Suzuki Motorbike workshop repair manual Workshop Manuals

Suzuki Motorbike workshop repair manual

Suzuki began manufacturing motorcycles in 1952, 1st brands being motorized bikes. A big factor in Suzuki's success in two-stroke competitors ended up being the East German Grand Prix racer Ernst Degner, which defected on western in 1961, bringing with him expertise

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(1986-1987) * GSX-R750R Limited Edition (1986) * GSX-R1100 (1986-1987) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Notes cautions and warnings / Safety first / Service hints / Special tips / Torque specifications / Fasteners / Lubricants / Expendable supplies / Parts replacement / Serial numbers /Basic hand tools / Tune-up and troubleshooting tools / Mechanic's tips / Riding safety / Specifications * TROUBLESHOOTING Operating requirements / Emergency troubleshooting / Engine starting / Engine performance * LUBRICANTS MAINTENANCE AND TUNE-UP Routine checks / Pre-checks / Service intervals / Tyres and wheels / Battery / Periodic lubrication / Engine oil and filter change / Front fork oil change / Drive chain lubrication / Control cable lubrication / Periodic maintenance / Drive chain inspection and adjustment / Drive lever / Shock absorber / Front caliper / Front brake hose / Front brake disc / Seats / Front fairing mounting bracket and side covers / Specifications * WIRING DIAGRAMS extra

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It does not include VX800 Marauder models. Contents: * Introduction * Acknowledgements * About this manual * Safety first! * Identification numbers * Buying spare parts * Daily (pre-ride) checks * Engine/transmission oil level check * Brake fluid level checks * Suspension steering and final drive checks * Legal and safety checks * Tyre checks * Routine maintenance and servicing * Specifications * Recommended lubricants and fluids * Maintenance schedule * Component locations * Maintenance procedures * Engine transmission and associated systems * Engine clutch and transmission * Cooling system * Fuel and exhaust systems: carburetor models * Fuel engine management and exhaust systems: fuel injected models * Ignition system * Chassis components * Frame and suspension * Final drive * Brakes * Tyres * Fairing and bodywork * Electrical system * Wiring diagrams (in colour) more advice

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warnings / Safety first / Service hints / Torque specifications / Fasteners/ Lubricants / Expendable supplies / Parts replacement / Emission control and battery labels / Basic hand tools / Precision measuring tools / Fabricating tools / Mechanic's tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications * TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine noises / Cylinder leak down test / Clutch / Transmission / Drive train noise / Handling / Frame noise / Brakes / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride check list / Maintenance schedule / Engine oil and filter change / Oil pan and sump filter / Oil pressure test / Control cable lubrication / Drive Rear brake pedal / Specifications * BODY AND FRAME Seats and rear tail piece / Front fairing / Fairing lower side panels / Upper fairing / Rear frame cover / Sidestand / Specifications * WIRING DIAGRAMS related info

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Repair Manual covers the following models: * Suzuki GSXR600-K1 2001 * Suzuki GSXR600-K2 2002 * Suzuki GSXR600-K3 2003 * Suzuki GSXR750-Y 2000 * Suzuki GSXR750-K1 2001 * Suzuki GSXR750-K2 2002 * Suzuki GSXR750-K3 2003 * Suzuki GSXR1000-K1 2001 * Suzuki GSXR1000-K2 2002 Contents: * Living With Your Suzuki GSX-R600 GSX-R750 & GSX-R1000 * Introduction - About This Manual - Safety First! - Identification Numbers - Buying Spare Parts * Daily (Pre-Ride) Checks - Engine/Transmission Oil Level Check - Brake Fluid Level Checks - Suspension Steering And Final Drive Checks - Legal And Safety Checks - Tyre Checks * Maintenance - Routine Maintenance And Servicing - Specifications - Recommended Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Transmission And Associated Systems - Engine Clutch And Transmission - Cooling System - Fuel And Exhaust Systems - Ignition System * Chassis Components - Frame And Suspension - Final Drive - Brakes - Tyres - Fairing And Bodywork * Electrical System - Wiring Diagrams click to go

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Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Special tools / Basic service methods / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the engine / Engine performance / Starting system / Charging system / Ignition system / Fuel system / Engine noises / Engine lubrication / Clutch / Transmission / Lighting system / Excessive vibration / Front suspension and steering / Brake problems / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Safety checks / Maintenance intervals / Tyres and wheels / Battery / Periodic lubrication / Engine oil and filter change / Air filter / Periodic maintenance / Non-scheduled maintenance / Engine tune-up / Spark Connecting rods / Break-in / Specifications * CLUTCH Clutch / Clutch hydraulic system / Clutch master cylinder / Clutch release cylinder / Clutch hose assembly replacement / Bleeding the hydraulic clutch system / Specifications * TRANSMISSION AND GEARSHIFT MECHANISMS Engine drive click the link

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TROUBLESHOOTING Operating requirements / Starting the engine / Engine spark test / Engine performance / Engine noise / Engine leakdown test / Clutch / External shift mechanism and transmission / Kickstarter / Brakes / Steering / Electrical testing / Electrical component replacement / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Service precautions and practices / Pre-ride inspection / Engine break-in / Maintenance intervals / Fuel and lubricants / Transmission and component lubrication / Maintenance and inspection / Engine tune-up / Spark plugs / Specifications * ENGINE TOP END Shop cleanliness / Exhaust system / Cylinder head / Cylinder / Exhaust valve system / Exhaust valves and shaft assembly / Exhaust valve solenoid / Exhaust valve governor and actuator / Piston and piston rings / Reed valves / Specifications * ENGINE LOWER END master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake system draining / Brake system bleeding / Brake disc / Specifications * BODY Seat / Frame covers / Radiator covers / Subframe / Specifications * WIRING DIAGRAMS here

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Service & Repair Manual Covers the following Models: * Suzuki GSF650K7 2007 * Suzuki GSF650SK7 2007 * Suzuki GSF650K8 2008 * Suzuki GSF650SK8 2008 * Suzuki GSX650FK8 2008 * Suzuki GSF1250K7 2007 * Suzuki GSF1250SK7 2007 * Suzuki GSF1250K8 2008 * Suzuki GSF1250SK8 2008 * Suzuki GSF1250K9 2009 * Suzuki GSF1250SK9 2009 Contents: * Maintenance * Engine * Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System Including Wiring Diagrams full details

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cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Special tools / Basic service methods / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the engine / Starting difficulties / Engine performance / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Transmission / Fuel system / Drivetrain noise / Electrical troubleshooting / Test equipment / Basic test procedures / Charging system / Ignition system / Starting system / Handling / Brakes / Frame noise / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride check list / Maintenance schedule / Engine oil and filter change / Tyres and wheels / Battery / Periodic lubrication / Periodic maintenance / Non-scheduled maintenance / Engine tune-up / Air filter / Spark plugs / Specifications * ELECTRICAL SYSTEM Preliminary information / Negative battery terminal / Charging system / Alternator / Ignition system / Starting system / Starter motor / Starter relay / Lighting system / Switches / Relays / Combination meter / Fuses / Main fuse / Wiring diagrams / further data

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Softcover - 128 pages - Suzuki GT250 X7 GT200 X5 & SB200 Twins 1978 - 1983 Haynes Owners Service & additional info.....

