Suzuki GS850G User manual

GROUP INDEX
GROUP INDEX ( 1/2 )

GROUP INDEX
GROUP INDEX ( 2/2 )

FORE Lj,;I.'O R D
FOREWORD
@
The SUZU KI GS850G has been dewloped as a companion motarcyclc to the GS750 and GSIMK). 1 t
is packed with highly advanced design concepts including a maintenance-free shaft drive
rncchanisrn. Combined with prccise control and easv handling, the GS850G providcs excellent
leriorm:ince and outstanding riding comfort.
IMPORTANT
All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to
Environmental Protection Agency emissio~~ regulations. These regulations set standards for emission
control. and also set specific servicing requirements. This manual contains all of tlie necessary
information that is required to properly inspect and service the GS850G in accordance with the
EPA regulations.
Prim:trily. tlie cnlission components which can effect the emission output of the GS850G consist of
Ihc carhuretorq and crankcase breather device. Emission control information is contained in the
Fucl System chapter and the Emission Control chapter. We strongly suggest that the chapter on
Emission Control be rcviewed hefore any type of service work is performed.
Further informar ion concerning the EPA emission regulations and U .S. Suzuki's emission control
-,rogram can bc found in he U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL.
SUZUKS MOTOR CO., LTD.
Motorcycle Technical Service Department
Quoting. copying or otherwise osing any part of I his mantra1 withoal explicit arrlhorizalion from
Suz~~ki Motor Co.. I,td. is not permitied as all rights to the publicarinn are reserved under
cop? right law.

SIDE VIEW
VIEW OF SUZUKI GS85OG
Right side
,-
Left side

GENERA L INFORMA TION
GENERAL INFORMATION
CONTENTS
...........................................
IDENTIFICATION TABLE 1-2
..........................
FUEL. OILS AND BRAKING-IN PROCEDURE
1-2
ORIENTATION .................................................... 1.3
.........................................
SERVlCE SPECIFICATIONS 1-4

GENERAL INFORMATION
IDENTIFICATION TABLE
SERIAL NUMBER LOCATION
The frame serial nurnberv is stamped on the
steering head pipe. The engine serial num-
ber @is located on the right side of the
crankcase, These numbers are required
especially for registering the machine and
ordering spare parts.
GEAR C)II,
- -
Use SAE 90 hypoid gear oil which is rated
GL-5 under API classification system. If you
operate the motorcycle where ambient
temperature is below 0°C (32"F}, use SAE 80
hypoid gear oil.
BRAKE FLUID (for Ront and rear brakes)
DOT 3, DOT 4
-
NOTE:
JISirzce rhe hrakp system of rhis
rnotorcr?cle is filled with a glvcol-based
brake flttid b-v [he tnanufacrurer, do
no I vse or mix different rypes of JIi4id
such as silicone-based and petroleurn-
haspd fluid +for refilling [he sys fern,
of her wise serious damage will resrrlr.
2) Do not use any brake flriid taken
from old or used or unsealed con-
ruiners.
3) Never re-use brake fluid lefi over
from the previous servicin~ and
siored for o fon~ priod.
FUEL, OILS AND BREAKING-
% IN PROCEDURE
- rj
3
FUEL
Use only l~nlended or low-lead type gasolinc
??- R + %I
$;
of at lea~z 85 - 95 pump octane I-T meth-
FRONT FORK OIL
odS or 89 octanc or higher rated by the
Rcscarcli method.
ENGINE OIL
Be sure that the engine oil used comes under
API classification oi SE and that its viscosity
rating is SAE 10W,'40. Tf SAE 1 OW140 nlotor
oil is 1104 availaide, select the oil viscosity
according to tl~c following chart:
SAE 10Wi'ZO
-- -

