Suzuki Motorbikes

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    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) lots more
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    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 chain slider service / Clutch adjustment (GSX-R750 Limited adjustment) / Air filter element / Fuel Carburetor operation / Carburetor service / Carburetor assembly / Carburetor / Carburetor separation / Carburetor adjustments / Throttle cable replacement / Air filter air case / Fuel tank / Fuel filter / Gasoline/alcohol blend test / Crankcase breather system (U.S. only) / Evaporative emission information
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    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 control systems / Clutch / Shift pedal height / Control cable lubrication / Tyres and wheels / Front suspension / Steering head / Rear suspension / Final drive / Brake system / General lubrication / control systems / Clutch / Shift pedal height / Control cable lubrication / Tyres and wheels / Front suspension / Steering head / Rear suspension / Final drive / Brake system / General lubrication / Fasteners / Specifications * ENGINE TOP END Cylinder head side cap / Cylinder head cover / Hydraulic more data
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    Contents: * Living With Your SUZUKI HAYABUSA * Introduction – Suzuki – Every Which Way – 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 click on
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    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 / Engine tune-up / Storage / Specifications * ENGINE Servicing engine in the frame / Engine removal/installation / Cylinder head cover / Rocker arms / Camshaft / Cylinder head / Valves / Valve panel / Front fender / Frame cover (ALT models) / Rear fender / Specifications * SUPPLEMENT / 1984-1987 SERVICE INFORMATION * WIRING DIAGRAMS Clymer motorcycle & ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you further data
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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) caliper / Rear caliper / Master cylinders / Brake pedal adjustment / Brake disc / Bleeding and changing fluid / Specifications * SUPPLEMENT / 1981 AND LATER SERVICE INFORMATION * WIRING DIAGRAMS more information…..
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    / 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 suspension inspection / Drive chain / Speedometer cable / Muffler / Fasteners / Specifications Specs * Engine Top End Exhaust system / Cylinder head cover / Rocker arm assemblies / Camshaft / Cylinder 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 here
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    numbers / Basic ahnd tools / Tune-up and troubleshooting tools / Mechanic’s tips / Of 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-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 (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 piston pin and piston rings / Primary drive gear balancer drive gear balancer driven gear and water extra info
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    the following models: * Suzuki GS500E (K to Y) 1989-2000 * Suzuki GS500 (K1 to K8) 2001-2008 * 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 further data
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    Manual Covers Shaft Drive Models including: * GS850G (1979-1982) * GS850GL (1979-1983) * GS1000G (1980-1983) * GS1000GL (1981) * GS1100G (1982-1983) * GS1100GL (1982-1983) * GS1100GK (1982-1984) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION How to use this manual / Chapter organization / Notes. cautions and warnings / Photos drawings and tables / Model identification / Safety first / 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 Carburetor adjustment / Carburetor balancing (synchronization) / Choke cable adjustment / Compression test / Storage / Specifications * ENGINE Crankshafts / Cylinder head / Valves / Cylinder block and pistons / Engine removal/installation / Lower end / Oil pump / Cam chain tensioner / more advice
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    Owners Service & Repair Manual Covers the following Models: * Suzuki GSX1000 Katana GS1000 Katana GS1000S U.K. 1981-1985 U.S. 1981-1982 * Suzuki GSX1100S GS1100S U.K. 1981-1985 U.S. 1982-1983 * 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 come here
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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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    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 full details
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    Owners Service & Repair Manual covers the following models: * Suzuki TS100ERN (TS100) U.K. only 1979 * Suzuki TS100ERT U.K. 1980 U.S. 1979 * Suzuki TS100ERX U.K. 1980 U.S. 1980 * Suzuki TS100ERZ U.K. only 1982 * Suzuki TS125ERN (TS125) U.K. only 1979 * Suzuki TS125ERT U.K./U.S. 1979 * Suzuki 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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    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 extra
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    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 more advice
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    Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System Including Wiring Diagrams details
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    TL1000RX 1999 * Suzuki TL1000RY 2000 * Suzuki TL1000RK1 2001 * Suzuki TL1000RK2 2002 * Suzuki 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 information
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    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 Instruments / Check panel / Fuses / Horns * FRONT SUSPENSION AND STEERING Front wheel / Wheel balancing / Front forks / Steering head * REAR SUSPENSION Rear wheel / Suspension units / Swing arm / Sprocket replacement / Drive chain * BRAKES Brake pad replacement / Calipers / Master cylinders / more details…..
