- 115

8.5- 11.5

61.5-83.0

Rear caliper housing bolt

28-32

2.8-3.2

20.0-22.5

Swingarm bearing holder bolt lock nut

2-19 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

ENGINE ~----------------CONTENTS----------------~

COMPRESSION CHECK

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CYLINDER PISTON

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STARTER PINION CLUTCH

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3-39 3-41 3-4 5

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3-1 ENGINE

COMPRESSION CHECK COMPRESSION TEST PROCEDURE The compression of a cylinder is good indicator of its internal condition. The decision to overhaul the cylinders is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.

COMPRESSION Standard

Limit

1 000 - 1 400 kPa (10- 14 kg/cm 2 ) (142- 200 psi)

800 kPa (8 kg/cm 2 ) (114 psi)

Difference in cylinders

200 kPa (2 kg/cm 2 (28 psi)

)

Low compression pressure can indicate any of the following conditions: * Excessively worn cylinder wall * Worn-down piston or piston rings * Piston rings stuck in the grooves * Poor seating of valves * Ruptured or otherwise defective cylinder head gasket * Damaged lash adjusters Overhaul the engine in the following cases: * Compression pressure in one of the cylinders is less than 800 kPa (8 kg/cm 2 , 114 psi). * Difference in compression pressure between any two cylinders is more than 200 kPa (2 kg/cm 2 , 28 psi). * All compression pressure are below 1 000 kPa (10 kg/cm 2 , 142 psi) (standard) even when they measure more than 800 kPa (8 kg/cm 2 , 114 psi).

NOTE: * Before testing the compression of the engine, make sure that the cylinder head bolts and nuts are tightened to specified torque values. * Warm up the engine before testing. • Remove the frame covers. (Refer to chassis section). • Remove all the spark plugs. • Fit the compression gauge CD in one of the plug holes, while taking care that the connection is tight. • Twist the throttle grip full open. • Crank the engine a few seconds with the starter, and record the maximum gauge reading as the compression of the cylinder. • Repeat this procedure with the other cylinders.

09915-6451 0

Compression gauge

09918-0241 0

Adapter

The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in this section for removal and reinstallation instructions.

"'Cm r-Z

)>C)

omZ

m

ENGINE CENTER

ENGINE LEFT SIDE See Secondary bevel gear case cover . . . . . . Gearshift lever . . . . . . . . . . . . . . . . . . . Secondary bevel gear case . . . . . . . . . . . Generator cover . . . . . . . . . . . . . . . . . . Starter pinion assembly . . . . . . . . . . . . Clutch cylinder ................... Generator rotor . . . . . . . . . . . . . . . . . . Gear position indicator switch body . . . Generator stator . . . . . . . . . . . . . . . . . . Signal generator . . . . . . . . . . . . . . . . . .

page 3- 7 3- 7 3-19 3-19 3-19 3-19 3-20 3-23 3-51 3-51

See Oil filter . . . . . . . . . . . . . . . . . . . . . . . . Radiator and cooling fan . . . . . . . . . . . Throttle cable and choke cable . . . . . . . Front exhaust pipe and muffler . . . . . . Carburetor . . . . . . . . . . . . . . . . . . . . . . Cylinder head breather cover ........ Thermostat . . . . . . . . . . . . . . . . . . . . . . Water temp. switch . . . . . . . . . . . . . . . . Fan relay switch . . . . . . . . . . . . . . . . . . Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . Starter motor . . . . . . . . . . . . . . . . . . . . Oil pump filter . . . . . . . . . . . . . . . . . . .

ENGINE RIGHT SIDE page 2- 6 3- 4 3- 5 3- 6 3- 6 3-13 3-13 3-13 3-13 3-20 3-20 3-21

See Clutch cover . . . . . . . . . . . . . . . . . . . . . Clutch pressure, drive and driven plates .................. . Oil pressure switch ............... . Oil pump drive gear .............. . Water pump drive chain ........... . Primary driven gear .............. . Water pump assembly ............. . Oil pump assembly ............... . Gearshift shaft .................. .

page 3-15 3-15 3-15 3-16 3-16 3-17 3-17 3-18 3-18

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C')

w

,:.,

3-3 ENGINE

ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine, remove the following parts from the chassis and drain engine oil and cooling solution etc. (Refer to the chassis section.)

* * * * * *

* * * * * * * * * * * * *

Seat Right and left frame covers Handlebar cover Battery and fuel tank cover Lower fairing Ornament, window screen cover and headlight grill Window screen Headlight aiming knob and speaker cover Rear view mirrors, fairing and speakers Screen bracket Audio box Ventilator cases Battery holder and coolant reservoir tank Air compressor unit Cruise control unit and monitor unit Headlight assembly Meter assembly Auto cruise actuator Electrical parts mounting brackets

The procedure of engine removal is sequentially explained in the following steps, and engine installation is effected by reversing the removal procedure. • Place an oil pan under the engine and remove the oil drain plug CD and filler plug to drain out engine oil. • Remove the engine guard. • Remove the radiator cap and drain plug ®,and drain cooling solution completely. • Remove air cleaner case cover and air cleaner. • Loosen the air inlet pipe clamp screws and remove the cleaner lower case. NOTE: When reinstalling the air inlet pipe clamps, refer to page 3-11 for securing clamps properly.

ENGINE 3·4

• Disconnect the electric fan lead wire CD. • Loosen the clamps and disconnect the following hoses. ®Cylinder head to radiator hose @ Radiator to reservoir hose • Remove the reservoir tank. @Breather hose @Reservoir tank to reservoir tank hose ®Reservoir tank to reservoir tank hose • Disconnect the breather hose clamps (J). • Loosen the clamps and disconnect the radiator to water pump hose @.

• Remove the radiator mounting bolts ®and remove the radiator with electric fan.

• Remove the radiator reservoir

®.

3-5 ENGINE

• Remove the right frame side member

CD.

• Remove the breather hose ®from the cylinder head cover cap. • Loosen the throttle cable holder nuts and disconnect the throttle cable from the throttle lever. NOTE: After all cables, hoses and clamps have been removed, the carburetor assembly may be removed with the engine still in place. • Loosen the intake pipe clamp screws. • Remove the choke cable holder screws ® and disconnect the two choke cables, right and left, from the carburetors. NOTE: When tightening the clamp screws, refer to page 3-11 for securing the clamps in the proper position. • Disconnect the four spark plug caps from the spark plugs. • Disconnect the 4-way joint pipe @from the canister. NOTE: This 4-way joint is provided on the motor· cycle for CA specification.

• Disconnect the pump.

fuel

hose @ from the fuel

CAUTION: When disconnecting the fuel hose, fuel in the hose may drain out. Treat the gasoline with extreme care as gasoline is very explosive.

ENGINE 3-6

• Remove the rear brake pedal and right footrest. NOTE: When removing the brake pedal, apply the rear brake and remove the bolt CD. • Remove the exhaust pipe clamp bolts for Nos. 2 and 4 cylinders. NOTE: When reinstalling the front exhaust pipes, install the two exhaust pipe plates to the each clamps. Replace exhaust pipe gaskets with new ones. Gasket Clamp

Exhaust pipe plate Exhaust pipe

• Remove the exhaust pipe mounting bolts CD. • Loosen the exhaust pipe - pre-muffler clamp bolts ® and pre-muffler - muffler clamp bolts

@. • Loosen the muffler cover clamp bolts @and muffler cover screws@. • Remove the exhaust pipes.

• Remove the muffler mounting bolts remove the right and left mufflers.

® and

3-7 ENGINE

• Loosen the rear exhaust clamp bolts remove the pre-muffler.

CD and

• Remove the left footrest and gearshift lever. NOTE: When reinstalling the footrest, select the suitable position for riding. Install the both right and left footrests at the same position. After installing the footrest adjust the rear brake pedal position and gearshift lever position. • Remove the secondary gear case cover. NOTE: When reinstalling the secondary gear case cover, install the rubber insulator behind the cover properly.

--·-----------------------------

• Remove the union bolt ® and disconnect the clutch hose from the clutch cylinder. CAUTION: Completely wipe off any clutch fluid adhering to any part of motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc. • Loosen the clamp screw® and remove the boot from the secondary drive gear case. • Remove the left frame side member.

ENGINE 3·8

• Use a jack and wooden block, and hold the engine assembly. CAUTION: When holding the engine with jack, place a piece of wood on the jack, or the oil pan may be damaged. • Loosen the engine mounting bolts and bracket bolts.

• Remove the right frame down tube securing bolts.

• Remove all the engine mounting bolts and remove the down tube bolts.

• Remove the down tube and slowly lower the engine assembly.

3-9 ENGINE

• Dismount the engine by pulling slightly forward and to the right side.

• Remove the exhaust pipes for Nos. 1 and 3 cylinders. NOTE: When reinstalling the exhaust pipes, install the pre-muffler to the exhaust pipes and tighten the exhaust pipe clamp bolts. Always use new gaskets.

ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. • Before mounting the engine, install the exhaust pipes for the rear cylinders. • Place the engine in the proper position using a jack, and install the right down tube to the frame. • Engage the engine to the universal joint. • After inserting the engine mounting bolts, tighten the engine mounting bracket bolts and engine mounting bolts. Insert all the mounting bolts from left side. Install the brackets, bolts and nuts properly as shown in the following illustration. CAUTION: The engine mounting nuts are self-locking. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts and tighten them to the specified torque.

ENGINE 3·10

Tightening torque

kg·m

lb-ft

Item

N-m

® ® ©

70-88

7.0-8.8 50.0-64.0

60-65

6.0-6.5 43.5-47.0

40-60

4.0-6.0 29.0-43.5

@

25-28

2.5-2.8 18.0-20.0

®

27-43

2.7-4.3 19.5-31.0

• Route the fuel hose properly and connect the fuel hose to the fuel pump. CD Hose to the carburetor

®

3-11 ENGINE

• Install the carburetor to the air chamber and tighten the intake pipe clamp screws securely. • Firmly secure the carburetors with the clamps. If the carburetors are not firmly secured, gas leakage, incorrect air-fuel ratio and unsatisfactory engine operation may result.

CARBURETOR TO INTAKE PIPE CLAMPS

AIR CHAMBER TO CARBURETOR CLAMPS

I

R

3

4

3

4

FRONT . .

FRONT . .

Clamp stopper 2

2

L

NOTE: Align the clamp position with the index mark on the intake pipe for Nos. 1 and 2 cylinders.

• Install the exhaust pipes, pre-muffler and mufflers properly. When securing exhaust pipe clamp bolts, make sure that clamps and connectors CD are positioned properly. Tightening torque Exhaust pipe clamp bolt Muffler mounting bolt

20-25 N-m (2.0- 2.5 kg-m) (14.5 - 18.0 lb-ft) 27-43 N·m (2.7- 4.3 kg-m) (19.5- 31.0 lb-ft)

L

ENGINE 3·12

• Mount the cooling solution reservoir tank and radiator, and route and connect the hoses properly. (Refer to the section "Cooling system") Radiator mounting bolt tightening torque

7-9 N·m (0.7- 0.9 kg-m) (5.0 - 6.5 lb-ft)

• Replace the plug caps on the spark plugs so that their code markings correspond to the cylinder numbers in the order of 1, 2, 3 and 4 from the rear left. CD Rear left cylinder ® Front left cylinder ®Rear right cylinder @Front right cylinder

• Install 4.2 L (4.4 US qt.) (when overhauling engine) of engine oil SAE 10W/40 under API classification SE or SF into the engine. Several minutes after starting and stopping the engine, check that the oil level remains between the marks on the oil inspection window. • Install 330 - 350 ml (11.2 - 11.8 US oz) of hypoid # 90 gear oil into the secondary gearcase to the level screw®. • Fill the proper cooling solution. • After remounting the engine, route w1rmg harness, hoses and cables properly by referring to the sections, wire routing and cable routing, and adjust the following items to the specification. Page * Throttle cable ....................... 2- 7 * Choke cables ....................... 2- 7 * Idling adjustment .................... 2- 7 * Clutch air bleeding ................... 2- 9 * Filling cooling solution ................ 2-10 * Rear brake pedal and fluid level ......... 2-12 * Brake light switch .................... 2-14 * Balancing carburetor ................. 6-26

3-13 ENGINE

ENGINE DISASSEMBLY CAUTION:

Be sure to identify each part removed such as intake pipe, camshaft, piston, conrod etc. as to its location. Lay the parts out in groups so that each will be restored to the original location during assembly. ------------------------~

• Disconnect the water hose from the union.

•

Remove the water temp. gauge ground lead wire.

•

Remove cylinder head covers and their gaskets. NOTE:

Do not miss the gasket located with screw. •

Remove the cam drive chain tensioners by using 5-mm hexagon wrench. NOTE:

First remove the center cap of the chain tensioners.

ENGINE 3·14

• Remove the sixteen camshaft holders. • Remove the four camshafts. NOTE: Be sure to loosen camshaft holder bolts evenly by shifting the wrench diagonally.

• Remove the cam follower pivots adjusters ®.

CD and

lash·

• Pull out cam chain guide@.

• The cylinder head becomes free for removal when its two nuts @ are removed.

3-15 ENGINE

• Remove the clutch cover and gasket.

NOTE: Disconnect the oil pressure switch lead from the pressure switch before removing the clutch cover.

• By holding the idler shaft sprocket with the special tool, remove the clutch spring mounting bolts in a criss-cross manner. • Remove the clutch springs and pressure plate with clutch push piece.

09930-40113

IRotor and sprocket holder

• Remove the clutch push piece, thrust washer, bearing and push rod.

• After removal of several clutch driven and drive plates, flatten clutch sleeve hub nut lock washer using a chisel. • Firmly secure clutch sleeve hub to remove mounting nut with clutch sleeve hub holder

CD. 09920-53722

Clutch sleeve hub holder

ENGINE 3-16

• Remove washer, clutch hub, the remaining plates, wave washer and seat. • Remove the primary driven gear assembly, spacer, bearing and wahser.

• Hold the idler sprocket with the special tool and remove the water pump drive sprocket bolt by turning the bolt clockwise.

09930-40113

Rotor and sprocket holder

CAUTION:

This bolt has left-hand thread. Turning it counter-clockwise, may cause damage to the threads.

•

Remove water pump driven sprocket E-ring.

• Remove water pump drive and driven sprockets with drive chain.

3-17 ENGINE

• Remove the water pump drive chain guide and water pump assembly.

• Hold the idler shaft sprocket with the special tool and remove the sprocket bolt by turning it clockwise. 09930-40113

Rotor and sprocket holder

CAUTION: This bolt has a left-hand thread. When loosening it, turn it clockwise.

• Remove the idler shaft drive chain tensioner. • Remove the idler shaft drive and driven sprockets with the drive chain.

• Remove the primary drive gear

CD.

ENGINE 3·18

•

Remove the oil pump driven gear circlip using the snapring pliers.

09900-06107

Snapring pliers

• Remove the pin, washer and oil pump assembly.

• Remove the gearshift shaft

CD by pulling.

• Remove the countershaft bearing retainer by using impact driver.

09900-09003

Impact driver set

• Remove the crankcase securing nut ®and bolt

@.

3-19 ENGINE

• Remove the generator cover and its gasket.

• Remove the secondary gearcase and clutch cylin· der.

• Remove the starter pinion and starter drive gear.

• Using 36 mm off-set wrench to secure the rotor, loosen the rotor securing bolt by several turns. At this stage, do not remove the rotor securing bolt.

ENGINE 3-20

• Install the rotor remover CD into the boss of rotor and remove the rotor assembly by turning its center bolt ® while holding the remover with the 36 mm off-set wrench. • Remove the rotor remover from the rotor and remove the rotor securing bolt.

NOTE: Do not hit the rotor with a hammer.

09930-30720

Rotor remover

• Remove the crankcase securing bolts @.

• Disconnect the starter motor lead wire and remove the starter motor. @:Starter motor lead wire @ : Engine ground lead wire

• Remove the oi I pan.

3-21 ENGINE

• Remove the oil sump filter.

• Remove oil guide and 0-ring.

CAUTION: Do not miss the 0-ring located under the oil guide.

• Remove the crankcase securing bolts from the upper crankcase.

• Remove the crankcase securing nut G). • Extract the clutch pushrod ®.

ENGINE 3-22

•

Remove the crankcase securing bolts. When removing the crankcase securing bolts, loosen them in the descending order of numbers assigned to these bolts. CAUTION: Make sure that all bolts are removed before using the crankcase separating tool.

• Make sure that all bolts are removed without fail. Hammer lightly the lower crankcase side with a plastic hammer to separate the upper and lower crankcase halves and then lift the latter. NOTE: Separating the crankcases is made easier by the use of the cylinder disassembling tool. 09912-34510

ICylinder disassembling tool

NOTE: Beware of dropping crankshaft journal bearings. • Remove the countershaft and drive shaft. NOTE: Carefully set aside the two "C" rings and oil seal. • Remove the bearing cap nuts and tap the bolt end lightly with plastic hammer to remove bearing cap. • When removing the bearing cap and piston, mark them to identify the cylinder position. NOTE: Never try to remove or loosen the conrod big end stud, otherwise, it will displace the stud and will not fit the bearing cap properly. • Remove the crankshaft thrust bearings CD.

assembly

and two

3-23 ENGINE

•

Remove the piston and con rod from the cylinder head side.

• Remove gearshift cam guide and pawl screws 09900-09003

CD.

Impact driver set

• Remove the gear position indicator switch body. NOTE: Do not miss the 0-ring, switch contact and its spring.

• Unhook the gearshift cam stopper spring

®.

ENGINE 3-24

• Remove the two snap rings CD from the gearshift fork shaft and remove the two gearshift fork shafts.

09900-061 04

Snap ring pliers

• Remove snapring ® from the gearshift cam by using snapring pliers.

09900-06107

Snapring pliers

• Extract gearshift cam from the lower crankcase. • Using snapring pliers (closing type), remove the bearing stopper snapring @.

09900-061 05

Snapring pliers

• Remove the gearshift cam bearing with a suitable drift. • Remove the water hose union and 0-ring.

• Remove the cam drive chain tensioners.

3·25 ENGINE

• Remove the idle shaft bearing retainer by using a impact driver. 09900·09003

Impact driver set

• Disengage the two cam drive chains from the idle shaft sprockets. • Remove the idle shaft from the upper crank· case.

• Using the special tools and remove the idle shaft bearing. 09930·301 02

Rotor remover slide shaft

09913·6071 0

Bearing remover (27- 45 mm)

CAUTION: The removed bearing should be replaced with a new one.

ENGINE 3·26

ENGINE COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD DISASSEMBLY CAUTION: Be sure to identify each removed part as to its location, and lay the parts out in groups designated as "No. 1 cylinder", "No. 2 cylinder", "Exhaust", "Inlet", "R" and "L", so that each will be restored to the original location during assembly.

• Using special tools, compress valve springs and take off two cotter halves CD from valve stem.

09916·14510

Valve lifter

09916·1491 0

Valve lifter attachment

09916-8451 0

Tweezers

• Take out the spring retainer and spring.

• From the other side, pull out the valve. NOTE: Removal of valves completes ordinary disassembling work. If valve guides have to be removed for replacement after inspecting related parts, carry out the steps shown in valve guide servicing.

3-27 ENGINE

CYLINDER HEAD DISTORTION • Decarbonize the combustion chambers. • Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places indicated. If the largest reading at any position of the straightedge exceeds the Ii mit, replace the cylinder head. 09900-20803

Thickness gauge

Service Limit

0.1 mm (0.004 in)

==-----==-~

LASH ADJUSTER AND CAM FOLLOWER • Inspect each cam follower and lash adjuster for wear,dentand/or damage. If any defect is found, replace it with a new· one. • Compress and stroke the plunger with your finger by using air bleeding tool and remove the oi I completely ·from the lash adjuster body. Wash it with kerosene and inspect the lash adjuster whether it strokes smoothly. If any hitches or stickiness is noted, replace it with a new one. CAUTION: When removing the camshaft holder, camshaft and/or cam follower from the cylinder head, always use kerosene to bleed the air from the lash adjuster before reinstalling. Never use any solvent, fluid or oil when bleeding the lash adjuster, or it may cause engine damage.

ENGINE 3·28

• Using the special tool, bleed the air from the lash adjusters in the kerosene as shown in the figure.

0 Air bleeding tool

Air bleeding tool

09913-10710

Lash adjuster

• After filling the lash adjuster with fresh kerosene, compress the plunger and body with your finger and inspect that it strokes 0 - 0.2 mm. If it strokes more than specified, bleed the air again and check it. If the stroke is not within the specification, replace the lash adjuster with a new one.

0-0.2 mm (0- 0.008 in)

Lash-adjuster plunger stroke

VALVE FACE WEAR • Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face. • The thickness (])decreases as the wear of the face advances. Measure the thickness and, if the thickness is found to have been reduced to the limit, replace it. Service Limit

0.5 mm (0.02 in)

VALVE STEM RUNOUT • Support the valve with "V" blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. Service Limit

0.05 mm (0.002 in)

0-0.2 mm (0 - 0.008 in)

3-29 ENGINE

VALVE HEAD RADIAL RUNOUT • Place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than limit, replace the valve. Service Limit

0.03 mm (0.001 in)

VALVE GUIDE-VALVE STEM CLEARANCE Measure the clearance in two directions "X" and "Y", perpendicular to each other, by rigging up the dial gauge as shown. If the clearance measured exceeds the limit, specified below, then determine whether the valve or the guide should be replaced to reduce the clearance to the standard range: Service Limit

Valve Intake valves

0.35 mm (0.014 in)

Exhaust valves

0.35 mm (0.014 in)

VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicated replace the valve, if the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the clearance.

09900-20205

Micrometer (0- 25 mm)

Valve

Standard

Intake valves

4.965 - 4.980 mm (0.1955- 0.1961 in)

Exhaust valves

4.950 - 4.965 mm (0.1949- 0.1955 in)

VALVE GUIDE SERVICING • Using valve guide remover CD, drive the valve guide out toward intake or exhaust camshaft side.

09916-44310

Valve guide remover

ENGINE 3-30

NOTE: Discard the removed valve guide subassemblies. * Only oversized valve guide is available.

*

• Re-finish the valve guide holes in cylinder head with a 10.8 mm reamer. 09916-34580

Valve guide hole reamer

09916-34541

Reamer handle

• Fit a ring to each valve guide. Be sure to use new rings and valve guides. Use of rings and valve guides removed during disassembly is prohibited. Remember that both valve guides for intake and exhaust and both oil seals are identical in shape. 11115-24A71

Valve guide

09289-05008

Valve guide oil seal

• Oil the stem hole of each valve guide and drive the guide into the guide hole with the valve guide remover and attachment. 09916-4431 0

Valve guide remover

09916-44920

Valve guide installer attachment

CAUTION: Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head. • Install valve spring lower seats. • After fitting all valve guides, refinish their guiding bores with a 5.0 mm reamer. Be sure to clean and oil the guide after reaming. 09916-34570

Valve guide reamer

09916-34541

Reamer handle

3-31 ENGINE

• Oil each oil seal, and drive them into position with the valve guide remover. 09916-44310

Valve guide remover

NOTE: Do not use the oil seals removed in disassembly: use new seals.

VALVE SEAT WIDTH • Coat the valve seat with Prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head. • The ring-like dye impression left on the valve face must be continuous- without any breakof the dye ring, which is the visualized seat "width", must be within the following specification: Valve seat width Seat width

Standard 0.9-1.1 mm (0.035 - 0.043 in)

If either requirement is not met, correct the seat by servicing it as follows:

VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut 45° and the area above the contact surface (closest to the combustion chamber) is cut to 15° . Parts list of valve seat servicing tools Valve seat cutter head

Solid pilot

N-116 (15° x 45° cutter) for EX. 15° and 45° N-209 (15° x45° cutter) for IN. 15° and 45° N-100-5.0 N-140-5.0

Adapter

N-503-1

T-handle

N-503

Valve seat

~''"

ENGINE 3·32

NOTE: The valve seat contact area must be inspected after each cut. • Insert the solid pilot CD with a slight rotation. Seat the pilot snugly. Install the 45o cutter, attachment and T handle. • Using the 45° cutter, descale and cleanup the seat with one or two turns. • Inspect the seat by the previously described seat width measurement procedure. If the seat is pitted or burned, additional seat conditioning with the 45° cutter is required. NOTE: Cut only the minimum amount necessary.

Contact area too high and too wide on face of valve

If the contact area is too high on the valve, or if it is too wide, use a 15° cutter to lower and narrow the contact area.

If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. • After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations. DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation. • Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. NOTE: Always use extreme caution when handling gasoline.

Contact area too low and too narrow on face of valve

3-33 ENGINE

VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length CD will not be reduced to less than 3.3 mm (0.13 in). If this length becomes less than 3.3 mm (0.13 in), the valve must be replaced. After installing a valve whose stem end has been ground off as above, check to ensure that the face ®of the valve stem end is above the cotters @.

®®

VALVE SPRINGS • The force of the coil spring keeps the valve seat tight. Weakened springs result in reduced engine power output, and often account for the chattering noise coming from the valve mechanism. • Check the spring for strength by measuring its free length and also the force required to compress it. If the limit indicated is exceeded by the free length reading or if the measured force does not fall within the range specified, replace with a SUZUKI spring.

Valve spring free length 9.4- 11.0 kg (20.7- 24.3 lbs)

Service Limit

34.5 mm (1.36 in)

.!} 31.5 mm (1.24 in)

Valve spring tension IN. and EX. spring

9.4- 11.0 kg at length 31.5 mm (20.7 - 24.3 lbs at length 1.24 in)

ENGINE 3-34

REASSEMBLY • Insert the valves, with their stems coated with high quality molybdenum disulfide lubricant (SUZUKI MOLY PASTE) all round and along the full stem length without any break. CAUTION: When inserting each valve, take care not to damage the lip of the stem seal.

99000-25140

SUZUKI Moly Paste

• Install the valve spring with the small pitch portion ® down. ® : Large-pitch portion. • Put on the spring retainer and, using the valve lifter, press down the spring, fit the two cotter halves to the stem end, and release the lifter to allow the cotter CD to wedge in between seat and stem. Be sure that the rounded lip ®of the cotter fits snugly into the groove ® in the stem end. CAUTION: Be sure to restore each spring, valve and spring retainer to their original positions.

CAMSHAFT

TDC

Four camshafts should be checked for the wear of cams and journals if the engine has been noted as giving abnormal noise or vibration or to lack power output. Any of these conditions may be caused by cam or camshafts journal worn down to the service limit.

BDC

3-35 ENGINE

• The camshaft can be distinguished by the punched-letters, "J", "K", "L" and "M", on the camshaft right end. "J" Front exhaust camshaft "K" Front intake camshaft "L" Rear intake camshaft "M" Rear exhaust camshaft

CAM WEAR • Worn-down cams are often the cause of mistiming valve operation resulting in reduced power output. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height ®, which is to be measured with a micrometer. Replace camshafts if found worn down to the limit. Cam height® IN.