--
GENERAL INFORMA TION
RREAK1NC-IN PROCEDURE
During manufacture only the best possibIe
materials are used and all machined parts are
finished to a very high standard but it is still
necessary to allow the moving parts to
"BREAK-IN" before subjecting the engine
to maximum stresses. The Future per-
m
formance and reliability of the engine
depends on I he care and restraint exercised
during its early fife. The general rules are as
fol!ows:
e
F . Keep to these break-in engine speed limits:
".Upon reaching an odometer reading of
1 000 miles (1 600 km). you can subject the
rnotorsyclc to full throttle operation.
However,
do not exceed 9 00 r/min at any
time.
Do not maintain a constant speed for a
long period. Try to vary throttle position.
ORIENTATION
CY Ll NDER IDENTlFlCATlON
The four cylinders of this engine are iden-
tified as No. f, No. 2. No. 3 and No. 4
cylinder, as counted from left to right (as
viewed by the rider on the seat).
LOCATION OF PARTS
,T Tachometer
8 lenition switch
13 Choke knob
@ Front brake lever
C3 Throttle grip
GI Rear brake pedal
8 Foot rests
#,PI Speedometer
@ Clutch lever
K@ Fuel tank cap
@ Gear shift lever
Fig. 1 -4 Left -Right

GENERAL INFORMA TION
SERVICE SPECIFICATIONS
DIMENSIONS AND WEIGHT
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Dry weight
Gross vehicle weight rating
ENGINE
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
TRANSMISSION
Clutch
Transmission
Gearshift pattern
Primary seduction
Gear ratios, Low
2nd
3 rd
4th
TOP
SECONDARY DRIVE
TY
Secondary reduction
Final reduction
CHASSIS
Front suspension
Rear suspension
Steering angle
Caster
Trait
2 230 rnm (87.8 in)
865 mm (34.1 in)
1 190 rnrn (46.9 in)
1 490 rnrn (58.7 in)
160 mrn 6.3 in)
253 kg (558 lbs)
455 kg (1 003 lbs)
Four-stroke cycle, air-cooled, DOHC
4
69.0 mrn (2.71 7 in)
56.4 mm (2.220 in)
843 cm' (51.4 cu.in)
8.8 : 1
MIKUNI VM26SS, four
Polyurethane foam element
Electric and kick
Wet sump
Wet multi-plate type
5-speed constant mesh
1 -dawn 4-up
1.775 (87/49$
2.500 (?5/ 14)
1 -777 (32/ 18)
1.380 (29/21)
1.125 (27/24)
0.961 (25/26)
Shaft drive
1.062 (I 7/16)
3,090 (34/11)
Telescopic, pneumatic/cail spring,
oil dampened
Swinging arm, oil dampened,
damper 4-way/spring 5-way adjustable
40" (right and left)
62" 00
1 I3 nrn (4.45 in)

Turning radius
Front brake
Rear brake
Front tire size
Rear tire size
Front tire pressure
Rear tire pressure
ELECTRICAL
Ignition type
Ignition timing
Spark plug
Spark plug gap
Battery
Generator
Fuse
CAPACITIES
Fuel tank including reserve
Reserve
fuel
Engine oil change
filter change
overhaul
Secondary bevel gear oil
GENERAL INFORMA TION
2.6 rn (8.5 ft)
Disc brake, twin
Disc brake
3 .SOH 19 4PR
4.50H 17 4PR
1 -75 kg/cmZ 125 psi)
(Normal solo riding)
7.00 kg/cmz (28 psi)
(Normal solo riding)
Battery ignition
17' B.T.D.C. below 1 500 r/rnin and
37' B.T.D.C. above 2 500 r/rnin
NGK B8ES or NIPPON DENSO W24ES
0.6-0.8 mm (0.024-0.031 in) balh NGK and
NTPPON DENSO
12V 50.4 kC 114 Al1)/10HR
Three-phase A.C. generator
10/10/10/15A
22L(5.8 US gal)
4.2 Lt I. 1 US gal)
2.8 L (3 .O US qt)
Final bevel gear oil
280-330 rnl ( 9.5-1 1.2 US oz)
Front fork air pressure
0.6-1.2 kg/crn2(8.5-1 7 psi)
Front fork oil
25 1 mI (8.48 US oz) in each leg
(At time of overhaul and replacement)
* Specifications subject to change without notice.

