Suzuki Madura GV700GL Manual de usuario

SUZUKI

SERVICE MANUAL

GV700GL SUZUKIMOTOR CORPORATIONOCTOBER, '90 PRINTED

JAPAN

99500-36040-03E @

99500-36040-0JE

(~)

FOREWORD

The

SUZUKI

GVlOOGL

has

been developed

new

generation motorcycle to the

GS-

models.

packed

with

highly

advanced

design

concepts including a V-4 engine, a

liquid

cooling system, a

new

highly

efficient

combustion system (TSCC), a

fully

transistorized

ignition system, a shaft drive mechanism

and

a full-floater suspension system. Combined

with

precise

control

and

easy

handling the GVlOOGL provides excellent performance and

outstanding riding comfort.

This service manual

has

been produced

primarily

for

experienced mechanics

whose

job

inspect, adjust, repair

and

service

SUZUKI

motorcycles. Apprentice mechanics and do-it-

yourself mechanics,

will

also

find

this manual

extremely useful repair guide. This manual

contains the

most

up-to-date information

the time

publication.

The

rights are reserved

update

make corrections

this manual

any time.

IMPORTANT

All

and

GV model Suzuki motorcycles

that

were

manufactured

after

January

1978 are

subject

Environmental Protection Agency emission regulations.

These

regulations set

specific standards

for

exhaust emission

output

levels

well

particular

servicing require-

ments. This manual includes specific

information

required

properly

inspect and service

the GVlOOGL in accordance

with

all

EPA regulations.

strongly recommended

that

the

chapter on Emission Control, Periodic Servicing

and

Carburetion

thoroughly reviewed

before

any

type

service

work

performed.

Further

information

concerning the EPA emission regulations

and

U.S.

Suzuki's emission

control

program

can

found

in the

U.S.

SUZUKI

EMISSION CONTROL PROGRAM

MANUAL/SERVICE

BULLETIN.

SUZUKI MOTOR CORPORATION

·Motorcycle

Technical

Service

Department.

Quoting,

copying

otherwise

using

any

part

this

manual

without

ex-

plicit

authorization

from

Suzuki

Motor

Corporation

not

permitted

all

rights

the

publication

are

reserved

under

law.

VIEW

SUZUKI

GV700GL

RIGHT

SIDE

LEFT

SIDE

GROUP

INDEX

GENERAL

INFORMATION

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

ENGINE

SERVICING

SHAFT

DRIVE

COOLING

SYSTEM

FUEL

AND

LUBRICATION

SYSTEM

EMISSION

CONTROL

REGULATIONS

ELECTRICAL

SYSTEM

CHASSIS·

SERVICING

INFORMATION

GENERAL

INFORMATION

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

SERIAL

NUMBER

LOCATIONS

················································1-

FUEL, OIL

AND

COOLING

SOLUTION

RECOMMENDATIONS······························································

BREAKING-IN

PROCEDURES ···················································

CYLINDER

IDENTIFICATION

···················································

1- 2

SPECIAL

MATERIALS

······························································1- 3

PRECAUTIONS

AND

GENERAL

INSTRUCTIONS

·····················1-

SPEC/FICA

TIONS

·····································································

1-1

GENERAL

INFORMATION

SERIAL

NUMBER

LOCATIONS

The frame serial number or V.I.N. (Vehicle Identi-

fication Number)

stamped on the steering

head

pipe. The engine serial number ®

located

on the right side

the crankcase.

These

numbers

are

required especially

for

registering the machine

and ordering

spare

parts.

FUEL,

OIL

AND

COOLING

SOLU-

TION

RECOMMENDATIONS

FUEL

Use

only

unleaded or low-lead type gasoline

least 85 -95 pump octane ( R; M method)

octane or higher rated by the

Research

method.

ENGINE

OIL

SUZUKI

recommends the

use

SUZUKI PER-

FORMANCE 4 MOTOR

L or

oil which

rated SE

under the API (American Petro-

not

available, select

alternate according

the

following

chart:

SAE

30 -

20W/50 I

10W/50

10W/30 I

20W

10W

Temp.

-20

-10

-4

104

GEAR

OIL

(SECONDARY

AND

FINAL

DRIVE)

Use

SAE 90 hypoid

gear

oil which

rated GL-5

under API classification system.

you operate the

motorcycle where ambient temperature

below

OoC

(32° F),

use

SAE

hypoid

gear

oil.