32.36 mm (1.274 in)

EX.

31.77 mm (1.251 in)

Service Limit

CAMSHAFT JOURNAL WEAR • Determine whether or not each journal is worn down to the limit by measuring the running clearance with the camshaft installed in place. ·Use plastigauge to read the clearance at the widest portion, which is specified as follows: Camshaft journal oil clearance (IN & EX)

I

Service Limit

I

0.150 mm (0.0060 in)

NOTE: Install each holder to their original positions. • Tighten the camshaft holder bolts evenly and diagonally to the specified torque. Initial

Final

Camshaft journal holder bolt

15 N-m (1.5 kg-m) (11.0 lb-ft)

23-27 N-m (2.3- 2.7 kg-m) (16.5- 19.5 lb-ft)

Cylinder head bolt

35N-m (3.5 kg-m) (25.5 lb-ft)

46-51 N-m (4.6 - 5.1 kg-m) (33.5 - 37.0 lb-ft)

ENGINE 3-36

• Remove the camshaft holders, and read the width of compressed plastigauge with envelope scale. This measurement should be taken at the widest part.

• If the camshaft journal clearance measured exceeds the limit, measure the inside diameter of camshaft bearing holder and outside diameter of the camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater.

09900-20205

Micrometer (0- 25 mm) Standard

Journal holder I.D. (In & Ex)

22.012-22.025 mm (0.8666- 0.8671 in)

Camshaft journal O.D. (In&. Ex)

21.959 - 21.980 mm (0.8645- 0.8654 in)

CAMSHAFT RUNOUT • Measure the runout with a dial gauge. Replace the camshaft if the runout exceeds the limit. Camshaft runout (IN & EX) Service Limit

0.10 mm (0.004 in)

3-37 ENGINE

CAM CHAIN TENSIONER For driving the four camshafts three cam chain tensioners are used on the respective cam drive chains. Unlock the rachet mechanism, and move the push rod in place to see if it slides smoothly. If any stickiness is noted or rachet mechanism is faulty, replace the chain tensioner assembly with a new one.

CD Front cam chain tensioner ®Rear cam chain tensioner ®Idle shaft drive chain tensioner ®Ratchet

CAM CHAIN 20-PITCH LENGTH Pull the chain tight to remove any slack, then using vernier calipers, measure the 20-pitch length of cam chain. If it measures more than limit, replace the cam chain/idle shaft chain. Service Limit

161.0 mm (6.34 in)

CAM CHAIN GUIDE NOTE: When replacing head cover chain guides, apply SUZUKI Thread lock super "13338" to the securing bolts. 99000-32020

Thread lock super "13338"

123

19 20 21

ENGINE 3·38

CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the crankcase assembly. Cylinder distortion Service Limit

0.10 mm (0.004 in)

CYLINDER BORE Measure the cylinder bore diameter at six places. If any one of the measurements exceeds the limit, overhaul the cylinder and replace the piston with an oversize, or replace the crankcase assembly. Once the reboring is done on any one cylinder which measurements is beyond the limit, the remaining cylinders must be also rebored accordingly. Otherwise the imbalance might causes excess vibration.

Cylinder bore

l)

II Service Limit

81.085 mm (3.1923 in)

\-"

I[ L...:l

1-

-----·-

PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place shown in Fig. If the measurement is less than the limit, replace the piston. Piston oversize

0.5, 1.0 mm

Service Limit

80.880 mm (3.1842 in)

09900-20204

IMicrometer (75 -

100 mm)

14 mm (0.6 in)

I

I

3-39 ENGINE

PISTON-CYLINDER CLEARANCE As a result of the prescribed measurement, if the piston clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both crankcase assembly and piston. Service Limit

0.120 mm (0.0047 in)

PISTON RING-GROOVE CLEARANCE Using a thickness gauge, measure the side clearances of the 1st and 2nd rings. If any one of the clearances exceeds the limit, replace both piston and piston rings. 09900-20803

Thickness gauge

Piston ring-groove clearance Piston ring

Service Limit

1st

0.18 mm (0.007 in)

2nd

0.15 mm (0.006 in)

Piston ring groove width Piston ring

Standard

1st

1.01 - 1.03 mm (0.0398- 0.0406 in)

2nd

1.21 -1.23 mm (0.0476- 0.0484 in)

Oil

2.51 - 2.53 mm (0.0988 - 0.0996 in)

Piston ring thickness Piston ring

Standard

1st

0.970 - 0.990 mm (0.0382 - 0.0390 in)

2nd

1.170 - 1.190 mm (0.0461 - 0.0469 in)

PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring. Piston ring free end gap Piston ring

Service Limit

1st

R

8.4 mm (0.33 in)

2nd

R

9.4 mm (0.37 in)

ENGINE 3-40

Piston ring end gap Piston ring

Service Limit

1st & 2nd

0.70 mm (0.028 in)

09900-20803

Thickness gauge

• Oversize piston rings The following two types of oversize piston rings are used. They bear the following identification numbers. SIZE

1st

2nd

0.5 mm O.S.

50

50

1.0 mm O.S.

100

100

0.5mm O.S.

• Oversize oil rings The following two types of oversize oil rings are available as optional parts. They bear the following identification marks. SIZE

1.0 mm O.S.

COLOR CODE

STD

NIL

0.5 mm O.S.

Painted Red

1.0 mm O.S.

Painted Yellow Oil ring spacer

• Oversize side rail Just measure outside diameter to identify its size. Paint code

PISTON PIN AND PIN BORE Using a small bore gauge, measure the piston pin bore ~nside diameter, and using a micrometer, measure the piston pin outside diameter. If the reading exceeds the following limit, replace both piston and piston pin. Piston pin bore I.D. Service Limit

20.030 mm (0.7886 in)

3-41 ENGINE

Using a micrometer, measure the piston pin outside diameter at three positions. Piston pin O.D. Service Limit

19.980 mm (0.7866 in)

09900-20205

Micrometer (0 - 25 mm)

CONNECTING ROD SMALL END BORE I.D. Using a small bore gauge, measure the connecting rod small end inside diameter. Connecting rod small end bore 1.0. Service Limit

I

20.040 mm (0.7890 in)

• If the connecting rod small end bore inside diameter exceeds the above mentioned limit, replace connecting rod.

CONNECTING ROD BIG END SIDE CLEARANCE Check the connecting rod big end side clearance by using thickness gauge. If the clearance exceeds the limit, replace connecting rod or crankshaft. Service Limit

0.30 mm (0.012 in)

Standard Big end width

19.95-20.00 mm (0.785- 0.787 in)

Crank pin width

40.10-40.15 mm (1.579- 1.581 in)

ENGINE 3-42

CONNECTING ROD-CRANK PIN BEARING SELECTION • Loosen bearing cap nuts and tap the bolt end lightly with plastic hammer to remove bearing cap. CAUTION: Be sure to install the bearing cap to the original position when reassembling. • Remove rods and mark them to identify the cylinder position. • Inspect bearing surfaces for any sign of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. NOTE: Never try to remove or loosen the connecting rod big end stud, otherwise, it will displace the stud and will not fit the bearing cap properly. • Place plastigauge axially on the crank pin, avoiding the oil hole and at the TDC or BDC as shown. • Tighten the bearing cap with two-step torque values. • Apply engine oil lightly to the nuts before tightening the bearing cap nuts. NOTE: When fitting bearing cap to crank pin, be sure to discriminate between its two ends, I.D. code side and the other. I. D. code always faces exhaust valve side.

Initial tightening torque

22-28 N·m (2.2- 2.8 kg-m) (16.0 - 20.0 lb-ft)

Final tightening torque

49-53 N·m (4.9 - 5.3 kg-m) (35.5 - 38.5 lb-ft)

NOTE: Never rotate crankshaft or connecting rod when a piece of Plastigauge is in the clearance.

3-43 ENGINE

• Remove the caps and measure the width of compressed plastigauge with envelope scale. This measurement should be taken at the widest part. Service Limit

0.090 mm (0.0035 in)

• If oil clearance exceeds the service limit, select the specified bearings from the following table. • Check the corresponding conrod 1.0. code number CD, "1" or "2". • Check the corresponding crank pin 0.0. code number 00, "1 ", "2" or "3". • The crank pin 0.0. code number is on the left crank web. Bearing selection table Crank pin 0.0. code Code

1

2

3

1

Green

Black

Brown

2

Black

Brown

Yellow

Con rod 1.0. code Oil clearance Standard

0.032 - 0.056 mm (0.0013- 0.0022 in)

Connecting rod 1.0. specification Code

1.0. Specification

1

43.000 - 43.008 mm ( 1.6929 - 1.6932 in)

2

43.008 - 43.016 mm (1.6932- 1.6935 in)

Crank pin 0.0. specification Code

0.0. Specification

1

39.992-40.000 mm (1.5745- 1.5748 in)

2

39.984 - 39.992 mm (1.5742- 1.5745 in)

3

39.976- 39.984 mm (1.5740- 1.5742 in)

CAUTION: Bearing should always be replaced as a set.

ENGINE 3-44

Bearing thickness Color (Part No.)

Thickness

Green (12164-05A01-0AO)

1.480- 1.484 mm (0.0583- 0.0584 in)

Black ( 12164-05A01-0BO)

1.484 - 1.488 mm (0.0584- 0.0586 in)

Brown ( 12164-0SAO 1-0CO)

1.488 - 1.492 mm (0.0586- 0.0587 in)

Yellow (12164-05A01-0DO)

1.492 - 1.496 mm (0.0587 - 0.0589 in)

BEARING ASSEMBLY • When fitting the bearing to the bearing cap and connecting rod, be sure to fix the stopper part CD first and press the other end.

CD

• Apply engine oil or SUZUKI Moly Paste to the crank pin and bearing surface. 99000-25140

SUZU Kl Moly Paste

• When mounting connecting rod on the crankshaft, make sure that 1.0. code® of the connecting rod faces as shown in the figure. • Apply engine oil lightly to the nuts and tighten the connecting rod fitting nuts to the specified torque.

Tightening torque

Initial

Final

22-28 N-m (2.2 - 2.8 kg-m) (16.0 - 20.0 lb-ft)

49-53 N-m (4.9 - 5.3 kg-m) (35.5 - 38.5 lb-ft)

FRONT

iJ

No. 4 cylinder

No.2

• Check the connecting rod for smooth turning.

No.3

No.1

3-45 ENGINE

CRANKCASE-CRANKSHAFT BEARING SELECTION • Inspect each bearing of upper and lower crankcases for any damage.

• Place plastigauge on each crankshaft journal in the usual manner. NOTE: Do not place the plastigauge on the oil hole, and do not rotate the shaft when plastigauge is in place.

• Mate the lower crankcase with the upper crankcase, and tighten the crankcase securing bolts with specified torque value in the indicated order. Tightening torque Initial

Final

12-mm bolt

40-50 N·m (4.0 - 5.0 kg-m) (29.0- 36.0 lb-ft)

60-70 N·m (6.0 - 7.0 kg-m) (43.5 - 50.5 lb-ft)

10-mm bolt

25-35 N·m (2.5- 3.5 kg-m) (18.0- 25.51b-ft)

45-55 N·m (4.5 - 5.5 kg-m) (32.5- 40.0 lb-ft)

• Remove the lower crankcase, and measure the width of compressed plastigauge in the usual manner. Crankshaft journal oil clearance

0.020 - 0.044 mm (0.0008- 0.0017 in)

Service Limit

0.080 mm (0.0031 in)

@ @

®

@

@ @

ENGINE 3-46

• If the width at the widest part exceeds the limit, replace the set of bearings with new ones by referring to the selection table. CAUTION: Bearing should always be replaced as a set. • Check the corresponding crankcase journal I.D. code letter CD "A" or "B" which are stamped on the rear of upper crankcase.

• Check the corresponding crankshaft journal O.D. code letter® "A", "B" or "C", printed on the left crank web. Bearing selection table Crank pin O.D. code

Crankcase I.D. code

Code

A

B

c

A

Green

Black

Brown

B

Black

Brown

Yellow

Crankcase 1.0. specification

Crankshaft journal 0.0. specification

Code

I.D. Specification

Code

O.D. Specification

A

44.000 - 44.008 mm (1.7323- 1.7326 in)

A

39.992 - 40.000 mm (1.5745- 1.5748 in)

B

44.008 - 44.016 mm (1.7326- 1.7329 in)

B

39.984- 39.992 mm (1.5742- 1.5745 in)

c

39.976 - 39.984 mm (1.5739- 1.5742 in)

Bearing thickness specification (Right and left journal bearings) Color (Part No.)

Specification

Green (12229-05AOO-OAO)

1.986 - 1.990 mm (0.0782 - 0.0783 in)

Black ( 12229-05AOO-O BO)

1.990 - 1.994 mm (0.0783- 0.0785 in)

Brown ( 12229-05AOO-OCO)

1.994 - 1.998 mm (0.0785- 0.0787 in)

Yellow ( 12229-05AOO-O DO)

1.998-2.002 mm (0.0787 - 0.0788 in)

Color code

3-47 ENGINE

NOTE: Center journal bearing is wider than R and L journal bearings, and their parts number are shown as follows. 12229-05A10-XXX

CRANKSHAFT THRUST CLEARANCE

Crankshaft

¢:J Front

Thrust clearance Standard

0.045-0.100 mm (0.0018- 0.0039 in)

If the thrust clearance exceeds the standard range, adjust the thrust clearance by the following procedure.

• Remove the right-side thrust bearing, and measure its thickness with a micrometer. If the thickness of the right-side thrust bearing is below standard, replace with a new bearing and once again perform the thrust clearance measurement listed above, checking to make sure it is within standard. Right-side thrust bearing thickness Standard

2.925 - 2.950 mm (0.1152-0.1161 in)

Left bearing Right bearing

• The right-side thrust bearing and left-side thrust bearing are inserted in the upper crankcase. Use a thickness gauge to measure the thrust clearance on the left side. NOTE: Push the crankshaft to the generator side, so that there is no clearance on the right-side thrust bearing.

Upper case

Push

ENGINE 3-48

• If the right-side thrust bearing is within the standard range, reinsert the right-side thrust bearing, and remove the left-side thrust bearing. • As shown in the illustration, use a thickness gauge to measure the clearance before inserting of the left-side thrust bearing, and select a leftside thrust bearing from the selection table.

Thrust bearing selection table Clearance before inserting of left-side thrust bearing

Color (Part No.)

Thrust bearing thickness

2.920-2.945 mm (0.1150- 0.1159 in)

Red ( 12228-05AOO-OAO)

2.850-2.875 mm (0.1122 -0.1132 in)

2.945 - 2.970 mm (0.1159- 0.1169 in)

Black ( 12228-05AOO-OBO)

2.875-2.900 mm (0.1132 - 0.1142 in)

2.970-2.995 mm (0.1169- 0.1179 in)

Blue ( 12228-05AOO-OCO)

2.900-2.925 mm (0.1142- 0.1152 in)

2.995 - 3.020 mm (0.1179- 0.1189 in)

Green ( 12228-05AOO-ODO)

2.925 - 2.950 mm (0.1152-0.1161 in)

3.020 - 3.045 mm (0.1189- 0.1199 in)

Yellow ( 12228-05AOO-OEO)

2.950- 2.975 mm (0.1161 -0.1171 in)

3.045 - 3.075 mm (0.1199-0.1211 in)

White (12228-05AOO-OFO)

2.975 - 3.000 mm (0.1171 -0.1181 in)

• After selecting a left-side thrust bearing, insert it and again perform the thrust clearance measurement to make sure it falls within the standard range. NOTE: Always install the Green bearing (1222805AOO-ODO) for right-side.

Standard thrust clearance

0.045 - 0.095 mm (0.0018 - 0.0037 in)

0.045-0.100 mm (0.0018 - 0.0039 in)

NOTE: Right-side thrust bearing has the same specification as the Green of left-side thrust bearing.

3-49 ENGINE

CRANKSHAFT RUNOUT Support the crankshaft with "V" blocks as shown, with the two end journal resting on the blocks. Set up the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout is greater than the limit.

Crankshaft runout

Service Limit

0.05 mm (0.002 in)

STARTER PINION • Inspect the pinion gear for smooth operation. • While holding idle gear, the pinion gear should turn freely, and not turn in the opposite direction. If the pinion gear turns both directions, or is locked on the shaft, replace the starter pinion assembly with a new one.

CLUTCH DRIVE PLATES AND DRIVEN PLATES Clutch plates in service remain in oily conditions as they were lubricated with oil. Because of this condition, both drive and driven plates are subject to little wearing action and therefore last much longer. Their life depends largely on the quality of oil used in the clutch and also on the way the clutch is operated.

Checking thickness

These plates are expendable: they are meant to be replaced when found worn down or distorted to the respective limit: use a caliper to check thickness and a thickness gauge and surface plate to check distortion. 09900-20101

Vernier calipers

09900-20803

Thickness gauge

Checking distortion

ENGINE 3-50

Unit: mm (in) Drive plate

Service Limit

Driven plate

No.1

No.2

Thickness

2.42 (0.095)

2.58 (0.1 02)

-

Distortion

-

-

0.1 (0.004)

Claw width

15.0 (0.59)

15.0 (0.59)

Checking claw width

CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with vernier calipers, and compare the elastic strength of each with the specified limit. Replace all the springs if any spring is not within the limit. Clutch spring free length Service Limit

34.0 mm (1.34 in)

CLUTCH BEARINGS Inspect clutch push piece bearing for any abnormality, particularly cracks, upon removal from the clutch, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing. NOTE: Thrust washer is located between the pressure plate and thrust bearing.

CLUTCH CYLINDER • Remove the clutch cylinder from the secondary drive gearcase.

3-51 ENGINE

• Remove the piston, oil seal and spring. • Inspect the clutch cylinder bore wall for nicks, scratches or other damage. • Inspect the each rubber part for damage and wear. • Inspect the piston surface for any scratches or other damage.

REASSEMBLY Reassemble the clutch cylinder in the reverse order of disassembly and by taking the following steps: CAUTION: Wash the clutch cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and piston to be inserted into the bore.

GENERATOR AND SIGNAL GENERATOR • Apply THREAD LOCK "1342" (99000-32050) to the stator set screws and its lead wire guide screws. NOTE: Wipe off oil or grease on screw completely, and then apply the screw lock. • Mount the lead wire clamp as shown in the photo.

OIL PUMP WARNING: Oil pump case securing screw is applied with SUZUKI THREAD LOCK SUPER "1303". If attempt is made to overhaul the oil pump assembly, screw may be damaged. As a replacement, only the oil pump unit is available.

ENGINE 3·52

TRANSMISSION GEARS AND RELATED PARTS Tightening torque ITEM

N·m

kg-m

lb-ft

CD ® ®

50-60 11 -13 50-70 7-9 8-12 20-25

5.0-6.0 1.1 - 1.3 5.0- 7.0 0.7-0.9 0.8-1.2 2.0-2.5

36.0-43.5 8.0-9.5 36.0-50.5 5.0-6.5 6.0-8.5 14.5- 18.0

@ @

®

GEAR-SHIFTING FORK CLEARANCE Using a thickness gauge, check the shifting fork clearance in the groove of its gear. This clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action. Each fork has its prongs fitted into the annular groove provided in its gear. In operation, there is sliding contact between fork and gear and, when a shifting action is initiated, the fork pushes the gear axially. Too much a clearance is, therefore, liable to cause the meshed gears to slip apart.

3-53 ENGINE

If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both. 09900-20803

Thickness gauge

Shift fork- groove clearance Service Limit No.1

for 4th driven gear

No.2

for 5th driven gear

No.3

for 3rd drive gears

0.50 mm (0.020 in)

Shift forks groove width Standard

5.50 - 5.60 mm (0.217- 0.220 in)

Shift fork thickness Standard

5.30 - 5.40 mm (0.209- 0.213 in)

COUNTERSHAFT ASSEMBLY • Before installing gears, apply lightly moly paste to the countershaft. 99000-25140

SUZUKI Moly paste

• Install the gears, bushings, washers and circlips in the order of the illustration on page 3-52. • When installing the 5th drive gear bushing, align the oil hole CD of the bushing with the hole CD of the countershaft.

ENGINE 3-54

DRIVES HAFT REASSEMBLY Reassemble the drive shaft gears in the reverse order of disassembly and also carry out the following steps. • Before installing gears, coat lightly moly paste to the drive shaft.

99000-25140

SUZUKI Moly paste

• When installing the 3rd driven gear bushings, align the oil hole CD of the drive shaft with the bushing oil hole®.

• When mounting the 3rd driven gear on the drive shaft and 5th drive gear on the countershaft, insert lock washer No. 2 CD into the drive shaft, and turn and fit it into the groove. Then, fit the lock washer No. 1 ® in the lock washer No. 2. • When mounting circlip, pay attention to the direction of the circlip. Fit it to the side where the thrust is as shown in the figure with the rounded side against the gear surface. NOTE:

Always use new circlip. Thrust-

CAUTION:

Never reuse a circlip after a circlip has been removed from a shaft. A used circlip should be discarded and a new circlip must be installed. When instaJiing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted.

tl

3-55 ENGINE

ENGINE REASSEMBLY This engine is reassembled by carrying out the steps of disassembly in the reverse order, but there are a number of steps which demand special descriptions or precautionary measures.

NOTE: Apply engine oil to each running and sliding part before reassembling.

• Clean the magnet crankcase.

CD and

install it to the lower

• Install a new 0-ring to the groove properly and install the union to the lower crankcase with two screws.

• Install the gearshift cam bearing and its circlip to the lower crankcase.

ENGINE 3-56

• Install the gearshift cam to the lower crankcase and install gearshift cam stopper CD on the positioning pin@.

• Refer to the following figure in regard to the correct positions and orientations of the forks when installing these parts.

CD: 00:

Gearshift Gearshift @: Gearshift @: Gearshift @: Circlip

fork for 5th driven gear. fork for 4th driven gear. fork for 3rd drive gear. cam stopper.

NOTE: Attach the cam stopper spring correct position.

®

in the

• The shape of each gear shifting pawl is different. Mount the one with the narrower width on the gear shifting cam side.

3-57 ENGINE

• Before driving in gearshift cam pawl screws CD and cam guide screws®, apply THREAD LOCK "1342" to their threads. 99000-32050

Thread lock "1342"

• Install a new circlip @to the groove of the gearshift cam and hold the gearshift cam in position. • Install the gear position indicator switch @. NOTE: When installing gear position indicator switch, be sure to locate spring, switch contact, and 0-ring.

• Mount the piston ring in the order of oil ring, 2nd ring and top ring. • Top ring and 2nd (middle) ring differ in the shape of ring face, and the face of top ring is chrome-plated whereas that of 2nd ring is not. The color of 2nd ring appears darker than that of the top one.

•

Top

2nd

• Top and 2nd (middle) rings have letter "R" marked on the side. Be sure to bring the marked side to top when fitting them to the piston.

;_

ENGINE 3·58

• The first member to go into the ring groove is spacer CD. After placing spacer, fit the two side rails®. Side designations, top and bottom, are not applied tQ the spacer and side rails: you can position each either way.

• Install the piston to the conrad so that the triangle mark CD on the piston top faces 1.0. code® of the conrad. • Apply engine oil lightly to the piston pin and install the piston pin to the piston with new circlip.

(j) Triangle mark Ex.¥

(V

• Position the gaps of the three rings as shown. Before inserting each piston into the cylinder, check that the gaps are so located.

-~~~......

I.D. code

EX. 2nd ring Lower side rail

IN.

Top ring Spacer

3-59 ENGINE

• Apply engine oil to the piston ring and piston surface. • Using the special tool, install the piston to the cylinder by tapping the piston top with wooden piece. 09916-77310

Piston ring compressor

• The piston is in correct position when its triangle (on the top) points exhaust valve side.

• Be sure to install the pistons in the cylinder from which they were taken out in disassembly, refer to the letter mark, "1" through "4" scribed on the piston.

FRONT

...

(:)

• REAR r'\/

~ v

• Check the oil jet CD for clogging. • Install the jet so that large diameter end faces inside. • Install the specified crankshaft journal bearings and conrad big end bearings. (See page 3-42 and 45) • Apply SUZU Kl Moly Paste to the bearings lightly. 99000-25140

SUZUKI Moly Paste

• When installing the crankshaft on the bearings, properly position the four conrods and do not scratch the crank pin journals with conrad's stud bolts. • Install the specified right and left thrust bearings ® facing the oil groove to the crank web. (See page 3-47)

" ""

~~ ~ /

~

ENGINE 3·60

• Install the conrad bearing caps to the original positions properly and tighten them to the specified torque. Tightening torque N·m

kg-m

lb-ft

Initial

22-28

2.2-2.8

16.0-20.0

Final

49-53

4.9-5.3

35.5-38.5

NOTE: Before installing the bearing cap nuts, lightly apply engine oil to the thread of studs or nuts. • Install the two C-rings

CD to the upper crankcase.

• Mount both countershaft and drive shaft on the upper crankcase. NOTE: * Be sure to install the bearing dowel pins ® in the respective positions. * Never fail to install the oil seal @ to the proper position and direction.

• Install a new 0-ring @at the water passage and install the positioning pins properly.

3-61 ENGINE

• Clean the mating surfaces of the crankcases before matching the upper and lower ones. • Apply SUZUKI BOND No. 1207B to the mating surface of the lower crankcase in the following procedure.

ISUZUKI Bond No. 1207B I

99104-31140

NOTE: Use of SUZUKI BOND No. 12078 is as follows: * Make surfaces free from moisture, oil, dust and other foreign materials. * Spread on surfaces thinly to form an even layer, and assemble the crankcases within a few minutes. * Take extreme care not to apply any bond No. 12078 to the bearing surfaces. * Apply to distorted surfaces as it forms a comparatively thick film. • Place the oil guide plate figure.

®

as shown in the top

• When securing the lower crankcase, tighten the 12-mm bolts and the 10-mm bolts in the ascending order of numbers assigned to these bolts, tightening each bolts a little at a time to equalize the pressure. 10 mm bolt

12 mm bolt

N-m

25-35

40-50

kg-m

2.5 - 3.5

4.0-5.0

lb-ft

18.0-25.5

29.0-36.0

N·m

45-55

60-70

kg-m

4.5 - 5.5

6.0-7.0

lb-ft

32.5-40.5

43.5-50.5

Tightening torque

Initial

Final

N·m

kg-m

lb-ft

20-28

2.0-2.8

14.5-20.0

12- 16

1.2- 1.6

8.5- 11.5

8 mm bolt

24

2.4

17.5

6 mm bolt

13

1.3

9.5

8 mm Allen bolt

6 mm Allen bolt

ENGINE 3-62

• Install the 0-ring

CD and

install the oil guide.