SER VICE SPECIFJCA TlONS
SERVICE SPECIFICATIONS
CONTENTS
SERVICE SPECIFICATIONS ...................................... -2- 2
(ETOPEND ........................................... 2. 2
(E LOWER END ....................................... -2- 4
.. ICATION SYSTEM ............. ,. ............ ... ... 2 4
................................................... CLUTCH 2- 4
TRANSMISSION ............................................ -2- 5
SHAFT DRIVE ............................................. -2- 5
CARBURETOR .............................................. 2. 6
ELECTRICAL ............................................... 2. 6
BRAKE + WHEEL ............................................ 2. 7
TIRE PRESSURE ............................................ 2. 7
SUSPENSION ............................................... 2. 7
FUEL ICCAPACITY .................................. -2- 8
TORQUE 'I ............................................... 2- 9
.................................................... ENGiP - 2- 9
................................................... CHASSIS 2-10
TIGHTENING TORQUE CHART .............................. -2-10
AND 01
'ABLE .
4E .....

-
SER VICESPECI'FSCA TIONS
SERVICE SPECIFICATIONS
ENGINE TOP END
VALVES -t GUIDES
-
Unit: mrn (in.)
CAMSHAFT
Unit: rnm (in)
Limit
36.020
(1.4181)
35.470
(1.3965)
0.150
(0.0059)
-
-
Item
(0.8646-0.8652)
Camshaft Deflection -
Cam Chain 20 Pitch Length - 157.80
(6.2 13)
Standard
EX
Camshaft-Journat Clearance IN /EX
Camshaft Journal Holder T.D. INlEX
Camshaft Journal O.D. INlEX
36.320-36.360
(I .4299- 1.43 1 5)
35.770-35.8 1E
(1.4083- I .4098)
0.0374.065
(0.00 154.0026)
22.012-22.025
(0.8664-0.867 I)
2 1.960-2 1.975

PlSTON + RING + CYLINDER
SER VICE SPECIFICA TIONS
Unit: rnm (in)
Piston Pin Bore 1.D. 16.002-16.008 -
(0.6300-0.6302)
-
Piston Pin O.D. 15.995-16.000
(0.6297-0.6300)
-

SER VICE SPECIFICA TIONS
ENGINE LOWER END
CRANKSHAFT
Unit: mrn tin)
OIL PUMP
LUBRICATION SYSTEM
Unit: mm (in)
Limit
0.08
(0.003 1)
-
Connecting Small End Bore -
Piston Pin Clearance
Item Standard
I
Oil Pressure (For 60°C)
Above 0.1 kg/cm2 (1.4 psi
I
(7.1 psi) at -: 000 rlmin
Tip Clearance -
Outer Rotor CTearance
-
Side Clearance -
Oil Pump Reductian Ratio
87/49 X 33/34 = 1.723
Standard
0.006-0.0 1 9
(0.0002 -0.0007)
CLUTCH Unit: rnm (in)
Connecting Rod Small End Bore E.D.
16.006-16.014
Piston Pin O.D.
Connecting Rod Rig End Side Clearance
Connecting
Rod Big End Wear
Crankshaft Runout
1 tern Stnndnrd Limit
15.995-16.000
(0.6297-0.6300)
0.10-0.55
(0.004-0.026)
-
-
Drive Plate Thickness
-
I .O
(0.039)
0.08
(0.003)
0.05
(0.001)
2.7-1.9
10. t 06-0.1 14)
2.4
(0.094)
-
0.1
(o.004)
Driven Plate Thickness 7 .O
- i
(0.08)
Driven Plate Distortion
-
Drive Piate Claw Width
(0.46-0.43) (0.43)
Clutch Spring Free Length 40.4
(1-59)
38.8
(1 .S3)