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    service methods / Storage / Specifications * TROUBLESHOOTING Operating requirements / Starting the 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 / Specifications * BRAKES Brake service / Front brake pad / Front caliper / Rear brake pad / Rear brake caliper / Front master cylinder / Rear master cylinder / Brake hose / Brake disc / Brake bleeding / Rear brake pedal / Specifications * BODY AND FRAME Seats / Front fender / Fairing lower come here
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    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 here…..
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    Hardcover – 304 pages – Suzuki Burgman 250 & 400 1998 – 2011 Haynes Owners Service & Repair Manual come here
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    Softcover – 120 pages – Suzuki 250 & 350 Twins 1968 – 1978 Haynes Owners Service & Repair Manual click
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    covers the following models: * Suzuki GP100-UN 1980-1982 * Suzuki GP100-UX 1982-1983 * Suzuki GP100-UD 1983-1991 * Suzuki GP100-UL 1991-1993 * Suzuki GP100-C 1978-1980 * Suzuki GP100-N 1980-1981 * Suzuki GP100-X 1981-1984 * Suzuki GP100-ED 1983-1986 * Suzuki GP125-C 1978-1979 * Suzuki GP125-N 1979-1982 1985-1986 * Suzuki GP125-X 1982-1983 * Suzuki GP125-D 1983-1989 Contents: * Maintenance * Engine Clutch And Transmission * Fuel System And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams more data
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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 replacement / Steering head and stem / Steering head bearing race replacement / Steering stem bearing replacement / Front fork / Specifications * REAR SUSPENSION Shock absorber / Shock lever assembly / Swing arm / Bearing replacement / Specifications * BRAKES Brake service / Front brake pad more…..
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    RM500 (1983-1984) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Notes cautions and warnings / Service hints / Special tips / Safety first / Torque specifications / Fasteners / Lubricants / Expendable supplies / Parts replacement / Serial numbers / Basic hand tools / 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 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 / Clutch / Gearshift mechanism / Primary drive gear / Transmission / Specifications * FUEL AND EXHAUST more tips
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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 rings / Camshaft chain tensioner adjuster / Specifications * ENGINE LOWER END Servicing engine in frame / Engine removal and installation / Right crankcase cover / Left crankcase cover / Recoil starter / Starter clutch and gears / Oil pump and gears / Oil strainer / Secondary driven output considerably more details
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    Softcover – 200 pages – Suzuki GT ZR & TS50 1977 – 1990 Haynes Owners Service & Repair Manual covers extra info
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    Covers the following Models: * DR250 (1990-1993) * DR250S (1990-1994) * DR350 (1990-1994) * DR350S (1990-1994) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Notes cautions and warnings / Service hints / Safety first / Washing the bike / Torque fasteners / Lubricants/ Expendable supplies / Parts replacement / Basic hand tools / Precision measring tools / 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 External shift mechanism / Clutch cable / Specifications * TRANSMISSION AND INTERNAL SHIFT MECHANISM Transmission operation / Transmission overhaul / Internal shift mechanism / Specifications * FUEL EXHAUST AND EMISSION CONTROL SYSTEMS Carburetor service / Carburetor adjustments / Throttle cable click to go
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    following models: * Suzuki GSXR600 2001-2005 (U.S. California Canada U.K. Europe) * Suzuki GSXR600 Alstare 2003 (U.S. California Canada) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Warnings 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 / 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 Intake air pressure IAP sensor / Intake air temperature IAT sensor / Engine coolant temperature ECT sensor / Camshaft position CMP sensor / Tip-over TO sensor / Exhaust system / Evaporative emissions control system / PAIR air supply system / Diagnostic system / Specifications * ELECTRICAL SYSTEM here
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    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 more advice
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    Living With Your Suzuki DL650 V-Strom & SFV650 Gladius 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 – 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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    Manual organization / Warnings cautions and notes / Safety / Basic service methods / Serial numbers / 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 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 * WIRING DIAGRAMS considerably more details
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    * TC185 (1974-1976) * TS185 (Through 1981) * RL250 (1974-1975) * TM250 (1972-1975) * TS250 (Through 1974 1980-1981) * TM400 (Through 1975) * TS400 (1972-1976) Contents: * QUICK REFERENCE DATA * 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 / Piston pin piston and piston rings / Clutch / Primary pinion / Kickstarter / Shifter mechanism / Crankcase / Transmission / Crankshaft / Oil seals / Bearings * FUEL AND EXHAUST SYSTEMS Carburetor / Carburetor components / Miscellaneous carburetor problems / Fuel tank * ELECTRICAL SYSTEM Flywheel related info
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    2005 * Suzuki GSX-R750K4 749cc 2004 * Suzuki GSX-R750K5 749cc 2005 * Suzuki GSX-R1000K3 988cc 2003 * 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 considerably more details