BRAKE

FLUID

Specification and

classification:

WARNING:

DOT3

DOT4

* Since the brake system

this motorcycle

filled

with

a glycol-based brake

fluid

the manufacturer, do

not

use

mix

differ-

ent types

fluid

such

silicone-based

and petroleum-based

fluid

for

refilling the

system, otherwise serious

damage

will

result.

not

use

any brake

fluid

taken from old

used

unsealed containers.

* Never

re-use

brake

fluid

left

over

from

the

previous servicing and stored

for

a long

period.

leum institute) classification system. The viscosity

FRONT

FORK

OIL

rating

SAE 10W/40.

anSAE

10W/40

motor

oil

Use

fork

oil#

15.

COOLING

SOLUTION

Use

anti-freeze & Summer coolant compatible

with

aluminum radiator, mixed

with

distilled

water only.

WATER

FOR

MIXING

Use

distilled water only. Water other than distilled

water

can

corrode and clog the aluminum radiator.

ANTI-FREEZE

& SUMMER

COOLANT

The coolant performs

corrosion and rust inhibi-

tor

well

anti-freeze. Therefore, the coolant

should

used

at all times

even

though the atmos-

pheric temperature in

your

area

does

not

down

freezing point.

SUZUKI

recommends the

use

SUZUKI

GOLD·

CRUISER 1 200 anti-freeze & summer coolant.

this

not

available, usean equivalent which

compatible

with

aluminum radiator.

REQUIRED

AMOUNT

WATER/COOLANT

Solution capacity (total): 3 500 ml (3.7

qt)

For coolant

mixture

information,

refer

cooling

system section,

page

5-3.

CAUTION:

Mixing

anti-freeze & summer coolant

should be

limited

60%. Mixing beyond

would reduce its efficiency.

the anti-freeze

& summer coolant

mixing

ratio

below 30%,

rust inhibiting performance

greatly reduced.

sure

mix

above 30%

even

though the

atmospherictemperature does

not

down

freezing point.

Every new

unit

contains Bar's leak.

GENERAL

INFORMATION

1-2

BREAKING-IN

PROCEDURES

During manufacture

only

the best possible materi-

als

are

used

and all machined parts

are

finished

very high standard

but

still necessary

allow

the moving parts

"BREAK-IN"

before subject-

ing the engine

maximum

stresses.

The future

performance and reliability

the engine depends

the

care

and restraint exercised during its early

life. The general rules

are

follows:

• Keep

these breaking-in engine

speed

limits:

Initial 800 km ( 500 mi) Below 4 000

r/min

1 600 km

000 mi) Below 6 000

r/min

Over 1 600 km

000 mi) Below 10 750

r/min

• Upon reaching

odometer reading

1 600

000 mi) you

can

subject the motorcycle

full

throttle

operation.

However, do

not

exceed 10 750 r/min

any

time.

• Do

not

maintain constant engine

speed

for

extended time period during any

portion

the

break-in.

Try

vary the

throttle

position.

CYLINDER

I.DENTIFICATION

The

four

cylinders

this engine

are

identified

No. 1, No. 2, No. 3 and No. 4 cylinder,

counted

from

left

rear

right

front

(as

viewed by the rider

on the seat).

1-3

GENERAL

INFORMATION

SPECIAL

MATERIALS

The materials listed below

are

needed

for

maintenance

work

on the GV700GL, and should

kept on

hand

for

ready

use.

They supplement such standard materials

cleaning fluids, lubricants, emery cloth

and the like.

How

use

them and where

use

them

are

described

the

text

this manual.

Material

SUZUKI

SUPER GREASE

"A"

99000-25030

~'~~·

~-·:c.-A

SUZUKI

SILICONE

GREASE

99000-25100

··

SUZUKI

MOLY

PASTE

99000-25140

SUZUKI

BOND

No. 1207B

99104-31140

THREAD

LOCK SUPER

"1361A"

99104-32020

Part

• Oil

seals

•

Throttle

grip

• Speedometer cable

• Gearshift lever linkage and

nti

boss

• Final driven

bevel

gear

coupling

• Starter

motor

oil

seal

• Propeller shaft coupling

• Caliper axle

• Valve stem

•

Cam

shaft journal

• Conrod big end bearing

• Crankshaft journal bearing

• Countershaft

• Drive shaft

• Propellar shaft splines

• Mating surfaces

upper

and

lower crankcase

• Mating surface

crankcase

and clutch cover, generator

cover

• Cylinder head cover gasket

• Secondary

gear

case

bolt

Page

4-8, 19,

28,30

4-36

9-41

9-10

3-35

3-76

3-45

3-62

3-56

4-18

Part

• Cushion lever dust

seal

•

Wheel

bearings

• Sprocket mounting drum bearing

• Swingarm bearing and dust

seal

• Brake pedal shaft

• Centerstand

spacer

• Steering stem bearings and

races

• Clutch lever and

release

• Side stand

• Final

gear

spline

•

Rear

brake camshaft

• Starter

motor

housing end bushing

• Clutch master cylinder pushrod

3-64 • Water temperature

gauge

• Engine thermo-switch

3-67 • Oil pressure switch

3-84 • Mating surface between swing-

arm and final

gearcase

3-82

3-67, •

Front

fork

damper rod

bolt

4-15

•

Cam

chain guide screw 3-38

• Idler shaft bearing retainer 3-68

screw

• Oil pan plate

bolt

3-65

Page

9-40.