• Install the oil sump filter in the proper direction. • Apply thread lock "1342" to the three screws.

99000-32050

Thread Lock "1342"

• Seat guide and tighten oil pressure regulator to the specified torque.

Tightening torque

®

25-30 N·m (2.5- 3.0 kg-m) (18.0 - 21.5 lb-ft)

• Place a new gasket and tighten the oi I pan bolts to the specified torque.

Tightening torque

8-12 N·m (0.8 - 1.2 kg-m) (6.0 - 8.5 lb-ft)

• Mount the starter motor to the lower crankcase and route the starter motor lead wire and engine ground lead wire properly.

3-63 ENGINE

• Degrease the tapered portion of the rotor and also the crankshaft. Use non-flammable cleaning solvent to wipe off the oily or greasy matter to make these surfaces completely dry. • Align the key groove with the key CD and install the rotor to the crankshaft. • After mounting the rotor, secure the rotor by tightening the center bolt to the specified torque value. Apply Thread Lock Super "1303" to the bolt.

Tightening torque

150- 170 N·m (15.0- 17.0 kg·m) (1 08.5- 123.0 lb-ft)

99000-32030

Thread Lock Super "1303"

• Engage the starter idle gear to the starter pinion. NOTE:

When installing the starter idle gear, protrusion side ® facing in. • Install the starter pinion assembly to the crankcase.

• Coat SUZUKI Bond No. 1207B lightly to the portion around mating surface between upper and lower crankcases as shown. 99104-31140

ISUZUKI BOND No. 1207B

I

ENGINE 3-64

• Install the secondary gear case to the crankcase. Secondary gear case bolt tightening torque N-m

kg-m

lb-ft

6 mm bolt

8-12

0.8-1.2

6.0-8.5

8 mm bolt

20-26

2.0-2.6

14.5- 19.0

NOTE: Make sure that clutch push rod is installed properly. • Apply SUZUKI Bond No. 1207B to the securing bolt®. 99104-31140

/ SUZUKI Bond No. 1207B

I

• Install the two positioning pins and a new gasket. • Tighten the generator cover bolts with 8-mm box wrench.

• Hold the two camshaft drive chains and engage the two chains to the idler shaft sprockets properly.

• Tighten the idler shaft bearing retainer with two screws. • Apply thread lock super "1333B" to the screws. 99000-32020

Thread lock super "1333B"

3-65 ENGINE

• Tighten the countershaft bearing retainer with three screws. • Apply thread lock "1342" to these screws.

99000-32050

Thread lock "1342"

• Install the gearshift shaft, with the center of the gear on shaft side aligned with the center of gearshift cam driven gear.

• Install a new 0-ring to the oil pump and install the oil pump to the crankcase. Oil pump bolt tightening torque

7-9 N·m (0.7 - 0.9 kg-m) (5.0 - 6.5 lb-ft)

• Install a washer, drive pin CD and driven gear ® to the oil pump shaft. • Using a snapring pliers, fix the circlip into the groove of the shaft.

ENGINE 3-66

• Install the primary drive gear to the crankshaft. • Using the special tool, turn the crankshaft so that the No. 1 piston is positioned at T.D.C. 09930-40113

• Install the spacer the idler shaft.

I Rotor and sprocket holder

CD and

two positioning pins to

• Engage the idler shaft drive sprocket so that the punched mark® on the end of crankshaft is positioned between the two punched marks @ on the drive sprocket.

• Engage the idler shaft drive chain to the drive sprocket and count the 29 chain pins starting from the pin @ located between the two punched marks on the sprocket and ending at the 29th pin which should align with the engraved line @on the driven sprocket. • Install the driven sprocket to the idler shaft with two positioning pins. • Using the special tool, tighten the idler shaft driven sprocket bolt to the specified torque. NOTE: This bolt has left-hand thread and "L" mark on the crown.

3·67 ENGINE

09930-40113

Tightening torque

I

Rotor and sprocket holder

I

50-60 N-m (5.0- 6.0 kg-m) (36.0 - 43.5 lb-ft)

• Unlock the ratchet mechanism and push the push rod fully in the holder body.

• While holding the chain tensioner push rod in the above position and install the tensioner to the upper crankcase.

99000-32050

Thread lock "1342"

CAUTION:

Do not turn the crankshaft until camshafts are installed.

• Apply grease to a new 0-ring lightly and hold the 0-ring in place.

ENGINE 3-68

• Install the two positioning pins and install the water pump and chain guide to the lower crankcase. CAUTION: Make sure that 0-ring is positioned in place.

• Tighten the six bolts to the specified torque.

Tightening torque

7- 11 N-m (0.7- 1.1 kg-m) (5.0 - 8.0 lb-ft)

• Install the E-ring CD and drive pin ® to the water pump shaft. • Install the water pump drive sprocket, drive chain and driven sprocket as shown in the figure. NOTE: Engage the drive sprocket with the idler shaft drive sprocket.

• Install the E-ring @to the water pump shaft. • Apply thread lock "1342" to the drive sprocket bolt and tighten the bolt to the specified torque. Hold the idler shaft driven sprocket with the special tool.

Tightening torque

50-60 N-m (5.0- 6.0 kg-m) (36.0 - 43.5 lb-ft)

99000-32050

Thread lock "1342"

NOTE: This bolt has left-hand thread and "L"-mark on the crown.

• When installing the thrust washer to the countershaft, chamfered side of the washer faces inwards.

3-69 ENGINE

• Align the notch CD of the oil pump drive gear with the positioning pin @ and install the pump drive gear to the primary driven gear assembly.

• Apply engine oil to the primary driven gear bearing and spacer and assemble the primary driven gear to the countershaft.

• Install the thrust washer on the countershaft.

• After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the washer. Tightening torque for the nut is specified. Clutch sleeve hub nut tightening torque

50-70 N-m (5.0 - 7.0 kg·m) (36.0 - 50.5 lb-ft)

09920-53722

Clutch sleeve hub holder

ENGINE 3·70

• Install the clutch push rod into the countershaft so that the large diameter end touches clutch push piece. • Install the clutch push piece, bearing and washer in that order. • Apply engine oil to the bearing.

• Install the wave washer seat CD, wave washer ® and driven plate No. 2 @(thicker cork plate as shown in the figure.

• Insert clutch drive plate and driven plate one by one into sleeve hub in the prescribed order, cork plate No.2 first. Insert clutch push piece, bearing and thrust washer into pressure plate, making sure that the thrust washer is between the bearing and sleeve hub. Then fit pressure plate into sleeve hub.

• Tighten clutch spring bolts in the order shown in the photo. NOTE:

Tighten the clutch spring set bolts in the manner indicated, tightening them by degrees until they attain a uniform tightness.

Clutch spring bolt tightening torque

11-13N·m (1.1 - 1.3 kg·m) (8.0 - 9.5 lb·ft)

3-71 ENGINE

• Slide the gasket CD on the bolt and install the front cam chain tensioner to the front chain cavity. 99000-32050

Thread lock "1342"

Tightening torque

20-25 N·m (2.0- 2.5 kg-m) (14.5- 18.0 lb-ft)

• Install the rear chain tensioner to the rear chain cavity in the same manner as front.

• Install the four kinds of positioning pins and 0-ri ngs properly.

®:

Short positioning pin with 0-ring. @: Long positioning pin with 0-ring. ©: Smaller diam. pin with 0-ring.

@: Positioning pin. • Make sure to install the positioning pin @ .

•

Identify the two different intake pipes by cutting part ®and I. D. code. CD: for No.2 and No.3 cylinders (I.D.: FL RR) ®: for No.1 and No.4 cylinders (I.D.: FR RL) • Install a new 0-ring to the intake pipe groove as shown. CAUTION: Always use new 0-rings to prevent sucking air from the joint part. • Each intake pipe should position properly.

FRONT

.t>..®

u @ @---I:U

IAr--.,

©

ENGINE 3-72

• Install the ground lead wire for engine Temp. gauge and fan switch to the No. 2 cylinder's intake pipe. • Install a new gasket between the cylinder head and cylinder. NOTE: The head gaskets will only fit on the cylinders one way with all holes lining up.

• Install the longer chain guide CD to the front cylinder and shorter chain guide to the rear cylinder.

• After charging lash adjuster with kerosene, install the lash adjuster to the proper position. (See page 3-27) NOTE: Pour engine oil into the hole for lash adjuster.

• Check the filters CD located under the camshaft journal holder for clogging. • If the filter is clogged, remove the screw ® located on right or left side of the cylinder head and clear the filter with compressed air. • Put cam followers on the valve stem and lash adjuster.

3-73 ENGINE

• Identify each camshaft with the identification letters CD, "J", "K", "L" or "M", which is punched at the right end of the camshaft. J K L M

: : : :

Front exhaust camshaft Front intake Rear intake Rear exhaust

NOTE: Just before placing the camshaft on the cylinder head, apply high quality molybdenum disulfide lubricant to its journals, fully coating each journal ® with the paste taking care not to leave any dry spot. Apply engine oil to the journal bearings.

99000-25140

SUZU Kl Moly Paste

CAMSHAFT TIMING • Before installing camshaft, make sure that punched mark on the crankshaft indicates the bottom and engraved line CD on the idler shaft driven sprocket meets the index mark ® on the crankcase. NOTE: Both front and rear cylinder are timed with the No. 1 cylinder at T.D.C. FRONT CYLINDER • Hold the crankshaft and idler shaft steady and lightly pull up the cam drive chain to remove the slack between the idler shaft sprocket and front exhaust cam sprocket. • Exhaust camshaft bears a marked "J" on its right end. Turn over the J-camshaft so that the engraved line on the right end of the J-camshaft points flush with the gasketed surface of the cylinder head. Engage the cam drive chain with this sprocket. • Count the chain pins toward the intake camshaft, which is identified by letter "K", starting from the pin directly above the engraved line on the J-camshaft sprocket and ending at the 18th pin. • Engage the chain with intake sprocket, locating the 18th pin at and above the engraved line on the intake sprocket.

ENGINE 3-74

NOTE: The timing chain is now riding on all three sprockets. Be careful not to disturb the crankshaft and idler shaft until the rear cam timing is done and the eight holders and chain tensioner adjuster are secured. • Each camshaft holder is identified with a east-on letter. A matching east-on symbol appears on the head. Install each holder at it's matching letter. Install positioning pins to each camshaft holder. • Secure the eight camshaft journal holders evenly by tightening the cylinder head bolts and the camshaft journal holder bolts sequentially. Try to equalize the pressure by moving the wrench diagonally from one bolt to another and from one camshaft journal holder to another, to push shafts down evenly. • Position the proper bolts in length as shown in illustration on the next page. • Tighten the cylinder head nuts to the specified torque. REAR CYLINDER • Repeat the above procedure when reinstalling the rear cylinder head, camshafts and camshaft journal holders. NOTE: Damage to head or cam journal holder thrust surfaces may result if the cam journal holders are not drawn down evenly. • When adjusting the valve timing for rear cylinders, the same procedure is applied as those of the front cylinders. • First install the intake camshaft which is identi· fied by fetter "L" and engage it with the timing chain. • Count out 18 pins and engage the 18th pin with the index mark on the sprocket of the rear exhaust camshaft "M". • Tighten the cylinder head bolts, camshaft journal holder bolts and head nuts to the specified torque. ~

Smaiii.D. washer

® Longer bolt

w

..:...

en m 2

CAMSHAFT TIMING • Turn the crankshaft so that the No. 1 piston is positioned at T.D.C.

Ci)

2 m

Aligning mark

!REAR

I

jFRONTI

Aligning mark on the crankshaft Aligning marks on the drive sprocket

Tightening torque Initial

Final

Camshaft journal holder bolt

15 N-m (1.5 kg·m) ( 11.0 lb-ft)

23-27 N-m (2.3- 2.7 kg·m) (16.5- 19.51b-ft)

Cylinder head bolt

35N-m (3.5 kg-m) (25.5 lb·ft)

46-51 N-m (4.6- 5.1 kg·m) (33.5- 37.0 lb-ft)

--

8- 12 N·m (0.8 - 1.2 kg·m) (6.0- 8.51b·ft)

Cylinder head nut

----

-

-

{§§)

--- --···--

When reinstalling the bearing caps, align the marks assigned to the bearing caps and cylinder head.

~

\

(J)-(ID- \/ . ' E A R CYLINDER HEAD

.·~

I!

\

·.~

~

O))::::JmD

01\) ___::..

~

/~

.

\

@)-\ (J)---Q)-·~

m

z

C)

FRONT CYLINDER HEAD

z

m w

..:... en

3-17 ENGINE

• Remove the spring holder bolt CD and two springs from the chain tensioner. • Unlock the ratchet mechanism and fully push in the push rod.

• Install a new gasket and the chain tensioner adjuster to the front cylinder. • Tighten the bolts to the specified torque.

Tightening torque

8-12 N-m (0.8 - 1.2 kg-m) (6.0 - 8.5 lb-ft)

• Install the two springs ®and tighten the spring holder with washer to the specified torque.

Tightening torque

20-25 N-m (2.0 - 2.5 kg-m) (14.5- 18.0 lb-ft)

• Unlock the ratchet mechanism and push in the push rod fully and while holding the push rod in this condition tighten the end bolt @ with washer by turning it counter-clockwise. This end bolt hold the push rod in position. • Install a new gasket and the chain tensioner adjuster to the rear cylinder. • Tighten the bolts to the specified torque.

Tightening torque

8-12 N-m (0.8- 1.2 kg-m) (6.0 - 8.5 lb-ft)

• Tighten the end bolt@ by turning it clockwise, which release the push rod from the end bolt. Tightening torque

20-25 N·m (2.0- 2.5 kg-m) (14.5- 18.0 lb·ft)

CAUTION: After installing both the tensioners, check to be sure that both tensioners work properly by checking the slack of timing chains.

ENGINE 3-78

• Tighten the engine oil drain plug and oil filter, and pour about 100 ml (cc) of engine oil in each oil pocket in the head. • Tighten the oil filter with the oil filter wrench by referring to the page 2-6. CAUTION: Install the longer bolts to the positions and small I.D. washers to the positions ®.

®

• Turn the crankshaft and check that all the moving parts such as cam follower, camshaft, work properly. • When reinstalling the cylinder head cover, apply SUZU Kl Bond No. 1207B to the mating surface between oil seal and head cover, and four camshaft end seals. 99104-31140

I SUZUKI

Bond No. 1207B

• Apply engine oil to the cover bolt gaskets lightly and tighten the cover bolts to the specified torque.

Initial

10 N-m (1.0 kg-m) (7 .0 lb-ft)

Final

13-15N-m (1.3- 1.5 kg-m) (9.5 - 11.0 lb-ft)

Tightening torque

NOTE: Always install a new gasket to the cylinder head cover bolts.

3-79 ENGINE

• Install the seal ring CD to the thermostat. • Install the thermostat to the cylinder head cover. NOTE: Check to be sure that by-pass hole clogged.

® is not

• Install the radiator hose union with three bolts. NOTE: Install the clamp for high tension cord as shown.

• Install the 0-ring to the connector.

• Install the connector to the cylinder head cover. Tighten the ground lead ® along with the connector. • Tighten the water hose clamps properly.

ENGINE 3-80

• Coat SUZUKI Bond No. 1207B lightly to the portion around mating surface between crankcases as shown. 99104-31140

ISUZUKI Bond No. 1207B I

• Replace clutch cover gasket with a new one to prevent oil leakage. • Install the clutch cover.

• Apply SUZUKI Bond No. 1207B to the oil pressure switch and install it to the clutch cover. • Install the clutch cover and connect the oil pressure switch lead wire.

®Clamp

• Install the exhaust pipes for rear cylinders.

Tightening torque

20-25 N·m (2.0- 2.5 kg-m) (14.5- 18.0 lb-ft)

CAUTION:

When tightening the both exhaust pipes. temporarily install the pre-muffler to the exhaust pipes as a guide.

SHAFT DRIVE

.-----------CONTENTS----------, SHAFT DRIVE···········································································4- 1 SECONDARY BEVEL GEARS CONSTRUCTION ...................... .. 4_ 2 REMOVAL AND DISASSEMBLY ....................................... 4_ 3 INSPECTION······················································· .............. 4_ 7 REASSEMBLY ···· ··· ··· ············ ··· ······ · ··· ·· · ······· ··· ···· ··············4- 7 BEARING PRE-LOAD ADJUSTMENT ................................ 4-10 SECONDARY GEAR SHIM ADJUSTMENT····· ···················4-11 BACKLASH ·······························································4-11 TOOTH CONTACT·····················································4-13 FINAL ASSEMBLY AND REMOUNTING ........................... 4-14 REASSEMBLY INFORMATION .......................... ·· ............ "4-17 FINAL BEVEL GEARS CONSTRUCTION .... · ............................... 4-18 AIR AND GEAR OIL FLOW IN FINAL GEAR CASE BREATHER CIRCUIT························································· 4-19 REMOVAL AND DISASSEMBLY ...................................... 4-20 INSPECTION······················· ........... ································· ··4-24 REASSEMBLY · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · ·4-24 FINAL GEAR SHIM ADJUSTMENT .................................. 4-27 FINAL GEAR BEARING CASE SHIM CLEARANCE .. "4-2 7 BACKLASH ·······························································4-27 TOOTH CONTACT········· ............................................ 4-29 FINAL ASSEMBLY AND REMOUNTING ........................... 4-30 REASSEMBLY INFORMATION ........................................ "4-34

4-1 SHAFT DRIVE

SHAFT DRIVE

/-1 \

i

··--r..

\

SHAFT DRIVE 4-2

SECONDARY BEVEL GEARS CONSTRUCTION Tightening torque Item

® @ @

®

CD

N·m

kg-m

120- 150 12.0-15.0 87.0-108.5 20-26 2.0 - 2.6 14.5- 19.0 20-25

2.0-2.5 14.5- 18.0

120- 150 12.0-15.0 87.0-108.5

Oil seal ®Nut @ Bearing @ Bolt (4 pes) @ Driven bevel gear housing @ 0-ring (]) Shims (9 kinds) @ Spacer Bearing Plug @ Shims (5 kinds) @ Secondary bevel gear set

® ®

lb-ft

@ Breather hose

@

® ®

@ @) @

®

@

@

@

®

Gasket Oil seal Dowel pin Dowel pin Secondary bevel gear case Oil filler plug Gasket Oil drain plug Gasket Oil level plug Shims (5 kinds)

® ®

0-ring Gallery pin ® Bearing @ 0-ring @ Bearing case ® Spacer @ Shim (9 kinds) @ Bearing @ Nut @Plug

4-3 SHAFT DRIVE

REMOVAL AND DISASSEMBLY SECONDARY GEAR CASE • Remove the rear wheel (See page 9-53). • Remove the final gear case (See page 4-20). • Slide the propeller shaft backward. • Place an oil pan under the secondary gear case and remove the oil drain plug to drain out gear oil. • Remove the secondary gear case cover.

• Remove the gearshift lever and the footrest by removing the bolts.

• Remove the generator cover. NOTE: When removing the generator cover, remove the oil drain plug to drain out engine oil.

• Remove the clutch hydraulic line by removing the union bolt, clamp bolt and nut. NOTE: Completely wipe off any clutch fluid adhering to any part of motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc.

SHAFT DRIVE 4-4

• Loosen the boot clamp and slide the boot from the secondary gear case. • Remove the secondary gear case from the crankcase by removing the five bolts.

• Take off the spring and cam dog.

SECONDARY DRIVE BEVEL GEAR • Remove the bolts and take off the secondary drive bevel gear assembly.

• Take off the gallery pin

CD and shims ®.

CAUTION: The removed 0-ring should be replaced with new ones.

4-5 SHAFT DRIVE

• Remove the 0-ring and plug.

CAUTION: The removed 0-ring and plug should be replaced with a new one.

• Straighten the bent portion of the nut. • Remove the drive bevel gear nut by using the special tools and vise. 09924·5241 0

Secondary bevel gear socket (41 mm)

09924-52430

Secondary drive bevel gear holder

CAUTION: The removed nut should be replaced with a new one. • Remove the drive bevel gear from the housing.

CD Shims ®Spacer

• Remove the inner bearing by using the special tools. 09941-8451 0

Bearing inner race remover

09924-52430

Secondary drive bevel gear holder

• Remove the bearing outer races.

CAUTION: The removed bearings should be replaced with a new one.

SHAFT DRIVE 4·6

SECONDARY DRIVEN BEVEL GEAR • Remove the driven bevel gear housing mounting bolts CD and secondary case bolts ®.

• Take off the driven bevel gear assembly and shims®. CAUTION: The removed 0-ring should be replaced with a new one.

• Remove the oil seal @) and plug@. CAUTION: The removed oil seal and plug should be replaced with new ones.

• Remove the driven bevel gear nut by using the special tools. 09924-5241 0

Secondary bevel gear socket (41 mm)

09924-52420

Secondary driven bevel gear holder

CAUTION: * Driven bevel gear nut has left-hand thread. * The removed nut should be replaced with a new one. @Shims

(j) Spacer

4-7 SHAFT DRIVE

• Remove the bearing inner race by using the special tools.

09924-52420

Secondary driven bevel gear holder

09941-8451 0

Bearing inner race remover

• Remove the bearing outer race from the housing.

• Remove the clutch cylinder. • Remove the oil seal by using the special tool.

09913-50121

Oil seal remover

CAUTION: The removed oil seal should be replaced with a new one.

INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gears damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear.

REASSEMBLY Reassemble the secondary bevel gears in the reverse order of disassembly and removal, and also carry out the following steps. NOTE: Before reassembly, thoroughly clean all parts in cleaning solvent.

SHAFT DRIVE 4-8

SECONDARY DRIVEN BEVEL GEAR • Install the bearing new races into the secondary driven bevel gear housing by using the special tools. 09913-70122

Bearing installer

09913-8521 0

Bearing installer

• Install the new bearing onto the secondary driven bevel gear shaft by using the special tool. 09913-8451 0

Bearing installer

CAUTION: When replacing the secondary driven bevel gear, replace the secondary drive bevel gear also, as they must be replaced together.

• Install the spacer onto the secondary driven gear shaft first and then the shims. Use the removed spacer and shims. NOTE: Coat the bearings with hypoid gear oil before installing. • Tighten a new nut to the specified torque by using the special tools.

Tightening torque

120-150 N-m (12.0- 15.0 kg-m) (87 .0 - 108.5 lb-ft)

09924-5241 0

Secondary bevel gear socket (41 mm)

09924-52420

Secondary driven bevel gear holder

NOTE: This nut has left-hand thread.

**

"BEARING PRE-LOAD ADJUSTMENT" is necessary (See page 4-10).

4-9 SHAFT DRIVE

SECONDARY DRIVE BEVEL GEAR • Install the new bearing races into the secondary drive bevel gear housing by using the special tools. 09913-70122

Bearing installer

09913-75510

Bearing installer

09924-8451 0

Bearing installer set

• Install the new bearing onto the secondary drive bevel gear shaft by using the special tool. 09913-8451 0

Bearing installer

CAUTION: When replacing the secondary drive bevel gear, replace the secondary driven bevel gear also, as they must be replaced together.

• Install the spacer onto the secondary drive bevel gear shaft first and then the shims. Use the removed spacer and shims. NOTE: Coat the bearings with hypoid gear oil before installing.

• Tighten the nut to the specified torque by using the special tools and torque wrench.

Tightening torque

**

120- 150 N·m (12.0- 15.0 kg-m ( 87.0 - 108.5 lb-ft)

09924-5241 0

Secondary bevel gear socket (41 mm)

09924-52430

Secondary drive bevel gear holder

"BEARING PRE-LOAD ADJUSTMENT" is necessary (See page 4-10).

SHAFT DRIVE 4-10

BEARING PRE-LOAD ADJUSTMENT • After the drive gear nut and driven gear nut are tightened to specification, rotate the gear several turns in both directions to seat the bearings. • Measure the bearing pre-load by using the special tools. 09900-211 07

Torque wrench (0 - 15 kg-em)

09915-24550

Adapter socket (12.7 x 6.3 mm)

09924-5241 0

Secondary bevel gear socket (41 mm)

Pre-load (Drive and driven)

30-70 N·cm (3.0 - 7.0 kg-em) (2.6- 6.0 lb-in)

• If the bearing pre-load is not within specification, the shims between the bearings must be changed. Refer to the chart at right and make the appropriate adjustment, re-check the preload measurement procedure as necessary. NOTE: Whenever the pre-load is checked after a shim change, the gear must be rotated in both directions to seat the bearings after the nut is retorqued to specification. NOTE: When changing the shims, measure the thickness of the old shims. Using the thickness of the old shims as a guide, adjust the pre-load by referring to the chart at right.

Pre-load

Shim adjustment

Under 30 N·cm (30 kg-em, 2.6 lb-in)

Decrease shim thickness

30-70 N·cm (3.0- 7.0 kg-em) (2.6- 6.0 lb-in) Over 70 N·cm (7 .0 kg-em, 6.0 Ib-in)

Correct

Increase shim thickness

List of shims

®

(Refer to page 4-17)

Part No.

Shim thickness

09181-32001

1.60 mm

09181-32002

1.62 mm

09181-32003

1.64 mm

09181-32004

1.66 mm

09181-32005

1.68 mm

09181-32006

1.70 mm

09181-32007

1.80 mm

09181-32008

1.90 mm

09181-32009

2.00 mm

4-11 SHAFT DRIVE

• Bend the collar of the nut over into the notch in the secondary drive and driven bevel gear shaft after the bearing pre-load has been adjusted to the specification.

• Install a new oil seal to the secondary case by using the special tool.

09913·85210

Oil seal installer

SECONDARY GEAR SHIM ADJUSTMENT

BACKLASH • Install the secondary drive bevel gear shims CD removed during disassembly onto the secondary case. • Install the secondary drive and driven bevel gear assemblies to the secondary gear case. NOTE: Do not install the 0-rings ( ® , ® and @ ) at this point. O·rings are installed after backlash and tooth contact are correct. • Tighten the bolts to the specification.

@

8-12 N·m ( 0.8- 1.2 kg-m) ( 6.0 - 8.5 lb-ft)

®

20-26 N.m ( 2.0- 2.6 kg-m) (14.5- 19.0 lb-ft)

Tightening torque

SHAFT DRIVE 4-12

• Install the secondary driven bevel gear shims removed during disassembly between the secondary driven bevel gear housing and secondary case.

CAUTION: The secondary driven bevel gear assembly must be installed with "6." mark facing upward as shown in the Fig. • Tighten the bolts to the specification.

