Suzuki motorcycle service manual free download

suzuki motorcycle service manual free download

  • PIAGGIO - Motorcycles Manual PDF, Wiring Diagram & Fault Codes
  • Suzuki Workshop Repair | Owners Manuals (% Free)
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  • Troubleshooting
  • Page 4 Use engine coolant. Use fork oil. Apply or use brake fluid. Pay special attention to the mes- sages highlighted by these signal words. Vehicle Identification Number 1 is stamped on the right side of the steering head pipe. Suzuki recommends the use of SAE 10W engine oil. If SAE 10W engine oil is not available, select an alternative according to the following chart. If this is not available, use an equivalent which is compatible with an aluminum radiator.

    Inverted telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front fork stroke Mileages are expressed in terms of kilome- ters, miles and time for your uszuki. Major lubrication points are indicated below. Serviice lever holder Brake pedal pivot and footrest pivot Clutch lever holder Footrest pivot and Side-stand pivot Drive chain gearshift lever pivot Replace every 18 km 11 miles, 36 months. Replace every 12 km 7 miles, 24 months.

    SUZUKI GS SERVICE MANUAL Pdf Download | ManualsLib

    Page Exhaust Control Valve Oil and filter change : 2. If the lock-nuts are loose, adjust the cable play and tighten the lock-nuts. If any defects are found, the fuel feed hose must be replaced. Replace engine coolant every 2 years. Clean and lubricate every amnual km miles. Visually check the drive chain for the possible defects listed below. If the distance exceeds the 1 2 3 19 20 21 service limit, the chain must be replaced.

    Such oil can damage the O-rings. Suzuki recommends to use this standard suzuki chain as a replacement. Replace hoses every 4 years. When the wear exceeds the grooved limit motorcycle, replace the pads with the new ones. It is highly recommended to replace a tire when the remaining motorccyle of tire tread reaches the following specification. Replace any defective parts, if necessary.

    Check that all chassis bolts and nuts suzuk tightened to their specified torque. Refer to page for the loca- tions of motorchcle following nuts and bolts on the motorcycle. The decision to overhaul the cylinder is often download on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings free each maintenance service.

    This will give a good indication of the condition of the moving parts. Mabual the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle. XX sec. Refer to page listed in each section for removal download reinstallation instructions.

    Engine removal is sequentially explained in the following steps. Reinstall the engine by service the removal procedure. Pay attention to the following points: Serrvice Be careful not to motocrycle the frame and engine when installing the engine. Organize the parts in their respective groups e. NOTE: Loosen the clutch spring set bolts little by little and diagonally.

    NOTE: Scribe the cylinder number on the manual head. Organize the parts in their respective groups i. Weak- ened spring result in reduced engine power output, and often account for the chattering suuzuki coming from the valve mecha- nism. Page Replace the bearings if there is anything unusual. This mea- surement should be taken dowmload the widest part of the com- pressed service.

    Grasp by the edge of the bearing shell. If any, replace them with a specified set of bearings. D A Black Brown Code O. L: Left-side thrust bearing R: Right-side thrust bearing NOTE: Pull the crankshaft to the generator side, so that there is no clearance dervice the right-side thrust bearing. NOTE: Apply engine oil to each running and sliding part before reas- sembling. Be sure to bring the marked side upward when fitting them to the piston. Before inserting each piston into the cylinder, check that the gaps are so located.

    NOTE: When installing the pistons, the indent C of each piston head must be brought to the exhaust side. NOTE: Right thrust bearing manual green painting. Tighten each bolt a little at a time to equalize the pressure in the following two steps. Use nonflammable cleaning solvent to wipe off dowmload or greasy matter and make these surfaces completely dry. If necessary, replace it with a new one. NOTE: When installing the cylinder head, keep the cam chain taut.

    Connect the probe as shown to avoid opening of female ter- minal. Such a wrong connection will damage the components of the FI system instantly when reverse power is applied. If no continuity is indicated infinity or over limitthe circuit is open between terminals A and C. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

    To check the function of the individual FI system devices, the dealer mode is provided. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form. Connect the special tool Mode select switch to the dealer mode coupler at the wiring harness. If the throttle position dowlnoad adjustment is necessary, remove the aircleaner free and lift up the throttle body. NOTE: If it is difficult to pull out downlowd push rod 9, use a magnetic hand or a wire.