TRANSMISSION
SER VICE SPECIFICA TIONS
Unit: rnm (in)
SHAFT DRIVE
Ttem Standard
Unit: mrn (in)
Limit
Primary Reduction 3.775 (87/49)
Secondary Reduction 1.062 (17116)
Final Rctluction
3.090 (341 t 1)
Gear Ratios Low 2.500 (35114)
2nd 1.777 (321 18)
3rd 1.380 (2912 1)
4th 1.1 35 (27124)
TOP
Shifl Fork-Groovc Clearance
Shift Fork Groove Width
Limit
-
Item
Standard
0.96 1 (25126)
0.4-0.6
(0.0 16-0.024)
5.45-5.55
(0.2 15-0.2 19):
-
Secondary Bevel Gear Backlash
0.8
(0.83 1)
-
-
Shift Fnrk TEiickness
-
0.08-0.1 3
(0.003-0.005)
-
4.95-5.05
(0.195 -0.199)
-
, Final Bevel Gear Backlash
0.03-0.64
.(o.oe i -0.025)
Sccondary Drive Bevel Gear Preload
3-5 krcm (2.40-4.35 Ib-in)
Secondary Driven Bevel Gear Preload
4-7 kg-cm (3.45-6.05 !bin)
Final Drive Bevel Gear Preload
4-8 kg.cm (3.45-6.9s Ib-in)
-

SER VICE SPECIFICA TlONS
CARBURETOR
Unit: mrn (in)
'ilot Air J
ELECTRICAL
Unit: rnm (in) e

SER VICE SPECIFICA TiONS
BRAKE + WHEEL Unit : mm (in)
Brake Caliper Front
Piston Dia.
Rear
Wheel Rim Runou t
(Radial W Axial)
Limit
0.25
(0.01 0)
5.5
(0.22)
6.0
Item
Axle Runout FrontlRear
Brake Disc Thickness Front
Rear
Tire Size Front
Rear
TIRE PRESSURE
Standard
-
5.9-6.1
(0.23-0.24)
6.5-6.9
42.82
(1.686)
38.15
(1 -502)
-
I
3.50H19 4PR
4.50H17 4PR
Tire Tread Depth Front
Rear
COLD INFLATION
TIRE PRESSURE
(0.26-0.27) (0.24)
Brake Disc Runeut Frontlreat - 0.30
(0.01 2)
-
-
-
-
2.0
(0.08)
SUSPENSION Unit: mm (in)
Master Cylinder Front
Piston Dia.
Rear
Brake Caliper Front
Cylinder Bore
Rear
-
-
-
15.80
(0.622)
13.96
(0.550)
42-85
(1.687)
38.18
(1.5 03)
1.6
(0.06)
2.0
(0.08)
Item Standard Limit
Front Fork Stroke I60
(6.3)
Rear Wheel Travel 100
13-91
Front Fork Spring Free Length 42 1 416
(16.6) (16-4)
-
-
-
Front Fork Oil Level
140
(5.5)

SER VICE SPECrFICA TIONS
FUEL AND OIL CAPACITY
method) or 89 octane or hi$er rated
* These specifications subject to change without notice.