Suzuki going production motorbikes in 1952, the initial products being motorized bicycles. From 1955 to 1976 the organization made motorcycles with two-stroke machines just, the biggest two-stroke model being the water-cooled triple-cylinder GT750.

A large factor in Suzuki’s triumph in two-stroke competitors had been the East German Grand Prix racer Ernst Degner, just who defected into the western in 1961, bringing with him expertise in two-stroke motors from the East German maker MZ. The tips Degner introduced with your are the job of Walter Kaaden, who blended three essential technology for the first time: the boost interface, the development chamber, therefore the rotary valve.

Suzuki hired Degner, and he won the 50 cc class F.I.M. route rushing World tournament for them in 1962 season. Suzuki became 1st Japanese producer to winnings a motocross world tournament when Joel Robert obtained the 1970 250 cc title. Within the 1970s, Suzuki founded on their own within the motorcycle racing globe with Barry Sheene and Roger De Coster winning globe championships within the premiere 500 cc unit in roadway rushing and motocross correspondingly.

In 1976 Suzuki introduced its first motorcycles because the Colleda COX of 1950s with four-stroke engines, the GS400 and GS750.

In 1994, Suzuki partnered with Nanjing Jincheng machines to produce a Chinese motorcycle maker and exporter known as Jincheng Suzuki.

Suzuki proceeded to participate in MotoGP and final claimed the subject into the 2000 period. Since 2006, the team ended up being sponsored by Rizla and ended up being generally Rizla Suzuki MotoGP employees. On 18 November 2011, Suzuki revealed your GP racing was suspended, partially because all-natural disasters and depression, until 2014.

Two-stroke motors
Suzuki T20 (front side) and T500 Titan (backside) at Le beauty salon de la Moto 2011 in Paris
Suzuki RGV250 at the Barber classic Motorsport Museum in 2006

X6 Hustler twin (aka T20 Super Six) was marketed from 1966 to 1968 as “the quickest 250cc bike in the world”. They have Suzuki’s newer Posi-Force automatic oils shot system (later called Suzuki CCI). Production peaked at above 5000 devices monthly. In 2013, Suzuki revived the Hustler bike trademark for Europe, leading to rumors of a retro style 250 twin. A 1967 T20 Super Six had been included in the nevada program of this Art of the Motorcycle convention.

T500 Titan (aka T500 Cobra, GT500) have a 500 cc air-cooled parallel-twin system which overcame problems with durability, overheating and vibration. With a production of 47 metric horse power (35 kW) at 6,500 rpm and top speeds of 180 kilometres hourly (110 mph), they became Suzuki’s leading machine in 1968, and remains favored by enthusiasts and caf racers.

GT750 Le Mans with a straight-three system was initial Japanese bike with a liquid-cooled engine, making it the moniker “Water Buffalo.” The Society of auto designers of Japan (Japanese) includes the 1971 Suzuki GT750 among their 240 Landmarks of Japanese Automotive Technology.

TM400 Cyclone production motocrosser had been built to take part in 500cc course Motocross World tournament racing. Introduced in 1971, it absolutely was notoriously tough also for competent cyclists to control. Redesigned in 1975.

The RM125 production motocrosser premiered in 1975 to replace the TM125. It absolutely was an effective forerunner for the future RM series line-up from 50cc to 500cc.

RM250 is fully redesigned in 1982 plus the liquid-cooled single-cylinder delivered most power than just about any manufacturing 250cc motorcrosser of that time period. They had Suzuki’s earliest full floater, link-type backside suspension introduced annually previously.

