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GS500E SERVICE MANUAL

1. Cylinder head warped This is caused by overheating or engine idles at the specified rpm Chapter 1 improperly tightened head bolts Machine shop resurfacing or head ipicement is necessary Chapter 2 i Rough idle L Valve spring broken or weak Caused by component failure or Ignition malfunction Chapter 4 wear the springs must be replaced Chapter 2 C Idle speed incorrect Chapter 1 O Valve not seating properly This is caused by a bent valve from CJ Carburettors not synchronised Adjust carburettors with vacuum over revving or improper valve adjustment burned valve or seat gauge or manometer set Chapter 1 improper carburation or an accumulation of carbon deposits on Carburettor malfunction Chapter 3 the seat from carburation or lubrication problems The valves L Fuel contaminated The fuel can be contaminated with either dirt must be cleaned and or replaced and the seats serviced if or water or can change chemically if the machine is allowed to sit possible Chapter 2 for several months or more Drain the tank and float chambers a Chapter 3 Stalls after starting Dj Intake air leak Check for loose carburettor to intake manifold C3 Improper choke action Make sure the choke linkage shaft is connections loose or missing vacuum gauge adapter caps or getting a full stroke and staying in the out position Chapter 3 loose carburettor tops Chapter 3 C Ignition malfunction Chapter 4 C Air filter clogged Replace
2. 8 2 REFe12 Filter air 1 5 1916 3e14 fuel 1 10 304 oil 1 10 Followers camshaft 2 12 Footrests and brackets 5 2 Frame 5 2 Frame serial number 0 9 Front brake caliper 6 3 checks 1 14 disc 6 5 fluid level check 0 11 master cylinder 6 6 pad check 1 13 pad replacement 6 2 Front forks check 1916 oil change 1 20 oil type level and capacity 192 5 1 overhaul 5 6 removal and installation 5 95 specifications 5 1 Front mudguard 7 2 Index neret Front wheel bearings 1 19 6 16 removal and installation 6 13 Fuel system carburettors 1 18 395 306 3e7 30 10 check 1 10 choke cable 1 17 3 13 cock and tap 3e4 filter 1 10 hoses replacement 1 17 idle fuel air mixture adjustment 3 5 specifications 3e1 tank 3e1 3 5 throttle cable 1917 3 12 Fuel type 3 1 Fuse 8 1 8 3 G Gasoline type 3 1 Gearbox see Transmission Gearchange mechanism 2 34 H Handlebar switches 8 13 Handlebars 5 3 Headlight aim check and adjustment 1 18 REF 6 removal and installation 8 5 bulb 8 2 894 Horn 8 16 HT coils 4 1 4 2 Idie speed check and adjustment 1 11 specification 1 1 Idle fuel air mixture adjustment 3 5 Ignition system control unit 4 4 HT coils 4 2 pulse generator coils 4 3 spark plugs 1 1 1 9 1 16 specifications 491 timing 494 ignition main switch 8 13 ins
3. Brake system cleaner is used to remove grease or brake fluid from brake system components where clean surfaces are absolutely necessary and petroleum based solvents cannot be used it also leaves no residue Silicone based lubricants are used to protect rubber parts such as hoses and grommets and are used as lubricants for hinges and locks Multi purpose grease is an all purpose lubricant used wherever grease is more practical than a liquid lubricant such as oil Some multi purpose grease is coloured white and specially formulated to be more resistant to water than ordinary grease Gear oil sometimes called gear lube is a specially designed oil used in transmissions and final drive units as well as other areas where high friction high temperature lubrication is required It is available in a number of viscosities weights for various applications Motor oil of course is the lubricant specially formulated for use in the engine It normally contains a wide variety of additives to prevent corrosion and reduce foaming and wear Motor oil comes in various weights viscosity ratings of from 5 to 80 The recommended weight of the oil depends on the seasonal temperature and the demands on the engine Light oil is used in cold climates and under light load conditions heavy oil is used in hot climates and where high loads are encountered Multi viscosity oils are designed to have characteristics of both light
4. Fault Finding REFe19 12 Poor handling or stability Handlebar hard to turn Steering head bearing adjuster nut too tight Check adjustment Chapter 1 O Bearings damaged Roughness can be felt as the bars are turned from side to side Replace bearings and races Chapter 5 J Races dented or worn Denting results from wear in only one position e g straight ahead from a collision or hitting a pothole or from dropping the machine Replace races and bearings Chapter 5 CJ Steering stem lubrication inadequate Causes are grease getting hard from age or being washed out by high pressure car washes Disassemble steering head and repack bearings Chapter 5 Steering stem bent Caused by a collision hitting a pothole or by dropping the machine Replace damaged part Don t try to straighten the steering stem Chapter 5 C Front tire air pressure too low Chapter 1 Handlebar shakes or vibrates excessively Tyres worn or out of balance Chapter 6 Swingarm bearings worn Replace worn bearings Chapter 5 OOOO Wheel bearings worn Worn front or rear wheel bearings can cause poor tracking Worn front bearings will cause wobble Chapter 6 Handlebar clamp bolts loose Chapter 5 Fork yoke bolts loose Tighten them to the specified torque Chapter 5 Engine mounting bolts loose Will cause excessive vibration with increased engine rpm Chapter 2 g 13 Braking problems Rim s warped o
5. Specific gravity is simply a measure of the electrolyte s density compared with that of water Water has an SG of 1 000 and fully charged battery electrolyte is about 2696 heavier at 1 260 Specific gravity checks are not possible on maintenance free batteries Testing the open circuit voltage is the only means of determining their state of charge Warning The gases produced by the battery are explosive Float type hydrometer for measuring battery specific gravity 1 To measure SG remove the battery from the motorcycle and remove the first cell cap Draw some electrolyte into the hydrometer and note the reading see illustration 5 Return the electrolyte to the cell and install the cap 2 The reading should be in the region of 1 260 to 1 280 If SG is below 1 200 the battery needs charging Note that SG will vary with temperature it should be measured at 20 C 68 F Add 0 007 to the reading for rere22 Fault Finding Equipment every 10 C above 20 C and subtract 0 007 from the reading for every 10 C below 20 C Add 0 004 to the reading for every 10 F above 68 F and subtract 0 004 from the reading for every 10 F below 68 F 3 When the check is complete rinse the hydrometer thoroughly with clean water Checking for continuity The term continuity describes the uninterrupted flow of electricity through an electrical circuit A continuity check will determine whether an open circuit situation ex
6. page number A Air filter cleaning 1 5 housing removal and installation 3 14 replacement 1 16 Alternator removal and installation 8 21 specifications 8 1 tests 8 20 8 23 Balancer shaft 2 93 2 54 Battery capacity 8 1 charging 8e3 electrolyte level 0 10 removal installation inspection and maintenance 8e2 specific gravity 192 16 REFe21 voltage REFe21 Bearings balancer shaft 2 54 connecting rod 2 56 main 2 51 rear suspension 1 16 1 21 5 15 steering head 1914 1 21 5 11 wheel 1919 6916 Bodywork 7 1 Brake bleeding 6 12 caliper 6 3 6 9 checks 1 14 disc 6 5 6 10 fluid change 1 16 fluid level check 0 11 hoses and unions 1 17 6 12 light bulb 8 6 light switches Be9 master cylinder 6 6 6 11 pad check 1 13 pad replacement 6 2 6 7 seal replacement 1 21 specifications 691 Brake fluid type 1 2 Bulbs brake tail light 8 6 headlight 8 4 instrument 8 11 side light 84 turn signal 8 7 wattage 8 2 Cables choke 1 17 3 13 clutch 1 12 2e32 fubrication 1 19 speedometer tachometer 8 9 throttle 1 11 1 17 3912 Caliper brake front 6 3 rear 699 Camchain 2 2 2911 Camchain tensioner and guide blades 2 9 Camshafts and foltowers 2 2 2 12 Carburettors float height check 3 10 overhaul 3e5 3e7 3e10 removal and installation 3 6 separation and joining 3 10 specification
7. x 1 333 2 491 1 868 27 68 ow X x x x x 0 868 x 885 x 7 233 x 0 738 x 9 804 x 0 0013 0 621 x 2 825 Inches in Feet ft Miles Cubic inches cu in in Imperial pints Imp pt Imperial quarts Imp qt imperial quarts Imp at US quarts US qt Imperial gallons Imp gal Imperial gallons Imp gal US gallons US gal Ounces oz Pounds Ib Ounces force ozf oz Pounds force tbf ib Newtons N Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibt in Ib in Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibf in Ib in Kilopascals kPa Millibar mbar Millibar mbar Millibar mbar Millibar mbar Millimetres of mercury mmHg Inches of water inH4O Pounds force inches Ibf in Ib in Pounds force inches Ibf in ib in Pounds force inches Ibf in 1b in Pounds force feet Ibf ft Ib ft Pounds force feet Ibf ft Ib ft Newton metres Nm Horsepower hp Miles per hour miles hr mph Miles per gallon mpg Degrees Celsius Degrees Centigrade C F 32 x 0 56 It is common practice to convert from miles per gallon mpg to litres 100 kilometres I 100km where mpg x 1 100 km 282 Index nere o i M M Note References throughout this index are in the form Chapter number
8. L Starter clutch defective Inspect and repair or replace Chapter 2 J Damaged idle reduction gear or starter gears Inspect and replace the damaged parts Chapter 2 Starter works but engine won t turn over seized LJ Seized engine caused by one or more internally damaged components Failure due to wear abuse or lack of lubrication Damage can include seized valves followers camshafts pistons crankshaft connecting rod bearings or transmission gears or bearings Refer to Chapter 2 for engine disassembly No fuel flow O No fuel in tank C Main fuel cock filter clogged Remove the fuel cock and clean it and the filter Chapter 3 C Fuel line clogged Pull the fuel line loose and carefully blow LJ OO through it Float needle valve clogged For both of the valves to be clogged either a very bad batch of fuel with an unusual additive has been used or some other foreign material has entered the tank Many times after a machine has been stored for many months without running the fuel turns to a varnish like liquid and forms deposits on the inlet needle valves and jets The carburettors should be removed and overhauled if draining the float chambers doesn t solve the problem Chapter 3 Engine flooded D Float height incorrect Check and adjust as necessary Chapter 3 C3 Float needle valve worn or stuck open A piece of dirt rust or other debris can cause the valve to seat improperly causing excess fue