Tightening torque

20-26 N-m (2.0- 2.6 kg-m) ( 14.5 - 19.0 lb·ft)

• lnstaH the backlash measuring tool on the driven bevel gear, and set-up a dial gauge as shown in the Fig.

09924-3451 0

Secondary bevel gear backlash

Backlash measuring tool (27- 50 mm)

0.05 - 0.32 mm (0.002- 0.013 in)

• Adjust the dial gauge so that it touches the backlash measuring tool arm at the mark; hold the drive bevel gear securely and turn the driven bevel gear slightly in each direction, reading the total backlash on the dial gauge.

NOTE: If the backlash is not within specification, adjust the shim thickness as follows.

4-13 SHAFT DRIVE

• If the backlash is not within specification, the shims must be changed and the backlash should be re-checked until correct. Refer to the chart at right for appropriate changes.

Backlash

Shim adjustment

Under 0.05 mm (0.002 in)

Increase shim thickness

0.05 - 0.32 mm (0.002 - 0.013 in)

Correct

Over 0.32 mm (0.013 in)

Decrease shim thickness

List of shims @ (Refer to page 4-17) NOTE:

* When changing the shims, measure the thickness of old shims. Using the thickness of the old shims as a guide, adjust the backlash by referring to the chart at right. * Make sure that the shim thickness of the right and left halves are same.

TOOTH CONTACT • After bringing the backlash within specification by changing the secondary driven bevel gear shims, it will be necessary to check tooth contact. • Remove the drive bevel gear assembly from the secondary gear case. • Clean and degrease the secondary drive bevel gear teeth, and apply a coating of machinist's layout dye or paste to several teeth. • Reinstall the secondary drive bevel gear assembly. • Rotate the secondary driven bevel gear several turns in both directions. • Remove the secondary drive bevel gear from the secondary gear case, and observe the tooth contact pattern made in the dye or paste. • Compare the tooth contact pattern to the examples as shown in CD,® and @. • If tooth contact is found to be correct, go the Final Assembly sub-section, and complete. • If tooth contact is found to be incorrect, the shims of the secondary drive bevel gear case and secondary drive bevel gear housing must be changed, tooth contact should be re-checked unti I correct.

Part No.

Shim thickness

24945 - 24AOO - 030

0.30 mm

24945 - 24AOO - 035

0.35 mm

24945 - 24AOO - 040

0.40 mm

24945 - 24AOO - 050

0.50 mm

24945 - 24AOO - 060

0.60 mm

CD

INCORRECT (Contact at tooth top)

(V CORRECT

SHAFT DRIVE 4-14

CAUTION: After the tooth contact adjustment is made, the backlash must be re-checked, as it may change. Refer to the backlash checking subsection, and re-adjust until both backlash and tooth contact are correct.

®

INCORRECT (Contact at tooth root)

Shim adjustment

Tooth contact Contact at tooth top CD

Decrease thickness of shims @ or ©

Contact at tooth root®

Increase thickness of shims @ or © List of shims

List of shims @ (Refer to page 4-17)

© (Refer to page 4-17)

Part No.

Shim thickness

Part No.

Shim thickness

24934 - 24A02 - 030

0.30 mm

24945 - 24AOO - 030

0.30 mm

24934 - 24A02 - 035

0.35 mm

24945 - 24AOO - 035

0.35 mm

24934 - 24A02 - 040

0.40 mm

24945 - 24AOO - 040

0.40 mm

24934 - 24A02 - 050

0.50 mm

24945 - 24AOO - 050

0.50 mm

24934 - 24A02 - 060

0.60 mm

24945 - 24AOO - 060

0.60 mm

FINAL ASSEMBL V AND REMOUNTING • After both gear backlash and tooth contact are correct, remove the secondary drive bevel gear assembly and secondary driven bevel gear assembly from the secondary gear case. • Uniformly apply SUZUKI Bond No. 1207B to the secondary gear case. 99104-31140

SUZUKI Bond No. 1207B

• Clean off any machinist's dye or paste from the gear teeth, and lubricate the teeth with Hypoid gear oil. • Install new 0-rings@, @ to the gear case gallery pin and drive bevel gear housing. Coat the 0-rings with grease. 99000-25030

ISUZUKI Super grease "A" I

4-15 SHAFT DRIVE

• Install a new plug and 0-ring to the driven bevel gear.

• Install the secondary driven bevel gear assembly into the secondary gear case and tighten the bolts to the specification.

CD

8-12N·m (0.8 - 1.2 kg-m) (6.0 - 8.5 lb-ft)

®

20-26 N·m (2.0 - 2.6 kg-m) ( 14.5 - 19.0 lb-ft)

Tightening torque

• Apply THREAD LOCK SUPER "1303" to the bolts and tighten them to the specified torque. 99000-32030

Thread Lock Super "1303"

Tightening torque

20-26 N·m (2.0- 2.6 kg-m) (14.5- 19.0 lb-ft)

CAUTION: "t::," mark on the gear housing should face

upward. • Install a new plug @to the drive gear housing and a new oil seal @ to the driven gear housing. • Apply Lithium Base Molybdenum Grease (N LG I # 2) to the driven bevel gear splines.

SHAFT DRIVE 4-16

• Before installing the secondary gear case to the crankcase, fit the dowel pin and new gasket to the crankcase. • Tighten the secondary gear case bolts to the specified torque. CAUTION: * Use new gaskets for secondary gear case and generator cover to prevent oil leakage. * When installing the secondary gear case, apply SUZUKI BOND NO. 1207B to the threaded parts of bolt ® to prevent oil leakage.

Tightening torque

20-26 N-m (2.0- 2.6 kg-m) (14.5- 19.0 lb-ft)

99104-31140

\ SUZUKI Bond No. 1207B

• Tighten the clutch union bolt cation.

Tightening torque

CD to

I

the specifi-

20-25 N-m (2.0- 2.5 kg-m) ( 14.5 - 18.0 lb-ft)

NOTE: After remounting the secondary gear case, the following service procedures are necessary. * Fill the secondary gear case with Hypoid gear oil. Specified capacity: 330-350 ml (11.2 -11.8 US oz). * Fill the engine with engine oil (See page 2-6). * Bleed air after reinstalling the clutch hydraulic line (See page 2-9). * Apply BOND NO. 1207B to mating surface of swingarm and final gear case (See page 4-33). * Apply Lithium Base Molybdenum grease to the final driven bevel gear coupling (See page 4-32).

4-17 SHAFT DRIVE

REASSEMBLY INFORMATION

,-·-T

. ..\ J

List of shims

~~..- - - -..l ~ it=__ ii~·~·

© Shim

Part No.

0.30 mm 0.35 mm 0.40 mm 0.50mm 0.60mm

~;;?'";;,~..............

J

120-150 N·m Tightening (12.0-15.0 kg-m) torque (87.0-108.5 lb-ft)

30-70 N·cm (3.0-7.0 kg-em) (2.6-6.0 lb-in)

List of shims

..-·-·

~=~---·

f1/"" 7

~,

..

·-

•.

.

__ __j_J

7" ·- ".

JI7

..