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Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Storage - Troubleshooting click here

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Riding safely * TROUBLESHOOTING Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems * LUBRICATION MAINTENANCE AND TUNE-UP Pre-checks / Engine lubrication / Service intervals maintenance schedule / Tyres and wheels / Periodic lubrication / Transmission clutch oil change / Control throttle clutch parking brake cable lubrication / Periodic maintenance / Drive chain adjustment / Fuel shut off valve and filter inspection / Air filter / Engine tune-up / Cylinder head nut torque / Spark plug plugs / Idle speed adjustment / Carbon removal / Specifications * ENGINE (1985-1986 MODELS) Engine operating principles / Engine lubrication / Servicing the engine in the frame / Engine removal and installation / Cylinder head / Cylinder / Reed valve assembly / Piston gear balancer drive gear balancer driven gear and water pump drive gear / Magneto / Drive sprocket / Kickstarter / Crankcase and crankshaft / Break-in procedure / Specifications * CLUTCH AND TRANSMISSION (1985-1986 MODELS) Clutch operation / Clutch release mechanism / Cable / External shift lots more

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Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Storage - Troubleshooting full details

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Suzuki GSX-R1000K4 988cc 2004 * Suzuki GSX-R1000K5 999cc 2005 * Suzuki GSX-R1000K6 999cc 2006 * Suzuki GSX-R1000K7 999cc 2007 * Suzuki GSX-R1000K8 999cc 2008 Contents: * Living With Your SUZUKI GSX-R - Introduction - About This Manual - Safety First! - Identification Numbers - Buying Spare Parts * Daily (Pre-Ride) Checks - Engine/Transmission Oil Level Check - Brake Fluid Level Checks - Suspension Steering And Final Drive Checks - Legal And Safety Checks - Tyre Checks * Maintenance - Routine Maintenance And Servicing - Specifications - Recommended Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Transmission And Associated Systems - Engine Clutch And Transmission - Cooling System - Fuel And Exhaust Systems - Ignition System * Chassis Components - Frame And Suspension - Final Drive - Brakes - Tyres - Fairing And Bodywork * Electrical System Wiring Diagrams more.....

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Suzuki GSX1100E GS1100E U.K. 1979-1984 U.S. 1980-1983 * Suzuki GSX1100ES GS1100ES U.K. 1983-1985 U.S. 1983 * Suzuki GSX1100E U.K. 1985-1988 * Suzuki GSX1100EF U.K. 1984-1988 * Suzuki GS1150E U.S. 1984-1986 * Suzuki GS1150ES U.S. 1984-1985 * Suzuki GS1100L U.S. 1980 Note: This manual does not cover the Suzuki GSXR1100 or GSX1100F models. Contents: * Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams much more info

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Expendable Supplies / Parts Replacement / Basic Hand Tools / Test Equipment / Precision Measuring Tools / Special Tools / Cleaning Solvent / Mechanics Tips / Bearing Replacement / Seals / Specifications * Troubleshooting Operating Requirements / Troubleshooting Instruments / Starting The Engine / Emergency Troubleshooting / Engine Starting Troubleshooting / Engine Performance / Engine Noises / Engine Lubrication / Clutch / Gearshift Linkage / Transmission / Electrical Troubleshooting / Test Equipment / Basic Test Procedures / Electrical Problems / Charging System Troubleshooting / Ignition System Troubleshooting / Electric Starter System Troubleshooting / Carburetor Troubleshooting / Excessive Vibration / Front Suspension And Steering / Brake Problems * Lubrication Maintenance And Tune-Up Pre-Checks / Service Intervals / Tyres And Wheels / Battery / New Battery Cylinder / Front Brake Hose Replacement / Bleeding The Brake System / Rear Drum Brake / Drum Brake Inspection / Specifications * Body Seat / Fuel Tank Top And Side Covers / Front Fender And Front Rack / Rear Fender And Rear Rack / Footrest Assembly / Tow Plate / Speedometer Housing / further data

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TS125ERX U.K./U.S. 1980 * Suzuki TS125ERZ U.K. only 1982 * Suzuki TS185ERN (TS185) U.K. only 1979 * Suzuki TS185ERT U.K./U.S. 1979 * Suzuki TS185ERX U.K./U.S. 1980 * Suzuki TS250ERN (TS250) U.K. only 1979 * Suzuki TS250ERT U.K./U.S. 1979 * Suzuki TS250ERX U.K./U.S. 1980 Contents: * Introduction To The Suzuki Ts100 125 185 And 250 Models * Safety First! * Maintenance * Engine * Clutch * Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System Including Wiring Diagrams * The U.K. Ts100 And 125 Erz Models extra info

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* GS550L 572cc 1982 - 1986 Contents: * Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams more here.....

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GSX-R750K7 750cc 2007 * Suzuki GSX-R750K8 750cc 2008 * Suzuki GSX-R750K9 750cc 2009 Contents: * Maintenance * Engine * Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System Including Wiring Diagrams more info

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with a single overhead camshaft (SOHC). Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Notes cautions and warnings / Safety first / Service hints / Washing the vehicle / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Parts replacement / Basic hand tools / Test equipment / Precision measuring tools / Special tools / Cleaning solvent / Mechanic's tips / Ball bearing replacement / Oil seals / Riding safely * TROUBLESHOOTING Operating requirement / Emergency troubleshooting / Starting the engine / Troubleshooting instruments / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Electric starter system troubleshooting / Carburetor troubleshooting / Excessive vibration / Front suspension and steering / Brake problems * LUBRICATION MAINTENANCE AND TUNE-UP Pre-checks / Service maintenance full details

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Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams extra

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Repair Manual covers the following models: * Suzuki GS250T (GS250) U.K. 1980-1984 U.S. 1980-1982 * Suzuki GSX250E (GSX25E) U.K. 1980-1985 * Suzuki GSX400E (GSX400) U.K. 1980-1985 * Suzuki GSX400T U.K. 1981-1985 * Suzuki GS450E (GS450) U.S. 1979-1983 * Suzuki GS450L U.S. 1980-1985 * Suzuki GS450S U.S. 1979-1981 * Suzuki GS450T U.S. 1980-1982 * Suzuki GS450TX U.S. 1981-1983 Contents: * Introduction To The Suzuki Gs And Gsx250 And 400 Twin Models * Routine Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System Including Wiring Diagrams * The U.K. Gsx250/400ez And U.S. Gs450 Models more info

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Mechanic's tips / Riding safety / Specifications * TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Starting the engine / Starting difficulties / Engine performance / Engine noises / Excessive vibration / Clutch / Transmission / Ignition system / Front suspension and steering / Brakes / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Pre-checks / Tyres and wheels / Lubricants / Battery / Periodic lubrication / Periodic maintenance / Engine oil and filter change / Oil strainer cleaning / Fork oil change / Control cable lubrication / Drive chain adjustment / Decompression lever / Spark arrestor cleaning / Valve clearance check adjustment / Carburetor Adjustment / Spark plugs / Engine tune-up / Storage / Specifications * ENGINE TOP END Engine principles / Servicing engine in frame / Cylinder head cover and rocker arms / Camshaft and Bleeding the system / Rear brake pedal / Specifications * FRAME AND BODY Sidestand / Footpegs / Fenders / Seat / Frame / Specifications * WIRING DIAGRAMS more advice

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(1989-1995) * Suzuki RMX250 (1989-1995) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Pre-ride check list / Engine lubrication / Maintenance schedule / Tyres and wheels / Periodic lubrication / Periodic maintenance / Engine tune-up * ENGINE TOP END Engine principles / Cleanliness / Cylinder head / Exhaust valve / Reed valve assembly / Engine lubrication / Servicing engine in frame / Cylinder / Piston piston pin and piston rings / Break-in procedure * ENGINE LOWER END Servicing engine in frame / Engine removal installation / Engine drive sprocket / Drive shaft oil seal replacement / Crankcase and crankshaft * CLUTCH AND EXTERNAL SHIFT MECHANISM Clutch cable replacement / Clutch / Clutch release mechanism / Kickstarter / External gearshift mechanism * TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission / Transmission overhaul / Inspection / Front wheel / Front hub / Rim and spoke service / Tyre changing / Tyre repairs / Handlebar / Steering stem and head / Steering head bearing race replacement / Front fork / Fork service * REAR SUSPENSION Rear wheel / Rear hub / Driven sprocket / Drive chain / Shock absorber / Swing arm and more here.....

