Suzuki Madura GV700GL User manual

SUZUKI
SERVICE MANUAL
GV700GL SUZUKIMOTOR CORPORATIONOCTOBER, '90 PRINTED IN JAPAN 99500-36040-03E @
99500-36040-0JE
(~)

FOREWORD
The SUZUKI GVlOOGL has been developed as a new generation motorcycle to the GS-
models. It is 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 is to
inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-it-
yourself mechanics, will also find this manual an extremely useful repair guide. This manual
contains the
most up-to-date information at the time of publication. The rights are reserved
to update or make corrections to this manual at any time.
IMPORTANT
All GS and GV model Suzuki motorcycles that were manufactured after January 1, 1978 are
subject
to Environmental Protection Agency emission regulations. These regulations set
specific standards
for exhaust emission output levels as well as particular servicing require-
ments. This manual includes specific
information required to properly inspect and service
the GVlOOGL in accordance
with all EPA regulations. It is strongly recommended that the
chapter on Emission Control, Periodic Servicing
and Carburetion be thoroughly reviewed
before
any type of service work is performed.
Further information concerning the EPA emission regulations and U.S. Suzuki's emission
control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM
MANUAL/SERVICE BULLETIN.
SUZUKI MOTOR CORPORATION
·Motorcycle Technical
Service Department.
Quoting, copying or otherwise using any part of this manual without ex-
plicit authorization from Suzuki Motor Corporation is not permitted as
all rights to the publication are reserved under copyright law.

VIEW OF 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- 1
FUEL, OIL
AND COOLING SOLUTION
RECOMMENDATIONS······························································ 1- 1
BREAKING-IN PROCEDURES ··················································· 1- 2
CYLINDER IDENTIFICATION ··················································· 1- 2
SPECIAL MATERIALS ······························································1- 3
PRECAUTIONS AND GENERAL INSTRUCTIONS ·····················1- 5
SPEC/FICA TIONS ····································································· 1- 6

1-1 GENERAL INFORMATION
SERIAL NUMBER LOCATIONS
The frame serial number or V.I.N. (Vehicle Identi-
fication Number) CD is stamped on the steering
head pipe. The engine serial number ® is located
on the right side
of 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 of at
least 85 -95 pump octane ( R; M method) or 89
octane or higher rated by the
Research method.
ENGINE OIL
SUZUKI recommends the use of SUZUKI PER-
FORMANCE 4 MOTOR
01 L or an oil which is
rated SE or SF under the API (American Petro-
is not available, select an alternate according to
the following chart:
SAE
r
40
30 -
20W/50 I
10W/50
10W/30 I
20W
(\ 10W
-
Temp.
oc
-20 -10 0
10 20 30 40
I
OF
-4 14
32
50 68 86 104
I
GEAR OIL (SECONDARY AND FINAL
DRIVE)
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
OoC (32° F), use SAE 80 hypoid gear oil.
BRAKE FLUID
Specification and
classification:
WARNING:
DOT3 or DOT4
* Since the brake system of this motorcycle
is filled with a glycol-based brake fluid by
the manufacturer, do not use or mix differ-
ent types
of fluid such as silicone-based
and petroleum-based
fluid for refilling the
system, otherwise serious
damage will
result.
* Do not use any brake fluid taken from old
or
used or 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 is SAE 10W/40. If anSAE 10W/40 motor oil Use fork oil# 15.

COOLING SOLUTION
Use an anti-freeze & Summer coolant compatible
with an 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 as corrosion and rust inhibi-
tor as well as anti-freeze. Therefore, the coolant
should
be used at all times even though the atmos-
pheric temperature in
your area does not go down
to freezing point.
SUZUKI recommends the use of SUZUKI GOLD·
EN CRUISER 1 200 anti-freeze & summer coolant.
If this is not available, usean equivalent which is
compatible with an aluminum radiator.
REQUIRED AMOUNT OF WATER/COOLANT
Solution capacity (total): 3 500 ml (3.7 US qt)
For coolant
mixture information, refer to cooling
system section,
page 5-3.
CAUTION:
Mixing of anti-freeze & summer coolant
should be
limited to 60%. Mixing beyond it
would reduce its efficiency. If the anti-freeze
& summer coolant mixing ratio is below 30%,
rust inhibiting performance is greatly reduced.
Be sure to mix it above 30% even though the
atmospherictemperature does
not go down to
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 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 breaking-in engine speed limits:
Initial 800 km ( 500 mi) Below 4 000
r/min
Up to 1 600 km (1 000 mi) Below 6 000
r/min
Over 1 600 km (1 000 mi) Below 10 750
r/min
• Upon reaching an odometer reading of 1 600
km (1 000 mi) you can subject the motorcycle
to full throttle operation.
However, do
not exceed 10 750 r/min at any
time.
• Do not maintain constant engine speed for an
extended time period during any portion of the
break-in.
Try to vary the throttle position.
CYLINDER I.DENTIFICATION
The four cylinders of this engine are identified as
No. 1, No. 2, No. 3 and No. 4 cylinder, as counted
from left rear to right front (as viewed by the rider
on the seat).
®
CD

1-3 GENERAL INFORMATION
SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the GV700GL, and should be kept on
hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth
and the like. How to use them and where to use them are described in the text of 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
m
ou nti ng 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 of upper
and lower crankcase
• Mating surface of crankcase
and clutch cover, generator
cover
• Cylinder head cover gasket
• Secondary gear case bolt
Page
4-8, 19,
28,30
4-36
8- 9
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- 4
9-39
9-24
9-30
9-31
8- 9
9-45
5-15
5-13
6-23
4-19,
4-36
9-41
9-17

Material
n
~
[~
'--::::;._..)
THREAD LOCK SUPER
"1363A"
99104-32030
[\
I
_,_.,.,..,..
~
'===="
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
•
To prevent leakage of
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 or no ventilation.
o Be sure to 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, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken not to expand the end gap larger than required to
slip the circlip over the shaft
After installing a circlip, always insure that it is completely seated in 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 to out-side diagonally, to the specified tightening torque.
o Use special tools where specified.
o
Use genuine parts and recommended oils.
o When 2 or more persons work together, pay attention to the safety of each other.
o After the reassembly, check parts for tightness and operation.
o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use
gasoline as cleaning solvent.
Warning, Caution and Note are included in this manual occasionally, describing the
following contents.
WARNING ............ When personal safety of the rider is involved, disregard of the information
could result in injury.
CAUTION ............ For the protection of the motorcycle, the instruction or rule must be strictly
adhered to.
NOTE ................ Advice calculated to facilitate the use of the motorcycle is given under this
heading.
USE OF GENUINE SUZUKI PARTS
To replace any part of the machine, use a genuine
SUZUKI replacement part. Imitation parts or
parts supplied from any other source than
SUZUKI, if used to replace SUZUKI parts can
reduce the machine's performance and, even worse,
could induce costly mechanical troubles.