9. Relays sidestand 8 15 starter 8 17 tum signal 8 8 Regulator rectifier check and replacement 8 23 specification 8 1 Remote fuel tap 3e4 S Safety checks 0 8 0 12 Seat 7 1 Selector drum and forks 2 4 2 48 Side light 8 2 8 5 Side panels 7 2 Spark plugs gap and type 1 1 gap check and adjustment 1 9 replacement 1 16 Specifications brakes 6 1 clutch 294 electrical system 8 1 engine 2 1 fuel system 3 1 ignition system 4 1 routine maintenance and servicing 1 1 lubricants and fluids 1 2 suspension 5 1 transmission 2e4 tyres 692 wheels 6 1 Speedometer bulbs 8 2 8 11 check and replacement 8 11 drive cable 8 9 Sprockets 5 16 Stands lubrication 1 19 removal and installation 5 3 sidestand switch and relay 8 15 Starter clutch and gear assembly 2 36 Starter motor overhaul 8 18 removal and installation 8 17 specifications 8e1 Starter relay 8 17 Steering check 0e11 head bearing freeplay check and adjustment 1 14 head bearing inspection and replacement 5 11 head bearing lubrication 1 21 stem 5 10 Storage REF 10 Sump oil pan 2 37 adjustment 5 13 check 0 11 1916 front forks 1 20 5 5 5 6 rear 1 21 5012 specifications 5 1 Swingarm inspection and bearing replacement 5915 removal and installation 5 14 Switches brake light 8 9 clutch 8 16 handlebar 8 13 ignition main 8 13
10. cylinder head Helicoil A thread insert repair system Commonly used as a repair for stripped spark plug threads see illustration Honing A process used to break down the glaze on a cylinder bore also called glaze busting Can also be carried out to roughen a rebored cylinder to aid ring bedding in HT High Tension Description of the electrical circuit from the secondary winding of the ignition Coil to the spark plug Hydraulic A liquid filled system used to transmit pressure from one component to another Common uses on motorcycles are brakes and clutches Hydrometer An instrument for measuring the specific gravity of a lead acid battery Hygroscopic Water absorbing In motorcycie applications braking efficiency will be reduced if DOT 3 or 4 hydraulic fluid absorbs water from the air care must be taken to keep new brake fluid in tightly sealed containers Ibt ft Pounds force feet An imperial unit of torque Sometimes written as ft Ibs Ibf in Pound force inch An imperial unit of torque applied to components where a very low torque is required Sometimes written as in Ibs IC Abbreviation for Integrated Circuit ignition advance Means of increasing the timing of the spark at higher engine speeds Done by mechanical means ATU on early engines or electronically by the ignition control unit on later engines Ignition timing The moment at which the spark plug fires expressed in the number of crankshaft degrees before the
11. suspension applications and in two stroke engines Nm Newton metres NOx Oxides of Nitrogen A common toxic pollutant emitted by petrol engines at higher temperatures O Octane The measure of a fuel s resistance to knock OE Original Equipment Relates to components fitted to a motorcycle as standard or replacement parts supplied by the motorcycle manufacturer Ohm The unit of electrical resistance Ohms Volts Current Ohmmeter An instrument for measuring electrical resistance Oil cooler System for diverting engine oil outside of the engine to a radiator for cooling purposes Oil injection A system of two stroke engine lubrication where oil is pump fed to the engine in accordance with throttle position Open circuit An electrical condition where there is a break in the flow of electricity no continuity high resistance O ring A type of sealing ring made of a special rubber like material in use the O ring is compressed into a groove to provide the Oversize OS Term used for piston and ring size options fitted to a rebored cylinder Overhead cam sohc engine An engine with single camshaft located on top of the cylinder head Overhead valve ohv engine An engine with the valves located in the cylinder head but with the camshaft located in the engine block or crankcase Oxygen sensor A device installed in the exhaust system which senses the oxygen content in the exhaust and converts this information into
12. 8 21 8 23 battery 0 10 1 6 8e2 8e3 REF 21 brake tail light 8 6 brake light switches 8 9 charging system tests 8 20 clutch switch 8 16 diode 8 16 fuse 8e3 handlebar switches 8 13 headlight 1918 8 4 8 5 hom 8 16 ignition main switch 8 13 instruments 8 11 lighting check 8 4 neutral switch 8 14 oil pressure switch 8 12 regulator rectifier 8 23 side light 8 4 sidestand switch and relay 8915 specifications 8 1 Electrical system continued starter motor 8 17 8 18 starter relay 8e17 tests REFe21 turn signals 8 7 8 8 wiring diagrams 8 25 Engine balancer shaft 2 54 camchain 2 11 camchain tensioner and blades 299 2011 camshafts and followers 2 12 compression check 1e20 REFe20 connecting rods 2e56 crankcase 2 39 2 41 crankshaft 2 51 cylinder block 2 20 cylinder head 1 6 2 15 2 17 idle speed 1911 main and connecting rod bearings 2951 oil change 1 10 oil level 0 10 oil pressure check 1 21 oil pressure regulator 2 37 oil pump 2 33 oil strainer 2937 piston rings 2 24 pistons 2 22 removal and installation 2e5 running in 2 58 serial number 0 9 specifications 1 1 2e1 sump oil pan 2 37 valve clearances 1 7 valve cover 2 8 valve overhaul 2 17 Evaporative emission control system 3 15 Exhaust system nut tightness check 196 removal and installation 3 14 F Fault finding
13. 9 Chain breaking 12 Stroboscope for 15 One man brake clutch Soft faced hammers and cold chisels riveting tool dynamic timing checks bleeder kit 3 Impact driver set 7 Selection of pullers 10 Wire crimper tool 13 Hose clamp 4 Vernier gauge wingnut type shown Specialist tools 1 Micrometer 4 Oylinder 7 Plastigauge kit 10 Piston ring removal and 13 Stud extractor external type compression gauge 8 Valve spring compressor installation tool 14 Screw extractor set 2 Telescoping gauges or 5 Vacuum gauges shown 4 stroke engines 11 Piston ring clamp 15 Bearing driver set small hole gauges or manometer 9 Piston pin drawbolt too 12 Cylinder bore hone 3 Dial gauge 6 Oil pressure gauge stone type shown Rere Maintenance Techniques Basic maintenance techniques There are a number of techniques involved in maintenance and repair that will be referred to throughout this manual Application of these techniques will enable the amateur mechanic to be more efficient better organised and capable of performing the various tasks properly which will ensure that the repair job is thorough and complete Fastening systems Fasteners basically are nuts bolts and screws used to hold two or more parts together There are a few things to keep in mind when working with fasteners Almost all of them use a locking device of some type either a lock washer locknut locking tab or thread locking compou
14. C Battery overcharged Fault Finding rere13 1 Engine doesn t start or is difficult to start Starter motor doesn t rotate Engine kill switch OFF O Fuse blown Check fuse Chapter 8 Battery voltage low Check and recharge battery Chapter 8 LJ Starter motor defective Make sure the wiring to the starter is secure Make sure the starter relay clicks when the start button is pushed If the relay clicks then the fault is in the wiring or motor Starter relay faulty Check it according to the procedure in Chapter 8 Starter switch not contacting The contacts could be wet corroded or dirty Disassemble and clean the switch Chapter 8 L Wiring open or shorted Check all wiring connections and harnesses to make sure that they are dry tight and not corroded Also check for broken or frayed wires that can cause a short to ground earth see wiring diagram Chapter 8 O Ignition main switch defective Check the switch according to the procedure in Chapter 8 Replace the switch with a new one if it is defective Lj Engine kill switch defective Check for wet dirty or corroded contacts Clean or replace the switch as necessary Chapter 8 C Faulty neutral or side stand switch Check the wiring to each Switch and the switch itself according to the procedures in Chapter 8 Faulty sidestand relay or diode Check according to the procedure in Chapter 8 Starter motor rotates but engine does not turn over
15. a broken component picked up by the gears This will cause early bearing failure Chapter 2 Engine oil level too low Causes a howl from transmission Also affects engine power and clutch operation Chapter 1 Final drive noise Chain not adjusted properly Chapter 1 Front or rear sprocket loose Tighten fasteners Chapter 5 Sprockets worn Replace sprockets Chapter 5 Rear sprocket warped Replace sprockets Chapter 5 Wheel coupling damper worn Replace damper Chapter 5 REF t8 Fault Finding 9 Abnormal frame and suspension noise Front end noise o E E EN cp ws s Low fluid level or improper viscosity oil in forks This can sound like spurting and is usually accompanied by irregular fork action Chapter 5 Spring weak or broken Makes a clicking or scraping sound Fork oil when drained will have a lot of metal particles in it Chapter 5 Steering head bearings loose or damaged Clicks when braking Check and adjust or replace as necessary Chapters 1 and 5 Fork yokes loose Make sure all clamp pinch bolts are tight Chapter 5 Fork tube bent Good possibility if machine has been dropped Replace tube with a new one Chapter 5 Front axle or axle clamp boit loose Tighten them to the specified torque Chapter 6 Shock absorber noise m a 10 Oil pressure light comes on Fluid level incorrect Indicates a leak caused by defective seal Shock will be covered with oil Replace shock or seek
16. additive that will dissolve the adhesive bonding the carbon particles to the piston crown and chamber is the easiest way to remove the build up Otherwise the cylinder head will have to be removed and decarbonized Chapter 2 C Improperly machined head surface or installation of incorrect gasket during engine assembly Chapter 2 Engine load excessive L Clutch slipping Can be caused by damaged loose or worn clutch components Overhaul clutch Chapter 2 OO ag 5 Clutch problems Li Engine oil level too high The addition of too much oil will cause pressurisation of the crankcase and inefficient engine operation Check Specifications and drain to proper level Chapter 1 1 Engine oil viscosity too high Using a heavier oil than the one recommended in Chapter 1 can damage the oil pump or lubrication system as well as cause drag on the engine L Brakes dragging Usually caused by debris which has entered the brake piston seals or from a warped disc or bent axle Repair as necessary C Excessive friction in moving engine parts due to inadequate lubrication worn bearings or incorrect assembly Overhaul engine Chapter 2 Lubrication inadequate Z Engine oil level too low Friction caused by intermittent lack of lubrication or from oii that is overworked can cause overheating The oil provides a definite cooling function in the engine Check the oil level Chapter 1 L Poor quality engine oil or incorrect viscosity or