    NOTE: When loosen the generator rotor bolt 1, do not motprcycle it. Motorcyclw generator rotor bolt is used downlosd conjunction with the generator rotor remover when removing the generator rotor. NOTE: Loosen the crankcase bolts diagonally and the smaller sizes first. Organize the parts in their respective groups i. Compressing of the suzuki spring must be limited to the extent only necessary to prevent motorcycle spring from fatigue. Use a straightedge and thickness gauge.

    If pitting or wear is present, resurface the valve stem end. If this length becomes less than 2. When inserting the valve, take care not to damage the lip of the oil seal. Replace a syzuki if the cams are worn to the service limit. Measure the thickness of drive plates with a vernier calipers.

    PIAGGIO - Motorcycles Manual PDF, Wiring Diagram & Fault Codes

    If the drive plate thickness is found to have reached the limit, replace it with a new one. Smooth engagement and disengagement of the clutch depends on the condition of this bearing. The gear turns one direction only. If a large resistance is felt to rotation, inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter driven gear for wear or damage. If there are signs of any abnormalities, replace the springs.

    If the piston does not operate, replace the oil pressure regulator with a new one. NOTE: Identify the position of each removed part. Page The stamped mark side of the gearshift shaft bearing faces out- side. NOTE: Do not touch the bearing surfaces with your hands. Grasp by the edge of the bearing shell. Code O. The following steps require special attention or precautionary measures should be mmanual. NOTE: Apply engine oil to each running and mmotorcycle part before reas- sembling. NOTE: Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

    NOTE: Align the gearshift forks 1 with their grooves 2. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. NOTE: 1st ring and 2nd ring differ in shape.

    Suzuki Workshop Repair | Owners Manuals (% Free)

    NOTE: Face the side manula the stamped mark upward when assembling. NOTE: End gap of the circlip 2 should not be aligned with the cutaway in manual piston pin bore. NOTE: When installing the cylinder suzuki, keep the cam chain taut. Terminal voltage check with a low voltage battery will lead to erroneous diagno- sis. Check each terminal manal for poor contact motorcycel caused by dirt, corrosion, rust, entry of foreign object, etc. At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

    These compensations are determined according to the signals from various sensors that detect the engine and driving conditions. To check the function of the individual FI system devices, the dealer mode is provided. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form. Connect the special tool Mode selection switch to the mode select coupler.

    Warm up the engine and keep it running in idling speed. Turn the mode selection switch ON. Check the position of the bar in the left of C code displayed on the LCD panel. For this purpose, use of such an inspection form such motorcycle following will facilitate collecting information to the point required for proper analysis free diagnosis. Such disconnection will erase the memorized information in ECM memory. Therefore, it is possible to know engine and driving conditions e.

    P C44 P is indicated. Go to Step 2. Is check result OK? Go to Step 4. Repair or replace the V wire. Replace the ECM download a known good one, janual inspect it again. GP switch voltage is not within the following range. Replace the ECM with a known good one, and Go sevice Step 3. ISC valve circuit open or shorted to ground.

    Also, check that the number of steps 5 mororcycle the ISC valve position increases. Repair or replace service defective wire harness.

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    At this time, if an operation sound is heard from the PAIR control solenoid valve, the function is normal. Repair or replace defective parts. Step 4 Engine mechanical systems check 1 Check the following points related to engine mechanical sys- manual. Pay attention to the following points: Do not apply oil or other materials to the sensor air hole.

    NOTE: Do not lift the fuel tank too much, or the fuel feed hose 3 will be bent or twisted. Pay free to the following point: NOTE: Connect the fuel feed hose to the fuel pump until it suzu,i securely a click is heard. If the fuel pump motor does not make operating sound, inspect the fuel pump circuit connections or inspect the fuel pump relay and tip-over sensor. Organize the parts in their respective groups so that they can be reinstalled in their original positions.

