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.

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ............................... .
Overa II width . . . . . . . . . . . .................... .
Overall height ............................... .
Wheelbase .................................. .
Ground clearance
............................ .
Seat height ................................. .
Dry
mass .................................. .
ENGINE
GENERAL INFORMATION 1-6
2 225 mm (87.6 in)
870 mm (34.3 in)
1 220 mm (48.0 in)
1 575 mm (62.0 in)
145 mm ( 5.7 in)
735 mm (29.0 in)
228
kg (503 lbs)
Type ....................................... Four-stroke, water-cooled, DOHC, TSCC,
82-degree V-four
Number
of cylinders ........................... 4
Bore
....................................... 69.0 mm (2.717 in)
Stroke ..................................... 46.7 mm (1.839 in)
Piston displacement
........................... 698 cm
3 (42.6 cu. in)
Compression ratio
....................... 1 0. 5 : 1
Carburetor
.................................. MIKUNI BDS33, four
Air cleaner .................................. Polyester fiber element
Starter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric
Lubrication system ............................ Wet sump
TRANSMISSION
Clutch ................... · ................. .
Transmission
............................... .
Gearshift pattern
............................ .
Primary reduction
........................... .
Secondary reduction
......................... .
Final reduction .............................. .
Gear ratios,
Low ............................ .
2nd
............................ .
3rd
4th
5th
Top ............................ .
Wet multi-plate type, hydraulically operated
6-speed constant mesh
1-down, 5-up
1.897 (74/39)
1.067 (16/15)
3.091 (34/11)
2.500 (35/14)
1. 777 (32/18)
1.391 (32/23)
1.153 (30/26)
0.960 (24/25)
0.806 (25/31)
Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft drive

1-7 GENERAL INFORMATION
CHASSIS
Front suspension ............................. Telescopic, pneumatic/coil spring, oil damped
Rear suspension .............................. Full floating suspension, oil damped, spring
pre-load fully adjustable
Steering angle ................................ 37° (right & left)
Caster ...................................... 60° 30'
Trail
....................................... 116 mm (4.57 in)
Turning radius
............................... 3.0 m (9.8 ft)
Front brake ................................. Disc brake, twin, hydraulically operated
Rear brake .................................. Internal expanding
Front tire
size ................................ 110/80-19 59H
Rear tire size ................................ 140/80-16 68H
Front
fork stroke ............................. 160 mm (6.3 in)
Rear wheel travel ............................. 115 mm (4.5 in)
ELECTRICAL
Ignition type ................................ Transistorized
Ignition timing ............................... 10°B.T.D.C. below 1 500 r/min and
35° B.T.D.C. above 3 500 r/min
Spark plug .................................. NGK D8EA or NIPPON DENSO X24ES-U
Battery ..................................... 12V 50.4 kC (14 Ah)/10 HR
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/1 0/1 0/10/1 OA
Circuit breaker ............................... 30A
Headlight . ; ................................. 12V 60/55W
Tail/Brake light
.............................. 12V 8/23W
Turn signal light
.............................. 12V 23W
Speedometer light
............................ 12V 3.4W
Tachometer light
............................. 12V 3.4W
Neutral indicator light ......................... 12V 3W
High beam indicator light ......... .-; ............ 12V 1.7W
Turn signal indicator light
...................... 12V 3W
Side stand check light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 3W
Cooling solution temperature meter light ........... 12V 3W
Fuel level indicator light ........................ 12V 3W
License plate Iight ............................ 12V 8W
CAPACITIES
Fuel tank including reserve ...................... 13.0 L (3.4 US gal)
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 L (3.2 US qt)
Engine oil
................................... 3 200 ml (3.4 US qt)
Cooling solution .............................. 3 500 ml (3.7 US qt)
Front
fork oil ................................ 479 ml (16.2 US oz)
Secondary bevel gear oil .................. 230-250 ml (7.8-8.5 US oz)
Final bevel gear oil ....................... 170-190 ml (5.8-6.4 US oz)
* These specifications are subject to change without notice.

PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES
~----------------CONTENTS----------------~
PERIODIC MAINTENANCE SCHEDULE···· ......... ·················· ..... 2- 1
MAINTENANCE AND TUNE-UP PROCEDURES ························ 2- 2
BATTERY ········································································· 2- 2
AIR CLEANER ·································································· 2- 3
SPARK PLUG ··································································2- 4
FUEL
LINES ····································································· 2- 5
ENGINE OIL AND OIL FILTER ······················ ···················· 2- 5
CARBURETOR ··········································· ······················· 2- 6
CLUTCH ···········································································2- 7
COOLING SYSTEM ··························································2- 8
SECONDARY AND FINAL GEAR OIL ································ 2- 9
BRAKES ··········································································· 2-10
TIRES ··············································································2-13
STEERING ········································································2-14
FRONT FORK ···································································· 2-14
CHASSIS BOLTS AND NUTS ··········································2-15

2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE
IMPORTANT: The periodic maintenance intervals and service requirements have been established in
accordance
with EPA regulations. Following these instructions will ensure that the motorcycle will not
exceed emission standards and it will also ensure the reliability and performance of the motorcycle.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions,
however,
it is not necessary for ensuring emission level compliance.
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and to maintain proper emission levels. Mileages are
expressed in terms of kilometers, miles and time for your convenience.
PERIODIC MAINTENANCE CHART
INTERVAL:
km 1 000 6000 12 000 18 000
24000
THIS INTERVAL SHOULD BE JUDGED mile
600 4000
7 500 11 000 15 000
BY ODOMETER READING OR
MONTHS WHICHEVER COMES FIRST month 2 12 24
36
48
Battery (Specific gravity of electrolyte) -I I I I
Air cleaner element
Clean every 3 000 km (2 000 miles) and
replace every 12 000 km (7 500 miles),
Spark plugs -c R c R
I I I I I
Fuel lines
Replace every four years
Engine oil and oil filter R -R -R
Carburetor I I I I I
I -I -I
Clutch
hoses
Replace every four years
Clutch fluid
Change every two years
Radiator
hoses
I I -1 I I -I I
Replace every four years
Cooling solution
Change every two years
Secondary and final
gear oil R -I -I
I I I I I
Brake hoses
Replace every four years
Brake fluid
Change every two years
Brakes
I I I I I
Tires I I I I I
Steering stem I I I I I
--I -I
Front fork
Check air pressure every 6 months
Chassis bolts and nuts T T T T T
NOTE: T= Tighten, I= Inspect, R =Replace, C =Clean

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for
each item of the Periodic Maintenance re-
quirements.
BATTERY
Inspect: 6 000, 12 000, 18 000, 24 000 km
(4 000, 7 500,
11 000, 15 000 mi)
• Remove the seat.
• Check electrolyte for level and specific gravity.
Add distilled water,
as necessary to keep the
surface
of the electrolyte above the MIN. level
line but not above the MAX. level line.
• For checking specific gravity, use a hydrometer
to determine the charged condition.
09900 -28403
Standard specific
gravity
Hydrometer
An
S.G. reading of 1.22 (at 20°C) or under means
that the battery needs recharging. Remove the
battery
from the machine and charge it with a
battery charger.
CAUTION:
* Never charge a battery while still in the
machine
as damage may result to the
battery
or regulator/rectifier.
* Be carefuI not to bend, obstruct, or change
the routing of the air vent tube from the
battery, make certain that the vent tube
is
attached to the battery vent fitting and
that the opposite end is always open.
WARNING:
When installing the battery lead wires, fix the
EB lead first and 8 lead last.
• Make sure that the breather pipe is tightly
secured and undamaged, and is routed as shown
in the figure.
Battery breather pipe