RG250 Gamma of 1983 had been among the newer generation of race reproduction sport bicycles of this 1980s. They had an aluminum framework, a full fairing and a top production straight-twin system. The 1983 RG250 is just one of the JSAE 240 Landmarks of Japanese Automotive tech.

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

RGV250 Gamma, the road-racing reproduction of Kevin Schwantz’s RGV500 GP race cycle, replaced the RG250 in 1988 with a V-twin motor.

Four-stroke engines
Suzuki GS1000S within Barber Vintage Motorsport Museum in 2006
Suzuki DR800S
Suzuki GSX-R1000 on Tokyo engine tv show in 2007

GS show — The 1976 GS750 is the first 4-stroke machine revealed by Suzuki in two decades. The following seasons spotted Suzuki’s very first 1-liter machine, the GS1000E, then in 1979 the GS1000S content of a Yoshimura GS1000 Superbike.

Katana — The GSX1100S was launched in Europe in 1980; the GSX1000S found its way to the U.S. and Canada later that 12 months as a 1981 model, and transformed sportbike styling. A 1982 Katana GS1000SV are in the AMA bike hallway of popularity’s a number of “classic bikes” that have been revealed when you look at the museum, and was at the skill of the bike exhibition.

GSX-R750 had been among Japanese athletics bicycles of the 1980s that began the present day competition replica era. It have air/oil cooling, lightweight, and a powerful motor. The community of auto designers of Japan (Japanese) include the 1984 Suzuki GSX-R750 as one of their particular 240 Landmarks of Japanese Automotive Technology, and was in the skill of the bike.

Intruder 750 featuring its OHC 4-valve 45 V-twin engine is 1st Japanese cruiser bike (built to attract U.S. bikers) in 1985. By 1997, cruiser-style motorcycles would account for almost 60 percentage of U.S. street-bike market.

GSX-R1100, related to the GSX-R750, starred in 1986. Exactly the same fundamental engine would reappear in 1995 to run the Bandit 1200 and stay in production through 2006.

The DR-BIG aka Desert Express DR800S (German) off-roader ended up being existent for two design many years as the DR750S (German) until 1990, whenever their displacement increased to 779cc, however the planet biggest single-cylinder motor in a manufacturing bike. For sale in Europe through 1999, it had been perhaps not shipped into U.S. market. Changed by the V-Strom twin, the DR-BIG has come back to where it started given that build determination for a 2014 overhaul associated with V-Strom 1000 ABS.

Suzuki RF show The Suzuki RF show were sport touring motorcycles. They was included with three engine variants: 400, 600 and 900 cc. It absolutely was in manufacturing from 1994 to 1998.

TL1000S premiered in the 1996 International bike and Scooter Show given that first Suzuki athletics bicycle with a V-twin engine. It was a liquid-cooled, 90 V-twin, DOHC engine with 4 valves per cylinder, which would take production through 2012. Even though TL1000S bike stopped production in 2001, the engine would carry-on inside TL1000R, the SV1000 and SV1000S, as well as the V-Strom 1000.

GSX-R600 — an inferior form of the GSX-R750. There were prior pretenders, but the genuine article arrived in 1997 and has now got regular updates from then on.

Hayabusa (GSX-1300R) is launched in 1998, and remains Suzuki’s flagship sport bicycle. The 1998 Suzuki Hayabusa is included within the JSAE 240 Landmarks of Japanese auto Technology. The introduction of another generation Hayabusa the 2008 model year facilitated the 2007 roll-out of the GSX-1300BK B-King, a very stylized nude variation.

SV650 is introduced in 1999 as a budget entry inside naked bike market and, and since 2001, offered both nude and completely faired. During 2009 the naked bike variation had been redesigned and rebranded the Gladius consistent with the sword theme Suzuki founded because of the Katana. The Gladius motorcycle won a great build honor (aka G level) through the Japan Institute of build advertising.

GSX-R1000 — This top-of-the-line superbike debuted in 2000, and continues to be the largest model of the GSX-R show.