, ___l

~~~kri ___. ·---~-~ £i:.q.r·-i ~ ~ C:::..r~ 1 I ,., 1 ~, 11r • · «:_-) '-; ,/

v------.-

~

thickness

I-0"-'9"-'1c.:::8c:._1·_,3-=c20::..:0~1-+'-'1.'76-=-0.:.:.m=m.;.;

~09::.c1~8:.!.1·..:::3=:20::..:0~2+'-11..'-'::66.::. 42 .:. :.mm:. :.:mm"-l

~

09181-32004 1.66 mm

~

09181-32003

~09::.c1~8:.!.1·..:::3=:20::..:0~5+'-1.'-'::6.:::_8.:..:.m:..:.:m"-l 1-0'!!9~1-"8'-'-1--"3-"'20~0,6'+-'-'1."-70"-"-m:.:.:m.;.; 09181-32007 1.80 mm

/

j-:0~9~1~8'-'-1-:!:!.3~20~0~8-f.!-'1.~90=--'-'-m:.:.:m.:;

. .l

"{""7; -

rT~

20-26 N·m (2 .6 _ 2 _6 kg-m) (14.5-19.0 lb-ft)

Sh•"m

Part No.

~,. ~

Lf~~

Thread lock super "1303"

# 2)

\ j

(3.0-7.0 kg-em) (2.6-6.0 lb-in)

ist of shims@

V {

L0~9::...:1..:::8.:..1·..:::3::;20:,:0::::9..J..::.:2.:.:.00::....:..:.m:;.:m.:..J

Lithium base molybdenum grease (N LG I

~

,

Pre-load

l?1[6J

f

-v

l

=

H...-----.--3-0---7-0_N_·_cm--,

1--

Ttghtentng torque

..~u~ ......,

'-··t>··· ":,-' Lt::)..t___._-1-t.

L . 1. . . .

®

Part No.

0.05-0.32 mm

5f~·lL . , . ::~·~ ~ ((2 i

I) - · - - · - / ( ) ..

Gear

backlash (0.002-0.013 in)

··-··~----)

•

r

""Pfnl"

·.

iL:=J· . JJJi.~~.:._-~:lt{ \ ...1:

.--~·· ,..1

T T

r Pre-load

I

I

I -. 1/ ~ r--T-1

thickness

24934-24A02-030 24934-24A02-035 24934-24A02-040 24934-24A02-050 24934-24A02-060

:

24945-24A00-030 24945-24A00-035 24945-24A00-040 24945-24A00-050

thickness 0.30 0.35 0.40 0.50

mm mm mm mm

24945-24A00-060 0.60 mm . . 120-150 N·m Ttghtenmg (12.0-15.0 kg-m) torque (87.0-108.51b-ft) left-hand thread

SHAFT DRIVE 4-18

FINAL BEVEL GEARS CONSTRUCTION Tightening torque Item

® (j) (j])

® @

CD

Oil seal Bolts (10 pes) @ Final gear bearing case @Bolt @ Lock washer ®Nut (j) Shims (4 kinds) ®Bearing ® Shims (8 kinds) @Screws (3 pes) (j]) Bearing retainer plate @) Needle bearing @Oil seal

®

@ @ @ @ @ @)

Final gear case Gasket Oil filler plug Gasket Oil drain plug Stud bolts (3 pes) ® Pilot bearing ® Final bevel gear set @ Shims (5 kinds) @ Washer ® Bearing ® Oil seal ® Final drive coupling

®

kg-m N-m 20-26 2.0-2.6 40-60 4.0-6.0 8-10 0.8- 1.0 90-130 9.0- 13.0 90 -110 9.0- 11.0

Bearing stopper

@ 0-ring

®l Stopper plate ®Nut ® Lock washer @ Washer @Nut @ Spring ® Propeller shaft coupling ® Circlip @ Oil seal @ Propeller shaft

lb-ft 14.5- 19.0 29.0-43.5 6.0-7.0 65.0-94.0 65.0-79.5

4-19 SHAFT DRIVE

AIR AND GEAR OIL FLOW IN FINAL GEAR CASE BREATHER CIRCUIT BREATHER CIRCUIT The GV1400 final gear case breather circuit (passage) consists of the final gear case and final gear bearing case. Air/oil mixed gas, flows through the following routes. Breather

Final gear case

AIR PASSAGE

When the air pressure in the final gear case becomes higher than atmospheric pressure, both air and oil flow in the following passages. • Air flows from hole ® to chamber@,© and passage through the gap (Q) to the atmosphere through the breather hole ® . OIL PASSAGE When the final gear case pressure rises abruptly or when the gear case oil level changes during cornering, the gear oil may sometime flow out into the air passage. • In this case, the gear oil which has traveled into hole ® goes into chamber @,where the oil is separated from the air. • The air flows through the chamber© and gap (Q), and goes out through the breather. • The gear oil, however, flows through the gaps (Q), ®and@, and returns to the gear case from gear oil return port C8) •

SHAFT DRIVE 4-20

REMOVAL AND DISASSEMBLY FINAL GEAR CASE • Remove the rear wheel (See page 9-53). • Place an oil pan under the final gear case and remove the drain plug to drain out gear oil. • Remove the final gear case from the swingarm by removing the nuts.

DRIVEN BEVEL GEAR • Remove the final gear bearing case bolts.

• Remove the final gear bearing case by using the two 5-mm screws.

• Remove the oil seal by using the special tools. 09924-7 451 0

Oil seal installer handle

09924-7 4520

Oil seal remover

4-21 SHAFT DRIVE

• Remove the bearing by using the special tool. 09924-74570

Bearing remover

• Take off the shims.

• Remove the oil seal. NOTE: The removed oil seal should be replaced with

a new one. • Remove the circlip by using the special tool. 09900-061 08

CD Circlip ®Coupling ®Spring

Snap ring pliers

SHAFT DRIVE 4-22

• Remove the bearing stopper by using the special tool and take off the final drive bevel gear assembly, washer and shims CD.

09924-6241 0

Final drive gear bearing holder wrench

CAUTION: The removed 0-ring ®should be replaced with a new one.

• Remove the oil seal.

CAUTION: The removed oil seal should be replaced with a new one.

• Remove the coupling nut by using the special tools.

09924-62420

22 mm long socket

09924-6451 0

Final drive gear coupling holder

CAUTION: The removed nut should be replaced with a new one.

4-23 SHAFT DRIVE

CD Nut ®Washer @Coupling CAUTION: The removed nut CD and bearing @ should be replaced with new ones.

• Remove the bearing retainer.

• Remove the needle roller bearing and oil seal from the final case by using the special tools.

09941-6451 0

Bearing and oil seal remover

09930-30102

Sliding shaft

CAUTION: The removed bearing and oil seal should be replaced with new ones.

• Remove the needle roller bearing of drive bevel gear side by using the special tools.

09923-73210

Bearing remover

09930-30102

Sliding shaft

CAUTION: The removed bearing should be replaced with a new one.

SHAFT DRIVE 4-24

INSPECTION Inspect the removed parts for the following abnormalities. * Drive and driven bevel gear damage or wear * Improper tooth contact * Abnormal noise of bearings * Bearing damage or wear

REASSEMBLY Reassemble the final bevel gears in the reverse order of disassembly and removal, and also carry out the following steps. NOTE: Before reassembly, thoroughly clean all parts in cleaning solvent.

DRIVE BEVEL GEAR • Install the bearing CD onto the final drive bevel gear shaft by using the special tool. 09941-74910

Bearing installer

CAUTION: When replacing the final drive bevel gear, replace the final driven bevel gear also, as they must be replaced together. • Install the new oil seal ®to the bearing stopper. • Apply THREAD LOCK SUPER "1303" to a new nut and tighten it to the specified torque by using the special tools. 99000-32030

Thread Lock Super "1303"

09924·62420

22 mm long socket

09924-6451 0

Final drive gear coupling holder

Tightening torque

90-110N·m (9.0 - 11.0 kg-m) (65.0 - 79.5 lb-ft)

• Bend the coller of the nut over into the notch in the drive bevel gear shaft.

4-25 SHAFT DRIVE

DRIVEN BEVEL GEAR Install the bearing to the driven bevel gear by using the special tool. 09924-74570

Bearing installer

CAUTION: When replacing the driven bevel gear, replace the drive bevel gear also, as they must be replaced together.

FINAL CASE • Install a new pilot bearing for the final drive bevel gear into the final gear case by using the special tools. 09924-7 451 0

Bearing and oil seal installer

09924-7 4550

Oil seal installer

• Install a new oil seal into the final gear case by using the special tools. 09924-7 4530

Bearing installer

09924-7 451 0

Handle

NOTE: The oil seal is correctly installed when the lip and spring is on the driven bevel gear side.

• Install the new needle roller bearing to the final gear case by using the special tools. 0991 3-8451 0

Bearing installer

09924-9451 0

Bearing installer

NOTE: The bearing case has a stamped mark on its one end, which must face inside.

SHAFT DRIVE 4-26

• Apply THREAD LOCK SUPER "1303" to the bearing retainer screws and tighten the specified torque.

99000-32030

Thread Lock Super "1303"

Tightening torque

8-10 N-m (0.8 - 1.0 kg-m) (6.0- 7.0 kg-ft)

• Install the removed washer, shims and drive bevel gear assembly to the final case. NOTE: Do not install the 0-ring at this point, 0-ring is installed after backlash and tooth contact are correct.

• Tighten the bearing stopper to the specification by using the special tool.

09924-6241 0

Tightening torque

Final drive gear bearing holder wrench

90-130 N·m (9.0- 13.0 kg-m) (65.0 - 94.0 lb-ft)

• Install the removed shims and driven bevel gear to the final case.

4-27 SHAFT DRIVE

• Install the removed shims to the final bearing case and tighten the bearing case bolts to the specification. Tightening torque

20-26 N-m (2.0- 2.6 kg-m) (14.5- 19.0 lb-ft)

NOTE: Do not install the oil seal and 0-ring at this point. Oil seal and 0-ring are installed after backlash and tooth contact are correct.

FINAL GEAR SHIM ADJUSTMENT FINAL GEAR BEARING CASE SHIM CLEARANCE Measure the clearance between the shims and bearing case. If not within specification, the shims must be changed. Final gear bearing case shim clearance List of shims

®

0.05-0.15 mm (0.002 - 0.006 in)

(Refer to page 4-34)

Part No.

Shim thickness

27327-45100

0.35 mm

27327-45102

0.40 mm

27327-45103

0.50 mm

27327-45104

0.60 mm

BACKLASH • Install the backlash measuring tool on the drive bevel gear coupling, and set-up a dial gauge as shown in the Fig.

09924-3451 0

Final gear backlash

Backlash measuring tool (27- 50 mm)

0.03 - 0.64 mm (0.001 - 0.025 in)

SHAFT DRIVE 4-28

• Adjust the dial gauge so that it touches the backlash meausring tool arm at the mark; hold the final driven bevel gear securely, and turn the final drive bevel gear coupling slightly in each direction, reading the total backlash on the dial gauge. NOTE: If the backlash is not within specification, adjust the shim thickness as follows:

• Remove the shims from the final gear bearing case and final gear case, and measure total thickness. • In order not to change the clearance between the final driven bevel gear and bearing, the total thickness of the shims installed after a change is made must equal the original total thickness of shims. • If backlash is too large: a) Install a thinner shim pack @ between the final driven bevel gear and final gear case. b) Increase thickness of shims ® between the final bearing case and bearing by an amount equal to decrease above. • If backlash is too small: a) Install a thicker shim pack @ between the final driven bevel gear and final gear case. b) Decrease thickness of shims ® between the final bearing case and bearing by an amount equal to increase above. EXAMPLE: @ Final gear to case shims; 1.35 mm + 1.05 mm = 2.40 mm ®Final gear to bearing shims; 0.50 mm + 0.40 mm = 0.90 mm Original total measurement= 3.30 mm Backlash too large: @Final gear to case shims; 1.25 mm + 1.10 mm = 2.35 mm ®Final gear to bearing shims; 0.60 mm + 0.35 mm = 0.95 mm Total thickness= 3.30 mm

List of shims @ (Refer to page 4-34) Part No.

Shim thickness

27 326-451 02

1.05 mm

27326-45103

1.10 mm

27326-45101

1.20 mm

27326-451 00

1.25 mm

27326-451 04

1.35 mm

27 326-451 00-140

1.40 mm

27 326-451 00-145

1.45 mm

27326-45100-150

1.50 mm

List of shims ® (Refer to page 4-34) Part No.

Shim thickness

27327-451 00

0.35 mm

27327-45102

0.40 mm

27327-451 03

0.50 mm

27327-45104

0.60 mm

Backlash too small: @Final gear to case shims; 1.35 mm + 1.10 mm = 2.45 mm ® Final gear to bearing shims; 0.50 mm + 0.35 mm = 0.85 mm Total thickness= 3.30 mm

4-29 SHAFT DRIVE

TOOTH CONTACT • After backlash adjustment is carried out, the tooth contact must be checked. • Remove the ten bolts from the final gear bearing case, and remove the case, using the screwdriver (see page 4-20). Do not misplace the shims. Remove the final driven bevel gear. • Clean and de-grease several teeth on the final driven bevel gear. Coat these teeth with machinist's dye or paste, preferably of a light color. • Re-install the final driven bevel gear with shims in place, positioning the coated teeth so that they are centered on the final drive bevel gear. • Re-install the final gear bearing case and bolts, and tighten to specification. Final gear bearing case bolt tightening torque

INCORRECT (Contact at tooth top)

20-26 N·m (2.0- 2.6 kg-m) (14.5- 19.0 lb-ft)

• Using a socket and handle on the final drive bevel gear coupling nut, rotate the final drive bevel gear several turns in each direction, while loading the final driven bevel gear. This will provide a contact pattern on the coated teeth of the driven bevel gear. • Remove the final gear bearing case and final driven bevel gear, and inspect the coated teeth of the driven bevel gear. The contact patch should be as shown at right. • If the tooth contact pattern is correct, as shown in ®,go to the Final Assembly sub-section. • If the tooth contact pattern is incorrect, as shown in CD, a thinner shim is needed between the final drive bearing washer and final gear case. • If the tooth contact pattern is incorrect, as shown in@, a thicker shim is needed between the final drive bearing washer and final gear case. • If the tooth contact pattern is incorrect for either reason, the appropriate shim must be installed, and the tooth contact pattern rechecked by repeating the tooth coating procedure above.

\ CORRECT

@

INCORRECT (Contact at tooth root)

SHAFT DRIVE 4-30

NOTE: If it is necessary to adjust the shim thickness between final drive bearing washer and final gear case, the final gear backlash may change, and should be re-checked according to the procedure outlined under the Backlash Measurement sub-section. Both adjustments may be needed until both backlash and tooth contact are correct.

FINAL ASSEMBL V AND REMOUNTING • After adjusting the backlash, tooth contact and clearance between the bearing case and the shim, remove the final gear bearing case and final drive bearing stopper from the final gear case. • Clean off any machinist's dye or paste from the gear teeth, and lubricate the teeth with Hypoid gear oil.

• Apply SUZUKI BOND NO. 12078 to the mating surface of final gear case and bearing case as shown in the illustration. 99104-31140

I SUZUKI Bond No. 12078 I

CAUTION: Do not apply SUZUKI BOND No. 1207B to the gaps®.

• Install a new oil seal by using the special tool. NOTE: The oil seal is correctly installed when the lip and spring is on the driven bevel gear side. 09924-7 451 0

Oil seal installer handle

09924-7 4520

Oil seal installer

List of shims

© (Refer to page 4-34)

Part No.

Shim thickness

27445-24A01-030

0.30 mm

27445-24A01-035

0.35 mm

27445-24A01-040

0.40 mm

27445-24A01-050

0.50 mm

27445-24A01-060

0.60 mm

4·31 SHAFT DRIVE

• Install new 0-ring to the final drive bevel gear bearing stopper. Coat the 0-ring with grease.

99000-25030

ISUZUKI Super grease "A" I

• Install the final drive bevel gear assembly into the final gear case and tighten the bearing stopper to the specified torque (See page 4-26).

• Install the gear case THREAD and tighten

final gear bearing case to the final and apply a small quantity of LOCK "1342" to the ten bolts them to the specified torque.

99000·32050

Thread Lock "1342"

Tightening torque

20-26 N-m (2.0- 2.6 kg-m) (14.5- 19.0 lb·ft)

• Apply Lithium Base Molybdenum grease (NLGI # 2) to the universal joint coupling.

•

Install the spring and coupling, and then fit the circlip.

SHAFT DRIVE 4-32

• Install a new oil seal.

• Tighten the bolt CD until resistance is felt, and loosen it 1/4 rotation. • Apply THREAD LOCK SUPER "1303" to the nut ®and tighten it to the specified torque.

99000-32030

IThread Lock Super "1303" I

Tightening torque

40-60 N-m (4.0 - 6.0 kg-m) (29.0 - 43.5 lb-ft)

• Bent the lock washer @ . • Apply Lithium Base Molybdenum grease (NLGI # 2) to the propeller shaft joint coupling@. • Apply grease to the final driven bevel gear coupling@.

99000-25030

ISUZUKI Super grease "A" I

• Select the proper plate bearing stopper.

® and

install it to the

CAUTION: When installing the plate, fit the protrution (j) of plate to the bearing stopper groove. NOTE: Two kind of plates are available to properly lock the bearing stopper as spare parts.

4-33 SHAFT DRIVE

• Apply SUZUKI Bond No. 1207B to the mating surface of swingarm and final gear case. 99104-31140

I SUZU Kl Bond No. 1207B

• Tighten the three nuts CD and shock absorber mounting nut ®to the specified torque.

CD

35-45 N·m (3.5 - 4.5 kg-m) (25.5 - 32.5 lb-ft)

®

20-30 N·m (2.0- 3.0 kg-m) ( 14.5- 21.5 lb-ft)

Tightening torque

NOTE:

After remounting the final gear case, the following service is necessary. * Fill the final gear case with Hypoid gear oil. Specified capacity: 330 - 350 ml (11.2 11.8USoz)

SHAFT DRIVE 4-34

REASSEMBLY INFORMATION

Lithium base molybdenum grease (NGLI #2)

90-110 N·m (9.0-11.0 kg-m) (65.0-79.5 lb-ft)

W'lill

\ j\\ \,

\J

~~· \~

I

f

~

\ \.L-

Tr

I

-"'

f-._

[E-1

List of shims @ Shim

2~7~:;~~~-4~N5~~~-0~2-+'~ ~ 7-:C: - '~"-'es '-'-m'-l I---"27326-45103 1.10mm / 27326-45101

1 20 mm

27~~i~]2ii~:40 ~1~.·!45:5 mm~~m

27326-45100-145 27326-45100-150 1.50 mm

Thread lock super "1303"

,/

..A

7~

~ -~ ~ "~:1

---,-----

'' ..

LJ.,.

=u

pzD'

J'r-t--r

~rr.l r:J'~

~~ 11J----.ool=:::::t ~) J c.---H---'l.JC:.u , - _,

c

Gear backlash

j 0.03-0.64 mm

I

(0.001-0.025 in)

~

.

-~··~

- , - - - - - - ----------'

lf==--

_ l!li:'

_

.-L-ist-of_sh_im_s_®_A...-------. PartNo. Shim thickness

r~~~l~~J ~~ ~~~~~ji~g~ g::g~~

27327-45104 0.60 mm 0.05-0.15 mm Shim clearance (0.002-0.006 in) . T .lghtenmg torque

I (2.0-2.6 20-26 N·m kg-m) (14.5-19.0 lb-ft)

Thread lock "1342"

COOLING SYSTEM

~----------------CONTENTS----------------~

COOLING SYSTEM .................................................................. 5_ 1 COOLING SOLUTION ............................................................... 5- 3 RADIATOR AND WATER HOSES ............................................. 5_ 4 THERMOSTAT ········································································5- 7 WATER PUMP ········································································5- 9 THERMO-SWITCH AND FAN MOTOR ...................................... 5-12 ENGINE THERMO-SWITCH ............................................... 5-12 FAN MOTOR ..................................................................... 5-14 WATER TEMPERATURE METER AND TEMPERATURE GAUGE ····················································································5-15

5·1 COOLING SYSTEM

COOLING SYSTEM DESCRIPTION The engine is cooled by coolant set in forced recirculation through jackets formed in the cylinder and head, and through the radiator. For the water pump, a high-capacity centrifugal pump is used. The radiator is a tube-and-fin type made of aluminum material, which is characterized by lightness in weight and good heat dissipation. The thermostat is of wax pellet type, complete with a valve as the means of temperature-dependent control over the flow of coolant through the radiator. The valve is actuated by the temperature-sensitive wax contained in the pellet. Referring to the following illustration, the thermostat is in the closed condition, so that water recirculates through the route comprising pump, engine, by-pass holes of the thermostat and radiator in the regulated condition. As the coolant temperature rises to 75°C and the thermostat valve unseats, the normal coolant flow is established. At about 90°C of coolant temperature, the thermostat becomes completely open and most of heat is released to the atmosphere through the radiator core.

Reservoir No.1

COOLING SYSTEM 5-2

5-3 COOLING SYSTEM

COOLING SOLUTION At the time of manufacture, the cooling system is filled with a 50 : 50 solution of distilled water and anti-freeze/summer coolant. This 50 : 50 mixture will provide excellent heat protection, and will protect the cooling system from freezing at temperatures above -31°C (-24° F). If the motorcycle is to be exposed to temperatures below -31°C (-24° F), this mixing ratio should be increased up to 55% or 60% according to the Fig. 2. NOTE: Also included in the cooling solution at the time of manufacture is bar's leak material to help ensure protection against coolant leakage.

50%

(oF)

Water

1 800 ml (1.90 US qt)

Coolant

1 800 ml (1.90 US qt)

(oC)

(kg/cm2)

302 150 1.5

284 140

....c:

·csc.

266 130

·=

248 120

"' 0.9 :l .... c. 0.5 &

230 110

o

Ill

1.._

0

!Q.)

, ....

...J

I~

'lD

SCR

'-------Y

.t'

~~

~

~~

-~')

...J..:

--

,,

~'

~I:

"'-------

L ___ ____________ .J

Function of Regulator While the engine r/min is low and the generated voltage of the AC generator is lower than the adjusted voltage of regulator, the regulator does not function. However, the generated current charges the battery directly at this time.

Regulator/Rectifier

r------------1 ,--

-D

~

IC

r--

--, ....

J

-

-

~

-

A~ A~ ~~

lg. switch

I>

"tl

,a.>

0 ...J

,:::: ICQ

.

~

1f

,SCR

II ') "'------1+------------.J

~"' J L ___

+

Ill

lil - -

J

,,.

r.':

ELECTRICAL SYSTEM 8-2

When the engine r/min becomes higher, the generated voltage of the AC generator also becomes higher and the voltage between the battery terminals becomes high accordingly. When it reaches the adjusted voltage of the I.C. (Integrated Circuit) and it is turned "ON," a signal will be sent to the SCR(Thyristor) gate probe and the SCR will be turned "ON." Then, the SCR becomes conductive in the direction from point @to point®. At this time, the current generated from the AC generator gets through the SCR without charging the battery and returns to AC generator again. At the end of this state, since the AC current generated from AC generator flows to point @, the reverse current tends to flow to SCR. Then, the circuit of SCR turns to the OFF mode and begins to charge the battery again. Thus these repetitions maintain charging voltage and current to the battery constant and protect it from overcharging.

Regulator/Rectifier

r------------,

AC Generator

~~ ~ ~

~

~~

lg. switch

-

v

IC

®

y

r-r-

- f.-

~---,-----Y

~

~

l

....

-o i> nl 1"Ia>

I~

In! I ell

SCR 1 lr

:p. ~ ~ :1\ 14

r- ....

0 ...J

+-

'-r-

""

''

I'-

L--- -----®-------_J

8-3 ELECTRICAL SYSTEM

INSPECTION CHARGING OUTPUT CHECK • Remove the lid and cowl box from the left side of the fairing (See page 9-3). • Start the engine and keep it running at 5 000 r/ min with dimmer switch turned HI position. • Using the pocket tester, measure the DC voltage between the battery terminal EB and 8. If the tester reads under 14 V or over 15V, check the AC generator no-load performance and regulator/rectifier. NOTE: When making this test, be sure that the battery is fully-charged condition.

IG. switch

---Y-

---Y- Regulator -RIW

STD charging output

09900-25002

14- 15 (DC) at 5 000 r/min Pocket tester

AC GENERATOR NO-LOAD PERFORMANCE • Remove the main fairing (See page 9-7). • Disconnect the AC generator lead wire. • Start the engine and keep it running at 5 000 r/min. • Using the pocket tester, measure the AC voltage between the three yellow lead wires. If the tester reads under 90V, the AC generator is faulty. STD No-load performance

09900-25002

More than 90V (AC) at 5 000 r/min Pocket tester

Rectifier

---Y-

ELECTRICAL SYSTEM 8-4

AC GENERATOR CONTINUITY CHECK • Using the pocket tester, check the continuity between the lead wires of the stator. Also check that the stator core is insulated. NOTE: When making this test, it is not necessary to remove the AC generator.

09900-25002

Pocket tester

REGULA TOR/RECTIFIER • Remove the main fairing (See page 9-7) • Using the pocket tester (X 1 kn range), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the regulator/rectifier. Pocket tester

09900-25002

Unit: kn

I~

EB

~ R

0 .....

0

....enIll ....Ill

B/W

...

....0

R

~

Approx.

80

Probe of tester to:

0

B/W

00

00

~

Approx. Approx.

8.5

5.2

Ill

.c

... CD 0

a..

YCD

Approx.

v®

Approx.

Y@

Approx.

3 3 3

vCD v® v@ 00

00

00

Approx. Approx. Approx. Approx.

35

I~

50

50

50

Approx. Approx. Approx.

3

I~

00

00

00

00

00

00

00

00

3

3

00

00

I~ 00

00

~

CAUTION: As transistors, capacitors, Zener diodes, etc. are used inside this regulator/rectifier, the resistance values will differ when an ohmmeter other than the SUZUKI pocket tester is used.

0

0

8-5 ELECTRICAL SYSTEM

IGNITION SYSTEM DESCRIPTION The fully transistorized ignition system consists of a signal generator, ignitor, ignition coils, and spark plugs. The signal generator comprises one rotor tip and four pickup coils. The signal generator coils are mounted on the generator cover. The output of the signal generator goes to the ignitor unit, where it turns ON and OFF the transistor alternately. As the transistor is turned ON and OFF, the current passing through the primary windings of the ignition coil is also turned OFF and ON accordingly. Thus, it induces the secondary current in the ignition coil secondary windings and produces the spark between spark plug gaps. Ignition cut-off circuit is incorporated in the ignitor unit to prevent over-running engine. If engine r/min. reaches 7 750 r/min., this circuit cuts off the ignition primary current for all spark plugs. CAUTION: The engine can run over 7 750 r/min, without a load, even if the ignition cut-off circuit is effective, and it may cause engine damage. Do not run the engine without load over 7 750 r/min. at anytime.

Engine stop switch

Ignition switch

~--~~"a----------Black coupler

~

Circuit breaker

~

I

Battery : I

I

I

2

1rul ~~

L.:=BI----~

INSPECTION IGNITION COILS (Checking with Electro Tester) • Remove the ignition coils from the frame. • Using the electro tester, test each ignition coil for sparking performance. The test connection is as indicated. Make sure that the three-needle sparking distance is at least 8 mm. If no sparking or orange color sparking occurs with this much gap, then it is defective and must be replaced.

09900-28106 STD Spark performance

Spark plug

Electro tester

8 mm (0.3 in)

ELECTRICAL SYSTEM 8-6

IGNITION COILS (Checking with Pocket Tester) • A SUZUKI pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary windings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values.

09900-25002

Pocket tester

Ignition coil resistance

r---------,

2-6n

Primary

10-25 kn

Secondary

kQ

SIGNAL GENERATOR (Checking with Pocket Tester) • Remove the fairing. • Measure the resistance between lead wires. If the resistance is infinity or less than the specifications, the signal generator must be replaced. Pocket tester

09900-25002

STD resistance Green- Blue Black- Yellow Pink - Green/Red Gray -White/Blue

50-200 n

8-7 ELECTFUCAL SYSTEM