17. an electric current Also called a Lambda sensor P Plastigauge A thin strip of plastic thread available in different sizes used for measuring clearances For example a strip of Plastigauge is laid across a bearing journal The parts are assembied and dismantled the width of the crushed strip indicates the clearance between journal and bearing Polarity Either negative or positive earth ground determined by which battery lead is connected to the frame earth return Modern motorcycles are usually negative earth Pre ignition A situation where the fuel air mixture ignites before the spark plug fires Often due to a hot spot in the combustion chamber caused by carbon build up Engine has a tendency to run on Pre load suapension The amount a spring is compressed when in the unloaded state Preioad can be applied by gas spacer or mechanical adjuster Premix The method of engine lubrication on older two stroke engines Engine oil is mixed with the petrol in the fuel tank in a specific ratio The fuel oil mix is sometimes referred to as petroil Primary drive Description of the drive from the crankshaft to the clutch Usually by gear or chain PS Pfedest rke a German interpretation of BHP PSI Pounds force per square inch Imperial measurement of tyre pressure and cylinder pressure measurement PTFE Polytetrafluroethylene A low friction substance Pulse secondary air injection system A process of promoting
18. and heavy oils and are available in a number of weights from 5W 20 to 20W 50 Petrol additives perform several functions depending on their chemical makeup They usually contain solvents that help dissolve gum and varnish that build up on carburettor and inlet parts They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers Some additives contain upper cylinder lubricants for valves and piston rings Brake and clutch fluid is a specially formulated hydraulic fluid that can withstand the heat and pressure encountered in brake clutch systems Care must be taken that this fluid does not come in contact with painted surfaces or plastics An opened container should always be resealed to prevent contamination by water or dirt Chain lubricants are formulated especially for use on motorcycle final drive chains A good chain lube should adhere well and have good penetrating qualities to be effective as a lubricant inside the chain and on the side plates pins and rollers Most chain lubes are either the foaming type or quick drying type and are usually marketed as sprays Take care to use a lubricant marked as being suitable for O ring chains Degreasers are heavy duty solvents used to remove grease and grime that may accumulate on engine and frame components They can be sprayed or brushed on and depending on the type are rinsed with either water or solvent Solvents
19. combustion chamber completely by positioning the piston at TDC on the compression chamber drain stub arrow and unscrew the drain screw Drain the carburettor s otherwise there is a risk of jets becoming blocked by gum deposits from the fuel see illustration 4 If the bike is going into long term storage consider adding a fuel stabiliser to the fuel in the tank If the tank is drained completely corrosion of its internal surfaces may occur if left unprotected for a long period The tank can be treated with a rust preventative especially for this purpose Alternatively remove the tank and pour half a litre of motor oil into it install the filler cap and shake the tank to coat its internals with oil before draining off the excess The same effect can also be achieved by spraying WD40 or a similar water dispersant around the inside of the tank via its flexible nozzle Make sure the cooling system contains the correct mix of antifreeze Antifreeze also contains important corrosion inhibitors The air intakes and exhaust can be sealed off by covering or plugging the openings Ensure that you do not seal in any condensation run the engine until it is hot then switch off and allow to cool Tape a piece of thick plastic over the silencer end s see illustration 5 Note that some advocate pouring a tablespoon of motor oil into the silencer s before sealing them off LI AX NAA 7 Exhausts can be sealed off
20. engine compression Low compression will result in exhaust smoke heavy oil consumption poor starting and poor performance A compression test will provide useful information about an engine s condition and if performed regularly can give warning of trouble before any other symptoms become apparent A compression gauge will be required along with an adapter to suit the spark plug hole thread size Note that the screw in type gauge adapter set up is preferable to the rubber cone type Before carrying out the test first check the valve clearances as described in Chapter 1 1 Run the engine until it reaches normal operating temperature then stop it and remove the spark plug s taking care not to scald your hands on the hot components 2 Install the gauge adapter and compression gauge in No 1 cylinder spark plug hole see illustration 1 3 On kickstart equipped motorcycles make sure the ignition switch is OFF then open the throttle fully and kick the engine over a couple of times until the gauge reading stabilises 4 On motorcycles with electric start only the procedure will differ depending on the nature of the ignition system Flick the engine kill switch engine stop switch to OFF and turn Screw the compression gauge adapter into the spark plug hole then screw the gauge into the adapter Fault Finding Equipment ner the ignition switch ON open the throttle fully and crank the engine over on the
21. neutral 8614 oil pressure 8 12 sidestand 8 15 Synchronisation carburettors 1 18 T Tachometer bulbs 8 2 8 11 check and replacement 8 11 drive cable 8 9 Tail light 8 2 8 6 Tank fuel 3 2 305 Tap fuel 3 4 Tensioner camchain 2 9 2 11 Throttle cable freeplay check 1 11 1 17 removal and installation 3912 Timing ignition 491 404 valve 2 14 Tools REFe2 Torque settings 1 2 2e4 3 2 4 1 5 1 692 82 Transmission gearshafts overhaul 2 43 gearshafts removal and installation 2 42 gearchange mechanism 2 34 oil change 1 10 oil level 0 10 selector drum and forks 2e48 specifications 2e4 Troubleshooting 8 2 REFe12 Turn signals bulbs 8 2 8 7 circuit check and relay 8 8 removal and installation 8 7 Tyre checks 0 12 general information and fitting 6 18 specifications 6 2 Tyre pressures 0 12 1 2 V Valve clearances 1 1 1 97 Valve cover 2 8 Vaive overhaul 2 2 2 17 Valve timing 2 14 VIN 0 9 W Weights REFe1 Wheel alignment 6 13 bearings 1 19 6 16 inspection and repair 1 14 6 13 removal and installation 6 13 6 15 specifications 5 1 Wiring diagrams 8 25 Electrode gap check use a wire type gauge for best results Normal condition A brown tan or grey firing end indicates that the engine is in good condition and that the plug type is correct Carbon fouling D
22. over revving or improper valve adjustment burned valve or seat improper carburation or an accumulation of carbon deposits on the seat from carburation or lubrication problems The valves must be cleaned and or replaced and the seats serviced if possible Chapter 2 Fault Finding rere1s 2 Poor running at low speeds continued Poor acceleration J Carburettors leaking or dirty Overhaul the carburettors Chapter 3 Timing not advancing Faulty pick up coils or ignitor unit Chapter 4 D Carburettors not synchronised Adjust them with a vacuum gauge set or manometer Chapter 1 n m Engine oil viscosity too high Using a heavier oil than that recommended in Chapter 1 can damage the oil pump or lubrication system and cause drag on the engine Brakes dragging Usually caused by debris which has entered the brake piston seals or from a warped disc or bent axle Repair as necessary Chapter 6 3 Poor running or no power at high speed Firing incorrect OOO O aaguu Air fitter restricted Clean or replace filter Chapter 1 Spark plugs fouled defective or worn out Chapter 1 Spark plug cap or HT wiring defective Chapters 1 and 4 Spark plug caps not making contact Make sure they are properly connected Incorrect spark plugs Wrong type heat range or cap configuration Check and install correct plugs Chapter 1 Ignition control unit defective Chapter 4 Pulse generator coils defective Chapte
23. piston reaches the top of its stroke or in the number of millimetres before the piston reaches the top of its stroke Infinity Description of an open circuit electrical state where no continuity exists Inverted forks upside down forks The sliders or lower legs are held in the yokes and the fork tubes or stanchions are connected to the wheel axle spindle Less unsprung weight and stiffer construction than conventional forks J S JASO Quality standard for 2 stroke oils Joule The unit of electrical energy Journal The bearing surface of a shaft K Kickstart Mechanical means of turning the engine over for starting purposes Only usually fitted to mopeds small capacity motorcycles and off road motorcycles Kill switch Handebar mounted switch for emergency ignition cut out Cuts the ignition circuit on all models and additionally prevent starter motor operation on others km Symbol for kilometre kph Abbreviation for kilometres per hour L Lambda A sensor A sensor fitted in the exhaust system to measure the exhaust gas oxygen content excess air factor ner2e Technical Terms Explained Lapping see Grinding LCD Abbreviation for Liquid Crystal Display LED Abbreviation for Light Emitting Diode Liner A steel cylinder liner inserted in a aluminium alloy cylinder block Locknut A nut used to lock an adjustment nut or other threaded component in place Lockstops The lugs on the lower triple clamp yoke w
24. steering heads Tappet A cylindrical component which transmits motion from the cam to the valve stem either directly or via a pushrod and rocker arm Also called a cam follower TCS Traction Control System An electronically controlled system which senses wheel spin and reduces engine speed accordingly TDC Top Dead Centre denotes that the piston is at its highest point in the cylinder Thread locking compound Solution applied to fastener threads to prevent slackening Select type to suit application Thrust washer A washer positioned between two moving components on a shaft For example between gear pinions on gearshaft Timing chain See Cam Chain Timing light Stroboscopic lamp for carrying out ignition timing checks with the engine running Top end A description of an engine s cylinder block head and valve gear components Torque Turning or twisting force about a shaft Torque setting A prescribed tightness specified by the motorcycle manufacturer to ensure that the bolt or nut is secured correctly Undertightening can result in the bolt or nut coming loose or a surface not being sealed Overtightening can result in stripped threads distortion or damage to the component being retained Torx key A six point wrench Tracer A stripe of a second colour applied to a wire insulator to distinguish that wire from another one with the same colour insulator For example Br W is often used to denote a brown insulator with a white trace