2·3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
AIR CLEANER
Clean Every 3 000 km (2 000 mi), and
replace Every 12 000 km (7 500 mi)
• Remove the seat.
• Remove the four screws and take off the air
cleaner element.
• Carefully
use an air hose to blow the dust from
the cleaner element outside.
CAUTION:
Always use air pressure on the outside of the
cleaner element. If air pressure is used on the
inside,
dirt will be forced into the pores of the
cleaner element thus restricting air flow
through the cleaner element.
• Reinstall the cleaned or new cleaner element in
the
reverse order of removal.
•
When installing the air cleaner element in the
cleaner case, make sure that the arrow mark CD
comes forward.
CAUTION:
If driving under dusty conditions, clean the
air cleaner element more frequently. The
surest way
to accelerate engine wear is to
run the engine without the element or to use
a ruptured element. Make sure that the air
cleaner is in good condition at all times.
Life
of the engine depends largely on this
component!
CORRECT
INCORRECT

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4
SPARK PLUG
Clean: 6 000, 18 000 km
(4 000,
11 000 mi)
Replace: 12 000, 24 000 km
(7 500, 15 000 mi)
The plug
gap is adjusted to 0.6- 0.7 mm (0.024-
0.028 in). The gap is correctly adjusted using a
thickness
gauge. When carbon is deposited on the
spark plug, remove the carbon
with a tool with a
pointed end.
If electrodes are extremely worn or
burnt, replace the plug. Also replace the plug if it
has a broken insulator, damaged thread, etc.
09930- 13210 Socket wrench
09930 -14530 Universal
joint
09914-24510
T handle
09900 -20803 Thickness
gauge
NGK D8EA or NIPPON DENSO X24ES-U listed
in the table should be used as the standard plug.
However, the heat range of the plug should be
selected to meet the requirements of speed, actual
load, fuel, etc.
If the plugs need to be replaced,
it is recommended that the standard plugs listed in
the table
be selected. Remove the plugs and inspect
the insulators. Proper heat
range would be indicat-
ed if all insulators were light brown in color. If
they are blackened by carbon, they should be
replaced by a hot type NGK D7EA or NIPPON
DENSO X22ES-U.
NOTE:
To check the spark plugs, first make sure that
the fuel tank contains unleaded gasoline, and
after a test ride
if the plugs are either sooty
with carbon or burnt white, replace them
all together.
NOTE:
Confirm the thread size and reach when
replacing the plug.
If the reach is too short,
carbon
will be deposited on the screw portion
of the plug hole and engine damage may
result.
NGK
D7EA
DSEA
*Gap 0.6- 0.7 mm
~~ (0.024- 0.028 in)
NIPPON REMARKS
DEN SO
If the standard plug is apt to
X22ES-U get wet, replace with this plug.
Hot type.
X24ES-U Standard

2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
FUEL LINES
Inspect:
1 000, 6 000, 12 000, 18 000, 24 000 km
(600, 4 000, 7 500, 11 000, 15 000 mi)
Replace Every 4 years
ENGINE OIL AND OIL FILTER
Replace (Change):
1 000, 12 000, 24 000 km
(600, 7 500, 15 000 mi)
The oil should be changed while the engine is hot.
Oil filter replacement at the above intervals should
be done together with engine oil change.
• Keep the motorcycle upright, supported on the
center stand.
• Place an oil pan below the engine and drain the
oil
by removing the drain plug CD and filler cap
®.
• Remove the oil filter® by using an oil filter
wrench.
• Apply engine oil lightly to the gasket of the new
filter before installation.
• Install the new filter turning it by hand until
you feel the filter gasket contacts the mounting
surface. Then tighten
5/6 turn using the oil filter
wrench.
09915 -47320 Oil
filter wrench
• Fit drain plug CD securely, and install fresh oil
through the filler. The engine will hold about
3.7 L (3.9
US qt) of oil.
Use API classification of SE or SF oil with SAE
10W/40 viscosity.
• Start up the engine and allow it to run for
several seconds at idling speed.
• Check for oil leakage around the oil filter.
• Turn off the engine and wait about one minute,
then check the oil level through the inspection
window@. If the level is below mark "F", sup-
ply oil to that level.
NECESSARY AMOUNT OF ENGINE OIL
Oil change
3.2 L (3.4 US qt)
Filter
change
3.7 L (3.9 US qt)
Overhaul engine 4.2 L (4.4
US qt)