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GENERAL INFORMATION Manual organization / Service hints / Tools / Expendable supplies / Safety first / Motor identification and parts replacement * TUNE-UP PERIODIC MAINTENANCE AND LUBRICATION Engine tune-up / Spark plugs / Breaker points / Ignition timing (magneto ignition) / Ignition timing (electronic ignition) / Air cleaner service / Carburetor adjustment / Idle Mixture Adjustment / Speed range adjsutment / Transmission oil / Front forks / Clutch adjustment / Electrical equipment / Drive chain / Brakes / Wheels and Tyres / Steering head bearings / Swing arm * TROUBLESHOOTING Operating requirements / Two-stroke pressure testing / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Backfiring / Engine noises / Piston seizure / Excessive vibration / Clutch slip or drag / Poor handling / Brake problems / Lighting problems / Crankcase / Transmission / Crankshaft / Oil seals / Bearings * FUEL AND EXHAUST SYSTEMS Carburetor / Carburetor components / Miscellaneous carburetor problems / Fuel tank * ELECTRICAL SYSTEM Flywheel magneto / Magneto troubleshooting and service / PEI ignition system / Rectifier / Battery / Lights / link here

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Transmission * Engine Dismantling * Engine Reassembly * Replacing Engine In Frame * Fuel System And Lubrication * Ignition System * Coils Spark Plugs Contact Breaker Automatic Timing Unit * Frame And Forks * Steering Head Bearings * Swing Arm And Rear Suspension * Wheels Brakes And Tyres * Master Cylinder Bleeding The Hydraulic System * Electrical System * Alternator Battery Fuses Starting Motor Headlamps Turn Signals Switches * Wiring Diagrams considerably more details

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Suzuki GS500F (K4 to K8) 2004-2008 Contents: * The Suzuki GS500 Twin - Introduction - Safety First! - Identification Numbers - Buying Spare Parts * Daily (Pre-Ride) Checks - Engine/Transmission Oil Level Check - Brake Fluid Level Checks - Suspension Steering And Final Drive Checks - Legal And Safety Checks - Tyre Checks * Maintenance - Routine Maintenance And Servicing - Specifications - Recommended Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Transmission And Associated Systems - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System * Chassis Components - Frame And Suspension - Final Drive - Brakes - Tyres - Fairing And Bodywork * Electrical System - Wiring Diagrams extra info

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Repair Manual covers the following chain-drive four-cylinder models: * GS1100ET (1980-1981) * GS1100LT (1980-1981) * GS1100EX (1980-1981) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Service hints / Safety first / Expendable supplies / Shop tools / Emergency tool kits / Troubleshooting and tune-up equipment * TROUBLESHOOTING Starting difficulties / Poor performance / Clutch and transmission / Drive train / Chassis / Brakes / Electrical system / Charging system / Lighting / Fuses / Wiring * PERIODIC MAINTENANCE LUBRICATION AND TUNE-UP Routine checks / Periodic maintenance / Drive chain adjustment and lubrication / Engine oil and filter change / Clutch cable adjustment / Air filter service / Front fork oil change / Oil pressure check / Speedometer drive / Suspension tuning / Engine tune-up / Valve clearance measurement and adjustment / Spark plugs / Throttle cable adjustment / Choke cable adjustment / Fuel strainer / Carburetor synchronization / Compression test / Model identification / Storage * ENGINE Camshafts / Rocker arms and shafts / Cylinder head / Valves / Cylinder block and pistons / Lower end / Oil pump / Cam chain lots more

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Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Oil pressure test / Leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system (carbureted models) / Electronic diagnostic system / Electrical testing / Lighting system / Charging system / Ignition system / Starting system / Suspension and steering / Brake system * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride check list / Maintenance schedule / Tyres and wheels / Battery / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Non-scheduled maintenance / Tune-up / Valve clearance / Compression test / Spark plugs / Ignition coolant temperature (ECT) sensor / Intake air temperature (IAT) sensor / Heated oxygen (HO2) sensor / Tip-over (TO) sensor / Fuel tank / PAIR (air supply) system / Evaporative emission control system (California models) / Exhaust system / Specifications * ELECTRICAL SYSTEM Peak voltage and click here.....

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/ Tune-up and troubleshooting tools / Mechanic's tips / Off the road rules / Safety / Storage / Specifications * TROUBLESHOOTING Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Poor handling / Brake problems * LUBRICATION MAINTENANCE AND TUNE-UP Pre-checks / Engine lubrication / Transmission and clutch oil change / Swing arm lubrication / Service intervals / Tyres and wheels / Periodic lubrication / Periodic maintenance / Drive chain cleaning lubrication and adjustment / Drive chain buffer roller and slider / Drive sprocket / Clutch adjustment / Throttle adjustment / Air filter element cleaning replacement / Fuel shut-off valve and filter / Coolant change / Front fork oil change / Front fork air pressure adjustment / Handlebar damper / Engine tune-up / Spark plug / Ignition timing / Pilot (1987-on models) / Piston piston pin and piston rings / Engine / Crankcase and crankshaft / Kickstarter (1984-on RM125 1986-on RM250) / Kickstarter (1981-1983 RM125 1981-1985 RM250 RM465 RM500) / Break-in procedure / Specifications * CLUTCH AND TRANSMISSION Clutch cable replacement / much more info

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/ Electrical system fundamentals / Basic service methods / Storage Specifications * TROUBLESHOOTING Engine operating requirements / Engine starting / Engine spark test / Starting system / Engine performance / Engine noise / Motorcycle noise / Engine leakdown test / Clutch / Shift mechanism and transmission / Brakes Steering and handling / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Fuel type / Pre-ride inspection / Engine break-in / Service intervals / Battery / Periodic lubrication / Engine oil and filter change / Fork oil change / Drive chain cleaning and lubrication / Air filter cleaning and oiling / Maintenance and inspection / Muffler cleaning / Carburetor float bowl draining / Coolant change / Drive chain adjustment / Throttle adjustment / Clutch cable adjustment / Tune-up / Valve clearance / Carburetor / Idle speed and mixture adjustment / Ignition fork adjustment / Specifications * REAR SUSPENSION Shock absorber / Shock absorber linkage / Swing arm / Swing arm service / Shock absorber adjustment / Specifications * BRAKES Brake service / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / more.....

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(1981-1983) * GS650ED (1981-1983) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Service hints / Safety first / Expendable supplies / Shop tools / Emergency tool kits / Troubleshooting and tune-up equipment * TROUBLESHOOTING Starting difficulties / Poor performance / Clutch and transmission / Drive train / Chassis / Brakes / Electrical system / Charging system / Lighting / Fuses / Wiring * PERIODIC MAINTENANCE LUBRICATION AND TUNE-UP Routine checks / Periodic maintenance / Drive chain adjustment and lubrication (chain-driven models) / Engine oil and filter change / Final drive gear oil change (shaft-drive models) / Air filter service / Clutch cable adjustment / Fork oil change / Swing arm lubrication / Oil pressure check / Speedometer drive / Suspension tuning / Engine tune-up / Valve clearance adjustment / Spark plugs / Ignition timing / Compression test / Model identification / Storage / General specifications * ENGINE Camshafts / Cylinder head / Valves and valve seats / Cylinder block and pistons / Removal installation / Engine installation and external assembly / Engine lower end / Oil pump / Cam chain tensioner * CLUTCH more advice

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Softcover - 354 pages - Suzuki LS650 Savage Boulevard S40 1986 - 2007 Clymer Owners Service & Repair additional info.....