IGNITOR UNIT (Checking with Ignitor Checker) • Remove the spark plugs from Nos. 1, 2, 3 and 4 cylinders. Install the respective plug caps and place the spark plugs on the cylinder head. • Remove the fairing, and then disconnect the ignitor lead wire couplers. • Connect the couplers on the ignitor checker to the ignitor lead wire couplers, as shown in the illustration. • Turn the ignition switch to the ON position and engine stop switch to the RUN position. • Turn the ignitor checker switch to the ON position and check the sparks of respective spark plugs.

09930-70710

Ignitor checker

NOTE: This checking presupposes that the ignition coil used for checking is good one.

Main wiring harness

Ignitor checker 3 & 4: Black coupler

ELECTRICAL SYSTEM 8-8

STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, interlock switch, starter button, engine stop switch, I G switch and battery. Depressing the starter button (on the right handlebar switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about 80 amperes to start the engine.

Starter interlock switch (Clutch switch)

Engine stop switch

Circuit breaker

I

I

I I

I

: Battery I

Starter relay Starter button

STARTER MOTOR REMOVAL AND DISASSEMBL V • Disconnect the starter motor lead wire by removing the nut, then remove the starter motor by removing the mounting bolts.

• Disassemble the starter motor as shown in Fig.

Ignition switch

I

8-9 ELECTRICAL SYSTEM

STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping. Service Limit

6 mm (0.24 in)

COMMUTATOR If the commutator surface is dirty, starting performance decreases. Polish the commutator with # 400 or similar fine emery paper when it is dirty. After polishing it, wipe the commutator with a clean dry cloth. Measure the commutator under-cut CD. Service Limit

0.2 mm (0.008 in)

ARMATURE COIL Using a pocket tester, check the coil for open and ground by placing probe pins on each commutator segment and rotor core (to test for ground) and on any two segments at various places (to test for open), with the brushes lifted off the commutator surface. If the coil is found to be open-circuited or grounded replace the armature. Continuous use of a defective armature will cause the starter motor to suddenly fail. 09900-25002

Pocket tester

SEGMENT

ELECTRICAL SYSTEM 8-10

OIL SEAL Check the seal lip for damage or sign of oil leakage. If any damage is found, replace it.

STARTER MOTOR REASSEMBLY 0-RING • Install new 0-rings on the correct positions as shown in Fig.

HOUSING END (Inside) • Apply grease to the lip of oil seal.

99000-25030

ISUZUKI Super grease "A" I

• When installing the housing end, align the grooves on the housing end with the pawls of washer.

HOUSING END (Outside) • Apply a small quantity of moly paste to the armature end.

99000-25140

SUZUKI moly paste

• When installing the housing end, align the protrusion CD of starter motor case with the groove ®on the housing end.

8-11 ELECTRICAL SYSTEM

HOUSING SCREW

• Apply a small quantity of Thread Lock "1342" to the starter motor housing screws. 99000-32050

Thread Lock "1342"

STARTER RELAY INSPECTION • Remove the right fairing cover. • Disconnect the lead wire of the starter motor at the starter relay. CAUTION:

When removing the lead wire from the starter relay terminal, do not touch the wrench to the other terminal. • Turn on the ignition switch, inspect the continuity between the positive and negative terminals, when squeezing the clutch lever and pushing the starter button. If the starter relay is in sound condition, continuity is found. 09900-25002

Pocket tester

• Disconnect the lead wire coupler of starter relay. • Check the coil for "open", "ground" and ohmic resistance. The coil is in good condition if the resistance is as follows. 09900-25002

Pocket tester

STD resistance

2-sn

ELECTRICAL SYSTEM 8-12

COMBINATION METER REMOVAL AND DISASSEMBLY • Remove the combination meter (See page 9-8). • Disassemble the combination meter as follows.

INSPECTION Using the pocket tester, check the continuity between lead wires in the following diagram. If the continuity measured is incorrect, replace the respective parts. 09900-25002

Pocket tester

NOTE: When making this test, it is not necessary to remove the combination meter.

8-13 ELECTRICAL SYSTEM

BJ ._,

I

Wire color

Item

B- B/W 0-Y/W O-BI Lg- B/W 0/Lg- Gr/G 0- BI/W 0- B/W

Turn signal indicator light ( L) High beam indicator light Neutral indicator light Turn signal indicator light ( R) Cruise indicator light Oil pressure indicator light Illumination light

R/W: CLOCK(+)

Blue coupler

Blue coupler

W/Y: HOUR W/G: MINUTE 0/Lg: CRUISE (+) Y/BI:4th W: Low

BI/W: 01 L (-) G/BI: BATTERY LEVEL G/W: SIDE STAND(-)

Red coupler

Y/B: FUEL UNIT BI/R: REED S/W B/W: GROUND

Y/W: HIGH BEAM(-) B/R: REED S/W Bl: NEUTRAL -) Lg: TURN ® (+) B: TURN (IJ (+)

WIRE COLOR :Black B :Blue Bl Dg : Dark green :Gray Gr : Light green Lg w :White B/G : Black with Green tracer B/R : Black with Red tracer B/W : Black with White tracer B/Y : Black with Yellow tracer

BI/R Br/R Br/W G/BI G/W G/Y Gr/G 0/G 0/Lg

0/G: IGNITION(+) B/Y: TACHOMETER (+)

W/R: STOP R/B: 2nd G/BI: 3rd Dg: CLOCK (-)

: Blue with Red tracer : Brown with Red tracer : Brown with White tracer : Green with Blue tracer : Green with White tracer : Green with Yellow tracer : Gray with Green tracer : Orange with Green tracer : Orange with Light green tracer

Y/G: HEAD Br/W: TAIL

R/B : Red with Black tracer R/W : Red with White tracer WIG : White with Green tracer W/R : White with Red tracer W/Y : White with Yellow tracer Y/B : Yellow with Black tracer Y/BI : Yellow with Blue tracer Y/G : Yellow with Green tracer Y/W : Yellow with White tracer

ELECTRICAL SYSTEM 8-14

COIL TYPE FUEL GAUGE As shown in Fig. 1, four coils are located in the fuel gauge (N1, N2, N3 and N4 ). As the resistance from the sending unit varies along with the fuel level, the current at points L1 and L2 will also vary. This in turn will cause the strength of the magnetic field generated in the four coils to increase or decrease (causing a related increase or decrease in the force vector H in Fig. 2) which will force the needle to move to the proper position (Fig. 3). When the ignition is turned off, the pointer remains in the position.

FUEL LEVEL SYSTEM The Fuel System can be divided into two sections: (1) The Fuel Meter: Located in the combination meter (2) The Fuel Tank Float Assembly (Fuel gauge sending unit)

Fuel meter

I

I I

Battery Float assembly

l Fig. 1

h4 (N4)

----------- hJ + h4

Fig. 2

Battery

Fig. 3

8-15 ELECTRICAL SYSTEM

NOTE: Prior to testing the Fuel Level system, verify that the battery is in a fully charged condition. FUEL METER INSPECTION To test the Fuel Meter two different checks may be used. The first, and simplest test will tell if the meter is operating but will not indicate the meters accuracy throughout the range. To perform this test, disconnect the 8/W and Y /8 lead wire of the fuel meter and the ground lead wire. Connect a jumper wire between 8/W and Y /8 wires coming from the main wiring harness. With the ignition switch turned ON, the fuel meter should indicate "F".

FUEL

The second test wi II check the accuracy of the meter in the full and empty positions. Connect a 90-ohm resistor between the Y /8 lead wire of the fuel gauge and the ground lead wire. The fuel gauge is normal if its pointer indicates the E (empty) position when the specified voltage is applied to the circuit and if its pointer indicates the F (full) position when the resistor is changed to 10 ohms. If either one or both indications are abnormal, replace the fuel meter with a new one.

FUEL

FUEL GAUGE SENDING UNIT • Remove the lead wires coming out of the fuel gauge and check resistance of each of them. • If the resistance measured is incorrect, replace the fuel gauge assembly with a new one. • The relation between the position of the fuel gauge float, resistance, and fuel quantity is shown in the following table.

E E E

Float position F 1/2

E

Resistance

Fuel quantity

n Approx. 31 n Approx. 90 n

Approx. 15.0L

Approx. 10

E M +I

"

M +I 0 M

E

E

M +I

O'l LO

1/2

0 N

Approx. 11.5L Approx. 2.2L

E

ELECTRICAL SYSTEM 8-16

WATER TEMPERATURE METER .......

INSPECTION As the coil spring is installed on the needle shaft of the water temperature meter, the needle is forced back to the original position when ignition switch is turned OFF. To test the water temperature meter two different checks may be used. The first, and simplest test will tell if the meter is operating but will no indicate the meters accuracy throughout the range. To perform this test, disconnect the B/G lead wire of the water temperature meter from the water temperature gauge. Connect a jumper wire between B/G wire coming from the main wiring harness and engine ground. With the ignition switch turned on, the water temperature meter should indicate "H".

B/G

TEMP Temp. gauge

'

B/G

TEMP

The second test will check the accuracy of the meter in the "H" and "C" positions. Connect a 230-ohm resistor between the B/G lead wire of the water temperature gauge and the ground lead wire. The water temperature gauge is normal if its pointer indicates the C position when the specified voltage is applied to the circuit and if its pointer indicates the H position when the resistor is changed to 15 ohms. If either one or both indications are abnormal, replace the water temperature meter with a new one.

Temp. gauge

CD Approx. 40°C ( 96°F)

® Approx. 106°C (235°F)

WATER TEMPERATURE METER POSITION

RESISTANCE

CD ® ®

230n 24n 15n

TEMP

® Approx. 125°C (258°F)

8-17 ELECTRICAL SYSTEM

MONITOR SYSTEM The monitor unit is installed left side of the fairing bracket (See page 9-8). It monitors open circuit in the headlight, taillight and brake light and also has a function for checking for disconnection of the monitor bulbs. The LCD monitor display when a disconnection occurs. The battery solution level is monitored in the same ways and LCD monitor display when the solution level drops below the MIN. level. The side stand is monitored in the same ways and LCD monitor display when the side stand is not fully retracted.

1-

Battery :..._G/BI Battery solution , level senser

_.1_

CD : Front and rear brake light switch

® : Highbeam indicator

Y/G MONITOR UNIT

light

W/R

@ : Dimmer switch @ : Meter Iight

B/W

Headlight

Brake light Taillight

DESCRIPTION LCD (LIQUID CRYSTAL DISPLAY) MONITOR • A liquid crystal display is used for monitor the display (as shown in Fig. 1) of this motorcycle. • When the ignition switch is switched from OFF to ON, all segments of the monitor will display for about 2 seconds, and then normal the display (clock and gear position) will appear. • When the battery voltage drops to 8V or less, all segment displays will go out and the condition will be the same as when the ignition switch is set to OFF. • All segment displays also go out when the battery voltage drops to or less during engine start, but normal display will be executed after lighting of all segments for about 2 seconds when the engine has started and the battery voltage again rises to 8V or more.

av

"-

~ HEAD

Ji' ,~ TAIL

STOP

~D

CJ: a:

AM

jr. ,-, ,...,

Fig. 1

-

1-.f· Lf Lf

GEAR POSITION

ELECTRICAL SYSTEM 8-18

INSPECTION MONITOR UNIT Before checking this monitor unit, check the following items. • LCD monitor • Switches (Ignition, Dimmer and Side stand) • Bulbs (Headlight and Tail/Brake light) • Battery electrolyte level sensor and Battery charged condition • Fuses and Wiring harness to and from the meter cluster

HEAD, TAIL AND BRAKE LIGHT CIRCUITS • Turn the ignition switch in the ON position and start the engine. • Disconnect the coupler from the headlight bulb, and also disconnect the tail/brake light coupler. Confirm that the LCD monitor displays when disconnecting coupler and LCD monitor goes out when reconnecting the coupler.

BATTERYELECTROLYTELEVELSENSOR Check the voltage between the level sensor lead and minus 8 terminal of the battery. If the specified voltage is not observed, replace the level sensor. NOTE: * The battery should be fully charged condition, and the solution be kept at an upper level. * Before checking the sensor, disconnect the sensor from the battery and wipe it with cloth. STD voltage

Over 3.0 V (DC)

8-19 ELECTRICAL SYSTEM

LCD MONITOR Check the LCD monitor according to the following outline. • Remove the main fairing (See page 9-7). • Disconnect the combination meter couplers. • When check connection is as indicated (Fig. 1 ), all segments of monitor display (Fig. 2) for about 2 seconds, and then normal display (Fig. 3) is executed. Battery

NOTE: When the LCD monitor is defective, replace the combination meter assembly.

.--F-=ig:.._._1_ _ _ _ _ _ _ _ _ _ _ _ _ _---,

'-

,\._ Ji'

~ HEAD

~D

TAIL

STOP

a: a::

Fig. 2

AM

j~,. ,~, ,~,

O·LfLf

GEAR POSITION

Fig. 3

ELECTRICAL SYSTEM 8-20

LAMPS BULB REPLACEMENT • Remove the front cowl cover (See page 9-6). • Remove the right and left main fairings (See page 9-7). • Remove the headlight (See page 9-8). • Disconnect the socket and remove the rubber cap. • Unhook the spring CD and take off the bulb.

HEADLIGHT

NOTE: Adjust the headlight, both vertical and holizontal, after reassembly.

TAIL/BRAKE.LIGHT

CAUTION: Do not overtighten the lens fitting screws.

8-21 ELECTRICAL SYSTEM

LICENSE LIGHT

TURN SIGNAL LIGHT

/ /; -\K/ ~ /

II

@

' CAUTION: Do not overtighten the lens fitting screws.

SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart. If any abnormality is found, replace the respective switch assemblies with new ones.

09900-25002

IGNITION SWITCH

Pocket tester

I

~

CAUTION: Do not overtighten the lens fitting screws.

ELECTRICAL SYSTEM 8-22

DIMMER SWITCH(!)

RC

RM HAZ.

N

OFF

LM LC

HORN SWITCH @

ENGINE STOP@AND START SWITCH@

~

0/W (Red tube)

0/W

OFF RUN START (Push)

0

0

Y/G

8-23 ELECTRICAL SYSTEM

CLUTCH SWITCH

~

B/W

Dg/W

ON (Squeeze lever) OFF

FRONT BRAKE SWITCH

----------

W/B

0/G

ON (Squeeze lever) OFF

GEAR POSITION INDICATOR SWITCH Gear position

Wire color

1st

W/Y

Neutral

Bl

2nd

R/B

3rd

G/BI

4th

Y/BI

Top

Br/R

Ground

REAR BRAKE SWITCH

----------

ON (Depress pedal) OFF

0/G

W/B

ELECTRICAL SYSTEM 8-24

SIDE STAND SWITCH

---------

B/W

G/W

ON

(Down position)

OFF (Upright position)

OIL PRESSURE SWITCH • Continuity, when engine is stopped. • No continuity, when engine is running. NOTE: Before inspecting the oil pressure switch, check the engine oil level at oil inspection window.

ONLY FOR GV1400GD MODEL TIME ADJUST SWITCH

------

Dg

W/Y

WIG

HOUR (Push)

MINUTE (Push)

MUTE .AND RADIO TU:NE SWITCHES

~

BI/G

B/W

G/W

G/Y

ON (Push) OFF UP DOWN

0 0

D D

8-25 ELECTRICAL SYSTEM

AUTO CRUISE POWER SWITCH

ITI

0/W

CD

0/Lg

0~-------+--0

SET SWITCH®

---------ON (Push)

V/W

8/W

0

-o

OFF

RESUME SWITCH @

THROTTLE SWITCH @

--------ON (Twist)

P/W

8/W

0

-o

OFF

CO-RIDER CONTROL SWITCH

TUNE VOL.,. UP VOLUME f-----+--+-----+-----11-----+----+---t DOWN

SEAT SWITCH

--------IN (Push) OUT

8r/G

81/W

0

-o

ELECTRICAL SYSTEM 8-26

CENTER STAND SWITCH

~

G/B

B/W

ON

(Down position)

OFF (Upright position)

AUTO-LEVELLING SWITCH

-------ON (Push)

Lg/0

R/G

0

-o

OFF

WIRE COLOR Black Blue Brown Dark green Green Gray Light blue Light green Orange w White y Yellow Black with Light green tracer B/Lg Black with White tracer B/W Blue with Green tracer BI/G Blue with White tracer BI/W Brown with Green tracer Br/G Brown with Red tracer Br/R Dg/W: Dark green with White tracer Green with Black tracer G/B Green with Blue tracer G/BI Green with Red tracer G/R

B Bl Br Dg G Gr : Lbl: Lg 0

G/Y G/W Lg/B Lg/0 0/G 0/Lg 0/W P/W R/B R/BI R/G R/W V/G V/W W/B

WIG W/Y Y/BI Y/G Y/W

Green with Yellow tracer Green with White tracer Light green with Black tracer Light green with Orange tracer Orange with Green tracer Orange with Light green tracer Orange with White tracer Pink with White tracer Red with Black tracer Red with Blue tracer Red with Green tracer Red with White tracer Violet with Green tracer Violet with White tracer White with Black tracer White with Green tracer White with Yellow tracer Yellow with Blue tracer Yellow with Green tracer Yellow with White tracer

8-27 ELECTRICAL SYSTEM

SELF-CANCELLING DEVICE DESCRIPTION The turn signal light self-cancelling device attached to this motorcycle functions as shown in the following diagram, and it is only an added circuit to the originary turn signal.

DIAGRAM Front turn signal light L

Rear turn signal light

R

R

L

Lg 8/W 8 Lbl Lg/8

~!'.

8/Lg-

I 8

Lbl

RC (AUTO CANCEL)

~)-

RM (LANE CHANGE)

,,.

N

LM (LANE CHANGE) LC (AUTO CANCEL)

Lg

~>-

I HAZ

I() ~

0

J.::l

I Lg/8

>10 t-0

8/Lg

~

8/W

)

o- K)

) )

().. ~

'})

IO ro

10 ~

o- f-0

T

I Battery I

--1-

'-~

Turn

signa~

control unit

, Turn signal control unit

Ignition switch Circuit breaker

IOFF

10 K) 10 K)

....---.--I-8/W

l

I

I

I I I

L----------.1 Distance Turn signal sensor Reed switch

indicator light

ELECTRICAL SYSTEM 8-28

SELF-CANCELLING DEVICE FUNCTIONS TIMER SPECIFICATION AND FUNCTION * The speed at which the timer starts to run: 15 km/h (9.5 mph).

* The speed at which the timer stops: Less than 12 km/h (7 .5 mph). * The time during which the timer runs: 10 ± 1 seconds (=Time needed for descharge from the condenser.)

* The timer calculates the amount of condenser discharge. Once the timer stops at the level before the complete discharge from the condenser, it restarts at this level; i.e. the condenser is partially discharged.

® After

the turn signal is on, any change of the switch cancels the device. Reapplying the switch begins at this position again. ®At the level that the condenser is fully charged. ©At the level that the condenser is partially discharged.

INSPECTION • If the self-cancelling device does not show the proper function. Check the device by the following steps. Disconnect the lead wire (Lg/B) from the turn signal control unit, and switch on the turn signal light. f-------


::!

c

Clamp (Radiator fan lead wire, Radiator fan noise filter lead wire)

Radiator fan noise filter Compressor relay

Clamp (Gear position indicator lead wire, Generator lead wire, Signal generator lead wire)

...C?z ... en

10-17 SERVICING INFORMATION Clamp (Wiring harness, Passenger footrest cable, Fuel hose, Fuel tank breather hose, Auto leveling air hose) Sub. fuel tank

Clamp (Rear radio controller lead, Antenna cable, Rear head phone set lead)

Clamp (Antenna cable, Passenger footrest cable)

Clamp (Wiring harness, Rear radio controller lead, Antenna cable, Rear head set lead) Antenna cable

Rear radio controller lead wire Antenna

Clamp (Rear radio controller lead wire,~--==-= Antenna cable, Rear head phone set lead) Rear turn signal lead wire (L) Clamp (Passenger footrest cable)

Trunk lamp read

Sub. tank fuel hose

Clamp (Wiring harness, Passenger footrest cable connector)

Clamp (Wiring harness, Passenger footrest cable, Fuel hose, Fuel tank breather hose, Auto leveling air hose) Clamp (Wiring harness, Rear radio control lead, Antenna cable)

p

(Fuel hose, Fuel tank breather hose)

iiirstl~+---- Clamp (Fuel hose between

fuel pump and carburetor)

Fuel filter

Rear turn signal lead (R)

Rear brake hose

Clamp (Passenger footrest cable, Fuel hose)

SERVICING INFORMATION 10-18

FRONT

Clamp----------.. (Gear position indicator lead wire, Generator lead wire, Signal generator lead wire, Rear radio controller lead wire, Antenna cable, Wiring harness, Rear head phone lead wire)

Clamp (Rear radio controller lead wire)

Clamp (High tension cord No. 1, High tension cord No. 3) Clamp (Rear brake lamp switch lead wire, High tension cord No.1) Clamp (Rear brake lamp switch lead wire, High tension cord No.3)

Wiring harness - - - -

Fuel tank breather hose

Clamp---------(Wiring harness, Rear radio controller lead wire, Antenna cable, Rear head phone lead wire)

Clamp (Fuel hose, Fuel tank breather hose)

Clamp-----(Gear position indicator lead wire, Generator lead wire, Signal generator lead wire) Clamo---------(Wiring harness, Rear radio controller lead wire, Antenna cable, Rear head phone lead wire)

Fuel hose

Molding clamp Fuel level gauge

Molding clamp

Passenger footrest lever Clamp (Wiring harness, Passenger footrest cable connector) Clamp-------./ (Rear radio controller lead wire, Antenna cable, Rear head phone lead wire)

Clamp (Wiring harness, Fuel level gauge lead wire, Passenger footrest cable, Fuel hose, Fuel tank breather hose, Auto leveling air hose)

Clamp (Wiring harness, Passenger footrest cable, Fuel hose, Fuel tank breather hose, Auto leveling air hose)

10-19 SERVICING INFORMATION

Trunk light

Trunk light switch Boot Cover Clamp -------11---F:±E:::~~ (Rear controller lead wire)

OUT hose No. 3

Air bag hose No. 1

INLET hose No.1, 2, 3

OUT hose No. 1, 2

"11

:D

0

z

Front brake master cylinder

-1

Front brake hose No. 1

Meter assembly

Ignition coil No. 2

OJ

:D )>

"m ::I:

0

en

m

)>

Front

z en "tl

¢::J

0

T"l(

/

m

Horn

m

0

0

Clamp (Front brake hose, Handle switch lead (R), Throttle cable)

Clamp (Wiring harness, Actuator lead wire) ~---

Clamp (Wiring harness)

Speedometer cable

~----Front

s:m

Pass the speedometer cable through the left side of the horn

-1

m

:D

0

)> OJ

brake hose No. 2

rm :D

0

Front brake hose

Front brake hose No. 2

c

-1

z G') en

m

:tl

< n 2

C')

Brake caliper

2 'TI

c

:::D

s: l>

::::!

NOTE: Do not fix the hose to the caliper/master cylinder with the extended condition.

Pass the brake hose outside the speedometer cable.

Cable guide

c 2

..... = "-' =

= N

jJ

en m

m jJ

:t>

"

Clamp (Passenger footrest cable, Fuel hose)

m

Rear brake caliper

:I:

0

en m jJ

0

c

-i

2

C)

Brake hose

Clamp Rear brake pipe NOTE:

Do not fix the hose to the caliper/master cylinder with the extended condition.

Rear brake master cylinder

.... ....

jJ

m :t>

:tl




Fuel hose

-" w en

c :::a

r-

uel tank breather hose

....

Cl

s: )> 2

)>

OUT hose No. 2

:D ""C

OUT hose No. 3

c

3:

Air seat bag No. 3

""C

Air seat control valve

::I:

0

(I)

Clamp

r seat bag No. 2

m

:D

0

Air bag

c

-t

2

G)

Auto leveling h

Clamp

Clamp

Air seat bag No. 1

en ::::c

m

< n 2

Ci)

2

Air filter

"'T'I

c :;g :s:: J>

Air bag hose

:::::!:

c

Auto leveling hose Exhaust port

2

Clamp

= N ~

)>

Auto levelling hose (To left side)

c

-i

0

rm < m r-

To air bag

z

C)

)>

:::0 :I:

0

en

m

:::0

0

Frame

Right side '

Stopper -------- ~ Left side - 1 0

NOTE: The stopper of shock absorber is positioned inside.

Auto leveling hose

\':!f---

*Air valve (*Only for GT model)

absorber

Tightening torque 10-16 N·m (1.0 -1.6 kg-m) l . . t . - - - Tightening torque

10-16N·m (1.0 -1.6 kg-m)

c

-i

zG)

...= N

U"'

en m

:::D


:::!

0

2

SERVICING INFORMATION 10-26

THROTTLE AND STARTER CABLE ROUTING

Clamp (Starter cable, Radio channel select switch lead, Handle switch lead (L), Clutch hose)

Clamp (Throttle cable, Handle switch lead ( R), Front brake hose)

Clamp (Throttle cable, Handle switch lead (R))

Auto cruise actuator

Clamp (Starter cable, Handle switch lead ( L), Radio channel selector switch lead) Clamp (Starter cable)

Starter cables

Throttle cable junction box

Clamp (High tension cord Nos. 1 and 3) Carburetor breather hose

Ignition coil No. 4

:I:

Ignition coil No. 3

G)

Ignition coil No. 2

:I:

-1

m

z en 0

::D

0 :::D

c:

-1

z G)

Clamp

2

2

0

High tension


() ®

10-33 SERVICING INFORMATION

TIGHTENING TORQUE ENGINE N-m

kg·m

lb-ft

Camshaft journal holder bolt

23-27

2.3-2.7

16.5- 19.5

Cylinder head bolt

46-51

4.6-5.1

33.5-37.0

Cylinder head cover bolt

13- 15

1.3- 1.5

9.5- 11.0

8-12

0.8- 1.2

6.0-8.5

49-53

4.9-5.3

35.5-38.5

12 mm

60-70

6.0-7.0

43.5-50.5

10 mm

45-55

4.5-5.5

32.5-40.0

8mm

24

2.4

17.5

6mm

13

1.3

9.5

8 mm Allen bolt

20-28

2.0-2.8

14.5-20.0

6 mm Allen bolt

12- 16

1.2- 1.6

8.5- 11.5

25-30

2.5-3.0

18.0-21.5

8- 12

0.8- 1.2

6.0-8.5

20-25

2.0-2.5

14.5- 18.0

150- 170

15.0- 17.0

108.5 - 123.0

7-9

0.7-0.9

5.0-6.5

50-60

5.0-6.0

36.0-43.5

7- 11

0.7- 1.1

5.0-8.0

Water pump drive sprocket bolt

50-60

5.0-6.0

36.0-43.5

Water pump drain plug

10- 14

1.0- 1.4

7.0- 10.0

Clutch sleeve hub nut

50-70

5.0-7.0

36.0-50.5

Clutch spring bolt

11 - 13

1.1 - 1.3

8.0-9.5

Cam chain tensioner bolt

20-25

2.0-2.5

14.5- 18.0

8-12

0.8- 1.2

6.0-8.5

20-25

2.0-2.5

14.5- 18.0

8-12

0.8- 1.2

6.0-8.5

Exhaust pipe clamp bolt

20-25

2.0-2.5

14.5- 18.0

Muffler mounting bolt

27-43

2.7-4.3

19.5- 31.0

7-9

0.7-0.9

5.0-6.5

Engine mounting bolt (Front & Rear lower)

70-88

7.0-8.8

50.0-64.0

Engine mounting (Rear upper)

60-72

6.0-7.2

43.5-52.0

@

60-65

6.0-6.5

43.5-47.0

@

30-35

3.0-3.5

21.5- 25.5

18-28

1.8-2.8

13.0-20.0

ITEM

Cylinder head nut Con-rod bearing cap bolt Crankcase bolt

Oil pressu·re regulator Oil pan bolt Engine oil drain plug Rotor bolt Oil pump bolt Idler shaft driven sprocket bolt Water pump bolt

Chain tensioner adjuster bolt Cam chain tensioner spring holder Cam chain guide bolt

Radiator mounting bolt

Down tube mounting bolt Engine mounting bracket bolt

SERVICING INFORMATION 10-34

SHAFT DRIVE

N-m

kg-m

lb-ft

120- 150

12.0- 15.0

87.0- 108.5

20-26

2.0-2.6

14.5-19.0

120- 150

12.0- 15.0

87.0- 108.5

6mm

8- 12

0.8- 1.2

6.0-8.5

8mm

20-26

2.0-2.6

14.5- 19.0

Secondary gear case bolt

20-26

2.0-2.6

14.5- 19.0

Final drive bevel gear nut

90- 130

9.0-13.0

65.0-94.0

8-10

0.8- 1.0

6.0-7.0

Final gear bearing case bolt

20-26

2.0-2.6

14.5-19.0

Final drive bevel gear coupling nut

90- 110

9.0- 11.0

65.0-79.5

Final driven bevel gear adjuster lock nut

40-60

4.0-6.0

29.0-43.5

N-m

kg-m

lb-ft

Steering stem head nut

30-40

3.0-4.0

21.5-29.0

Front fork upper clamp bolt

15-25

1.5-2.5

11.0- 18.0

Front fork lower clamp bolt

20-25

2.0-2.5

14.5- 18.0

Front fork cap bolt

15-30

1.5-3.0

11.0-21.5

Front fork damper rod bolt

34-46

3.4-4.6

24.5-33.5

Front axle nut

36-52

3.6-5.2

26.0-37.5

Front axle clamp nut

15-25

1.5-2.5

11.0- 18.0

5-8

0.5-0.8

3.6-6.0

Front caliper mounting bolt

25-40

2.5-4.0

18.0-29.0

Front caliper housing bolt

30-36

3.0-3.6

21.5-26.0

Brake hose union bolt (Front & Rear)

20-25

2.0-2.5

14.5- 18.0

6-9

0.6-0.9