Burgman 650 (AN650) was the largest of a number of urban scooters produced in Japan (promoted as Skywave domestically) along with Italy and Spain with motor capacities of 125cc or more. When it appeared in 2002 the 650 had been the largest-displacement scooter in the world, and very first two-wheel vehicle to own an electrically monitored constantly Variable Transmission. The Japan Institute of Design marketing awarded the G Mark Effective Design prize into Skywave 650 in 2003, towards the whole Skywave series in 2006 and to the up-to-date Skywave 650LX in 2013.
Choinori is a lightweight, affordable, 50cc scooter as well as the antithesis of the Skywave 650, nonetheless they had been introduced as well in an attempt to augment domestic selling responding to shrinking bike exports. The 2002 Choinori is among the JSAE 240 Landmarks of Japanese Automotive technologies. The Choinori ended up being granted the grams level Effective Design honor in 2003.

Boulevard M109R (VZR1800) V-twin, dubbed the Intruder M1800R in European countries, found its way to 2006 boasting a 112 mm (4.4 in) bore with a 90.5 mm (3.56 in) stroke, among the largest gas system pistons ever used in any manufacturing bike (or passenger vehicle).

GSX-650F — introduced in 2008, this newer athletics touring model fills the void for the retired Katana. This year’s model has actually ABS standard.

DL-650 V-Strom — a dual-sport bike

Falcorustyco idea design in the 1985 Tokyo Motor program envisaged the bike technologies that might be introduced into enjoy by 1995, including a 4-cycle square 4-cylinder 500 cc engine, frameless body, front-and-rear swingarm suspension system, center hub hydraulic power steering, chainless hydraulic drive and pop-up display screen cowling.
Nuda was a full-time two-wheel drive model, incorporating power steering and a-swing seat, in a carbon fibre honeycomb monocoque human anatomy, shown in the 1986 Tokyo Motor program. Nuda concepts affected the look for the Suzuki Hayabusa.
B-King — The concept design was well received by the general public with regards to proceeded screen at 2001 Tokyo engine program. The addition of a turbocharger into the GSX1300R engine testified to massive energy output, while electronic devices eg cellular phone and GPS had been stowed into the ultra-modern angular bodywork. The production design made an appearance six years later, mostly unchanged excluding their obviously aspirated engine. B-King styling are mirrored within the award-winning build associated with GSR600 and the GSR750, along with the Inazuma GW250 and GW250S.
G-Strider concept model with 916 cc engine, made community on 2003 Tokyo engine program, had been a half-scooter, half-cruiser (bike) mash-up with an electrically controlled Continuously Variable Transmission integrating a push-button handbook mode, just like the Burgman 650. Accentuating luxury, the G-Strider’s handlebars, footrests, chair backrest, passenger backrest and windscreen were all electrically flexible while under option to ensure the beloved driving position feasible.
Stratosphere prototype ended up being revealed at Tokyo engine Show in 2005, with an 1100 cc engine pushed to the limitations of space-saving design, causing an in-line six-cylinder as wide as a conventional in-line four-cylinder system. Hammered aluminum and Damascus metallic merge material characteristics into styling build. Customers for a production design appeared good, due to the fact Suzuki’s previous considerable concept motorcycle, the B-King have managed to get into manufacturing, although markets altered before Stratosphere got the go-ahead.
Biplane is a blue-sky concept announced at the 2007 Tokyo Motor Show, built to communicate the happiness of two-wheel mobility, impressed by the sense of traveling an airplane. Their form produces a feeling of openness in a contemporary machine run on a V-four motor.
Crosscage idea design had been presented on 2007 Tokyo Motor Show. Incorporating a superior secondary electric battery and a concise, lightweight air-cooled fuel-cell system from Uk specialist company Intelligent Energy enabled fast activation with low gasoline consumption. The lithium-ion battery pack guaranteed reserve energy including minimal environmental influence. Light weight not only made this bicycle environment-friendly but additionally sporty.
Gemma prototype model ended up being introduced during the 2007 Tokyo Motor Show. The unique “full-flat 2-seater,” 250 cc four-stroke single-cylinder scooter is reduced and streamlined and provides the rider and traveler feel a better sense of intimacy. The luggage storage space in front of the rider keeps a helmet. Gemma moved into production in Japan these seasons for domestic marketplace.
Recursion turbo parallel-twin middleweight, shown at 2013 Tokyo Auto Show