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schedule / Engine tune-up / Compression test / Spark plugs / Servicing breaker points / Replacing breaker points / Ignition timing / Air cleaner / Oil pump adjustment / VW carburetor adjustment / Carburetor synchronization / BS 40 Carburetor adjustment / Idle speed / Periodic checks Fuel strainer * ENGINE TRANSMISSION AND CLUTCH Engine principles / Engine lubrication / Oil pump / Preparation for engine disassembly / Engine removal / Cylinder head / Cylinders / Piston pin and rings / Clutch / Primary pinion / Crankcase / Crankshaft / Transmission / Kickstarter / Shifter / Oil seals / Bearings * LIQUID COOLING SYSTEM Radiator / Thermostat / Water pump / Cooling system maintenance / Fan circuit / Troubleshooting / Starter relay / Starter clutch / Lights / Horn / Battery * ELECTRICAL SYSTEM Ignition system / Alternator / Rectifier / Voltage regulator / Electric drag / Poor handling / Brake problems / Lighting problems / Troubleshooting guide * APPENDIX / SPECIFICATIONS: GT380 / GT550 / GT750 * WIRING DIAGRAMS click here

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/ Troubleshooting instruments / Starter / Charging system / Ignition / Engine / Engine noises / Excessive vibration / Lubrication / Fuel system / Clutch / Transmission / Brakes / Lighting system / Front suspension and steering / Specifications * PERIODIC MAINTENANCE Routine checks / Periodic maintenance / Drive chain adjustment and lubrication / Engine oil and filter change / Air filter service / Clutch cable adjustment / Brake pad inspection / Front fork oil / Stering head check / Speedometer drive / Engine tune-up / Valve clearance adjustment / Ignition timing (1980 and later models) / Spark plugs / Ignition timing / Contact breaker point and timing adjustment (1979 and earlier models) / Throttle cable adjustment / Carburetor adjustment / Caburetor balancing (synchronization) / Compression test / Storage / Specifications * ENGINE (1979 AND EARLIER) models) / Spark plugs / Ignition timing / Contact breaker point and timing adjustment (1979 and earlier models) / Throttle cable adjustment / Carburetor adjustment / Caburetor balancing (synchronization) / Compression test / Storage / Specifications * ENGINE (1979 AND EARLIER) related info

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TROUBLESHOOTING Starting the engine / Starting procedure / Engine will not start / Poor engine performance / Fuel system / Engine / Engine lubrication / Leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Electrical troubleshooting / Steering and suspension / Brake system / Specifications * LUBRICATION / MAINTENANCE AND TUNE-UP Maintenance intervals / Pre-ride inspection / Tune-up / Compression test / Ignition timing / Valve clearance / Spark plug / Engine oil / Air filter / Throttle cable / Idle speed / Throttle valve synchronization / Fuel line inspection / Pair system / Evaporative emission control system / Exhaust control valve / Specifications * ENGINE TOP END Cylinder head / Camshaft / Cam chain tensioner / Cam chain guides and timing rotor / Valve lifter and shim / Valves and components / Specifications * ENGINE LOWER END module ECM / Starting system / Starter and relay / Sidestand / Gear position GP sensor / Turn signal / Lighting / Horn / Meter assembly / Speed sensor / Oil pressure switch / Switches / Specifications * COOLING SYSTEM Temperature warning system / Inspection / Reservoir / Radiator / Fan / Fan relay / more here.....

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organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Cylinder leakdown test / Clutch / Transmission / Electrical testing / Electrical systems / Steering and suspension / Shaft drive / Brake system * LUBRICATION MAINTENANCE AND TUNE-UP Cylinder firing order / Engine rotation / Tune-up / Air filter / Compression test / Spark plugs / Engine oil and filter / Engine oil pressure test / Fuel filter (1998-2004 models) / Auto-decompression cable adjustment / Throttle cable free play / Engine idle speed / Fast idle speed (fuel injected models) / Throttle valve synchronization / Fuel line inspection / Emission WHEELS HUBS AND TYRES Motorcycle stand / Brake rotor precaution / Wheel inspection / Wheel bearing inspection / Front wheel / Front hub / Rear wheel / Rear hub / Wheel balance / Tyres / Specifications * FRONT SUSPENSION AND STEERING Fork / Handlebar / Grip / Steering head and stem / extra

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* Suzuki GSX750F 1989 - 1996 * Suzuki GSX1100F 1987 - 1996 US Models: * Suzuki GSXR750 1986 - 1992 * Suzuki GSXR1100 1986 - 1988 * Suzuki GSXR1100 1988 - 1992 * Suzuki Katana 600 1988 - 1996 * Suzuki Katana 750 1989 - 1996 * Suzuki Katana 1100 1988 - 1993 Note: This manual covers models with air/oil-cooled engines only the liquid-cooled GSX-R750W and GSX-R1100W are not covered. Contents * Suzuki GSX GSX-R Maintenance - Identification Numbers - Buying Spare Parts - Engine Oil Level - Brake Fluid Levels - Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Storage - Troubleshooting link here

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SV650A/SA 2007 - 2008 * Suzuki SV650 Sport 2008 Table of Contents * The Suzuki SV650 - Introduction - Safety First! - Identification Numbers - Buying Spare Parts * Daily (Pre-Ride) Checks - Engine/Transmission Oil Level Check - Brake Fluid Level Checks - Suspension Steering And Final Drive Checks - Legal And Safety Checks - Tyre Checks * Maintenance Routine Maintenance And Servicing - Specifications - Recommended Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Transmission And Associated Systems - Engine Clutch And Transmission - Cooling System - Fuel And Exhaust Systems - X Y K1 And K2 Models - Fuel And Exhaust Systems - K3 Models Onwards - Ignition System * Chassis Components - Frame And Suspension - Final Drive - Brakes - Tyres - Fairing And Bodywork * Electrical System - Wiring Diagrams information

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Electrical system fundamentals / Service methods / Storage / Specifications Specs * Troubleshooting Starting the engine / Engine spark test / Engine performance / Electrical testing / Starting system / Engine noise / Motorcycle noise / Engine lubrication / Engine leakdown test / Clutch / Gearshift linkage and transmission / Brakes / Disc brake troubleshooting / Specifications Specs * Lubrication Maintenance and Tune-up Periodic inspection / Tune-up / Air filter / Engine oil and filter / Idle speed adjustment / Spark plugs / Compression test / Ignition timing inspection / Brake system / Clutch / Fuel hose inspection / Emission control system / Throttle cables / Choke cable / Tyres and wheels / Valve clearance / Lights and horn inspection / Sidestand switch and ignition cut-off system / Steering head bearing inspection / Front suspension inspection / Front fork oil change / Rear Shift Mechanism Clutch / Clutch release mechanism / External shift mechanism / Clutch cable replacement / Specifications Specs * Transmission and Internal Shift Mechanism Mainshaft / Countershaft / Transmission inspection / Shift drum and forks / Specifications Specs * Fuel and click the link

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Softcover - 120 pages - Suzuki 250 & 350 Twins 1968 - 1978 Haynes Owners Service & Repair Manual find out more.....

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Maintenance - Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Storage - Troubleshooting here

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Suzuki DR-Z400E (Electric Start) 2000 - 2009 * Suzuki DR-Z400S 2000 - 2010 * Suzuki DR-Z400SM 2005 - 2010 Contents: * Living With Your Suzuki DR-Z400 Motorcycle - Identification Numbers - Buying Spare Parts - Pre-Ride Checks - Engine Oil Level - Brake Fluid Levels - Tyres - Bike Specs * MAINTENANCE - Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * REPAIRS And OVERHAUL - Engine Clutch And Transmission - Cooling System - Fuel And Exhaust Systems - Ignition And Electrical Systems - Wiring Diagrams * REFERENCE - Tools And Workshop Tips - Security - Storage - Troubleshooting considerably more details

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TROUBLESHOOTING Engine / Starting difficulties / Poor performance / Clutch and transmission / Drive train / Chassis / Brakes / Electrical system / Charging system / Lighting / Fuses / Wiring * LUBRICATION MAINTENANCE AND TUNE-UP Model differences / Routine checks / Periodic maintenance / Engine oil and filter change / Drive chain adjustment and lubrication / Air filter service / Front fork oil change / Steering head check / Swing arm / Speedometer drive / Valve clearance adjustment / Contact breaker point and timing adjustment / Spark plug / Throttle cable adjustment / Fuel strainer / Carburetor synchronization / Compression Test / Suspension tuning / Engine tune-up * ENGINE Camshafts / Rocker arms and rocker shafts / Cylinder head / Valves / Cylinder block and pistons * CLUTCH AND TRANSMISSION Clutch / Gearshift mechanism / Kickstarter assembly * FUEL AND EXHAUST adjustment / Brake disc / Bleeding and changing brake fluid * SUPPLEMENT / 1985 AND LATER SERVICE INFMORMATION * WIRING DIAGRAMS come here