25. to negative ve Incorrect connections can damage the meter A sound fully charged 12 volt battery should produce between 12 3 and 12 6 volts across its terminals 12 8 volts for a maintenance free battery On machines with a 6 volt battery voltage should be between 6 1 and 6 3 volts 1 Set a multimeter to the 0 to 20 volts dc range and connect its probes across the Warning The gases produced by the battery are explosive 4 LEAD Measuring open circuit battery voltage battery terminals Connect the meter s positive 4ve probe usually red to the battery positive ve terminal followed by the meter s negative ve probe usually black to the battery negative terminal ve see illustration 4 2 If battery voltage is low below 10 volts on a 12 volt battery or below 4 volts on a six volt battery charge the battery and test the voltage again If the battery repeatedly goes flat investigate the motorcycle s charging system Checking battery specific gravity SG A never smoke or create any sparks in the vicinity of the battery Never allow the electrolyte to contact your skin or clothing if it does wash it off and seek immediate medical attention The specific gravity check gives an indication of a battery s state of charge A hydrometer is used for measuring specific gravity Make sure you purchase one which has a small enough hose to insert in the aperture of a motorcycle battery
26. to vent to the atmosphere Castellated Resembling the parapets along the top of a castle wall For example a castellated wheel axle or spindle nut Catalytic converter A device in the exhaust system of some machines which converts certain pollutants in the exhaust gases into less harmful substances Charging system Description of the components which charge the battery ie the alternator rectifer and regulator Circlip A ring shaped clip used to prevent endwise movement of cylindrical parts and shafts An internal circlip is installed in a groove in a housing an external circlip fits into a groove on the outside of a cylindrical piece such as a shaft Also known as a snap ring Clearance The amount of space between two parts For example between a piston and a Cylinder between a bearing and a journal etc Coil spring A spiral of elastic steel found in various sizes throughout a vehicle for example as a springing medium in the suspension and in the valve train Compression Reduction in volume and increase in pressure and temperature of a gas caused by squeezing it into a smaller space Compression damping Controls the speed the suspension compresses when hitting a bump Compression ratio The relationship between cylinder volume when the piston is at top dead centre and cylinder volume when the piston is at bottom dead centre Continuity The uninterrupted path in the flow of electricity Little or no measurabie resistance C
27. will cause compression pressure to leak past the rings This is usually accompanied by worn rings as well A top end overhaul is necessary Chapter 2 L Piston rings wom weak broken or sticking Broken or sticking piston rings usually indicate a lubrication or carburation problem that causes excess carbon deposits or seizures to form on the pistons and rings Top end overhaul is necessary Chapter 2 ner 14 Fault Finding 1 Engine doesn t start or is difficult to start continued Piston ring to groove clearance excessive This is caused by C Carburettor maifunction Chapter 3 excessive wear of the piston ring lands Piston replacement is CJ Fuel contaminated The fuel can be contaminated with either dirt necessary Chapter 2 or water or can change chemically if the machine is allowed to sit C Cylinder head gasket damaged If the head is allowed to become for several months or more Drain the tank and float chambers loose or if excessive carbon build up on the piston crown and Chapter 3 combustion chamber causes extremely high compression the O Intake air leak Check for loose carburettor to intake manifold head gasket may leak Retorquing the head is not always connections loose or missing vacuum gauge adapter caps or sufficient to restore the seal so gasket replacement is necessary loose carburettor tops Chapter 3 Chapter 2 C Engine idle speed incorrect Turn idle adjusting screw until the
28. with a plastic bag Battery Remove it from the bike in extreme cases of cold the battery may freeze and crack its case see illustration 6 Disconnect the negative lead A first followed by the positive lead B Check the electrolyte level and top up if necessary conventional refillable batteries Clean the terminals Store the battery off the motorcycle and away from any sources of fire Position a wooden block under the battery if it is to sit on the ground Give the battery a trickle charge for a few hours every month see illustration 7 Use a suitable battery charger this kit also assess battery condition Storage nere Tyres Place the bike on its centrestand or an auxiliary stand which will support the motorcycle in an upright position Position wood blocks under the tyres to keep them off the ground and to provide insulation from damp If the bike is being put into long term storage ideally both tyres should be off the ground not only will this protect the tyres but will also ensure that no load is placed on the Steering head or wheel bearings Deflate each tyre by 5 to 10 psi no more or the beads may unseat from the rim making subsequent inflation difficult on tubeless tyres Pivots and controls Lubricate all lever pedal stand and footrest pivot points If grease nipples are fitted to the rear suspension components apply lubricant to the pivots Lubri
29. Newton metres Nm Power Horsepower hp Velocity speed Miles per hour miles hr mph Fuel consumption Miles per gallon mpg Temperature X X x x x Degrees Fahrenheit C x 1 8 32 1 152 0 113 0 083 0 138 1 356 0 102 Wo 745 7 1 609 0 354 Millimetres mm Metres m Kilometres km Cubic centimetres cc cm Litres 1 Litres I US quarts US qt Litres I Litres l US gallons US gal Litres l Grams g Kilograms kg Newtons N Newtons N Kilograms force kgf kg Kilograms force per square centimetre kgf cm kg cm Atmospheres atm Bars Kilopascals kPa Kilograms force per square centimetre kgf cm kg cm Pascals Pa Pounds force per square inch psi Ibf in Ib in Millimetres of mercury mmHg Inches of water inH5O inches of water inH5O Pounds force per square inch psi Ibf in Ib in Kilograms force centimetre kgf cm kg cm Newton metres Nm Pounds force feet Ibf ft Ib ft Kilograms force metres Kgf m kg m Newton metres Nm Kilograms force metres Kgf m kg m Watts W Kilometres per hour km hr kph x Kilometres per litre km l x 0 0394 3 281 x 0 621 x 0 061 1 76 0 88 0 833 1 057 0 22 0 833 0 264 x x KK KK KK 0 035 x 2 205 x x 0 225 x 9 81 x 14 223 x 14 696 x 145 x 0 145 x 98 1 x 0 01 68 947
30. Reference rere1 Dimensions and Weights REF 1 TOONS seruo c ate EN She qb S EAS REFe2 Maintenance Techniques ss REFe4 Motorcycle Chemicals and Lubricants REFe5 MOT Test Checks 00 0 cece eee REF 6 Storage ss sind ExRu RENE EADEM REF 10 Dimensions and Weights Fault Finding llle REF 12 Fault Finding Equipment REF 20 Technical Terms Explained REFe24 Conversion Factors 00 e ce eee REFe28 Indexes areae eque Pacha BRO REFe29 Wheelbase W msnen ugen aa aean e e a hera Overall length D 00 20 00 cee ccc cee cee e eee ee nernees Overall width K models 04 L M N P and R models eee See ae E S T and V models Overall height H Seat height S veena du P eee mere ees Minimum ground clearance 2200 6 cee ens Weight dry jose e Sa arai i eaa lang dt ead 1410 mm 2075 mm 725 mm REFe2 TOOIS Buying tools A toolkit is a fundamental requirement for servicing and repairing a motorcycle Although there will be an initial expense in building up enough tools for servicing this will soon be offset by the savings made by doing the job yourself As experience and confidence grow additional tools can be added to enable the repair and overhaul of the motorcycle Many of the specialist tools are expensive and not often used so it may be preferabl
31. SOOE model development Suspension and steering adjustment and A complete step by step guide to servicing and overhaul routine maintenance Comprehensive fault finding that helps pinpoint Engine and transmission servicing and specific problems overhaul Electrical system fault finding and repairs Braking system safety checks and repairs Comprehensive colour wiring diagrams Fuel and ignition systems explained Fully indexed to help you find information easily ISBN 1 85960 238 X LMNOPOR 38345 03238 ARCNFFGHL IK
32. a horizontal line on the wall at this height Position the motorcycle 3 8 metres from the wall and draw a vertical i ag i AeA Headlight beam height checking equipment line up the wall central to the centreline of the motorcycle Switch to dipped beam and check that the beam pattern falls slightly lower than the horizontal line and to the left of the vertical line see illustration 2 2 H29003 Home workshop beam alignment check MOT Test Checks perez Exhaust System and Final Drive Exhaust v Check that the exhaust mountings are secure and that the system does not foul any of the rear suspension components Y Start the motorcycle When the revs are increased check that the exhaust is neither holed nor leaking from any of its joints On a linked system check that the collector box is not leaking due to corrosion v Note that the exhaust decibel level loudness of the exhaust is assessed at the discretion of the tester If the motorcycle was first used on or after 1st January 1985 the silencer must carry the BSAU 193 stamp or a marking relating to its make and model or be of OE original equipment manufacture If the silencer is marked NOT FOR ROAD USE RACING USE ONLY or similar it will fail the MOT Steering and Suspension Final drive v On chain or belt drive machines check that the chain belt is in good condition and does not have excessive slack Als
33. advice on repair from a Suzuki dealer Chapter 5 Defective shock absorber with internal damage This is in the body of the shock and can t be remedied The shock must be replaced with a new one Chapter 5 Li e E g D Bent or damaged shock body Replace the shock with a new one Chapter 5 Loose or worn linkage components Check and replace as needed Chapter 5 Brake noise Squeal caused by pad shim not installed or positioned correctly Chapter 6 Squeal caused by dust on brake pads Usually found in combination with glazed pads Clean using brake cleaning solvent Chapter 6 Contamination of brake pads Oil brake fluid or dirt causing brake to chatter or squeal Clean or replace pads Chapter 6 Pads glazed Caused by excessive heat from prolonged use or from contamination Do not use sandpaper emery cloth carborundum cloth or any other abrasive to roughen the pad surfaces as abrasives will stay in the pad material and damage the disc A very fine flat file can be used but pad replacement is suggested as a cure Chapter 6 Disc warped Can cause a chattering clicking or intermittent squeal Usually accompanied by a pulsating lever and uneven braking Replace the disc Chapter 6 Loose or worn wheel bearings Check and replace as needed Chapter 6 Engine lubrication system D C o o Engine oil pump defective blocked oil strainer gauze or failed relief valve Carry out oil pressure ch