CARBURETOR
IDLE RPM
Inspect:
1 000, 6 000, 12 000, 18 000, 24 000 km
(600, 4 000, 7 500, 11 000, 15 000 m i)
NOTE:
Make this adjustment when the engine
is hot.
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6
• Start up the engine and set its speed at anywhere
between 1
000 and 1 200 r/min by turning
throttle stop screw CD.
Engine idle speed
1 100 ± 100 r/min
CAUTION:
No adjustment except the procedure men·
tioned above is necessary because calibration
is performed by carburetor manufacturer.
THROTTLE CABLE PLAY
There should be 2 - 3 mm (0.08 -0.12 in) play
® on the throttle cable. To adjust the throttle
cable play:
• Remove the seat and fuel tank.
• Push the throttle cable to check the amount of
play.
• Loosen the lock nuts ®and slide the adjuster
® upper or lower until the specified play is
obtained.
CAUTION:
To remove the carburetor cover may cause
the imbalance of the carburetors. Do not
remove the carburetor cover when adjusting
the
throttle cable play.
CHOKE CABLE ADJUSTMENT
• Loosen the lock nut@ and turn the adjuster
@ to adjust the cable play.
Choke cable
play@
0.5-1.0 mm
(0.02- 0.04 in)

2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
CLUTCH
Inspect: 1 000, 12 000,24 000 km
(600, 7 500, 15 000 mi)
Change fluid Every 2 years
Replace
hoses Every 4 years
CLUTCH FLUID LEVEL
• Support the motorcycle on the center stand,
and place the handlebars straight.
• Check the clutch fluid level in the reservoir.
• If the level is found to be lower than the lower
mark, replenish with BRAKE FLUID that
meets the following specification.
Specification and
classification DOT3
or DOT4
BLEED AIR FROM THE CLUTCH FLUID
CIRCUIT
The clutch fluid circuit may be purged of air in the
following manner:
• Fill up the master cylinder reservoir to the
upper end
of the inspection window. Replace
the reservoir cap to prevent entry of dirt.
• Attach a pipe to the bleeder valve and insert the
free end
of the pipe into a receptacle.
•
Squeeze and release the clutch lever several times
in rapid succession, and
squeeze the lever fully
without releasing it. Loosen the bleeder valve by
turning
it a quarter of a turn so that the fluid
runs into the receptacle; this will remove the
tension
of the clutch lever causing it to touch
the handlebars grip. Then, close the valve, pump
and
squeeze the lever, and open the valve.
Repeat this process until the fluid flowing
into the receptacle no longer contains air
bubbles.
NOTE:
Replenish the clutch fluid reservoir as neces-
sary while bleeding the clutch system.
Make
sure that there is always some fluid
visible in the reservoir.
WARNING:
The clutch system of this motorcycle is
filled with a glycol-based brake fluid. Do not
use or mix different types of fluid such as
silicone-based and petroleum-based. Do not
use any brake fluid taken from old, used or
unsealed containers. Never re-use the brake
fluid left over from the last servicing and
stored
for long periods.
• Close the bleeder valve, and disconnect the pipe.
Fill the reservoir to the upper end of the inspec-
tion window.
Bleeder valve
tightening torque
CAUTION:
6-9 N-m
(0.6- 0.9 kg-m)
(4.5- 6.5 lb-ft)
Handle the brake fluid with care: the fluid
reacts chemically with paint, plastics, rubber
materials, etc.