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1978-1982 U.S. 1977-1980 * Suzuki GS550L U.K./U.S. 1979-1982 * Suzuki Katana GS550M U.K./U.S. 1981-1982 * Suzuki GS550T U.S. 1981-1982 * Suzuki GS750 U.K. 1976-1977 U.S. 1976-1979 * Suzuki GS750D U.K. 1977-1979 * Suzuki GS750E U.K./U.S. 1977-1979 * Suzuki GS750L U.S. 1979 Contents: * Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams click here

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Manual organization / Warnings cautions and notes / Safety first / Service hints / Washing the vehicle / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Threadlock / Gasket remover / Expendable supplies / Parts replacement / Basic hand tools / Test equipment / Precision measuring tools / Special tools / Cleaning solvent / Mechanics tips / Bearing replacement / Seals / Specifications * TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Starting the engine / Emergency troubleshooting / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Electric starter system troubleshooting / Carburetor filter service / Fuel shut off valve and filter service / Engine tune-up / Cylinder head cylinder and exhaust torque tightening check / Valve clearance adjustment / Compression test / ignition timing / Idle speed adjustment / Oil pressure check / Coolant change / Exhaust system carbon removal click on

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Softcover - 200 pages - Suzuki GT ZR & TS50 1977 - 1990 Haynes Owners Service & Repair Manual covers link here

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Brakes And Tyres * Electrical System Including Wiring Diagrams click here

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Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Engine starting / Engine will not start / Engine performance / Engine noises / Engine lubrication / Leak down test / Clutch / Gearshift linkage / Transmission / Fuel system / Electrical testing / Electrical troubleshooting / Steering and suspension / Brake system / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Maintenance intervals schedule / Air filter / Compression test / Ignition timing / Valve clearance / Spark plugs / Engine oil and filter / Engine oil pressure test / Throttle cable / Idle speed / Fast idle speed / Throttle valve synchronization / Specifications * ENGINE TOP END Cylinder head cover / Camshaft / Cam chain tensioner / Cam chain chain guides and timing rotor / Cylinder head / Valve lifter and shims / Sidestand switch / Gear position GP sensor / Turn signal / sidestand relay / Lighting system / Horn / Meter assembly / Speed sensor / Oil pressure switch / Switches / Fuses / Wiring diagrams / Specifications * COOLING SYSTEM Hoses and clamps / Cooling system / Coolant reservoir / Radiator / more advice

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Softcover - 112 pages - Suzuki TS50X 1984 - 2000 Haynes Owners Service & Repair Manual covers the link here

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Softcover - 224 pages - Suzuki GS125 GS125ES GN125 GZ125 Marauder DR125S 1982 - 2005 Haynes Owners information

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start / Poor idle speed performance / Poor medium and high speed performance / Electrical testing / Starting system / Charging system / Ignition system / Lighting system / Fuel system / Engine overheating / Engine noises / Cylinder leakdown test / Clutch / Transmission / Suspension / Frame / Brakes * LUBRICATION MAINTENANCE AND TUNE-UP Maintenance schedule / Pre-Ride inspection / Air box drain plug / Air filter / Engine oil / Oil pressure check / Spark plug / Spark arrestor cleaning / Fuel line inspection / Fuel tank vent hose / Carburetor / Ignition timing / Valve clearance inspection / Compression check / Control cables / Cooling system / Tyres and wheels / Battery / Drive chain and sprockets / Brake system / Shock absorbers / Front suspension / Swing arm bearing inspection / Rear suspension inspection / Skid plate inspection / Specifications * ENGINE TOP END maintenance and troubleshooting all the way to complete teardown and rebuild. more tips

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cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Engine starting / Engine will not start / Engine performance / Lubrication system / Leakdown test / Clutch / Gearshift linkage / Transmission / Fuel system / Fuel pump / Electrical testing / Electrical systems / Steering and suspension / Brake system / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Maintenance intervals shedule / Tune-up / Ignition timing / Valve clearance / Spark plugs / Engine oil and filter / Engine oil pressure / Throttle cable free play / Idle speed adjustment / Fast idle speed / Throttle body synchronization / Fuel line inspection / Emission control systems / Control cable / Fasteners / Specifications * ENGINE UPPER END Cylinder head cover / Camshaft / Cam Fuel injection self-diagnosis / Specifications * ELECTRICAL SYSTEM Fuel system and cooling / Electrical basics / Electrical connectors / Battery / Charging system / Voltage regulator / rectifier / Stator assembly / Ignition system / Crankshaft position CKP sensor / Engine control click to go

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TL1000RK3 2003 * Suzuki DL1000K2 2002 * Suzuki DL1000K3 2003 * Suzuki DL1000K4 V-Strom 2004 Contents: * SUZUKI TL1000 DL1000 Motorcycles - Identification Numbers - Buying Spare Parts - Pre-Ride Checks - Engine Oil Level - Brake Fluid Levels - Tyres - Bike Specs * Maintenance - Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repairs And Overhaul - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Storage - Troubleshooting link here

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Chapter organization / Notes cautions and warnings / Photos drawings and tables / Model identification / Special service tips / General maintenance hints / Tune-up and troubleshooting tools / Expendable supplies / Safety first / Off road rules / Ride safely * TROUBLESHOOTING Operating requirements / Emergency troubleshooting / Engine performance / Excessive vibration / Front suspension and steering / Brake problems * LUBRICATION MAINTENANCE AND TUNE-UP Service intervals / Routine checks / Tyres and wheels / Lubricants and solvents / Periodic maintenance / Drive chain / Engine oil and filter change / Engine sump screen cleaning / Control cables lubrication / Miscellaneous chassis lubrication / Air filter service / Fuel strainer / Cam tensioner adjustment / Clutch adjustment / Frame and engine fasteners / Brakes / Wheel bearings / Steering / Transmission and internal gearshift mechanism / Transmission gearset disassembly assembly / Specifications * FUEL AND EXHAUST SYSTEMS Fuel tank fuel strainer and fuel pump / Carburetor operation / Carburetor service / Throttle and choke cables / Exhaust system / Specifications * click here

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/ Fasteners / Shop supplies / Basic tools / Precision measuring tools / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the engine / Engine spark test / Engine performance / Engine noise / Engine leakdown test / Clutch / External shift mechanism / and transmission / Kickstarter / Brakes / Steering / Electrical testing / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Service precautions and practices / Pre-ride inspection / Engine break-in / Tune-up and service intervals / Fuel and lubricants / Transmission and component lubrication / Maintenance and inspection / Engine tune-up / Spark plugs /Specifications * ENGINE TOP END Shop cleanliness / Exhaust system / Cylinder head / Cylinder / Exhaust valve system / Exhaust valve and shaft assembly / Exhaust valve governor and actuator / Piston and piston ring / Reed valves shaft assembly / Exhaust valve governor and actuator / Piston and piston ring / Reed valves /Specifications * ENGINE LOWER END Shop cleanliness / Engine / Crankcase / Crankcase seal replacement / Crankcase bearing replacement / Crankshaft /Specifications * CLUTCH AND GEARSHIFT additional info.....

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Expendable supplies / Tools / General maintenance and repair hints / Specifications * TROUBLESHOOTING Operating requirements / Troubleshooting instruments / Emergency troubleshooting / Starter / Charging system / Ignition / Engine noises / Excessive vibration / Lubrication troubles / Fuel system / Clutch / Transmission / Brakes / Lighting system / Front suspension and steering / Specifications * PERIODIC MAINTENANCE LUBRICATION AND TUNE-UP Routine checks / Periodic maintenance / Engine oil and filter change / Air filter / Spark plugs / 4 000 mile 12 month service / Engine oil a nd filter change / Air cleaner service / Clutch adjustment / Check secondary gear oil level / Final drive gear oil level check / 7 500 mile 24 month service / Front forks oil change / Changing gear oil / Every 2 years / Suspension tuning / Engine tune-up / Valve clearance adjustment / Spark plugs / Contact breaker point and timing adjustment (1979 models only) / Throttle cable adjustment / Carburetor adjustment / Carburetor balancing (synchronization) / Choke cable adjustment / Compression test / Storage / Specifications * ENGINE Crankshafts / Cylinder head / Valves / Cylinder additional info.....