4.5-6.5

Handlebar holder nut

30-40

3.0-4.0

21.5-29.0

Handlebar clamp bolt

25-30

2.5-3.0

18.0-21.5

Disc plate bolt (Front & Rear)

15-25

1.5-2.5

11.0- 18.0

Auto level hose mounting nut

10- 16

1.0- 1.6

7.0- 11.5

7-9

0.7-0.9

5.0-6.5

Front foot rest bolt

27-43

2.7-4.3

19.5-31.0

Rear axle nut

85- 115

8.5- 11.5

61.5-83.0

8-12

0.8-1.2

6.0-8.5

20-30

2.0-3.0

14.5-21.5

7-9

0.7-0.9

5.0-6.5

Rear swingarm pivot bolt

3.5-4.5

0.35-0.45

2.5-3.0

Rear swingarm pivot nut

110-130

11.0- 13.0

79.5-94.0

ITEM

Secondary driven bevel gear nut Secondary driven bevel gear housing bolt Secondary drive bevel gear nut Secondary drive bevel gear housing bolt

Final driven gear bearing retainer screw

CHASSIS ITEM

Front brake master cylinder bolt

Air bleeder valve (Front & Rear)

Air compressor hose union bolt

Rear wheel driven joint bolt Rear shock absorber nut (Upper & Lower) Rear shock absorber air valve

10-35 SERVICING INFORMATION

N-m

kg-m

lb-ft

Rear caliper mounting bolt

25-40

2.5-4.0

18.0-29.0

Brake pedal link nut

15-25

1.5-2.5

11.0- 18.0

Rear caliper housing bolt

28-32

2.8-3.2

20.0-23.0

Brake pedal link arm bolt

10- 15

1.0- 1.5

7.0-11.0

Rear torque link nut (Front & Rear)

20-30

2.0-3.0

14.5-21.5

Rear brake master cylinder bolt

15-25

1.5-2.5

11.0- 18.0

Rear brake rod lock nut

15-25

1.5- 2.5

11.0- 18.0

Rear axle clamp bolt

18-28

1.8-2.8

13.0-20.0

5-8

0.5-0.8

3.5-6.0

ITEM

Clutch master cylinder bolt

TIGHTENING TORQUE CHART For other bolts and nuts not listed above, refer to this chart: Bolt Diameter ® (mm)

N-m

kg-m

lb-ft

N-m

4

1.0-2.0

0.1-0.2

0.7- 1.5

1.5-3.0

0.15-0.3

1.0-2.0

5

2.0-4.0

0.2-0.4

1.5-3.0

3.0-6.0

0.3-0.6

2.0-4.5

6

4.0-7.0

0.4-0.7

3.0-5.0

8.0- 12.0

0.8- 1.2

6.0-8.5

8

10.0- 16.0

1.0- 1.6

7.0- 11.5

18.0-28.0

1.8-2.8

13.0-20.0

10

22.0- 35.0

2.2 - 3.5

16.0-25.5

40.0-60.0

4.0-6.0

29.0-43.5

12

35.0- 55.0

3.5-5.5

25.5-40.8

70.0- 100.0

7.0- 10.0

50.5-72.5

14

50.0-80.0

5.0-8.0

36.0-58.0

110.0- 160.0 11.0- 16.0

16

80.0- 130.0

8.0- 13.0

58.0-94.0

170.0 - 250.0 17.0- 25.0 123.0- 181.0

18

"7" marked bolt

Conventional or "4" marked bolt

130.0 - 190.0 13.0- 19.0

Conventional bolt

kg-m

lb-ft

79.5- 115.5

94.0- 137.5 200.0 - 280.0 20.0-28.0 144.5- 202.5

"4" marked bolt

"7" marked bolt

SERVICING INFORMATION 10-36

SERVICE DATA VALVE + GUIDE

Unit: mm (in)

ITEM Valve diam.

STANDARD

IN. EX.

Valve lift

(

IN

(

EX.

(

Lash-adjuster plunger stroke (

Valve guide to valve stem clearance

IN. EX.

Valve guide I.D. Valve stem O.D.

IN. & EX. IN. EX.

Valve stem runout Valve head thickness Valve stem end length Valve seat width Valve head radial runout

30.0 1.18 26.0 1.02 7.0 0.28 6.0 0.24

(

--

)

--

)

--

)

--

)

0-0.2 0-0.008 ) 0.020-0.04 7 ( 0.0008-0.0019 0.035-0.062 ( 0.0014-0.0024 5.000-5.012 ( 0.1969-0.1973 4.965-4.980 ( 0.1955-0.1961 4.950-4.965 ( 0.1949-0.1955

IN. & EX.

--

IN. & EX.

--

IN. & EX.

--

IN. & EX.

(

-)

(

)

(

Valve spring free length

9.4-11.0 kg 20.7-24.3 lbs ) at length 31.5 mm ( 1.24 in

( ( (

( (

Camshaft journal oil clearance Camshaft journal holder I. D. Camshaft journal O.D. Camshaft runout

) )

0.03 0.001 34.5 1.36

) )

-Unit: mm (in)

STANDARD

IN.

(

EX.

(

IN. & EX.

(

IN. & EX.

(

IN. & EX.

(

IN. & EX.

)

)

CAMSHAFT + CYLINDER HEAD Cam height

0.05 0.002 0.5 0.02 3.3 0.13

--

)

(

ITEM

)

--

)

--

Valve spring tension

)

--

)

0.9-1.1 0.035-0.043

0.35 0.014 0.35 0.014 --

)

--

IN. & EX.

I

LIMIT

32.652-32.692 1.2855-1.2871 ) 32.065-32.105 1.2624-1.2640 ) 0.032-0.066 0.0013-0.0026 ) 22.012-22.025 0.8666-0.8671 ) 21.959-21.980 0.8645-0.8654 ) --

LIMIT ( ( (

32.36 1.274 31.77 1.251 0.150 0.0060

) ) )

--(

0.10 0.004

)

10-37 SERVICING INFORMATION

f---

ITEM

STANDARD

Cam chain 20-pitch length Cam chain pin (at aligning mark)

LIMIT

Front

18th pin

161.0 6.34 --

Rear

18th pin

--

--

Idler chain 20-pitch length

(

--

(

Idler chain pin (at aligning mark)

29th pin

Cylinder head distortion

(

CYLINDER + PISTON + PISTON RING STANDARD

--

(

0.045-0.055 0.0018-0.0022

)

(

81.000-81.015 3.1890-3.1896

)

Cylinder bore Piston diam.

80.950-80.965 3.1870-3.1876 ) Measure at 14 mm (0.6 in) from the skirt end. (

Cylinder distortion Piston ring free end gap

Piston ring end gap

--

1st

R

Approx.

2nd

R

Approx.

1st

R

2nd Piston ring to groove clearance

Piston ring groove width

R

1st (

Piston pin bore

(

2 kg/cm 2 ) 28 psi

(

0.120 0.0047

)

(

81.085 3.1923

)

(

80.880 3.1842

)

(

0.10 0.004

)

(

8.4 0.33

)

(

11.7 0.46

)

(

9.4 0.37

)

(

0.20-0.35 0.008-0.014

(

0.20-0.35 0.008-0.014

--

Oil

8 kg/cm 2 114 psi )

)

2nd 1st

(

10.5 0.41

--

2nd

)

(

1st

2nd

Piston ring thickness

0.10 0.004

LIMIT

10-14 kg/cm 2 142-200 psi )

Compression pressure difference Piston to cylinder clearance

)

Unit: mm (in)

ITEM (

161.0 6.34 ---

--

Compression pressure

)

)

)

)

(

1.01-1.03 0.0398-0.0406

)

(

1.21-1.23 0.0476-0.0484

)

(

2.51-2.53 0.0988-0.0996

)

(

0.970-0.990 0.0382-0.0390

)

1.170-1.190 0.0461 -0.00469

0.70 0.028

(

(

0.18 0.007

)

(

0.15 0.006

)

--

--

---

--

)

(

20.002-20.008 0.7875-0.7877

)

(

20.030 0.7886

)

(

19.996-20.000 0.7872-0.7874

)

(

19.980 0.7866

)

Piston pin 0.0.

I

SERVICING INFORMATION 10-38

CONROD + CRANKSHAFT

Unit: mm (in)

ITEM

STANDARD

Conrod small end I.D. (

20.01 0-20.018 0.7878-0.7881

)

(

20.040 0.7890

)

(

0.10-0.25 0.004-0.010

)

(

0.30 0.012

)

(

19.95-20.00 0.785-0.787

)

(

40.10-40.15 1.579-1.581

)

(

0.032-0.056 0.0013-0.0022

)

(

39.976-40.000 1.5739-1.5748

)

(

0.020-0.044 0.0008-0.0017

)

(

39.976-40.000 .1.5739-1.5748

)

Conrod big end side clearance Conrod big end width Crank pin width Conrod big end oil clearance Crank pin O.D. Crankshaft journal oil clearance Crankshaft journal O.D. Crankshaft thrust bearing thickness

Left side

I

LIMIT

Right side

Crankshaft thrust clearance

(

(

2.925-2.950 0.115-0.116

)

24.05-24.13 0.947-0.950

)

(

30.00-30.05 1 .181 -1 .183

)

Crankshaft runout

---

----

--

0.05 0.002

(

OIL PUMP + FUEL PUMP + WATER PUMP ITEM Oil pressure (at 60°C, 140°F)

1.756 ( Above Below

)

Unit: mm (in)

STANDARD

Oil pump reduction ratio

)

-)

(

)

0.080 0.0031

(

2.850-3.000 0.112-0.118

)

0.0035 --

(

0.045-0.100 0.0018-0.0039

Crankshaft journal width

-0.090

(

Crankshaft journal holder width

--

72/41

X

LIMIT

37/35

5.0 kg/cm 2 ( 8.0 kg/cm 2 (

71 psi 114 psi at 3 000 r/min.

Fuel pump discharge

Over 500 ml/min.

Fuel pump resistance

1-2 Q

Water pump drive chain 1 0-pitch length

--

--

) ) )

--

--(

CLUTCH

64.5 2.54

)

Unit: mm (in)

ITEM Drive plate thickness

STANDARD No.1 No.2

Drive plate claw width (

LIMIT

(

2.72-2.88 0. 104-0. 11 6

)

(

2.42 0.095

)

(

3.45-3.55 0.128-0.140

)

(

2.58 0.102

)

(

15.0 0.59

)

15.8-16.0 0.62-0.63

)

10-39 SERVICING INFORMATION

ITEM

LIMIT

STANDARD

Driven plate distortion

--

Clutch spring free length

(

--

Clutch master cylinder bore

(

(

14.000-14.043 0.5512-0.5529

)

(

13.957-13.984 0.5495-0.5506

)

(

38.100-38.162 1 .5000-1 .5024

)

(

38.042-38.07 5 1.4977-1.4990

)

Clutch master cylinder piston diam. Clutch release cylinder bore Clutch release cylinder piston diam.

0.1 0.004

)

34.0 1.34

)

----

--

THERMOSTAT + RADIATOR + FAN STANDARD

ITEM

Thermostat valve opening temperature

75.0°

Thermostat valve lift

167°

± 2.7°F

--

)

--

Over 8 mm (0.13 in) at 90°C (194°F)

Radiator cap valve release pressure (

Electric fan thermo-switch operating temperature

± 1.5°C (

LIMIT

E-03

ON

±

105°

OFF E-33

±

0.90 0.1 5 kg/cm 2 12.8 2.1 psi, 90 1 5 kPa

±

± 3°C (

.±.

221°

5.4°F

Approx. 98°C ( 208.4°F

± 3°C (

ON

95°

OFF

Approx. 84°C (

±

203°

--

)

---

)

--

)

5.4°F

183°F

)

--

)

---

Approx. 70 Q

Electric fan relay resistance Thermo-gauge resistance

27.4 Qat 100°C ( 212°F

TRANSM.ISSION

)

Unit: mm (in) Except ratio

ITEM

LIMIT

STANDARD

Primary reduction ratio

1.756 (

72/41

)

--

Secondary reduction ratio

1.000 (

16/16

)

Final reduction ratio

2.666 (

32/12

)

---

Low

2.750 (

33/12

)

--

2nd

1.684 (

32/19

)

3rd

1.250 (

25/20

)

4th

1.000 (

25/25

)

----

Top

0.851 (

23/27

)

--

(

0.10-0.30 0.004-0.012

)

(

5.5-5.6 0.217-0.220

)

(

5.3-5.4 0.209-0.213

)

Gear ratios

Shift fork groove clearance Shift fork groove width Shift fork thickness

(

0.50 0.020

)

--

--

SHAFT DRIVE

Unit: mm (in) STANDARD

ITEM

Secondary bevel gear backlash (

0.05-0.32 0.002-0.013

LIMIT )

--

SERVICING INFORMATION 10-40 ITEM

STANDARD

Final bevel gear backlash

Drive side

LIMIT

0.03-0.64 0.001-0.025

(

(

0.02-0.35 ( 0.0008-0.0138 3-7 kg-em 2.6-6.1 lb-in )

(

3-7 kg-em 2.6-6.1 lb-in

Driven side Secondary drive bevel gear preload Secondary driven bevel gear preload

)

--

)

--

--

)

CARBURETOR SPECIFICATION

ITEM Carburetor type

E-03

E-33 (for CA)

MIKUNI BDS33SS

+-

33 mm (

Bore size I.D. No.

1.30 in

)

+-

24A10

24A20

(

± 100 r/min. 17.0 ± 0.5 mm 0.67 ± 0.02 in

(

11.5 0.45

Idler/min.

950

Fuel level Float height (M.J.)

Main jet

(M.A.J.)

Main air jet

±

+-

-

)

1.0 mm

± 0.04 in #/05

--

)

0.6mm

Jet needle

(J.N.)

5D24

Needle jet

(N.J.)

Y-1

+-

(Th.V.)

#125

+-

Throttle valve

+-

Pilot jet

(P.J.)

#cS

By-pass

(B.P.)

0.8 mm, 0.8 mm, 0.8 mm

Pilot outlet

(P.O.)

0.7 mm

Valve seat

(V.S.)

1.5 mm

Starter jet

(G.S.)

#25

Pilot screw

(P.S.)

PRE-SET

Pilot air jet

(P.A.J. 1 & 2)

PRE-SET

Throttle cable play

++-

(

2-3 mm 0.08-0.12 in

)

(

0.5-1.0 mm 0.02-0.04 in

)

Choke cable play

---

ELECTRICAL

Unit: mm (in)

ITEM Ignition timing

SPECIFICATION

±

7° B.T.D.C Below 1 500 250 r/min. and 35° B.T.D.C. Above 3 000 250 r/min.

Firing order Spark plug

NOTE

±

1·3·2-4 Type Gap

N.D.: X22EPR-GL (

0.6-0.7 0.024-0.028

)

10-41 SERVICING INFORMATION

ITEM

STANDARD

Spark performance

LIMIT

Over 8 (0.3) at 1 atm.

Signal coil resistance

P-G/R,Gr-W/81 B-Y, G-BI

50-200 Q

I

Ignition coil resistance

Primary

2-6Q

0/W-W or B/Y

Secondary

10-25 kQ

Plug capW or B/Y

More than 90 V (AC) at 5 000 r/min.

Generator no-load voltage Regulated voltage

14-15 Vat 5 000 r/min.

Starter motor

Brush length

Limit:

6 (0.24)

Commutator under-cut

Limit:

0.2 (0.008)

Starter relay resistance

MITSUBA

2-6Q

Battery

Fuse size

Type designation

SY50-N 18L-A

Capacity

12V72kC(20Ah)/1 OHR

Standard electrolyte S.G.

1.28 at 20°C (68°F)

Headlight

10 A

Signal

10 A

Ignition

10 A

Tail

10 A

Power source

10 A

CB

Circuit breaker

3A

GD

Audio

3 A, 5 A

GD

ALC

10 A

GD

30A

WATTAGE

Unit:W ITEM

Headlight Tail/Brake light

SPECIFICATION HI

60

LO

55 8/23

Turn signal light

23

Combination meter light

3.4

Turn signal indicator light

3.4

High beam indicator light

1.7

Neutral indicator light

3.4

Oil pressure indicator light

3.4

Cruise indicator light

3.4

Licence light

8

Travel trunk light

5

--

SERVICING INFORMATION 10-42

BRAKE + WHEEL

Unit: mm (in)

ITEM

STANDARD

Rear brake pedal height Brake disc thickness

Above 15 ( 0.6 Front (R. & L.)

(

5.0 0.197

Rear

(

6.7 0.264

Brake disc runout Master cylinder bore

Front

Front

Wheel rim runout

Wheel axle runout

Tire size Tire tread depth

(

4.5 0.18

)

)

(

6.0 0.24

)

(

0.30 0.012

)

15.870-15.913 0.6248-0.6265

)

(

12.700-12.743 0.5000-0.5017

)

(

15.827-1 5.854 0.6231-0.6242

)

(

Front (R. & L.)

)

(R. & L.)

(

42.770-42.820 1.6839-1.6858

)

Rear

(

44.930-44.980 1.7689-1.7709

)

Axial

--

Radial

--

Front

--

Rear

--

Front

130/90-16 67H

Rear

150/90-15 74H

Front

--

Rear

--

---

---

--(

2.0 0.08

)

(

2.0 0.08

)

(

0.25 0.010

)

(

0.25 0.010

)

---

SUSPENSION IT ME

--

)

45.000-45.076 1.7717-1.7746

Front

--

)

(

Rear Brake caliper piston diam.

)

(

12.657-12.684 0.4983-0.4994 42.850-42.926 ( 1.6870-1.6900

Rear Brake caliper cylinder bore

± 0.2 ± 0.008 ± 0.2 ± 0.008

--

Rear Master cylinder piston diam.

LIMIT

--

)

(

1.6 0.06

)

(

2.0 0.08

)

Unit: mm (in)

STANDARD

Front fork stroke (

Front fork spring free length

150 5.9 ) --

121 4.8

(

106 4.2 )

Rear wheel travel

)

NOTE

--

(

(

Front fork oil level

LIMIT

454 17.9 ----

)

10-43 SERVICING INFORMATION

REAR SHOCK ABSORBER AIR PRESSURE (GT model only) SOLO RIDING kPa

DUAL RIDING

kg/cm 2

psi

kPa

psi

kg/cm 2

Empty saddle bags and travel trunk 150-200 1.5-2.0

21-28 300-350 3.0-3.5

43-50

200-300 2.0-3.0

28-43 350-450 3.5-4.5

50-64

Full saddle bags and travel trunk

TIRE PRESSURE SOLO RIDING

DUAL RIDING

MAX. LOAD

COLD INFLATION TIRE PRESSURE

kPa

kg/cm 2

psi

kPa

kg/cm 2

psi

kPa

kg/cm 2

psi

FRONT

225

2.25

32

225

2.25

32

250

2.50

36

REAR

280

2.80

40

280

2.80

40

280

2.80

40

FUEL

+ OIL + COOLANT ITEM

Fuel type

SPECIFICATION

NOTE

Use only unleaded or low-lead type gasoline of at least 85-95 pump octane (R~M method) or 89 octane or higher rated by the Research Method.

Fuel tank including reserve Engine oil type and grade Engine oil capacity

23 L ( 6.1 US gal

)

SAE 1OW/40, API SE or SF Change Filter change Overhaul

Front fork oil type

(

3 200 ml 3.4 us qt

)

(

3 700 ml 3.9 us qt

)

(

4 200 ml 4.4 us qt

)

Fork oil #15

Front fork oil capacity (each leg) (

Bevel gear and propeller shaft oil type Bevel gear oil capacity

Coolant including reserve tank reserve tank

)

SAE 90 hypoid gear oil with GL-5 under API classification Secondary Final

Brake and clutch fluid type

407 ml 13.8 us oz

(

330-350 ml 11.2-11.8USoz

)

(

330-350 ml 11.2-11.8 us oz

)

DOT3 or DOT4 3.6 L (

3.8

0.6 L ( 0.6

us us

qt

)

qt

)

--~1 (Q)~[b't(' ~(Q)~

©&

r-I--S-ER_VI_CIN_G_IN_Fo_RM...;.;.AT.;...,;;IO;....N..;.;;;10....;.;,·44

VAPOR HOSE ROUTING

Charge hose No. 1 *Painted line in red (From fuel tank)

Charge hose No. 1 (From fuel tank)

¢Front

Charge hose No. 1 *Painted line in red (From fuel tank)

Clip

¢Front

Charcoal canister Front

¢:J

Clip

Charge hose No. 1 (From fuel tank)

Rear fender

¥

Fuel tank breather valve

Charcoal Fuel tank

~ Rear fender

Cl

"'0

Ul

:::0 ::I:

en m :::u

0

0

(/)

m n

r-

)>

s: "'0 "'0

0(/)

---4

0

Clamp--Clutch hose

...

< )>

.i::o

::::;

52 2

C)

..,2 0

:::u

:s:

)>

:::! 0

2

z

.. I Clamp Starter cable

Rear suspension hose (GO model)

@ ~

~ c:uu

@ ~ Starter cabie Clutch hose Clamp

(Q) ~

---1 [p(Q)~ &[b[b ~(Q)[g)~[b~~~

_SER_V_ICI_NG_IN_FO_RM_AT_IO_N_10-_46

NOTE: Hose routing has been changed as follows. Routing illustrations for the early type are shown in the pages 10-17 and 10-23. Pages 10-44 and 10-45 are exclusive for CA model. FUEL HOSE AND FUEL TANK BREATHER HOSE ROUTING

Fuel tank breather hose

Fuel tank breather hose

Pass the fuel tank breather hose above the frame bridge. Fuel tank Fuel hose breather hose Clamp Fuel tank

Separate tank fuel hose

Separate tank breather hose Fuel tank breather hose Clamp Pass the fuel tank breather hose inside the separate tank breather hose. Fuel tank breather hose Clamp

Clamp (Wiring harness and pillon footrest cable)

Clamp (Radio control lead, Antenna cable and rear headphone set lead) Clamp (Antenna cable and pillion footrest cable)

Separate fuel tank breather hose

Clamp (Wiring harness, Radio control lead, Antenna cable and Rear headphone set lead)

Antenna cable

~~=:::;:~~i(f~~tj.~- Clamp (Fuel tank breather hose, Rear turn signal lead wire ( L)) Clamp (Rear turn signal lead wire(L))

Separate tank fuel hose Connector

Rear turn signal lead wire ( L)

GV1400GCG ('86-MODEL)

FOREWORD This section descrilbes service data and servicing procedures which differ from those of the GV1400GTG!GDG ('86-model).

NOTE: Any differences between GV1400GTG!GDG and GV1400GCG in specifications and service data are clearly indicated with the asterisk marks (*). Refer to the previous section for details which are not given in this section.

~-------------------CONTENTS--------------------~

VIEW OF SUZUKI GV1400GCG ................................................. 11- 1 SPEC/FICA TIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11- 2 SERVICE DATA ·········································································· 11- 3 TIGHTENING TORQUE································································ 11-11 MOD/FICA TIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · 11-14 FAIRING EXTENSION WITH VENTILATION SYSTEM·············· 11-14 ENGINE GUARD AND CORNERING LAMP · · ... · ... · ·· · · ·· · ··· · ·· · · · ·· · · 11-21 CORNERING LAMP RELAY AND IGNITION SWITCH · · ··· · · ·· · · · · · · 11-23 AIR SEAT··············································································· 11-25 REAR SPEAKERS AND CO-RIDER'S CONTROL SWITCH · · · · · ·· · 11-28 BRAKES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 11-32 CABLE, HARNESS AND HOSE ROUTING · ··· · · · · · ·· · · · ·· · · · ·· · ·· · · ·· · · · · ... 11-38 EMISSION CONTROL CARBURETOR COMPONENTS ·· · ·· · · ·· · · ·· ·· · · 11-51 WIRING DIAGRAM···························································· ATTACHED

11-1 GV14DOGCG ('86-MODEL)

VIEW OF SUZUKI GV1400GCG

RIGHT SIDE

LEFT SIDE

GV1400GCG ('86-MODEL) 11·2

SPECIFICATIONS DIMENSIONS AND DRY MASS

CHASSIS Front suspension

Telescopic, coil spring, oil damped

Rear suspension

Swinging arm, pneumatic/ coil spring, oil damped with Suzuki Auto Leveling system

780 mm (30.8 in)

Steering angle

35° (right & left)

*366 kg (807 lbs) *367 kg (809 lbs) .............. for CA

Caster

61°

Trail

119 mm (4.7 in)

Turning radius

3.3 mm (10.8 ft)

Front brake

Disc brake, twin

Rear brake

Disc brake

Front tire size

130/90-16 67 H

Rear tire size

150/90-15 74H

Overall length

2530 mm (99.6 in)

Overall width

935 mm (36.8 in)

Overall height

*1620 mm (63.8 in)

Wheelbase

1670 mm (65.7 in)

Ground clearance

130 mm (5.1 in)

Seat height Dry mass

ENGINE Type

Four-stroke, water-cooled, DOHC, 82-degree V-four

Number of cylinders

4

Bore

B1.0 mm (3.189 in)

Front fork stroke

150 mm (5.9 in)

Stroke

66.0 mm (2.598 in)

Rear wheel travel

106 mm (4.2 in)

Piston displacement

1360cm 3 (83.0cu. in)

Compression ratio

9.5: 1

Carburetor

MIKUNI BDS 33 SS

Air cleaner

Polyester fiber element

Starter system

Electric

Lubrication system

Wet sump

TRANSMISSION

ELECTRICAL Ignition type

Transistorized

Ignition timing

B.T.D.C. below 1500 r/min and 35° B.T.D.C. above 3000 r/min

Spark plug

N.D.: X22EPR-GL

Battery

12V 72 kC (20Ah)/1 OH R

r

Generator

Clutch

Wet multi-plate type, hydraulically operated

Three-phase A.C. generator

Fuse

10/10/10/10/10/5/3/1 OA

Transmission

5-speed constant mesh

Circuit breaker

30A

Gearshift pattern

1-down, 4-up

Primary reduction

1.756 (72/41)

Secondary reduction

1.000 (19/19)

Fuel tank

23 L (6.1 US gal)

Final reduction

2.666 (32/12)

Gear ratios, Low 2nd 3rd 4th Top

2.750 1.684 1.250 1.000 0.851

Engine oil with filter change

3.2 L (3.4 US qt) 3.7 L (3.9 US qt)

Front fork oil

482 ml (16.3 US oz)

Secondary gear oil

330-350 ml ( 11.2 - 11.8 US oz)

Drive system

Shaft drive

Final gear oil

330-350 ml (11.2 -11.8 USoz)

(33/12) (32/19) (25/20) (25/25) (23/27)

CAPACITIES

Coolant including reservoir tank reservoir tank

3.6 L (3.8 US qt) 600 ml (0.6 US qt)

These specifications are subject to change without notice. Asterisk mark(*) indicates the New GV1400GCG specifications.

11-3 GV1400GCG ('86-MODELJ

SERVICE DATA VALVE+ GUIDE

Unit: mm (in)

Valve diam.

Valve lift

IN.

(

EX.

(

IN

IN.

(

EX.

(

IN. & EX.

(

IN.

(

EX. Valve stem runout Valve head thickness Valve stem end length Valve seat width Valve head radial runout

--

)

--

)

6.0 ) 0.24 0-0.2 0-0.008 ) 0.020-0.04 7 0.0008-0.0019 0.035-0.062 0.0014-0.0024 5.000-5.012 0.1969-0.1973 4.965-4.980 0.1955-0.1961 4.950-4.965 0.1949-0.1955

(

Valve stem O.D.

--

)

--

(

Lash-adjuster plunger stroke Valve guide to valve stem clearance

30.0 1.18 26.0 1.02 7.0 0.28

(

EX.

Valve guide I.D.

LIMIT

STANDARD

ITEM

(

IN. & EX.

--

IN. & EX.

-·-

IN. & EX.

--

IN. & EX.

(

--

)

(

(

)

Valve spring free length

--

) ( ( (

9.4-11.0 kg 20.7-24.3 lbs ) at length 31.5 mm ( 1.24 in

(

(

Camshaft runout

0.03 0.001 34.5 1.36

) )

LIMIT

STANDARD IN. EX.

Camshaft journal O.D.

)

Unit: mm (in)

ITEM

Camshaft journal holder I.D.

)

)

CAMSHAFT+ CYLINDER HEAD

Camshaft journal oil clearance

)

--

(

Cam height

0.05 0.002 0.5 0.02 3.3 0.13

--

)

--

Valve spring tension

)

--

)

--

IN. & EX.

)

--

)

0.9-1.1 0.035-0.043

0.35 0.014 0.35 0.014

( (

IN. & EX.

(

IN. & EX.

(

IN. & EX. IN. & EX.

(

32.652-32.692 1.2855-1.2871 32.065-32.105 1.2624-1.2640 0.032-0.066 0.0013-0.0026 22.012-22.025 0.8666-0.8671 21.959-21.980 0.8645-0.8654 --

)

(

)

(

)

(

32.36 1.274 31.77 1.251 0.150 0.0060

) ) )

--

)

--

) (

0.10 0.004

)

GV1400GCG ('86-MODEL) 11-4

ITEM

STANDARD

Cam chain 20-pitch length Cam chain pin (at aligning mark)

LIMIT

--

(

Front

18th pin

Rear

18th pin

Idler chain 20-pitch length

(

--

(

CYLINDER+ PISTON+ PISTON RING STANDARD

Compression pressure

10-14 142-200 psi

Compression pressure difference

8 kg/cm 2 114 psi )

(

2 kg/cm 2 28 psi )

)

(

0.120 0.0047

)

(

81.000-81.015 3.1890-3.1896

)

(

81.085 3.1923

)

(

80.880 3.1842

)

(

0.10 0.004

)

80.950-80.965 ( 3.1870-3.1876 ) Measure at 14 mm (0.6 in) from the skirt end.

-(

10.5 0.41

)

(

8.4 0.33

)

(

11.7 0.46

)

(

9.4 0.37

)

)

(

0.70 0.028

)

)

(

0.70 0.028

)

(

0.18 0.007

)

(

0.15 0.006

)

1st

R

Approx.

2nd

R

Approx.

1st

R

(

0.20-0.35 0.008-0.014

2nd

R

(

0.20-0.35 0.008-0.014

1st

--

2nd

--

1st 2nd Oil

Piston ring thickness

(

0.045-0.055 0.0018-0.0022

Cylinder distortion

Piston ring groove width

)

(

Cylinder bore

Piston ring to groove clearance

)

--

Piston to cylinder clearance

Piston ring end gap

0.10 0.004

LIMIT

kg/cm 2

(

Piston ring free end gap

)

Unit: mm (in)

ITEM

Piston diam.

161.0 6.34 --

29th pin

Cylinder head distortion

)

---

--

Idler chain pin (at aligning mark)

161.0 6.34

1st 2nd

Piston pin bore

(

1.01-1.03 0.0398-0.0406

)

(

1.21-1.23 0.04 76-0.0484

)

(

2.51-2.53 0.0988-0.0996

)

(

0.970-0.990 0.0382-0.0390

)

(

1 .170-1.190 0.0461-0.0469

)

------

(

20.002-20.008 0.7875-0.7877

)

(

20.030 0.7886

)

(

19.996-20.000 0. 7872-0.7874

)

(

19.980 0.7866

)

Piston pin 0.0.

11-5 GV1400GCG ('86-MODELl

CONROD +CRANKSHAFT

Unit: mm (in)

(

20.010-20.018 0. 7878-0.7881

)

(

20.040 0.7890

)

(

0.10-0.25 0.004-0.010

)

(

0.30 0.012

)

(

19.95-20.00 0.785-0.787

)

(

40.10-40.15 1.579-1.581

)

(

0.032-0.056 0.0013-0.0022

)

(

39.976-40.000 1.5739-1.5748

)

(

0.020-0.044 0.0008-0.0017

)

(

39.976-40.000 1.5739-1.5748

)

Conrad small end I.D. Conrad big end side clearance Conrad big end width Crank pin width Conrad big end oil clearance Crank pin O.D. Crankshaft journal oil clearance Crankshaft journal O.D. Crankshaft thrust bearing thickness

LIMIT

STANDARD

ITEM

Left side Right side

)

)

(

30.00-30.05 1.181 -1 .183

)

Crankshaft journal width Crankshaft runout

--

-----

--

0.05 0.002

(

OIL PUMP+ FUEL PUMP+ WATER PUMP 1.756 (

Oil pump reduction ratio

LIMIT

72/41

X

37/35

--

)

Above 5.0 kg/cm 2 ( 71 psi ) Below 8.0 kg/cm 2 ( 114 psi ) at 3 000 r/min.

--

Fuel pump discharge

Over 500 ml/min.

--

Fuel pump resistance

1-2Q

--

Water pump drive chain 1 0-pitch length

--

Oil pressure (at 60°C, 140°F)

)

Unit: mm (in)

STANDARD

ITEM

)

--

2.925-2.950 0.115-0.116

24.05-24.13 0.947-0.950

0.080 0.0031

(

(

(

)

--

)

)

0.090 0.0035

(

2.850-3.000 0.112-0.118

0.045-0.100 0.0018-0.0039

Crankshaft journal holder width

--

(

(

Crankshaft thrust clearance

--

(

CLUTCH

64.5 2.54

)

Unit: mm (in)

Drive plate thickness

LIMIT

STANDARD

ITEM No.1

(

2.72-2.88 0.104-0.116

)

(

2.42 0.095

)

No.2

(

3.45-3.55 0.128-0.140

)

(

2.58 0.102

)

(

15.0 0.59

)

Drive plate claw width (

15.8-16.0 0.62-0.63

)

GV1400GCG ('86-MODEL) 11-6

ITEM

STANDARD

Driven plate distortion

LIMIT

--

Clutch spring free length

(

--

14.000-14.043 0.5512-0.5529

)

(

13.957-13.984 0.5495-0.5506

)

(

38.100-38.162 1.5000-1.5024

)

(

38.042-38.075 1.4977-1.4990

)

Clutch master cylinder piston diam. Clutch release cylinder bore Clutch release cylinder piston diam.

)

34.0 1.34

(

(

Clutch master cylinder bore

0.1 0.004

)

--

----

THERMOSTAT+ RADIATOR+ FAN STANDARD

LIMIT

75.0° ± 1.5°C ( 167°±2.7°F )

--

ITEM Thermostat valve opening temperature

Over 8 mm ( 0.13

Thermostat valve lift Radiator cap valve release pressure

(

Electric fan thermo-switch operating temperature

E-03 E-33

0.90 ± 0.1 5 kg/cm 2 12.8 ± 2.1 psi, 90 ± 15 kPa

--

)

ON

105° ± 3°C ( 221° ± 5.4°F )

OFF

Approx. 98°C ( 208.4°F )

ON

95° ± 3°C ( 203° ± 5.4°F )

OFF

Approx. 84°C ( 183°F )

-----

Approx. 70 Q

--

27.4 Qat 100°C ( 212°F )

--

Electric fan relay resistance Thermo-gauge resistance

--

in) at 90°C ( 194°F )

TRANSMISSION

Unit: mm (in) Except ratio

ITEM

STANDARD

LIMIT

Primary reduction ratio

1.756

(

72/41

)

--

Secondary reduction ratio

1.000 (

16/16

)

--

Final reduction ratio

2.666 (

32/12

)

Low

2.750 (

33/12

)

2nd

1.684

(

32/19

)

3rd

1.250 (

25/20

)

-----

4th

1.000 (

25/25

)

--

Top

0.851 (

23/27

)

--

(

0.10-0.30 0.004-0.012

)

(

5.5-5.6 0.217-0.220

)

(

5.3-5.4 0.209-0.213

)

Gear ratios

Shift fork groove clearance Shift fork groove width Shift fork thickness

(

0.50 0.020

---

)

11-7 GV14DOGCG ('86-MODEL)

SHAFT DRIVE

Unit: mm (in) STANDARD

ITEM

Secondary bevel gear backlash

0.05-0.32 0.002-0.013

(

Final bevel gear backlash

LIMIT

Drive side Driven side

(

0.03-0.64 0.001 -0.025

)

(

0.02-0.35 0.0008-0.0138

)

(

3-7 kg-em 2.6-6.1 lb-in

)

(

3-7 kg-em 2.6-6.1 lb-in

)

Secondary drive bevel gear preload Secondary driven bevel gear preload

--

)

----

CARBURETOR SPECIFICATION

ITEM

E-03

E-33 (for CA)

Carburetor type

MIKUNI BDS33SS

+-

Bore. size

33mm ( 1.30 in )

+-

24A10

24A20

I.D. No.

± 100 r/min. 17.0 ± 0.5 mm

Idle r/min.

950

Fuel level

± 11.5 ± 0.45 ±

( 0.67

0.02 in )

(

1.0 mm 0.04 in )

Float height (M.J.)

Main jet

(M.A.J.)

Main air jet

+-

+-

+-

#/05

+-

0.6mm

+-

Jet needle

(J.N.)

5D24