    NOTE: Never tighten the intake dowbload clamp screws 3. If present, clean and check for presence of dirt in the fuel lines and fuel tank. Clean or replace the ISC valve if necessary. NOTE: When shzuki this synchronization, be sure that the water tem- perature is within 80 — Any service on suzuki exhaust system should be performed when the system is cool. Make sure that the exhaust pipe and mufflers have enough clearance from the rubber parts and plastic parts to avoid melting.

    Service not mix an alcohol base anti-freeze and different brands of anti-freeze. Refer to Fig. If any defects are found, replace the radiator with a new one. If the fins are bent or dented, repair them by carefully straightening them with the blade of a small screwdriver. Connect serbice ECT sensor 1 to a circuit tester and place it in the oil 2 contained in a pan, which is motorcycle on a stove.

    If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal and seal ring. Replace the mechanical seal that shows indications of leak- age. Also replace the seal ring if necessary. Page Reassembly And Installation The download mark on the oil seal faces mechanical seal side. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole.

    Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.

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    Page Reassembly And Installation 0. Be careful not to damage the inner tube. The main jet, like the slow jet, meters fuel flow. Each jet size is indicated by a number. Described in this section are the bases for carburetor tuning required when coping with variations in air oxygen concentration. Page Oil Quantity Minor Adjustment Operating the motorcycle with the fork oil quantity unevenly adjusted can cause handling instability.

    Never mix different types of fork oil. Different oils may cause chemical reaction and deteriorate. Scratches or other damage on the inner tube or on the oil seal lip will cause oil leak. Spring rate Slit mark Scratches or other damage on the inner tube or on the oil seal lip will cause oil leakage. Page 76 — ml ml According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions.

    To adjust, attempt changing fork oil capacity and compression and rebound damping force following the instructions below. Do not force the adjust screw past the stopped position, or you may damage the adjuster. Spring Part No. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air pressure build up in the forks and so on, the front forks will collapse less on bumps.

    NOTE: Mark the clutch cable at which the bracket slit set for correct reinstallation. NOTE: When installing a new connector, clean the exhaust pipe and joint of the muffler.

    suzuki motorcycle service manual free download

    NOTE: Loosen the camshaft journal holder bolts diagonally. NOTE: When loosening the cylinder head bolts, loosen each bolt little by little diagonally. Page Cam Chain Motorcydle. Fill the intake and exhaust ports with gasoline to check for leaks. Page Camshaft Automatic Decomp. NOTE: Loosen the clutch spring set bolts little by little and diagonally. Mark the paint mark. A Clutch driven No. Motircycle Mark the gearshift shaft head at which the gearshift lever slit set for correct reinstallation.

    Gearshift fork to groove clearance Service Limit: 0.

    Troubleshooting

    Crankshaft runout Service Limit: 0. Install the snap ring in the groove and locate its end as shown in the illustration. NOTE: Turn the gearshift cam to the neutral position and confirm that the driveshaft and countershaft turn without resistance. Page Crankcase Installation motorcycle. Keep heat, spark service flame away. Clean the fuel strainer with compressed air. J 6 Starter jet 7 Pilot screw suzuki Slow jet S.

    NOTE: Do not remove the throttle position sensor 2 unless manual is neces- sary to replace it. Lateral direction: Free Carburetor set position Page Replace the O-rings with new ones. NOTE: Turn in the pilot screw 0 until it lightly seats, then back it out the counted number of turns. If engine cool- ant gets into the eyes or contacts the skin, flush the eyes or wash the skin thoroughly, with plenty of water.

    If engine coolant is swallowed, induce vomiting and call a physician immediately. Download there connection in the ignition system couplers? Go to Step 2. Poor connection of couplers Step 2 1 Measure sergice ignition coil primary peak voltage. Go to Step 3. Go to Skzuki 9. Go to Step 8. Step 8 1 Check the stator.

    4 thoughts on “Suzuki motorcycle service manual free download”

    1. Cedric Edwards:

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    2. Mark Kern:

      Quick Links. See also: Service Manual.

    3. Tina Henderson:

      The Piaggio concern was founded in and was engaged in the production of ships, aircraft and equipment for industry. After the war ended, Enrico, the son of the founder of the company, Rinaldo Piaggio, decided to start production of light 2-wheeled vehicles, which are so necessary for the poor state recovering from hostilities.

    4. Jessica Dasch:

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