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Engine Oil Level - Brake Fluid Levels - Tyres - Bike Specs * MAINTENANCE - Routine Maintenance And Servicing - Specifications - Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * REPAIRS And OVERHAUL - Engine Clutch And Transmission - Fuel And Exhaust Systems - Ignition System - Frame And Suspension - Brakes Wheels And Final Drive - Fairing And Bodywork - Electrical System - Wiring Diagrams * REFERENCE - Tools And Workshop Tips - Security - Storage - Troubleshooting much more info

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GS850GLX U.S. 1980-1981 * Suzuki GS850GZ U.K. 1983-1985 U.S. 1981-1982 * Suzuki GS850GLZ U.S. 1981-1982 * Suzuki GS850GD U.S. 1982-1983 * Suzuki GS850GLD U.S. 1982-1983 * Suzuki GS850GE U.K. 1985-1986 * Suzuki GS850GG U.K. 1986-1988 Contents: * Introduction To Suzuki Gs850 Models * Routine Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams * The 1981 To 1988 Models more information.....

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Acknowledgements - About This Manual - Identification Numbers - Buying Spare Parts - Safety First! * Daily (Pre-Ride Checks) - Engine/Transmission Oil Level - Brake Fluid Levels - Clutch Fluid Level - Tyres - Suspension Steering And Drive Chain - Legal And Safety Checks - Bike Specs - Model Development * Maintenance - Routine Maintenance And Servicing - Specifications - Recommended Lubricants And Fluids - Maintenance Schedule - Component Locations - Maintenance Procedures * Repair And Overhaul - Engine Transmission And Associated Systems - Engine Clutch And Transmission - Cooling System - Fuel And Exhaust Systems - Ignition System * Chassis Components - Frame Suspension And Final Drive - Brakes Wheels And Tyres - Bodywork * Electrical System * Wiring Diagrams * Reference - Tools And Workshop Tips - Security - Lubricants And Fluids - Conversion Factors - Rego Test Checks - Storage - Fault Finding - Fault Finding Equipment further data

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LT230G Shaft Drive (1985-1986) * LT250S Chain Drive (1989-1990) Table of Contents * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Service hints / Torque specifications / Safety first / Service hints / Special tips / Expendable supplies / Parts replacement / Serial numbers / Basic hand tools / Tune-up and troubleshooting tools / Mechanic's tips / Off road rules / Riding safely * TROUBLESHOOTING Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride checklist / Service intervals schedule / Periodic lubrication / Engine oil and filter change / Control cable lubrication / Non-scheduled lubrication / Periodic maintenance / Non-scheduled maintenance / Reverse cable adjustment / Tune-up fender / Rear fender / Front hand grip / Rear hand grip / Front and rear carriers (shaft-driven models) / Specifications * SUPPLEMENT / 1987 AND LATER SERVICE INFORMATION * WIRING DIAGRAMS Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step more advice

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Repair Manual Covers the following models: * Suzuki GS400 1977-1978 * Suzuki GS425 1979 * Suzuki GS450 1980-1983 1985-1987 Contents: * General Information * Troubleshooting * Lubrication Maintenance and Tune-up * Engine * Clutch and External Gearshift Linkage * Transmission and Internal Shift Mechanism * Fuel and Emission Systems * Exhaust System * Electrical System * Wheels Tyres and Drive Chain * Front Suspension and Steering * Rear Suspension * Brakes * Body and Frame * Wiring Diagrams more tips

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KFX400 (398cc) 2003 - 2006 * Arctic Cat DVX400 (398cc) 2004 - 2008 Contents: * LT-Z400 KFX400 DVX400 MAINTENANCE - Buying Parts - Engine Oil Level - Brake Fluid Levels - Tyres - Routine Maintenance And Servicing - Specifications - Maintenance Schedule - Component Locations - Maintenance Procedures * REPAIRS And OVERHAUL - Engine Clutch And Transmission - Fuel And Exhaust Systems (Carburetor Models) - Fuel And Exhaust Systems (Fuel Injection Models) - Ignition System - Suspension - Brakes Wheels And Final Drive - Bodywork And Frame - Electrical System - Wiring Diagrams * REFERENCE - Tools And Workshop Tips - Storage - Troubleshooting information

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RM400 (1978-1980) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Service hints / Tools / Expendable supplies / Safety first / Motor identification and parts replacement * TROUBLESHOOTING Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Excessive vibration / Clutch slip or drag / Poor handling / Brake problems/ Troubleshooting guide/ Power loss / Overheating / Backfiring / Engine noises / Piston seizure * LUBRICATION MAINTENANCE AND TUNE-UP Air filter / Engine lubrication / Drive chain / Frame and suspension component fasteners / Front forks / Transmission oil / Cable lubrication / Drive chain buffers / Drive chain guide and tensioner rollers / Swinging arm bearings / Brake pedal lubrication / Front torque link lubrication / Full-floating brake hub lubrication / Brake linkage lubrication / repair hints / Cylinder head / Cylinder / Piston and rings / Reed valve assembly / Crankshaft and crankcase / Bearing and seal replacement / Service and adjustment * CLUTCH TRANSMISSION AND KICKSTARTER Clutch / Gearshift / Primary drive gear / Transmission / Kickstarter * FUEL AND EXHAUST more info

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engine / Starting difficulties / Engine is difficult to start / Poor idle speed performance / Poor medium and high speed performance / Starting system / Charging system / Ignition system / Fuel system / Engine overheating / Engine / Engine noises / Cylinder leakdown test / Clutch / Transmission / Drive train noise / Handling / Frame noise / Brakes / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Pre-ride check list / Maintenance schedule / Engine oil and filter change / Tyres and wheels / Battery / Periodic lubrication / Periodic maintenance / Engine tune-up / Spark plugs / Specifications * ENGINE TOP END Engine principles / Exhaust system / Cylinder head cover / Camshaft / Cam chain tension and guides / Cam chain / Cylinder head / Valve lifters and shims / Valves and valve components / Cylinder block / Piston and piston rings / Specifications * ENGINE side panels / Upper fairing / Rear frame cover / Sidestand / Specifications * WIRING DIAGRAMS click on

Suzuki began manufacturing motorcycles in 1952, 1st brands being motorized bikes. From 1955 to 1976 the organization made motorcycles with two-stroke motors just, the biggest two-stroke model being the water-cooled triple-cylinder GT750.

A big factor in Suzuki's success in two-stroke competitors ended up being the East German Grand Prix racer Ernst Degner, which defected on western in 1961, bringing with him expertise in two-stroke motors from East German producer MZ. The strategy Degner introduced with your were the job of Walter Kaaden, whom combined three crucial technology for the first time: the increase port, the growth chamber, and the rotary device.

Suzuki employed Degner, and he claimed the 50 cc course F.I.M. track racing World tournament for all of them when you look at the 1962 season. Suzuki became the very first Japanese maker to win a motocross globe tournament whenever Joel Robert claimed the 1970 250 cc title. Inside 1970s, Suzuki set up themselves into the bike rushing globe with Barry Sheene and Roger De Coster winning globe championships into the premiere 500 cc unit in road race and motocross correspondingly.

In 1976 Suzuki launched its earliest motorcycles because the Colleda COX of this 1950s with four-stroke motors, the GS400 and GS750.

In 1994, Suzuki partnered with Nanjing Jincheng Machinery to produce a Chinese motorcycle manufacturer and exporter called Jincheng Suzuki.

Suzuki proceeded to compete in MotoGP and final claimed the subject when you look at the 2000 period. Since 2006, the group was sponsored by Rizla and had been known as Rizla Suzuki MotoGP staff. On 18 November 2011, Suzuki revealed your GP rushing is suspended, partially because of natural disasters and depression, until 2014.