34. again once released Brake caliper pistons can stick due to corrosion around the piston head or on the sliding caliper types due to corrosion of the slider pins If the brake doesn t free after repeated operation take the caliper off for examination Similarly drum brakes can stick due to a seized operating cam cable or rod linkage if the motorcycle has been in long term storage renew the brake fluid and clutch fluid where applicable Depending on where the bike has been stored the wiring cables and hoses may have been nibbled by rodents Make a visual check and investigate disturbed wiring loom tape Battery f the battery has been previously removal and given top up charges it can simply be reconnected Remember to connect the positive cable first and the negative cable last On conventional refillable batteries if the battery has not received any attention remove it from the motorcycle and check its electrolyte level Top up if necessary then charge the battery If the battery fails to hold a charge and a visual checks show heavy white sulphation of the plates the battery is probably defective and must be renewed This is particularly likely if the battery is old Confirm battery condition with a specific gravity check On sealed MF batteries if the battery has not received any attention remove it from the motorcycle and charge it according to the information on the battery case if the batte
35. alves and one for the exhaust valves Drivebelt A toothed belt used to transmit drive to the rear wheel on some motorcycles A drivebelt has also been used to drive the camshafts Drivebelts are usually made of Kevlar Driveshaft Any shaft used to transmit motion Commonly used when referring to the final driveshaft on shaft drive motorcycles E Earth return The return path of an electrical circuit utilising the motorcycle s frame ECU Electronic Control Unit A computer which controls for instance an ignition system or an anti lock braking system EGO Exhaust Gas Oxygen sensor Sometimes called a Lambda sensor Electrolyte The fluid in a lead acid battery EMS Engine Management System A computer controlled system which manages the fuel injection and the ignition systems in an integrated fashion Endfloat The amount of lengthways movement between two parts As applied to a crankshaft the distance that the crankshaft can move side to side in the crankcase Endless chain A chain having no joining link Common use for cam chains and final drive Chains EP Extreme Pressure Oil type used in locations where high loads are applied such as between gear teeth Evaporative emission control system Describes a charcoal filled canister which stores fuel vapours from the tank rather than allowing them to vent to the atmosphere Usually only fitted to California models and referred to as an EVAP system Expansion chamber Section o
36. are commonly used on motorcycles plain shell bearings ball bearings tapered roller bearings and needle roller bearings Bevel gears Used to turn the drive through 90 Typical applications are shaft final drive and camshaft drive see illustration i e ae ors inus n 5 Bevel gears are used to turn the drive through 90 BHP Brake Horsepower The British measurement for engine power output Power output is now usually expressed in kilowatts Bias belted tyre Similar construction to radial tyre but with outer belt running at an angle to the wheel rim Big end bearing The bearing in the end of the connecting rod that s attached to the crankshaft Bleeding The process of removing air from an hydraulic system via a bleed nipple or bleed screw Bottom end A description of an engine s crankcase components and all components contained there in BTDC Before Top Dead Centre in terms of piston position Ignition timing is often expressed in terms of degrees or millimetres BTDC Bush A cylindrical metal or rubber component used between two moving parts Burr Rough edge left on a component after machining or as a result of excessive wear C Cam chain The chain which takes drive from the crankshaft to the camshaft s Canister The main component in an evaporative emission control system California market only contains activated charcoal granules to trap vapours from the fuel system rather than allowing them
37. are used alone or in combination with degreasers to clean parts and assemblies during repair and overhaul The home mechanic should use only solvents that are non flammable and that do not produce irritating fumes Gasket sealing compounds may be used in conjunction with gaskets to improve their sealing capabilities or alone to seal metal to metal joints Many gasket sealers can withstand extreme heat some are impervious to petrol and lubricants while others are capable of filling and sealing large cavities Depending on the intended use gasket sealers either dry hard or stay relatively soft and pliable They are usually applied by hand with a brush or are sprayed on the gasket sealing surfaces Thread locking compound is an adhesive locking compound that prevents threaded fasteners from loosening because of vibration It is available in a variety of types for different applications Moisture dispersants are usually sprays that can be used to dry out electrical components such as the fuse block and wiring connectors Some types can also be used as treatment for rubber and as a lubricant for hinges cables and locks Waxes and polishes are used to help protect painted and plated surfaces from the weather Different types of paint may require the use of different types of wax polish Some polishes utilise a chemical or abrasive cleaner to help remove the top layer of oxidised dull paint on older vehicles In
38. ate in the low and high beam Switch positions b Position lights Check that the front position or sidelight and tail light illuminate in this switch position c Turn signals Check that all flash at the correct rate and that the warning light s function correctly Check that the turn signal switch works correctly c Hazard warning system where fitted Check that all four turn signals flash in this Switch position d Brake stop light Check that the light comes on when the front and rear brakes are independently applied Models first used on or after 1st April 1986 must have a brake light switch on each brake amp Horn Check that the sound is continuous and of reasonable volume Y Check that there is a red reflector on the rear of the machine either mounted separately or as part of the tail light lens Check the condition of the headlight tail light and turn signal lenses Headlight beam height v The MOT tester will perform a headlight beam height check using specialised beam setting equipment see illustration 1 This equipment will not be available to the home mechanic but if you suspect that the headlight is incorrectly set or may have been maladjusted in the past you can perform a rough test as follows v Position the bike in a straight line facing a brick wall The bike must be off its stand upright and with a rider seated Measure the height from the ground to the centre of the headlight and mark
39. cal condition where current shorts to earth ground bypassing the circuit components Skimming Process to correct warpage or repair a damaged surface eg on brake discs or drums Slide hammer A special puller that screws into or hooks onto a component such as a shaft or bearing a heavy sliding handle on the shaft bottoms against the end of the shaft to knock the Component free Small end bearing The bearing in the upper end of the connecting rod at its joint with the gudgeon pin Spatiing Damage to camshaft lobes or bearing journals shown as pitting of the working surface Specific gravity SG The state of charge of the electrolyte in a lead acid battery A measure of the electrolyte s density compared with water Straight cut gears Common type gear used on gearbox shafts and for oil pump and water pump drives Stanchion The inner sliding part of the front forks held by the yokes Often called a fork tube Technical Terms Explained rere27 L M Stoichiometric ratio The optimum chemical air fuel ratio for a petrol engine said to be 14 7 parts of air to 1 part of fuel Sulphuric acid The liquid electrolyte used in a lead acid battery Poisonous and extremely corrosive Surtace grinding lapping Process to correct a warped gasket face commonly used on cylinder heads T Tapered roiler bearing Tapered inner race of caged needle rollers and separate tapered outer race Examples of taper roller bearings can be found on
40. cate all control cables Cycle components Apply a wax protectant to all painted and plastic components Wipe off any excess but don t polish to a shine Where fitted clean the screen with soap and water Coat metal parts with Vaseline petroleum jelly When applying this to the fork tubes do Getting back on the road not compress the forks otherwise the seals will rot from contact with the Vaseline Apply a vinyl cleaner to the seat Storage conditions Aim to store the bike in a shed or garage which does not leak and is free from damp Drape an old blanket or bedspread over the bike to protect it from dust and direct contact with sunlight which will fade paint This also hides the bike from prying eyes Beware of tight fitting plastic covers which may allow condensation to form and settle on the bike Engine and transmission Change the oil and replace the oil filter If this was done prior to storage check that the oil hasn t emulsified a thick whitish substance which occurs through condensation Remove the spark plugs Using a spout type oil can squirt a few drops of oil into the cylinder s This will provide initial lubrication as the piston rings and bores comes back into contact Service the spark plugs or fit new ones and install them in the engine Check that the clutch isn t stuck on The plates can stick together if left standing for some time preventing clutch operatio
41. chiometric ratio Fuse An electrical device which protects a circuit against accidental overload The typical fuse contains a soft piece of metal which is calibrated to melt at a predetermined current flow expressed as amps and break the circuit G Gap The distance the spark must travel in jumping from the centre electrode to the side electrode in a spark plug Also refers to the distance between the ignition rotor and the pickup coil in an electronic ignition system Gasket Any thin soft material usually cork cardboard asbestos or soft metal installed between two metal surfaces to ensure a good seal For instance the cylinder head gasket seals the joint between the block and the cylinder head Gauge An instrument panel display used to monitor engine conditions A gauge with a movable pointer on a dial or a fixed scale is an analogue gauge A gauge with a numerical readout is called a digital gauge Gear ratios The drive ratio of a pair of gears in a gearbox calculated on their number of teeth Glaze busting see Honing Grinding Process for renovating the valve face and valve seat contact area in the cylinder head Gudgeon pin The shaft which connects the connecting rod small end with the piston Often called a piston pin or wrist pin H Helical gears Gear teeth are slightly curved and produce less gear noise that straight cut gears Often used for primary drives insert in a installing a Helicoil thread
