1982-1983 Suzuki GS1100G OEM Service & Repair Manual

SUZUKI - SERVICE MANUAL

FOREWORD The SUZUK I GSI l OOG has been developed as a companion rnotorcycle to the GS-models. If is packed with highly advanced design concepts including a maintenance free shaft drive mechanism and a fully transistorized ignition system with electronic advance. Combined with precise control and easy handling, the GSl 7 DaG provides excellent performance and outstanding riding corn fort. This service manual has been produced primari- ly for experienced mechanics whose job is to inspect, adjust, repair and sewice SUZUKE motorcycles. Apprentice mechanics and do-it-yourself mechanics, will also find this manual an extremely useful guide. Model GS 7 1 OOG manufactured to standard specifications is the main subject matter of this manual. However, the GS 7 1 OOG machines distributed in your country might differ in minor respects from the standard-specification and, i f they do, it is because some minor modi fica fions (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. This manual contains up- to-date information at the time of its issue. SUZUKI MOTOR CO,,LTD. Administration Department Overseas Sewice Division Quo ting, cop ying or other wise using an y part of this manual withou f ex - plicit authorization from Suzuki Motor Co., L fd, is not permitted as all rights to the publicafion are reserved under copyright law.

VIEW OF SUZUKl GS1100G Right side /: 0 \" Left side

GENERAL INFORMA TON PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES - - SERVICING ENGINE SHAFT DRIVE FUEL AND LUBRICATION SYSTEM EMISSION CONTROL & REGULATIONS ELECTRICAL SYSTEM - CHASSIS

CONTENTS SERIAL NUMBER LmAnoNS ............................................. 1- 1 FUa Am OfL RECOMM~~AnoNS .................................... 1- 1 BREAKING-lN PmEDURES ............................................... 1- 2 CYuNDEff lQE#nFJCATmN ................................................ 1- 2 SPECIAL FEATURES ......................................................... I- 2 &LOWBY GAS REcYalNG ............................................ 1- 2 CAMSHAFT DRIVE CHAIN TENSIoNER ........................... 1- 3 TRANSISTORIZED IGN\TION SYSTEM WITH ELECTRoNfC ADVANCE ........................................ 1- 4 PRECAUTIONS AND GENERAL INSTRUCTIONS ..................... 1- 5 SPECIAL MATERIALS ......................................................... 1- 6 spEC\flCAT/oNs ............................................................... 1- 8

1-1 GENERAL IlNFORMATlON SERIAL NUMBER LOCATIONS The VIN (Vehicle Identification Number) ,? is stamped on the steering head pipe. The engine serial number 8 is located on the right side of the crankcase. These numbers are required especial1 y for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL Use only unleaded or low-lead type gasoline of at R + M least 85 - 95 pump octane ( 7 method) or 89 octane or higher rated by the Research Method. ENGINE OIL Be sure that the engine oil you use comes under APl classification of SE or SF and that its viscosity rating is SAE 10W/40. If SAE 10Wj40 motor oil is .I I I I . .I .I . .- I. . SAE 40 - 30 - I 20WJ50 - d 10W/50- - 1 ow130 - - 4 I 20W - - i ! TOW- - ', 'I OC -20-10 0 10 20 30 40 1 OF -4 14 32 50 68 85 104 { GEAR OIL (SECONDARY AND FINAL GEARBOXES) Use SAE 90 hypoid gear oil which is rated G L-5 under API classification system. If you operate the motorcycle where ambient temperature is below 0°C (32OF1, use SAE 80 hypoid gear oil. BRAKE FLUID WARNING: * Since he brake system of this motwcycle ', is filled wlth a glycol-based brake fluid by the manufacturer, do not use or mix differ- 1 ent types of fluid such as siliconebased I and petroleum-based fluid for refilling the system, orhewise serious damage will resu IF. I * Do not use any 'brake fluid taken from old I or used or unsealed containers. ! * Never re-use brake fluid left over from zhe previous servicing and stored for a long period. Specification and I FRONT FORK OIL F r k oil #15 classification: DOT3, DOT4

GENERAL INFORMAT1ON 1-2 BREAKING-IN PROCEDURES 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 subject- ing 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 b reakingin engine speed limits: Upon reaching an odometer reading of 1,600 krn (1,000 miles) you can subject the motorcycle to full throttle operation, However, do not exceed 9,000 rlmin at any time. Do not maintain constant engine speed for an A extended time period during any portion of the break-in. Try to vary the throttle position. CYLINDER IDEMTI FTCATION The four cylinders of this engine are identified as Na. 1, No. 2, No. 3 and No. 4 cylinder, ascounted from left to right (as viewed by the rider on the seat). SPECIAL FEATURES BLOWBY GAS RECYCLING Blowby gases in the crankcase are constantly drawn into the chain chamber provided in the middle section of the cylinder block. The top section of this chamber is cannmed with the air chamber assembly through a rubber tube. In the air chamber, the gases merge with incoming air and thus are recycled to the engine through the normal intake system. - -

1-3 GENERAL INFORMATION CAMSHAFT DRIVE CHAIN TENSIONER The chain tensioner used in the Model GSI TOOG is of self-adjusting type in that it adjusts itself to apply a constant tensioning force to the chain by compensating for the stretch of the chain. PUSH ROD AND LOCK SCREW During normal service the cam drive chain will stretch. A spring controlled push rod is used to constantly reposition the cam chain guide firmly against the chain to prevent slack from occurring. A lock screw and nut are utilized to eliminate the constant, high spring pressure exerted on the push rod. The lock screw is only used during either removal or installation of the adjuster push rod to ease the procedures. LOCK SHAFT The cam drive chain tension tries to vary during engine operation. The spring cornrolled push rod is designed so as to only move in, towards the chain guide preventing slack from occurring if the spring pressure on the push rod were overcome. A steel ball is "jammed" against a angled surface prevent- c*,? Fng backwards movement of the push rod. The lock shaft is preload& with a light spring $ 1 which 1 I keeps the ball in contact with the push rod and 0 0 angled surface \ri) ,

GENERAL INFORMATION 1-4 TRANSlSTORlZEP IGNITION SYSTEM WITH ELECTRONIC ADVANCE On the Model GS? 100G, the timing advance characteristics of the ignition timing have been changed from the previously-employed mechanical timing advance system incorporating a centrifugal advance governor to an electronic timing advance system. The introduction of this new electronic timing advance system minimizes fluctuations in the ignition timing and also has improved the timing advance performance during high-speed operations, When the signal rotor is rotated in the system block diagram above, the signal "A" is generated in the pick- up coil. The thus-generated signal will be converted to the signal waveform "B" at the inside of the ignitor unit. Based on this "B" waveform, control is made by means of the advancing control circuit and the closing angle control circuit. As a result, the timing advance takes place, as shown in Fig. "C". b revolution I b+ Advanced angle 8' revolution 1 Advanced angle 0' High-speed 5 revolution

1982-1983 Suzuki GS1100G OEM Service & Repair Manual

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