Two-stroke motors
Suzuki T20 and T500 Titan at Le beauty salon de la Moto 2011 in Paris
Suzuki RGV250Γ within Barber Vintage Motorsport Museum in 2006

X6 Hustler twin is marketed from 1966 to 1968 as "the quickest 250cc motorcycle on earth". It have Suzuki's latest Posi-Force automated oils shot system. Manufacturing peaked at above 5000 devices per month. In 2013, Suzuki restored the Hustler bike trademark for Europe, causing gossip of a retro design 250 twin. A 1967 T20 Super Six is within the Las Vegas program for the Art of the Motorcycle event.

T500 Titan have a 500 cc air-cooled parallel-twin motor which overcame difficulties with toughness, overheating and vibration. With an output of 47 metric horse power at 6,500 rpm and top speeds of 180 kilometres hourly, it became Suzuki's leading device in 1968, and stays popular with enthusiasts and café racers.

GT750 Le Mans with a straight-three motor is the initial Japanese motorcycle with a liquid-cooled motor, making they the moniker "liquid Buffalo." The Society of Automotive Engineers of Japan includes the 1971 Suzuki GT750 among their particular 240 Landmarks of Japanese Automotive Technology.

TM400 Cyclone production motocrosser had been made to take part in 500cc class Motocross globe Championship race. Introduced in 1971, it had been infamously difficult even for competent cyclists to manage. Redesigned in 1975.

The RM125 production motocrosser debuted in 1975 to displace the TM125. It had been a successful forerunner into the future RM show line-up from 50cc to 500cc.

RM250 had been totally redesigned in 1982 while the liquid-cooled single-cylinder delivered most power than just about any production 250cc motorcrosser of that time. They have Suzuki's earliest full floater, link-type back suspension introduced annually earlier on.

RG250 Gamma of 1983 had been the newer generation of battle replica athletics bicycles regarding the 1980s. They have an aluminum frame, the full fairing and a high production straight-twin system. The 1983 RG250Γ is among the JSAE 240 Landmarks of Japanese Automotive tech.

RG500 Gamma of 1985 had been like RG250, but with a square-four motor.

RGV250 Gamma, the road-racing reproduction of Kevin Schwantz's RGV500 GP competition cycle, changed the RG250 in 1988 with a V-twin engine.

Four-stroke engines
Suzuki GS1000S in the Barber classic Motorsport Museum in 2006
Suzuki DR800S
Suzuki GSX-R1000 at Tokyo Motor tv show in 2007

GS series – The 1976 GS750 ended up being initial 4-stroke device circulated by Suzuki in 20 years. The next season spotted Suzuki's first 1-liter machine, the GS1000E, after which in 1979 the GS1000S content of a Yoshimura GS1000 Superbike.

Katana – The GSX1100S premiered in European countries in 1980; the GSX1000S arrived in the U.S. and Canada later on that season as a 1981 model, and revolutionized sportbike styling. A 1982 Katana GS1000SV are from the AMA Motorcycle hallway of Fame‍ '​s listing of "classic bikes" which were shown within the museum, and was in The Art of the Motorcycle convention.

GSX-R750 ended up being the Japanese recreation bicycles for the 1980s that started the modern competition replica era. It had air/oil air conditioning, light-weight, and a robust engine. The people of Automotive designers of Japan includes the 1984 Suzuki GSX-R750 among their 240 Landmarks of Japanese auto Technology, and was at The Art of the bike.

Intruder 750 using its OHC 4-valve 45° V-twin system ended up being the very first Japanese cruiser bike in 1985. By 1997, cruiser-style motorcycles would account fully for nearly 60 percent for the U.S. street-bike marketplace.

GSX-R1100, pertaining to the GSX-R750, appeared in 1986. Similar fundamental motor would reappear in 1995 to power the Bandit 1200 and stay static in manufacturing through 2006.

The DR-BIG aka Desert Express DR800S off-roader was existent for just two model many years as the DR750S until 1990, whenever its displacement risen up to 779cc, still the world biggest single-cylinder system in a manufacturing bike. For sale in European countries through 1999, it absolutely was perhaps not shipped to the U.S. marketplace. Changed by the V-Strom twin, the DR-BIG has now come back to where it started as build inspiration for a 2014 renovation of this V-Strom 1000 ABS.

Suzuki RF Series The Suzuki RF series is sport touring motorcycles. They included three system variations: 400, 600 and 900 cc. It was in production from 1994 to 1998.

TL1000S debuted in the 1996 worldwide bike and Scooter tv show once the very first Suzuki recreation cycle with a V-twin system. It was a liquid-cooled, 90° V-twin, DOHC engine with 4 valves per cylinder, which will be in manufacturing through 2012. Although the TL1000S motorcycle ceased production in 2001, the engine would continue inside TL1000R, the SV1000 and SV1000S, plus the V-Strom 1000.

GSX-R600 – a smaller sized type of the GSX-R750. There have been early in the day pretenders, although genuine article arrived in 1997 and contains got regular news afterwards.

Hayabusa was launched in 1998, and continues to be Suzuki's leading recreation cycle. The 1998 Suzuki Hayabusa is roofed inside JSAE 240 Landmarks of Japanese auto Technology. The introduction of another generation Hayabusa when it comes to 2008 design 12 months facilitated the 2007 roll-out of this GSX-1300BK B-King, an extremely stylized nude variant.

SV650 had been launched in 1999 as a spending plan entry within the naked cycle market and, and because 2001, provided both nude and fully faired. In '09 the nude cycle version had been redesigned and renamed the Gladius commensurate with the blade motif Suzuki established because of the Katana. The Gladius motorcycle obtained good Design prize from Japan Institute of Design marketing.

GSX-R1000 – This top-of-the-line superbike premiered in 2000, and continues to be the biggest type of the GSX-R series.

Burgman 650 was the biggest of some urban scooters manufactured in Japan along with Italy and Spain with engine capacities of 125cc or over. With regards to appeared in 2002 the 650 was the largest-displacement scooter on earth, and very first two-wheel vehicle to possess an electrically influenced Continuously Variable Transmission. The Japan Institute of build marketing awarded the G level Effective Design Award toward Skywave 650 in 2003, to your whole Skywave series in 2006 also to the up-to-date Skywave 650LX in 2013.
Choinori was a lightweight, affordable, 50cc scooter and antithesis of this Skywave 650, nonetheless they were launched on top of that in an attempt to increase domestic selling in reaction to shrinking bike exports. The 2002 Choinori is one of the JSAE 240 Landmarks of Japanese auto technologies. The Choinori was awarded the grams Mark Effective Design honor in 2003.

Boulevard M109R V-twin, dubbed the Intruder M1800R in European countries, arrived in 2006 boasting a 112 mm bore with a 90.5 mm swing, amongst the biggest gasoline system pistons ever before found in any production bike.

GSX-650F – launched in 2008, this newer sport touring model fills the void of the retired Katana. The 2009 model has ABS standard.

DL-650 V-Strom – a dual-sport motorcycle

The Suzuki Hayabusa is a hobby cycle motorcycle made by Suzuki since 1999. They immediately claimed acclaim as the earth's fastest manufacturing motorcycle, with a high speed of 188 to 194 miles per hour.

In 2000, fears of a European regulating backlash or import ban, generated a casual contract amongst the Japanese and European makers to control the utmost effective rate of these motorbikes at an arbitrary restriction. The media-reported worth when it comes to speed agreement in kilometers hourly ended up being regularly 186 miles per hour, whilst in kilometers hourly they varied from 299 to 303 km/h, which is typical given unit conversion rounding errors. This figure are often affected by many additional issues, as can the energy and torque values.

The circumstances under which this limitation ended up being used resulted in the 1999–2000 Hayabusa's name staying, at the least officially, unassailable, since no subsequent model could run faster without getting tampered with. Therefore, following the much expected Kawasaki Ninja ZX-12R of 2000 dropped 4 miles per hour short of saying the name, the Hayabusa protected its spot given that fastest standard manufacturing bike regarding the 20th century. This gives the unrestricted 1999–2000 systems a lot more cachet with collectors.