42. come loose Each bolt depending on the material it s made of the diameter of its shank and the material it is threaded into has a specific torque value which is noted in the Specifications Be sure to follow the torque rec ommendations closely Fasteners laid out in a pattern ie cylinder head bolts engine case bolts etc must be loosened or tightened in a sequence to avoid warping the component Initially the bolts nuts should go on finger tight only Next they should be tightened one full turn each in a criss cross or diagonal pattern After each one has been tightened one full turn return to the first one tightened and tighten them all one half turn following the same pattern Finally tighten each of them one quarter turn at a time until each fastener has been tightened to the proper torque To loosen and remove the fasteners the procedure would be reversed Disassembly sequence Component disassembly should be done with care and purpose to help ensure that the parts go back together properly during reassembly Always keep track of the sequence in which parts are removed Take note of special characteristics or marks on parts that can be installed more than one way such as convex washers and gear pinions It s a good idea to lay the disassembled parts out on a clean surface in the order that they were removed it may also be helpful to make Sketches or take instant photos of components before removal When removing fa
43. correct clearance is important if too small the valve won t close fully and will burn out whereas if too large noisy operation will result Valve lift The amount a valve is lifted off its seat by the camshaft lobe Valve timing The exact setting for the opening and closing of the valves in relation to piston position Vernier caliper A precision measuring instrument that measures inside and outside dimensions Not quite as accurate as a micrometer but more convenient VIN Vehicle Identification Number Term for the bike s engine and frame numbers Viscosity The thickness of a liquid or its resistance to flow Volt A unit for expressing electrical pressure in a circuit Volts current x ohms W Water pump A mechanically driven device for moving coolant around the engine Watt A unit for expressing electrical power Watts volts x current Wear limit see Service limit Wet liner A liquid cooled engine design where the pistons run in liners which are directly surrounded by coolant see illustration 1 P dE anit oie Spee Lm n mem mel ml mnm ee Wet liner arrangement Wheelbase Distance from the centre of the front wheel to the centre of the rear wheel Wiring harness or loom Describes the electrical wires running the length of the motorcycle and enclosed in tape or plastic sheathing Wiring coming off the main harness is usually referred to as a sub hamess Woodruff key A key of semi circular or square sec
44. ctive Check the coils referring to Chapter 4 for details Ignition HT coils defective Check the coils referring to Chapter 4 for details Ignition or kill switch shorted This is usually caused by water corrosion damage or excessive wear The switches can be disassembled and cleaned with electrical contact cleaner If cleaning does not help replace the switches Chapter 8 t Wiring shorted or broken between a Ignition main switch and engine kill switch or blown fuse b Ignition control unit and engine kill switch C Ignition control unit and ignition HT coils d Ignition HT coils and spark plugs e Ignition control unit and pulse generator coils C Make sure that all wiring connections are clean dry and tight Look for chafed and broken wires Chapters 4 and 8 Compression low L1 Spark plugs loose Remove the plugs and inspect their threads Reinstall and tighten to the specified torque Chapter 1 t Cylinder head not sufficiently tightened down If the cylinder head is suspected of being loose then there s a chance that the gasket or head is damaged if the problem has persisted for any length of time The head bolts should be tightened to the proper torque in the correct sequence Chapter 2 improper valve clearance This means that the valve is not closing completely and compression pressure is leaking past the valve Check and adjust the valve clearances Chapter 1 Z Cylinder and or piston worn Excessive wear
45. e Caused by inattention to master cylinder fluid level or by leakage Locate problem and bleed brakes Chapter 6 Pad or disc worn Chapters 1 and 6 Brake fluid leak Causes air in brake line Locate problem and bleed brakes Chapter 6 Contaminated pads Caused by contamination with oil grease brake fluid etc Clean or replace pads Clean disc thoroughly with brake cleaner Chapter 6 Brake fluid deteriorated Fluid is old or contaminated Drain system replenish with new fluid and bleed the system Chapter 6 Master cylinder internal parts worn or damaged causing fluid to bypass Chapter 6 Master cylinder bore scratched by foreign material or broken spring Repair or replace master cylinder Chapter 6 Disc warped Replace disc Chapter 6 Brake lever or pedal pulsates Disc warped Replace disc Chapter 6 Axle bent Replace axle Chapter 6 Brake caliper bolts loose Chapter 6 Brake caliper sliders damaged or sticking rear caliper causing caliper to bind Lubricate the sliders or replace them if they are corroded or bent Chapter 6 1 Wheel warped or otherwise damaged Chapter 6 jj Wheel bearings damaged or worn Chapter 6 Brakes drag Master cylinder piston seized Caused by wear or damage to piston or cylinder bore Chapter 6 Lever balky or stuck Check pivot and lubricate Chapter 6 Brake caliper binds Caused by inadequate lubrication or damage to caliper sliders Cha
46. e machine and security of attachment and V Check that the rider and pillion footrests handlebar levers and brake pedal are securelv mounted Swivel joints plus specific wheel alignment toe in requirements Additionally tyre and lighting requirements differ from conventional Tyre direction of rotation arrow can be found on tyre sidewall USE COMPETITION USE ONLY or similar will fail the MOT v lf the tyre sidewall carries a direction of rotation arrow this must be pointing in the direction of normal wheel rotation see illustration 16 v Check that the wheel axle spindle nuts where applicable are properly secured A self locking nut or castellated nut with a split pin or R pin can be used see illustration 17 v Wheel alignment is checked with the motorcycle off the stand and a rider seated With the front wheel pointing straight ahead two perfectly straight lengths of metal or wood and placed against the sidewalls of both tyres see illustration 18 The gap each side of the front tyre must be equidistant on both sides Incorrect wheel alignment may be due to a cocked rear wheel often as the result of poor chain adjustment or in extreme cases a bent frame v Check for corrosion on the frame or any load bearing components If severe this may affect the structure particularly under stress motorcycle use Owners are advised to check MOT test requirements with an official test centre rerei0 Stora
47. e of the commonly used tools such as rotor pullers are available in aftermarket form from mail order motorcycle tool and accessory suppliers Maintenance and minor repair tools Set of Torx keys or bits 12 Steel rule A and 1 Set of flat bladed 6 Feeler gauges 16 Funnel and Screwdrivers 7 Pliers and self locking 13 Spark plug gap measuring vessel straight edge B 2 Set of Phillips head grips Mole grips measuring and 17 Strap wrench chain 22 Continuity tester screwdrivers 8 Adjustable spanner adjusting tool wrench or oil filter 23 Battery charger 3 Combination open end 9 C spanner ideally 14 Spark plug spanner A removal tool 24 Hydrometer for battery amp ring spanners adjustable type or deep plug socket B 18 Oil drain tray specific gravity check 4 Socket set 3 8 inch 10 Tyre pressure gauge A 15 Wire brush and 19 Pump type oil can 25 Anti freeze tester for or 1 2 inch drive amp tread depth gauge B emery paper 20 Grease gun liquid cooled engines 5 Set of Allen keys or bits 11 Cable pressure oiler Tools rere3 Repair and overhaul tools 1 Torque wrench 5 Circlip pliers internal and 8 Breaker bars A 11 Multimeter measures 14 Magnetic arm small and mid ranges extemal or combination and length of tubing B amps volts and ohms telescopic type shown 2 Conventional plastic or 6 Set of punches
48. e to hire them or for a group of friends or motorcycle club to join in the purchase As a rule it is better to buy more expensive good quality tools Cheaper tools are likely to wear out faster and need to be renewed more often nullifying the original saving Warning To avoid the risk of a poor quality tool breaking in use causing injury or damage to the component being worked on always aim to purchase tools which meet the relevant national safety standards The following lists of tools do not represent the manufacturer s service tools but serve as a guide to help the owner decide which tools are needed for this level of work in addition items such as an electric drill hacksaw files hammers soldering iron and a workbench equipped with a vice may be needed Although not classed as tools a selection of bolts screws nuts washers and pieces of tubing always come in useful For more information about tools refer to the Haynes Motorcycle Workshop Practice Manual Bk No 1454 Manufacturer s service tools Inevitably certain tasks require the use of a service tool Where possible an alternative tool or method of approach is recommended but sometimes there is no option if personal injury or damage to the component is to be avoided Where required service tools are referred to in the relevant procedure Service tools can usually only be purchased from a motorcycle dealer and are identified by a part number Som