+-

Needle jet

(N.J.)

Y-'7

+-

#125

++-

(Th.V.)

Throttle valve Pilot jet

(P.J.)

#25

By-pass

(B.P.)

0.8 mm, 0.8 mm, 0.8 mm

+-

Pilot outlet

(P.O.)

0.7mm

+-

Valve seat

(V.S.)

1.5 mm

+-

Starter jet

(G.S.)

#25

+-

Pilot screw

(P.S.)

PRE-SET

+-

Pilot air jet

(P.A.J. 1 & 2)

PRE-SET

+-

Throttle cable play

2-3mm

+-

( 0.08-0.12 in )

Choke cable play (

0.5-1.0 mm 0.02-0.04 in )

+-

ELECTRICAL

Unit: mm (in) ITEM

Ignition timing Firing order

SPECIFICATION

7° B.T.D.C Below 1 500 35° B.T.D.C. Above 3 000 1·3·2·4

NOTE

± 250 r/min. and ±

250 r/min.

GV1400GCG ('86-MODEL) 11-8

ITEM

SPECIFICATION

Spark plug

Type

N.D.: X22EPR-GL

Gap

(

Spark performance

0.6-0.7 0.024-0.028

)

Over 8 (0.3) at 1 atm.

Signal coil resistance

P-Lg/R, Gr-BI/W

50-200 Q

Ignition coil resistance

Generator no-load voltage

Primary

2-6 Q

0/W-W or B/Y

Secondary

10-25 kQ

Plug capW or B/Y

More than 90 V (AC) at 5 000 r/min. 14-15 V at 5 000 r/min.

Regulated voltage Starter motor

Starter relay resistance

Brush length

Limit:

6 ( 0.24)

Commutator under-cut

Limit:

0.2 (0.008)

*108-162 Q

Type designation Capacity

SY50-N 18L-A 12V 72 kC (20 Ah)/1 0 HR

Standard electrolyte S.G.

1.28 at 20°C (68°F)

Headlight

10 A

Signal

10 A

Ignition

10 A

Tail

10 A

Power source

10 A

Fuse size

MITSUBA

2-6 Q

Cornering light relay resistance Battery

NOTE

CB

3A

Audio

5A

ALC

10 A

Circuit breaker

30A

WATTAGE

Unit:W SPECIFICATION

ITEM

Headlight

HI

60

LO

55

Tail/Brake light Turn signal light Cornering light

8/23 23 *35

Combination meter light

3.4

Turn signal indicator light

3.4

High beam indicator light

1. 7

Neutral indicator light

3.4

Oil pressure indicator light

3.4

Cruise indicator light

3.4

License light

8

Travel trunk light

5

Asterisk mark ( *) indicates the New GV 1400GCG specifications.

11-9 GV1400GCG ('86-MODELJ

BRAKE+ WHEEL+ VENTILATOR

Unit: mm (in) STANDARD

ITEM

Above 15 ( 0.6

Rear brake pedal height Brake disc thickness

Front (R. & L.) Rear

Brake disc runout Master cylinder bore

Brake caliper cylinder bore

Wheel rim runout

Wheel axle runout

Tire size Tire tread depth

5.0 0.197

(

6.7 0.264

± 0.2 ± 0.008 ± 0.2 ± 0.008

)

(

4.5 0.18

)

)

(

6.0 0.24

)

(

0.30 0.012

)

(

15.870-15.913 0.6248-0.6265

)

(

12.700-12.743 0.5000-0.5017

)

(

15.827-15.854 0.6231 -0.6242

)

Rear

(

12.657-12.684 0.4983-0.4994

)

Front (R. & L.)

(

42.850-42.926 1.6870-1.6900

)

(

45.000-45.076 1.7717-1.7746

)

(R. & L.)

(

42.770-42.820 1.6839-1.6858

)

Rear

(

44.930-44.980 1. 7689-1.7709

)

Front

Front

Rear Brake caliper piston diam.

(

--

)

--

Rear Master cylinder piston diam.

LIMIT

Front

------

---

(

2.0 0.08

)

(

2.0 0.08

)

(

0.25 0.010

)

(

0.25 0.010

)

Axial

--

Radial

--

Front

--

Rear

--

Front

130/90-16 67H

--

Rear

150/90-15 74H

--

Front

--

Rear

-*0.5-1.0 0.02-0.04

Ventilator control cable play (

(

1.6 0.06

)

(

2.0 0.08

)

--

)

SUSPENSION IT ME

--

Unit: mm (in) STANDARD

Front fork stroke (

Front fork spring free length

150 5.9 ) --

Front fork oil level (

121 4.8

)

(

NOTE

--

(

106 4.2 ) Asterisk mark(*) indicates the New GV1400GCG specification. Rear wheel travel

LIMIT

454 17.9 ---

)

GV1400GCG ('86-MODEL) 11-10

TIRE PRESSURE DUAL RIDING

SOLO RIDING

COLD INFLATION TIRE PRESSURE

kPa

kg/cm 2

psi

kPa

kg/cm 2

psi

FRONT

225

2.25

32

225

2.25

32

REAR

280

2.80

40

280

2.80

40

FUEL + OIL + COOLANT SPECIFICATION

ITEM

Use only unleaded or low-lead type gasoline of at least 85-95 pump octane (R+M method) or 89 octane or higher rated by th~ Research Method.

Fuel type

23 L (

Fuel tank including reserve

6.1 US gal

)

SAE 1OW/40, API SE or SF

Engine oil type and grade Engine oil capacity

(

3 200 ml 3.4 us qt

)

Filter change

(

3 700 ml 3.9 us qt

)

Overhaul

(

4 200 ml 4.4 us qt

)

Change

Fork oil #15

Front fork oil type Front fork oil capacity (each leg) (

Bevel gear and propeller shaft oil type Bevel gear oil capacity

NOTE

407 ml 13.8 us oz

)

SAE 90 hypoid gear oil with GL-5 under API classification

Secondary

(

330-350 ml 11.2-11.8 us oz

)

Final

(

330-350 ml 11.2-11.8 us oz

)

Brake and clutch fluid type

*DOT4

Coolant including reserve tank

3.6 L ( 3.8

reserve tank

0.6 L ( 0.6

us us

Asterisk mark(*) indicates the New GV1400GCG specification.

qt

)

qt

)

11-11 GV1400GCG ('86-MODELI

TIGHTENING TORQUE ENGINE ITEM

N·m

kg-m

lb-ft

Camshaft journal holder bolt

23-27

2.3-2.7

16.5- 19.5

Cylinder head bolt

46-51

4.6-5.1

33.5-37.0

Cylinder head cover bolt

13- 15

1.3- 1.5

9.5- 11.0

8-12

0.8- 1.2

6.0-8.5

49-53

4.9-5.3

35.5-38.5

12 mm

60-70

6.0-7.0

43.5-50.5

10 mm

45-55

4.5-5.5

32.5-40.0

8mm

24

2.4

17.5

6mm

13

1.3

9.5

8 mm Allen bolt

20-28

2.0-2.8

14.5-20.0

6 mm Allen bolt

12- 16

1.2- 1.6

8.5- 11.5

25-30

2.5 - 3.0

18.0-21.5

8-12

0.8- 1.2

6.0-8.5

20-25

2.0-2.5

14.5- 18.0

150-170

15.0- 17.0

108.5 - 123.0

7-9

0.7-0.9

5.0-6.5

50-60

5.0-6.0

36.0-43.5

7- 11

0.7- 1.1

5.0-8.0

Water pump drive sprocket bolt

50-60

5.0-6.0

36.0-43.5

Water pump drain plug

10- 14

1.0- 1.4

7.0- 10.0

Clutch sleeve hub nut

50-70

5.0-7.0

36.0-50.5

Clutch spring bolt

11 - 13

1.1 - 1.3

8.0-9.5

Cam chain tensioner bolt

20-25

2.0-2.5

14.5- 18.0

8-12

0.8- 1.2

6.0-8.5

20-25

2.0-2.5

14.5- 18.0

8-12

0.8- 1.2

6.0-8.5

Exhaust pipe clamp bolt

20-25

2.0-2.5

14.5- 18.0

Muffler mounting bolt

27-43

2.7-4.3

19.5- 31.0

Radiator mounting bolt

7-9

0.7-0.9

5.0-6.5

Engine mounting bolt (Front & Rear lower)

70-88

7.0-8.8

50.0-64.0

Engine mounting (Rear upper)

60-72

6.0-7.2

43.5-52.0

60-65

6.0-6.5

43.5-47.0

30-35

3.0-3.5

21.5- 25.5

18-28

1.8-2.8

13.0-20.0

Cylinder head nut Con-rod bearing cap bolt Crankcase bolt

Oil pressure regulator Oil pan bolt Engine oil drain plug Rotor bolt Oil pump bolt Idler shaft driven sprocket bolt Water pump bolt

Chain tensioner adjuster bolt Cam chain tensioner spring holder Cam chain guide bolt

Down tube mounting bolt Engine mounting bracket bolt

GV1400GCG ('86-MODEL) 11-12

SHAFT DRIVE lb-ft

N·m

kg-m

120- 150

12.0- 15.0

87.0- 108.5

20-26

2.0-2.6

14.5- 19.0

120- 150

12.0- 15.0

87.0- 108.5

6mm

8-12

0.8-1.2

6.0-8.5

8mm

20-26

2.0-2.6

Secondary gear case bolt

20-26

2.0-2.6

14.5- 19.0

Final drive bevel gear nut

90- 130

9.0- 13.0

65.0-94.0

8-10

0.8-1.0

6.0-7.0

Final gear bearing case bolt

20-26

2.0-2.6

14.5- 19.0

Final drive bevel gear coupling nut

90- 110

9.0- 11.0

65.0-79.5

Final driven bevel gear adjuster lock nut

40-60

4.0-6.0

29.0-43.5

N·m

kg-m

lb-ft

Steering stem head nut

30-40

3.0-4.0

21.5-29.0

Front fork upper clamp bolt

15-25

1.5-2.5

11.0-'- 18.0

Front fork lower clamp bolt

20-25

2.0-2.5

14.5-18.0

Front fork cap bolt

15-30

1.5-3.0

11.0- 21.5

Front fork damper rod bolt

34-46

3.4-4.6

24.5-33.5

Front axle nut

36-52

3.6-5.2

26.0-37.5

Front axle clamp nut

15-25

1.5-2.5

11.0-18.0

5-8

0.5-0.8

3.6-6.0

Front caliper mounting bolt

25-40

2.5-4.0

18.0-29.0

Front caliper housing bolt

30-36

. 3.0-3.6

.21.5- 26.0

Brake hose union bolt (Front & Rear)

20-25

2.0-2.5

14.5- 18.0

6-9

0.6-0.9

4.5-6.5

Handlebar holder nut

30-40

3.0-4.0

21.5-29.0

Handlebar clamp bolt

25-30

2.5-3.0

18.0-21.5

Disc plate bolt (Front & Rear)

15-25

1.5-2.5

11.0- 18.0

Auto level hose mounting nut

10- 16

1.0- 1.6

7.0- 11.5

7-9

0.7-0.9

5.0-6.5

Front footrest bolt

27-43

2.7-4.3

19.5-31.0

Rear axle nut

85- 115

8.5- 11.5

61.5-83.0

8-12

0.8-1.2

6.0-8.5

20-30

2.0-3.0

14.5-21.5

7-9

0.7-0.9

5.0-6.5

Rear swingarm pivot bolt

3.5-4.5

0.35-0.45

2.5-3.0

Rear swingarm pivot nut

110- 130

11.0- 13.0

79.5-94.0

ITEM

Secondary driven bevel gear nut Secondary driven bevel gear housing bolt Secondary drive bevel gear nut Secondary drive bevel gear housing bolt

Final driven gear bearing retainer screw

14.5- 19.0

1

CHASSIS ITEM

Front brake master cylinder bolt

Air bleeder valve (Front & Rear)

Air compressor hose union bolt

Rear wheel driven joint bolt Rear shock absorber nut (Upper & Lower) Rear shock absorber air valve

11-13 GV1400GCG ('86-MODEL)

N·m

kg-m

lb-ft

Rear caliper mounting bolt

25-40

2.5-4.0

18.0-29.0

Brake pedal link nut

15-25

1.5-2.5

11.0- 18.0

Rear caliper housing bolt

28-32

2.8-3.2

20.0-23.0

Brake pedal link arm bolt

10- 15

1.0- 1.5

7.0- 11.0

Rear torque link nut (Front & Rear)

20-30

2.0-3.0

14.5- 21.5

Rear brake master cylinder bolt

15-25

1.5- 2.5

11.0- 18.0

Rear brake rod lock nut

15-25

1.5-2.5

11.0- 18.0

Rear axle clamp bolt

18-28

1.8-2.8

13.0-20.0

5-8

0.5-0.8

3.5-6.0

ITEM

Clutch master cylinder bolt

TIGHTENING TORQUE CHART For other bolts and nuts not listed above, refer to this chart: Bolt Diameter ® (mm)

N·m

kg-m

lb-ft

N·m

4

1.0-2.0

0.1 -0.2

0.7-1.5

1.5-3.0

0.15-0.3

1.0-2.0

5

2.0-4.0

0.2-0.4

1.5-3.0

3.0-6.0

0.3-0.6

2.0-4.5

6

4.0-7.0

0.4-0.7

3.0-5.0

8.0- 12.0

0.8- 1.2

6.0-8.5

8

10.0- 16.0

1.0- 1.6

7.0- 11.5

18.0-28.0

1.8-2.8

13.0-20.0

10

22.0-35.0

2.2-3.5

16.0-25.5

40.0-60.0

4.0-6.0

29.0-43.5

12

35.0-55.0

3.5 - 5.5

25.5-40.8

70.0- 100.0

7.0-10.0

50.5 -72.5

14

50.0-80.0

5.0-8.0

36.0-58.0 110.0- 160.0

11.0- 16.0

79.5- 115.5

16

80.0- 130.0

8.0- 13.0

58.0-94.0 170.0 - 250.0

17.0-25.0 123.0-181.0

18

130.0- 190.0

13.0- 19.0

Conventional or "4" marked bolt

Conventional bolt

"7" marked bolt kg-m

lb-ft

94.0- 137.5 200.0 - 280.0 20.0-28.0 144.5 - 202.5

"4" marked bolt

"7" marked bolt

GV1400GCG ('86-MODEL) 11-14

MODIFICATIONS FAIRING EXTENSION WITH VENTILATION SYSTEM

f

'f

~~-J

-:: I ,

I \ ~

..,.... ..0

-

0

LO

co

"3"

I q

0

...,; t"'i

0

I

ai

LO

N

co

0

E cri cO c, I I

..:.:: q

" co

0

...,; 0

E co co

z

I

0

" :2

w 1-

I

0 "3"

@@

11-15 GV1400GCG ('86-MOOEL)

REMOVAL • Loosen the screw CD and pull out four snap fasteners. • Remove the left frame cover.

-

11\JIIIVVW

LIIV

LVVV

;)\,lt;;VV;)

\.6)

OIIU

I~IIILIUII

;:tVVIl\...11

ring by turning it counter-clockwise. NOTE: When turning the switch ring, turn the handlebar cover with it.

GV1400GCG ('86-MODELI 11-16

• Disconnect the coupler and remove the handlebar cover. • Remove the screw CD and bolt ®.

• Remove the screws® and@, and dismount the upper frame cover.

• Remove the headlight adjusting knob.

• Pull out the speaker cover and remove the left cowl box and cowl panel. • Pull out the ventilator lever knob.

11-17 GV14DOGCG ('86-MODELJ

• Disconnect the ALC switch lead coupler and driver's seat switch lead wire coupler. • Disconnect the hoses from the seat switch panel and remove the cowl panel.

• Remove the map case and cowl box after disconnecting the fuse box lead wire coupler. • Pull out the speaker cover and cowl panel.

• Remove the lower side panel CD. • Remove the fairing extension screws

®.

• Remove the screw @ and dismount the leg shield.

NOTE: Remove the left fairing extension in the same manner as right one.

GV1400GCG ('86-MODELJ 11-18

• Remove the fairing extension cover screws®.

CD

loosening

CAUTION:

Do not lose tiny screws

®, washers and nuts.

• Loosen the two clamp screws and disconnect the control cables, ® for opening and ® closing the ventilator.

• Pull out the inner cover@.

• Disconnect each cable from the control lever. • Remove the two screws CD and remove the control lever.

11-19 GV1400GCG ('86-MODELl

• Remove the reel

CD

and lower bracket

®.

REMOUNTING • After mounting the ventilator to the fairing extension as shown in the Fig., check that the ventilator moves smoothly without any stickiness.

• Route the two longer control cables upper side of the reservoir hose @.

• Route the other two cables as shown in the Fig.

GV1400GCG ('86-MODEL) 11·20

• Temporarily route the two cables through the upper part of the grill of the bottom fairing.

• Install the longer one CD of the two cables to the reel for closing ventilator. • Clamp the two cables at the proper position.

®

Closing cable for left ventilator

@ Closing cable for right ventilator

©

@

Opening cable for left ventilator Opening cable for right ventilator

• Apply SUZUKI super grease "A" to the slider® of the ventilator lever.

• When connecting the driver's seat hoses to the switch, connect the "4" hose to the "BACK" switch and "5" hose to the "CUSHION" switch respectively.

11-21 GV1400GCG ('86-MODEL)

• Before assembling the bottom fairing and fairing extension, adjust the cable play ® to 0.5 - 1.0 mm (0.02 - 0.04 in) by turning the adjuster CD. • Make sure that the ventilators open or close completely when sliding the lever up or down.

NOTE:

Check the cable play if the lever does not operate smoothly.

ENGINE GUARD AND CORNERING LAMP REMOVAL • After removing the bottom fairing unclamp the cornering lamp lead wire. NOTE:

When replacing the cornering lamp bulb, it is not necessary to remove the engine guard.

• Disconnect the cornering lamp lead wire coupler.

NOTE:

Cornering lamp lead wire is clamped under the cornering lamp cover at two positions.

• Remove the engine guard mounting bolts and dismount the engine guard.

GV1400GCG ('86-MODEL) 11-22

• Remove the cornering lamp cover from the engine guard. This lamp cover is mounted on the rubbers.

NOTE: When reinstalling the lamp cover, install the rubber dampers, washers and spacers properly.

• Take off the boot from the lamp reflector.

NOTE: When reinstalling the boot, face the "TOP" mark on the boot to the upside.

• Unhook the spring and disconnect the bulb lead wire. • Remove the cornering lamp assembly from the engine guard. Cornering lamp is float-mounted on the engine guard and install the rubbers, washers and spacers properly.

• When reassembling, first install the cornering lamp covers.

11-23 GV1400GCG ('86-MODEL)

CORNERING LAMP RELAY AND IGNITION SWITCH • Remove the emblem from the center cowl cover CD, right and left cowl covers. • Remove the center cowl cover and window screen®.

• Remove the rear view mirrors.

• Remove the right and left main fairings.

• Disconnect the three cornering lamp relay couplers. • Remove the cornering lamp relay ® from the bracket. • The bracket is mounted on the monitor unit@.

GV1400GCG ('86-MODEL) 11-24

• Separate circuit is added on the GO-model wiring harness because of the addition of the two cornering lamps. • Disconnect the ignition switch lead wire couplers CD and CV.

•

Remove the ignition switch from the front fork upper bracket using hexagon wrench.

INSPECTION IGNITION SWITCH Inspect the ignition switch with the pocket tester referring to the table at right. If any abnormality is found, replace it with a new one.

CORNERING LAMP RELAY Check the cornering lamp relay for "open", "ground" and ohmic resistance. The coil is in good condition if the coil resistance is as follows and continuity is found between CD and CV terminals when applying DC12V to the terminals ® (+)and

® (-). Cornering lamp relay resistance

®-®

135 ± 20%

n

R/P p

ON ACC OFF LOCK

R/W

Q- t=Q

0

o--1--0-~ o-- t=Q

Gr

Br

R/BI

R/B

-o

o-- t-o

o- t-o o-- t-o

11-25 GV1400GCG ('86-MODEL)

AIR SEAT REMOVAL • Remove the left cowl panel from the motorcycle. • Remove the driver's seat switch from the cowl panel.

• Separate the switch panel, rubber and switch body.

• Remove the audio box. • The two driver's seat air hoses are routed between two ignition coils as shown in the Fig. NOTE: Each hose has identification number on it. "4" hose is connected to the seat back and to the back switch. "5" hose is connected to the seat cushion and to the cushion switch.

• The two hoses CD and ® are clamped on the right frame tube at four positions.

GV1400GCG ('86-MODEL) 11-26

• After removing the four clamps remove the two hoses from the frame.

INSPECTION • Connect the pocket tester to the two lead wire of the driver's seat switch. • When pushing the "IN" button of the back or cushion switch, continuity is found. If there is no continuity, replace the switch assembly with a new one.

REMOUNTING • After connecting the lead wire couplers, make sure that these lead wires do not touch the ventilator control cables when installing the cowl panel. • Connect the "4 ' and "5" hoses to the "BACK" and "CUSHION" switches respectively.

• Connect the "4" hose and "5" hoses to the "Blue" and "Black" hoses properly. • When installing the seat on the frame, do not bent or pinch the hoses.

NOTE:

After installing and assembling the each part, make sure that air seat system works properly.

11-27 GV1400GCG ('86-MODEL)

HOSE ROUTING (SEAT)

Compressor holder

I

Hole

Pass the air hose No. 4, No.5 under the relay holder. Pass the air hose No. 4. No. 5 between the ignition coils

Air hose No. 5

Pass the air hose No. 4, No. 5 from inside of the frame to outside.

Air hose Clamp Air hose (No. 4) Pass the two air hose over the fuel pump & Carburetor hose. Seat cushion hose Fuel pump & Carburetor hose Clamp

GV1400GCG ('86-MODEL) 11-28

REAR SPEAKERS AND CO-RIDER'S CONTROL SWITCH REMOVAL • Disconnect the seat switch lead wire, travel trunk switch lead wire and passenger's seat air hoses. NOTE: When re-connecting the hoses, refer to the page 10-19 of the GV1400 service manual.

• Remove the travel trunk light switch boot and remove the clamp CD.

• Remove the travel trunk light switch.

• Remove the travel trunk cover and passenger's backrest.

11-29 GV1400GCG ('86-MODEL)

• Remove the travel trunk cover from the backrest seat. • Remove the headrest from the backrest seat.

• Remove the speaker cover from the backrest seat. NOTE:

Rear speakers are assembled in the backrest seat. The rear speakers are not removed without cutting the seat cloth.

• Disconnect the co-rider's remote control switch couplers, and remove the switch assembly.

• Remove the switch assembly from the switch housing.

GV1400GCG ('86-MODEL) 11-30

INSPECTION REAR SPEAKERS • Pop sound is heard when the two probe pins of the pocket tester touch the two speaker lead wires with an ohm range if the speaker is in good condition. • The tester shows approx. 4 ohms when the speaker is in good condition.

CO-RIDER'S CONTROL SWITCH VOL. • Touch the two probe pins of pocket tester with kQ range to G/R and G/81 lead wires and turn the VOL. dial. Then change lead wires to G/8 and G/81. If the tester shows variable resistance (0 - 12 kQ) while turning the VOL. dial, this dial is in good condition.

TUNE • Touch the two probe pins to the GIW and 8/W, and push the TUNE button for down ...,... Change probe pins to G/Y and 8/W, and push the button for up "JJ..". If the tester indicates ON in the above two inspection, the TUNE switch is in good condition.

I

I

G/R

G/B

G/BI

-volume

G/Y

G/W

B/W

-Tune

FADER • Set the two probe pins of testers as shown in the following table and check the resistance. Probes of tester to:

Fader switch

Resistance (Q)

CD-® ®-® @-® ®-® CD-® @-®

R+F

2+50

R +F R+F R+F

50+2

Black coupler (Fader) (Red tube) (Green tube) (Orange tube)

~

CD

®

@

Gr

G/B

G/B

2+50 50+2

R~F

CONST. 50

R~F

CONST. 50

• If the tester shows different value from the above table, replace the fader switch with a new one.

@

®

®

Gr

G/B

G/B

(Orange tube) (White tube) (Orange tube)

11-31 GV1400GCG ('86-MODEL)

REASSEMBLY • Connect the co-rider's remote control switch lead wire couplers and install the switch box to the travel trunk. • Connect the rear speakers lead wires.

• Pass the co-rider's remote control switch and rear speakers lead wires through the bottom hole of the travel trunk and route them along with the right frame tube as shown in the Fig.

• Connect the co-rider's remote control switch coupler and rear speakers lead wire couplers.

GV140 OGCG ('86-MODELJ 11-32

BRAKES

CD ®

® ® ® ® (J)

· 9 bolt Caliper housm Air bleeder 0-ring Piston seal Dust boot

Pad Caliper mou nting bolt ®Pin Spring (j]) Dust cover

®

11-33 GV1400GCG ('86-MODEL)

BRAKE FLUID Use only DOT4 brake fluid. Never use the other brake fluid than DOT4. Specification and classification

DOT4

WARNING: * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored for a long period.

FRONT BRAKE CALIPER BRAKE PAD REPLACEMENT • Remove the caliper mounting bolts and remove the caliper assembly. • Remove the dust cover.

Tightening torque

25-40 N·m ( 2.5 - 4.0 kg-m ) 18.0- 29.0 lb-ft

• Pull out the clips and draw out the pins. • Take out the springs and brake pad set.

GV1400GCG ('86-MODEL) 11-34

PAD INSPECTION Wear limit line CD is provided on the upper part of the each pad. When the wear exceeds the limit line, replace the pads with new ones.

INSTALLATION Reassemble the brake pads in the reverse order of removal.

REAR BRAKE CALIPER

CD ® ®

Air bleeder 0-ring Rear pad guide @ Front pad guide @ Piston seal ® Dust boot (j) Caliper mounting bolt ® Housing bolt @Clip ® Spring (jJ) Pin @ Dust cover

Tightening torque

ITEM

N·m

kg-m

CD

6-9 25-40 28-32

0.6-0.9 2.5-4.0 2.8- 3.2

(j)

®

lb-ft 4.5 - 6.5 18.0-29.0 20.0-23.0

11-35 GV1400GCG ('86-MODELJ

DISASSEMBLY • Remove the rear caliper assembly from the caliper mounting brackets. (Refer to the page 9-62 of the GV1400 service manual.) • Remove the dust cover.

• Pull out the clips and draw out the pins. • Take out the springs and brake pad set.

• Remove the two guide plates from the caliper. • While holding the mounting boss with vise, loosen the four housing bolts.

Tightening torque

28-32 N·m ( 2.8 - 3.2 kg-m ) 20.0 - 23.0 lb-ft

• Remove the 0-ring and push out the piston by using an air gun.

NOTE: Do not use high pressure air to prevent piston

damage.

GV1400GCG ('86-MODEL) 11-36

INSPECTION • The wear limit line Q) is provided on the upper part of each pad. If wear exceeds the limit line, replace the pads as a set with new ones.

• Inspect the piston seal ®, dust seal ®, bore wall and piston wall for any damage or wear. If there is anything unusual, replace the respective parts with new ones.

REASSEMBLY • Wash the caliper components with fresh brake fluid before reassembly. • Apply brake fluid to the caliper bore and piston to be inserted into the bore.

• Install a new 0-ring @to the proper position.

11-37 GV1400GCG ('86-MODELI

• Tighten the four housing bolts to the specified torque.

Tightening torque

28-32 N·m ( 2.8- 3.2 kg-m ) 20.0 - 23.0 lb-ft

• Install the guide plates to the proper position as shown in the Fig.

• Install the pads, springs, pins and clips. • Push the both pistons fully in.

NOTE:

After mounting caliper to the motorcycle, bleed air from the caliper.

GV1400GCG ('86-MODELI 11-38

CABLE, HARNESS AND HOSE ROUTING HARNESS ROUTING

Clamp

Clamp Trunk lamp

Tuner indicator Clamp

'%'!:?:.

"' SWITCH

WIRE COLOR W ·-····-White B ........ Black R .. - ..... Red Bl. .... _.. Blue Y ........ Yellow Br ....... Brown G _. - .. _. . Green Gr . _.. _. . Gray 0 _. _... _. Orange Lg . _. . . . . Light blue Dg . . . . . . . Dark green V __ .... _. Violet P ........ Pink

Lbl. ____ . . W/B ..... W /R .. _. . W /Y . . . . . WIG .. - .. W/BI ..... B/W __ ... B/R .. - ... B/Y ...... B/G-.- ... B/Lg ..... R/W . . . . . R/B . - ....

Light blue White with Black tracer White with Red tracer White with Yellow tracer White with Green tracer White with Blown tracer Black with White tracer Black with Red tracer Black with Yellow tracer Black with Green tracer Black with Light green tracer Red with White tracer Red with Black tracer

R/Y _.. __ . Red with Yellow tracer R/G . . . . . . Red with Green tracer R/BI ...... Red with Blue tracer BI!R. ..... Blue with Red tracer BI/Y ..... Blue with Yellow tracer BI/W ..... Blue with White tracer BI/G _.. _. Blue with Green tracer BI/Lg ..... Blue with Light green tracer Bl/0 .... _ Blue with Orange tracer Y/W .... _ Yellow with White tracer Y /R . . . . . . Yellow with Red tracer Y /BI ..... Yellow with Blue tracer Y /G . . . . . . Yellow with Green tracer

Y /B ..... _ Yellow with Black tracer Br/Y .... _ Brown with Yellow tracer Br/W .. __ Brown with White tracer Br/P _... _ Brown with Pink tracer Br/R ..... Brown with Red tracer Br/B _.... Brown with Black tracer Br/G ..... Brown with Green tracer Br/BI .. _.. Brown with Blue tracer G/W .. _.. Green with White tracer G/Y . _. _. . Green with Yellow tracer G/B ...... Green with Black tracer G/R . _. _. . Green with Red tracer G/BI .. _.. Green with Blue tracer

Gr/G .... Gr/B - .... Gr/R ..... Gr/BI. .... 0/G . _.. _. 0/Lg ... _. 0/W . _. _. 0/B .. ____ 0/BI ..... 0/R _. . . . . Lg/B . _... Lg/W . _.. Lg/R .....

Gray with Green tracer Gray with Black tracer Gray with Red tracer Gray with Blue tracer Orange with Green tracer Orange with Light green tracer Orange with White tracer Orange with Black tracer Orange with Blue tracer Orange with Red tracer Light green with Black tracer Light green with White tracer Light green with Red tracer

Lg/Y _.. _. Lg/0 _.. _. Lg/BI. .... Lg!V ... _. Dg/Y ... _. Dg/W . . . . V /G ...... V !W ..... P/W _....

Light green with Yellow tracer Light green with Orange tracer Light green with Blue tracer Light green with Violet tracer Dark green with Yellow tracer Dark green with White tracer Violet with Green tracer Violet with White tracer Pink with White tracer

GV1400GDG E-33

WIRING DIAGRAM

G

r-Bl

TRUNK LAMP• SWITCH

TRUNK LAMP

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II

THERM? SWITCH

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FRONT BRAKE LIGHT

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STANO CHECK SIDE LIGHT BRAKE' REAR

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NEUTRAl RELAY

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W/B

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DIODE

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FUEL PUMP RELAY

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~ION SWITCH

DIODE

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IGNITION COIL

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BI/R

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R/81 R/B

AIR FEED SWITCH

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SPEAKER {R)

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BOX I

DAN

lo-K

P

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OFF

CORNERING LIGHT IR)

SUSPENSION SWITCH

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