Suzuki GS1100G 1982 User manual

SUZUKI -
SERVICE MANUAL

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

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

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

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

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

GENERAL INFORMAT1ON 1-2
BREAKING-IN PROCEDURES
During manufacture only the best possible materi-
als are used and all machined parts are finished to a
very high standard but it is still necessary to allow
the moving parts to "BREAK-IN'" before subject-
ing the engine to maximum stresses. The future
-
performance and reliability of the engine depends
on the care and restraint exercised during its early
life. The general rules are as follows:
Keep to these b
reakingin engine speed limits:
Upon reaching an odometer reading of 1,600 krn
(1,000 miles) you can subject the motorcycle
to full throttle operation,
However,
do not exceed 9,000 rlmin at any
time.
Do not maintain constant engine speed for an
A
extended time period during any portion of the
break-in. Try to vary the throttle position.
CYLINDER IDEMTI FTCATION
The four cylinders of this engine are identified as
Na. 1, No. 2, No. 3 and No. 4 cylinder, ascounted
from left to right (as viewed by the rider on the
seat).
SPECIAL FEATURES
BLOWBY GAS RECYCLING
Blowby gases in the crankcase are constantly
drawn into the chain chamber provided in the
middle section of the cylinder block. The top
section of this chamber is cannmed with the air
chamber assembly through a rubber tube. In the
air chamber, the gases merge with incomingair and
thus are recycled to the engine through the normal
intake
system.
- -

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

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