49. ead worn or damaged Lack of lubrication at high rpm is usually the cause of damage Insufficient oil or failure to change the oil at the recommended intervals are the chief causes Since there are no replaceable bearings in the head the head itself will have to be replaced if there is excessive wear or damage Chapter 2 Other noise t Cylinder head gasket leaking Chapter 1 Exhaust pipe leaking at cylinder head connection Caused by improper fit of pipe s or loose exhaust flange All exhaust fasteners should be tightened evenly and carefully Failure to do this will lead to a leak Chapter 3 L Crankshaft runout excessive Caused by a bent crankshaft from over revving or damage from an upper cylinder component failure Can also be attributed to dropping the machine on either of the crankshaft ends Chapter 2 Engine mounting bolts loose Tighten all engine mount bolts Chapter 2 Crankshaft bearings worn Chapter 2 Cam chain tensioner defective Replace Chapter 2 Cam chain sprockets or guides worn Chapter 2 G L OOO Clutch noise Clutch housing friction plate clearance excessive Chapter 2 Loose or damaged clutch pressure plate and or bolts Chapter 2 Transmission noise Bearings worn Also includes the possibility that the shafts are worn Overhaul the transmission Chapter 2 Gears worn or chipped Chapter 2 O Metal chips jammed in gear teeth Probably pieces from
50. eck Chapter 2 Engine oil level tow Inspect for leak or other problem causing low oil level and add recommended oil Chapter 1 Engine oil viscosity too low Very old thin oil or an improper weight of oil used in the engine Change to correct oil Chapter 1 Camshaft or journals worn Excessive wear causing drop in oil pressure Replace cam and or cylinder head Abnormal wear could be caused by oil starvation at high rpm from low oil level or improper weight or type of oil Chapter 1 11 Excessive exhaust smoke o Crankshaft and or bearings wom Same problems as paragraph 4 Check and replace crankshaft and or bearings Chapter 2 Electrical system rH D Oil pressure switch defective Check the switch according to the procedure in Chapter 8 Replace it if it is defective Oil pressure indicator light circuit defective Check for pinched shorted disconnected or damaged wiring Chapter 8 White smoke g DO L O OO t Piston oil ring worn The ring may be broken or damaged causing oil from the crankcase to be pulled past the piston into the combustion chamber Replace the rings with new ones Chapter 2 Cylinders worn cracked or scored Caused by overheating or oii starvation The cylinders will have to be rebored and new pistons installed Chapter 2 Valve oil seal damaged or worn Replace oil seals with new ones Chapter 2 Valve guide worn Perform a complete valve job Chapter 2 Engine o
51. erminal of the battery and also the main earth ground point on the wiring harness If corroded dismantle the connection and clean all surfaces back to bare metal 1 To check the earth on a component use an insulated jumper wire to temporarily bypass its earth connection see illustration 16 Connect one end of the jumper wire between the earth terminal or metal body of the component and the other end to the motorcycle s frame A selection of jumper wires for making earth ground checks 2 If the circuit works with the jumper wire installed the original earth circuit is faulty Check the wiring for open circuits or poor connections Clean up direct earth connections removing all traces of corrosion and remake the joint Apply petroleum jelly to the joint to prevent future corrosion Tracing a short circuit A short circuit occurs where current shorts to earth ground bypassing the circuit components This usually results in a blown fuse A short circuit is most likely to occur where the insulation has worn through due to wiring chafing on a component allowing a direct path to earth ground on the frame 1 Remove any bodypanels necessary to access the circuit wiring 2 Check that all electrical switches in the circuit are OFF then remove the circuit fuse and connect a test light buzzer or voltmeter set to the dc scale across the fuse terminals No voltage should be shown 3 Move the wiring from side
52. ezing of the coolant in winter Antifreeze also contains chemicals to inhibit corrosion and the formation of rust and other deposits that would tend to clog the radiator and coolant passages and reduce cooling efficiency Anti dive System attached to the fork lower leg slider to prevent fork dive when braking hard Anti seize compound A coating that reduces the risk of seizing on fasteners that are subjected to high temperatures such as exhaust clamp bolts and nuts API American Petroleum Institute A quality standard for 4 stroke motor oils Asbestos A natural fibrous mineral with great heat resistance commonly used in the composition of brake friction materials Asbestos is a health hazard and the dust created by brake systems should never be inhaled or ingested ATF Automatic Transmission Fluid Often used in front forks ATU Automatic Timing Unit Mechanical device for advancing the ignition timing on early engines ATV Ali Terrain Vehicle Often called a Quad Axial play Side to side movement Axie A shaft on which a wheel revolves Also known as a spindle Backlash The amount of movement between meshed components when one component is held still Usually applies to gear teeth Ball bearing A bearing consisting of a hardened inner and outer race with hardened steel balls between the two races Bearings Used between two working surfaces to prevent wear of the components and a build up of heat Four types of bearing
53. f two stroke engine exhaust system so designed to improve engine efficiency and boost power F Feeler blade or gauge A thin strip or blade of hardened steel ground to an exact thickness used to check or measure clearances between parts Final drive Description of the drive from the transmission to the rear wheel Usually by chain or shaft but sometimes by belt Firing order The order in which the engine cylinders fire or deliver their power strokes beginning with the number one cylinder Flooding Term used to describe a high fuel level in the carburettor float chambers leading to fuel overflow Also refers to excess fuel in the combustion chamber due to incorrect starting technique Technical Terms Explained rers2s L a ua aaa Free length The no load state of a component when measured Clutch valve and fork spring lengths are measured at rest without any preload Freepiay The amount of trave before any action takes place The looseness in a linkage or an assembly of parts between the initial application of force and actual movement For example the distance the rear brake pedal moves before the rear brake is actuated Fuel injection The fuel air mixture is metered electronically and directed into the engine intake ports indirect injection or into the cylinders direct injection Sensors supply information on engine speed and conditions Fuel air mixture The charge of fuel and air going into the engine See Stoi
54. g Chapter 2 Gearchange lever return spring weak or broken Chapter 2 Gearchange lever broken Splines stripped out of lever or shaft caused by allowing the lever to get loose or from dropping the machine Replace necessary parts Chapter 2 OO 8 7 Abnormal engine noise L Gearchange mechanism stopper arm broken or worn Full engagement and rotary movement of shift drum results Replace the arm Chapter 2 Stopper arm spring broken Allows arm to float causing sporadic shift operation Replace spring Chapter 2 Jumps out of gear C Selector fork s worn Overhaul the transmission Chapter 2 C Gear groove s wom Overhaul the transmission Chapter 2 C Gear dogs or dog slots worn or damaged The gears should be inspected and replaced Don t service the worn parts Chapter 2 Overshifts Stopper arm spring weak or broken Chapter 2 1 Gearchange shaft return spring post broken or distorted Chapter 2 Knocking or pinging L Carbon build up in combustion chamber Use of a fuel additive that will dissolve the adhesive bonding the carbon particles to the piston crown and chamber is the easiest way to remove the build up Otherwise the cylinder head will have to be removed and decarbonized Chapter 2 Incorrect or poor quality fuel Old or improper fuel can cause detonation This causes the pistons to rattle thus the knocking or pinging sound Drain the old fuel and always use the rec
55. ge Preparing for storage Before you start If repairs or an overhaul is needed see that this is carried out now rather than left until you want to ride the bike again Give the bike a good wash and scrub all dirt from its underside Make sure the bike dries completely before preparing for storage Engine Remove the spark plug s and lubricate the cylinder bores with approximately a teaspoon of motor oil using a spout type oil can see illustration 1 Reinstall the spark plug s Crank the engine over a couple of times to coat the piston rings and bores with oil If the bike has a kickstart use this to turn the engine over If not flick the kill switch to the OFF position and crank the engine over on the starter see illustration 2 If the nature on the ignition system prevents the starter operating with the kill switch in the OFF position E k Squirt a drop of motor oil into each cylinder and ensure that the metal bodies of the plugs arrows are earthed against the cylinder head remove the spark plugs and fit them back in their caps ensure that the plugs are earthed grounded against the cylinder head when the starter is operated see illustration 3 Warning It is important that the plugs are earthed grounded away from the spark plug holes otherwise there is a risk of atomised fuel from the cylinders igniting TE Ona single cylinder four stroke engine you can seal HINT the
56. hen with slip joint pliers grab the hose at the clamp and rotate it around the union Work it back and forth until it is completely free then pull it off silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the union Apply the same lubricant to the inside of the hose and the outside of the union to simplify installation If the hose is particularly stubborn slit the hose with a sharp knife and peel it off the union The hose will obviously be destroyed using this method If a hose clamp is broken or damaged do not reuse it Also do not reuse hoses that are cracked split or torn Motorcycle Chemicals and Lubricants eres A number of chemicals and lubricants are available for use in motorcycle maintenance and repair They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber plastic and vinyl Contact point spark plug cleaner is a solvent used to clean oily film and dirt from points grime from electrical connectors and oil deposits from spark plugs It is oil free and leaves no residue It can also be used to remove gum and varnish from carburettor jets and other orifices Carburettor cleaner is similar to contact point spark plug cleaner but it usually has a stronger solvent and may leave a slight oily reside it is not recommended for cleaning electrical components or connections