9-39

9-24

9-30

9-31

9-45

5-15

5-13

6-23

4-19,

4-36

9-41

9-17

Material

'--::::;._..)

THREAD

LOCK SUPER

"1363A"

99104-32030

_,_.,.,..,..

'===="

THREAD

LOCK cement

99000-32040

GENERAL

INFORMATION

1-4

Part

Page

Part

Page

• Gearshift arm return spring • Secondary driven

bevel

gear

4-11

stopper shaft

nut

• Generator rotor

bolt

3-66 • Final drive

bevel

gear

shaft 4-28,

• Oil pump

case

screw 3-53

nut

4-31

• 2nd drive

gear

3-54 • Final

gear

case

bearing retainer 4-30

screw

• Final driven

joint

bolt

9-30

• Carburetor bracket screw 6-19

• Front

fork

damper rod

bolt

9-17

• Generator stator securing screw 3-52 •

Throttle

valve

screw 6-16

8-10

• Generator

lead

wire guide screw 3-52 • Starter

motor

housing screw

• Countershaft bearing retainer

screw

• Chain tensioner

bolt

• Gearshift

fork

shaft stopper

screw

• Gearshift

cam

guide screw

3-68

3-74

3-60

• Secondary driven

bevel

gear

housing

bolt

• Secondary drive

bevel

gear

cover

bolt

• Idler shaft drive chain tensioner

bolt

• Water pump drive sprocket

bolt

• Final

gear

bearing

case

bolt

4-14

4-15

3-70

3-71

4-36

THREAD

LOCK

"1363C"

• Oil sump

filter

screw

99104-32050

3-60

3-65

SUZUKI BAR's

LEAK

99000-24240

THREAD

LOCK

"1360"

991

04-32130

"""'

...J

"'~

SUZUKI GOLDEN

CRUISER 1200

99000-24120

•

prevent

leakage

cooling solution

from

small

hole.

2-8

5-3

• Pre-muffler mounting

bolt

3-5

• Disc mounting

bolt

9-5

• Coolant

1-5

GENERAL

INFORMATION

PRECAUTIONS

AND

GENERAL

INSTRUCTIONS

Observe the

following

items

without

fail when servicing, disassembling and reassembling motorcycles.

o Do

not

run engine indoors

with

little

ventilation.

sure

replace packings, gaskets, circlips, 0 rings and

cotter

pins

with

new ones.

CAUTION:

Never

reuse

a circlip after a circlip

has

been

removed from a shaft,

should

discarded and a new

circlip must

installed.

When installing a new circlip, care must

taken

not

expand the end

gap

larger than required to

slip the circlip over the

shaft

After

installing a circlip, always insure

that

completely seated

its

groove and securely fitted.

o Tighten

cylinder

head and

case

bolts and nuts beginning

with

larger diameter and ending

with

smaller

diameter, and

from

inside

out-side diagonally,

the specified tightening torque.

Use

special tools where specified.

Use

genuine parts and recommended oils.

o When 2

more persons

work

together, pay

attention

the safety

each

other.

After

the reassembly, check parts

for

tightness and operation.

o Treat gasoline, which

extremely flammable and

highly

explosive,

with

greatest care. Never

use

gasoline

cleaning solvent.

Warning, Caution and Note are included in this manual occasionally, describing the

following

contents.

WARNING

............

When personal safety

the rider

involved, disregard

the

information

could result in

injury.

CAUTION

............

For the protection

the motorcycle, the instruction

rule must

strictly

adhered

to.

NOTE

................

Advice calculated

facilitate the

use

the motorcycle

given under this

heading.

USE OF GENUINE

SUZUKI

PARTS

replace any

part

the machine,

use

a genuine

SUZUKI

replacement part.

Imitation

parts

parts supplied

from

any other source than

SUZUKI,

used

replace

SUZUKI

parts

can

reduce the machine's performance and,

even

worse,

could induce costly mechanical troubles.

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