Besides their speed, the Hayabusa is lauded by many reviewers because of its all-round performance, in that it does not considerably compromise more properties like handling, benefits, dependability, sound, fuel economy or cost in pursuit of a single work. Jay Koblenz of Motorcycle customer reports commented, "if you were to think the ability of a motorcycle to means 190 mph or achieve the quarter-mile in less than 10 seconds are at most readily useful frivolous and at worst offensive, this however continues to be a motorcycle worthy of simply consideration. The Hayabusa try accelerate in every its glory. But rate is not all Hayabusa try."

When initially demonstrated to the press in 1999, 1st Hayabusas made a powerful impression. No earlier bike has damaged the production model top rate record by these types of a margin, 10 to 14 miles per hour, based which sized speeds the foundation ended up being counting on for the CBR1100XX in addition to GSX-1300R.

Hayabusa a bird very often functions as a metaphor for rate due to its straight hunting plunge, or stoop, rate of 180 to 202 kilometers per hour, the quickest of every bird. Particularly, the decision of title ended up being made due to the fact peregrine falcon preys on blackbirds, which mirrored the intent of this initial Hayabusa to unseat the Honda CBR1100XX Super Blackbird given that world's fastest manufacturing bike. Fundamentally, the Hayabusa managed to exceed the Super Blackbird by at the least a full 10 kilometers per hour.

Initial generation have a 1,299 cc liquid-cooled, inline-4 engine with sixteen valves driven by double-overhead cams. This setup, technologically unremarkable for the time, delivered a record-setting advertised 173 braking system horse power on crankshaft by virtue regarding the largest displacement previously in a sport bike, and a ram air system that required cool, pressurized atmosphere into the cylinders at speeds. Coupled with sophisticated aerodynamics, this effective engine pressed the Hayabusa's top speeds far over the Honda CBR1100XX Blackbird by a substantial jump, contrasting with the incremental gains that preceded the Suzuki hyper recreation entry. The 1997 carbureted CBR1100XX have earlier best inched through the previous top speed record holder, the Kawasaki Ninja ZX-11 of 1990.

The Hayabusa system have a good amount of energy throughout its whole rpm musical organization. The 1,299 cc powerplant had been the biggest and most powerful athletics cycle system when launched in 1999, and stayed the largest until Kawasaki's ZX14 was released.

The Hayabusa's abundance of energy at any system speed made the Hayabusa easier to drive by providing the rider a larger range of gear selection for a given speeds and stunning acceleration.

The ram air ducts in front of this drooping, curved nose squeezed front area out of the headlight, which, along with the dependence on a narrow frontal region, necessitated a stacked headlight and high beam behind one lens. Moreover, the necessity to lessen the severe drag encountered at highest rates determined the Hayabusa's entire bulbous, and much-criticized, bodywork build. Koblenz remarked, "non-traditional styling creates the main debate regarding the Hayabusa." When seen through the vision of the which judged their beauty on the basis of their function, or given some time getting familiar with they, the bike's seems did get a hold of admirers. The striking two-tone copper/silver paint plan was similarly treasured by some and hated by other individuals, but is effective if the intention of an all-new, flagship product is to create a striking report. Therefore whilst it ended up being known as ugly by some within the hit, this aerodynamic shape is crucial on Hayabusa's power to attain record-setting speeds.
The medial side for the bodywork of an activity bike using the legend Hayabusa superimposed on a Japanese character

Reflecting in '09 from the initial build, the creator for the Hayabusa's search, Suzuki's Koji Yoshirua, stated the intention in 1999 had been, "to produce a somewhat grotesque build and produce a very good preliminary effect... The mission was to produce a total new styling that will not become out of date within several years, and a styling that will be the ‘Face’ of Suzuki." Yoshirua additionally said that objective wasn't to ultimately achieve the reputation of quickest manufacturing motorcycle, which in first stages had been slated to be just 900 to 1,100 cc, but that, "as a result of, pursuing the best maneuvering, speed, security, power, riding potential, initial styling, etc., the close for the clients, it became the ‘Fastest manufacturing motorcycle’ … using this method, when the model was out in industry as well as the efficiency from it are proven, I thought that folks will start to show interest on weird design, after which the design will be caked in individuals brain.”

The system utilized a gear-driven counterbalancer to reduce vibration to the level your engine might be solidly mounted towards frame, for the true purpose of increasing framework rigidity. Employing a conventional twin ray framework, totally flexible upside down forks, utilizing especially developed Bridgestone tires, and being reasonably light at 473 weight dried out, the Hayabusa's control is considered exemplary for a device of this course. One reviewer, Koblenz, mentioned a hesitation possibly related to bad low-rpm mapping at lower speeds, noticeable as a "pause and slight lurch" whenever moving in and back away the throttle. Mild reduced speeds FI changes were addressed with both a "Yosh package" or "Teka SFI" FI adjusting device.

The 600 cc and 900 cc version were both based on the GSX1100R base end – a 16-valve inline-four, four-stroke, water-cooled device. The RF possess small carburetors, and small valves. This leads to a smoother energy distribution and a more functional motor. The motor are canted forwards in framework by 19 levels to allow for a reduced center of gravity, and enables the gasoline air combination to-be "dropped" in to the cylinders on the intake swing. And also this allows for a 6-litre airbox. The 900 cc motor features a redline of 12,000 rpm, as well as the 600 cc motor have a somewhat greater 13,500 rpm redline.

There is absolutely no gas measure, nevertheless a "fuel low" light is present, which gets better given that reserve degree try approached. Filling within most affordable brightness of light can lead to best 1 / 2 the gasoline ability of this bike used. The bicycle possess a 4 L book, turned to using the normal fuel cock on left-hand chair product fairing.

The 400 cc variation was somewhat different, and utilizes the engine through the Suzuki GSF400 installed with 32 mm Mikuni carburetors.

The 900 utilizes a stainless 4-2-1 fatigue header whilst 600 and 400 bikes utilize metallic 4-1 headers. The later 600, and all the 900 variations incorporate a tri-bolt can fitment. The sooner 600 and all 400 RF bikes incorporate a slip on with link pipeline system, with a join underneath the center of the cycle.
Air Conditioning

The RF series utilizes a U-shaped water-filled radiator, allowing the system to stay lower, and nearer to leading wheel. The oil filter is also water-cooled, and there's a cooling lover suited to the rear associated with radiator. This really is capable of cooling the bike to the point where you can use it happily at 9,000 ft without overheating. There is a temperature measure for tracking liquids temperatures.
Transmission

The 900 cc model is equipped with a 5-speed constant mesh box, even though the 400 and 600 utilize 6-speed versions to make the all the small displacement power products. The lubrication associated with the gearbox and clutch try shared with the crank and motor lubrication. The 900 uses a RK532GSV2 x 110 hyperlinks chain, although may be transformed into make use of most available specifications. The 600 utilizes a RK50MF0Z1 x 108 backlinks string. The usual 1-N-2-3-4-5 gearbox shifting structure is observed. The 900 uses a hydraulically actuated clutch, even though the 600 and 400 usage cable actuation.
Chassis and braking

A hollow steel perimeter framework can be used to lessen size and value as well as perfect benefits. Reaching the exact same power with aluminum would need much bigger framework spars making the framework much wide. The hollow metallic frame allows knee reliefs that are combined in to the contours associated with the tank and bodywork.

In 1996, Suzuki enhanced the front forks from the 900 offering rebound modification. The additional dimensions regarding the prior and soon after forks are identical so that they tend to be a direct bolt-on substitution. However, many elect to spend the equivalent money on a Racetech cartridge improvement which provides better damping compared to 96+ forks.

The OEM suspension provides a reasonable amount of comfort however stays composed while operating across real-world roadway surfaces even if the pace crests triple digits. Only in a track environment will the RF suspension system become a limiting factor. Braking is great from the stock Nissin brake system, which gain substantially with upgraded steel braided braking system outlines.



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