In 2001, Suzuki unveiled a unique idea bike known as the B-King (or Boost-King). With a tuned GSXR-1300 Hayabusa system, also a radical design for a street cycle, they kept a major impression to bike enthusiasts every where. But the B-King did not hit production (even though it eventually did in 2007). Instead, the GSR600 a stripped-naked bicycle had been launched in December 2005, using the tag of “todays Art meets battle technologies”. With an extremely comparable design styling, it was initially nicknamed the “kids B-King” or “infant King”. It had components usually reserved for higher-end leading models but incorporated into this motorcycle, like the four-piston Tokico braking system program utilized in addition regarding the GSX-R600 series.
2006 model

The initial design arrived at dealerships in January 2006.
2006 S-model

a variant regarding the design, called the GSR600S or ‘S’-model, premiered middle of 2006. They differs through the standard design with a stock windshield, a radiator protector barbecue grill as well as carbon-fibre lamination for chosen parts.
2007 model

ABS was launched on number between 2007 and 2008 across different areas.
GSR400
Suzuki GSR400

A Japanese domestic market design, the GSR400, be open to picked region in the middle of 2006. With the exact same exact measurements whilst the GSR600, the only real difference had been the motor capability (399 cc as opposed to 599 cc), a smaller exhaust outlet, small RPM range and a useful vinyl safety address from the remaining side of the engine. The cycle appealed towards Japanese markets along with chosen Asian markets where 400 cc bicycles become popular because operating license classifications and road-usability and practicality.

All RGV250 models, with the exception of japan domestic markets’s variation (limited to 40 hp), render 50+ hp. The design designations tend to be:

VJ21:1988-1990: quoted energy; 1988=58 hp, 1989=59 hp (90 V-Twin, i.e. the space involving the cylinders)
VJ22:1991-1996: quoted power; 1991=62 hp (modified engine with increased power, nonetheless 90 V-Twin)
VJ23:1997-1998: quoted power; 1997=70 hp (from really special ‘SP’ design (recreations production) with brand-new 70 V-Twin engine)

Technical

The VJ21 is the first RGV250 production bike available in Japan in 1988. Technical items were:-

Alloy ray framework
90-degree, water-cooled two-cylinder two-stroke V-Twin style V-engine (individual crankcases, solitary in-line crankshaft)
2 piece, blade style, exhaust valves that have two positions – open and shut
Twin Reed valves, with Suzuki Intake Pulse Control program (SIPC), much like Yamaha power Induction program (YEIS) but prevents patent dilemmas
32 mm Mikuni Carburettors on 88/89 versions, changed with 34 mm versions with solitary atmosphere bleed on 1990 design
17″ forward, 18″ rear three talked alloy rims with twin 296 mm front disc brake system and solitary rear
Forward suspension system try standard 41 mm damper means telescopic motorcycle forks (maybe not cartridge)
Suzuki Pointless Electronic Ignition (PEI) analogue ignition system on 1988 designs, replaced with digital program on 1989/90 models which was a forerunner toward SAPC as installed on VJ22
Twin, side-by-side development chambers

The VJ22 device relied heavily from the VJ21, but have the following improvements:-

Suzuki Advanced Power Control (SAPC) electric power valve and ignition time control
3 part, blade design, exhaust valves with three positions – shut, half open and fully available
34 mm Mikuni carburettors with double atmosphere bleed system
41 mm inverted cartridge kind telescopic motorcycle forks
modified move supply suited to permit both growth chambers become routed regarding right hand side
17″ back wheel
310 mm front disks

Additionally, a limited VJ22 model had been for sale in Japan as activities manufacturing (SP) design, which included dried out clutch and close-ratio gearbox as standard. A later SPII model reverted to accepted wide-ratio gearbox. The VJ23 uses a completely redesigned system with few compatible section with all the early systems.
Reception

Within the UK, the motorcycle hit responded favourably towards the VJ21. However, the initial VJ22 models had a design flaw when you look at the ‘improved’ 3 part exhaust valves where they crack most likely because carbon build up from boiling oil in the apparatus and failed to open up from idle/low energy position. It was corrected on later VJ22 products, but still needs to be examined on a regular basis. The VJ23 just isn’t proven to have actually powervalve dilemmas.


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