SER VICE SPECIFPCA TIONS
TORQUE TABLE
ENGINE
lrive gear
l rive gear
CHASSIS
I
Thread
dia.
~ndEe hold
on! fork 1
.P , .
kg-m
Clutch sleeve hub nut
Clutch release arm bolt
Gear shifting cam stopper spring holder bolt
Gear shift lever bolt
Generator rotor hoIt
Secondary ( nut
Secondary ( housing bolt
Secondary driven gear nut
Secondary driven gear housing bolt
I b-ft
7.5
6.5
27.0
6.5
7.5
Camshaft holder holt
Cylinder head bolt
Cylinder head nut
Cylinder head cover
Crankcase holt
H; Icr bolt
Ft lpper bracket rear bolt
Fronl IOFK lube upper pinch bolt (R, L)
Fronl fork tube lower pinolr bolt (R, L)
Steering stem head nut
Front axle shaft nut
Front axle Ilolder nut
Swinging arm pivot shaft bolt
Swinging am] pivot shaft nut
Rear torqirc link nut .
Rear axle nut
Rear sliock absorber nut
Rear wheeE driven joint nut
Front step bolt
6 I .O
6 0.9
10 3.7
6 0.9
h 1 .O
36.0-50.5
4.5-7.5
13 -0-20.0
9.5-16.5
65.0-72.5
87.0-108.5
14.5-19.0
65 .O-79.5
14.5-19.0
24
6
14
8
12
32
8
14
8
Crankcase hol t
Starter n~otor bolt
Oil pan nut
Engine mounting boll
Engine mounting bolt
Starter clutc1-1 ho!t
Cam chain guide No. 2 bolt
Cam chain ~dler bolt
Air cleaner bolt
Exhaust pipe bolt
Muffler bolt
OiI pressure switch housing bolt
Clutc.11 spring bolt
5 -0-7.0
0.6-1.0
1.8-2.8
1.3-2.3
9.0-10.0
12.0-15.0
2.0-2.6
9.0-1 1 .O
2.0-2.6
Thread
dia.
8
8
10
8
18
1 I?
8
24
24
10
I6
10
10
10
kg-rn Ih-ft
1.2-2.0 8.5- 14.5
I 14.5
I 4.5-6.5
1 4.5-6.5
I 25.5
25.5
1 1 -0- 14.5
3.0-5.0
4.5-7.5
3.0-5.0
6.5- 10.0
13.0-20.0
4.5-6.5
8.0-9.5
8 2.0
6 0.6-0.9
6 0.6-0.9
10 3.5
12 3 -5
1 .S-2.5
2 .O-3.0
8
6
6
6
8
10
6
6
1 1.0- 18.0
14.5-2 1.5
1.5-2.0
0.4-0.7
0.6-1 .O
0.4-0.7
0.9- 1.4
1.8-2.8
0.6-0.9
1.1-1.3
1 .S-2.5 I ? 1.0-18.0
3.5-5.0 25 .S-36.0
3-6-52 ' 76.0-37.5
1 .S-2.5
0.35-0.45
11.0-18.0
2.5-3.5
11.0-13.0 79.5-94.0
2.0-3.0 14.5-2 1.5
8.5-1 1.5
2.0-3.0
5.0-6.0
61.5-83.0
14.5-2 1.5
3h.O-43.5
2.7-4.3 10.5-31.0

SER VJCE SPECIFICA TIONS
Thread
dia. kg+"
Ib-ft
Front brake caliper mounting bolt I0 2.5-4.0 18.0-29.0
Front and rear brake disc plate bolt 8 1.5-2.5
I 1 .O-18.0
Front brake caliper axle bolt
I0 2.5-3.5 18.0-25.5
Front brake master cylinder mounting bolt 6 0.5-0.8
3.5-6.0
Front and rear brake hose union bolt
10 1.3-1.8 9.5-13.0
Front and rear brake oil bleeder bolt
8 0.6-0.9 4.5-6.5
Rear brake caliper mounting bolt
10 2 .O-3 .O 14.5-21 .S
Rear brake caliper axle bolt
10 2.5 -3.5 18.0-25.5
8
I
Rear brake master cylinder mounting bolt
1 -5-2.5 11.0-18.0
Final drive gear housing nut
10 3.54.5 25.5-32.5
Final drive gear nut
14 9.0-1 1.0 65.0-79.5
PropelIer shaft bolt
8 2.5-3.0 t 8.0-2 1 "5
I
:I
2.0-3.0
14.5-21.5
Final case oil filler plug
Final gear bearing case bolt 2.0-2.6 14.5-I9,O
Final gear case shock mount stud bolt
9.0-1 1 .O 65.0- 79.5
TIGHTENING TORQUE CHART
For other bolts and nuts not listed above, refer to this chart:
TIGHTENING TORQUE
Conventional Bolt "4" Marked Bolt
''7'' Marked Bolt