57. hich abut those on the frame preventing handlebar to fuel tank contact Lockwasher A form of washer designed to prevent an attaching nut from working loose LT Low Tension Description of the electrical circuit from the power supply to the primary winding of the ignition coil Main bearings The bearings between the crankshaft and crankcase Maintenance free MF battery A sealed battery which cannot be topped up Manometer Mercury filled calibrated tubes used to measure intake tract vacuum Used to synchronise carburettors on multi cylinder engines Micrometer A precision measuring instrument that measures component outside diameters see illustration Tappet shims are measured with a micrometer MON Motor Octane Number A measure of a fuel s resistance to knock Monograde oil An oil with a single viscosity eg SAEBOW Monoshock A single suspension unit linking the swingarm or suspension linkage to the frame mph Abbreviation for miles per hour Multigrade oll Having a wide viscosity range eg 10W40 The W stands for Winter thus the viscosity ranges from SAE10 when cold to SAE40 when hot Multimeter An electrical test instrument with the capability to measure voltage current and resistance Some meters also incorporate a continuity tester and buzzer Needle roller bearing Inner race of caged needle rollers and hardened outer race Examples of uncaged needle rollers can be found on some engines Commonly used in rear
58. holes clogged Remove carburettor and blow out all i Sa bipes ss assi scene hui rtp and g females oo sealed or missing Chapter 1 combustion chamber causes extremely high compression the Air filter boing oer sedied Look for cracks holes or loose head gasket may leak Retorquing the head is not always 7 n 4 sufficient to restore the seal so gasket replacement is necessary clamps and replace or repair defective parts Chapter 3 Chapter 2 Fuel level too high or too low Check the float height Chapter 3 i Carburettor intake manifolds loose Check for cracks breaks 1 Cylinder head warped This is caused by overheating or tears or loose clamps Replace the rubber intake manifold joints if improperly tightened head bolts Machine shop resurfacing or split or perished Chapter 3 head replacement is necessary Chapter 2 Compression low C Valve spring broken or weak Caused by component failure or 3 Spark plugs loose Remove the plugs and inspect their threads wear the springs must be replaced Chapter 2 Reinstall and tighten to the specified torque Chapter 1 O Valve not seating properly This is caused by a bent valve from Cylinder head not sufficiently tightened down If the cylinder head is suspected of being loose then there s a chance that the gasket or head is damaged if the problem has persisted for any length of time The head bolts should be tightened to the proper torque in the correct sequence Chapter 2
59. il level too high which causes the oil to be forced past the rings Drain oil to the proper level Chapter 1 Head gasket broken between oil return and cylinder Causes oil to be pulled into the combustion chamber Replace the head gasket and check the head for warpage Chapter 2 Abnormal crankcase pressurisation which forces oil past the rings Clogged ventilation system or breather hose Chapter 2 Black smoke O Air filter clogged Clean or replace the element Chapter 1 ra m Main jet too large or loose Compare jet size with the Specifications Chapter 3 4 Choke cable or linkage shaft stuck causing fuel to be pulled through choke circuit Chapter 3 Li Fuel level too high Check and adjust the float height s as necessary Chapter 3 Float needle vaive held off needle seat Clean the float chambers and fuel line and replace the needles and seats if necessary Chapter 3 Brown smoke D OC Main jet too small or clogged Lean condition caused by wrong size main jet or by a restricted orifice Clean float chambers and jets and compare jet size to Specifications Chapter 3 Fuel flow insufficient Float needle valve stuck closed due to chemical reaction with old fuel Float height incorrect Restricted fuel line Clean line and float chamber and adjust floats if necessary Chapter 3 Carburettor intake manifold clamps loose Chapter 3 Air filter poorly sealed or not installed Chapter 1
60. ists Continuity can be checked with an ohmmeter multimeter continuity tester or battery and bulb test circuit see illustrations 6 7 and 8 Digital multimeter can be used for all electrical tests Battery and bulb test circuit All of these instruments are self powered by a battery therefore the checks are made with the ignition OFF As a safety precaution always disconnect the battery negative ve lead before making checks particularly if ignition switch checks are being made if using a meter select the appropriate ohms scale and check that the meter reads infinity Touch the meter probes together and check that meter reads zero where necessary adjust the meter so that it reads zero After using a meter always switch it OFF to conserve its battery Switch checks 1 If a switch is at fault trace its wiring up to the wiring connectors Separate the wire connectors and inspect them for security and condition A build up of dirt or corrosion here will most likely be the cause of the problem clean up and apply a water dispersant such as WD40 Continuity check of front brake light switch using a meter note split pins used to access connector terminals 2 If using a test meter set the meter to the ohms x 10 scale and connect its probes across the wires from the switch see illustration 9 Simple ON OFF type switches such as brake light switches only have two wire
61. k adjustment cable or rod operation and shoe lining thickness Wheels and tyres Y Check the wheel condition Cast wheels should be free from cracks and if of the built up design al fasteners should be secure Spoked wheels should be checked for broken corroded loose or bent spokes v With the wheel raised off the ground spin the wheel and visually check that the tyre and wheel run true Check that the tyre does not foul the suspension or mudguards des Brake torque arm must be properly secured at both ends Check for wheel bearing play by trying to move the wheel about the axle spindle Y E AN i Castellated type wheel axle spindle nut must be secured by a split pin or R pin v With the wheel raised off the ground grasp the wheel and attempt to move it about the axle spindle see illustration 14 Any play felt here indicates wheel bearing failure v Check the tyre tread depth tread MOT Test Checks eres Two straightedges are used to check wheel alignment condition and sidewall condition see illustration 15 w Check the tyre type Front and rear tyre types must be compatible and be suitable for road use Tyres marked NOT FOR ROAD General checks and condition v Check the security of all major fasteners bodypanels seat fairings where fitted and mudguards Sidecars A motorcycle fitted with a sidecar requires additional checks relating to the stability of th
62. k also that the operating lever doesn t foul any other components v On disc brakes examine the flexible hoses from top to bottom Have an assistant hold the brake on so that the fluid in the hose is under pressure and check that there is no sign of fluid leakage bulges or cracking If there are any metal brake pipes or unions check that these are free from corrosion and damage Where a brake linked anti dive System is fitted check the hoses to the anti dive in a similar manner WY Check that the rear brake torque arm is secure and that its fasteners are secured by self locking nuts or castellated nuts with split pins or R pins see illustration 13 Y On models with ABS check that the self check warning light in the instrument panel works v The MOT tester will perform a test of the motorcycle s braking efficiency based on a calculation of rider and motorcycle weight Although this cannot be carried out at home you can at least ensure that the braking Brake pad wear can usually be viewed without removing the caliper Most pads have wear indicator grooves 1 and some also have indicator tangs 2 On drum brakes check the angle of the operating lever with the brake fully applied Most drum brakes have a wear indicator pointer and scale systems are properly maintained For hydraulic disc brakes check the fluid level lever pedal feel bleed of air if its spongy and pad material For drum brakes chec
63. l to be admitted to the float chamber in this case the float chamber should be cleaned and the needle valve and seat inspected If the needle and seat are worn then the leaking will persist and the parts should be replaced with new ones Chapter 3 Li Starting technique incorrect Under normal circumstances i e if all the carburettor functions are sound the machine should start with little or no throttle When the engine is cold the choke should be operated and the engine started without opening the throttle When the engine is at operating temperature only a very slight amount of throttle should be necessary If the engine is flooded hold the throttle open while cranking the engine This will allow additional air to reach the cylinders No spark or weak spark 2 Ignition switch OFF Engine kill switch turned to the OFF position Battery voltage low Check and recharge the battery as necessary Chapter 8 1 Spark plugs dirty defective or worn out Locate reason for fouled plugs using spark plug condition chart and follow the plug maintenance procedures Chapter 1 Spark plug caps or secondary HT wiring faulty Check condition Replace either or both components if cracks ot deterioration are evident Chapter 4 Spark plug caps not making good contact Make sure that the plug caps fit snugly over the plug ends Ignition control unit defective Check the unit referring to Chapter 4 for details Pulse generator coils defe
64. lt Finding This Section provides an easy reference guide to the more common faults that are likely to afflict your machine Obviously the opportunities are almost limitless for faults to occur as a result of obscure failures and to try and cover all eventualities would require a book Indeed a number have been written on the subject Successful troubleshooting is not a mysterious black art but the application of a bit of knowledge combined with a systematic and logical approach to the problem Approach any troubleshooting by first accurately identifying the symptom and then checking through the list 1 Engine doesn t start or is difficult to start Starter motor doesn t rotate Starter motor rotates but engine does not tum over Starter works but engine won t turn over seized No fuel flow Engine flooded No spark or weak spark Compression low Stalls after starting Rough idle 2 Poor running at low speed D Spark weak J Fuel air mixture incorrect O Compression low O Poor acceleration 3 Poor running or no power at high speed C Firing incorrect D Fuel air mixture incorrect C Compression low L1 Knocking or pinging Miscellaneous causes Overheating Engine overheats Firing incorrect Fuel air mixture incorrect Compression too high Engine load excessive Lubrication inadequate Miscellaneous causes 5 Clutch problems J Clutch slipping Clutch not disengaging completely 6 Gear shifting problems D
65. lts function at a range suitable for the battery voltage Connect the meter red probe ve to the power supply wire and the black probe to a good metal earth ground on the motorcycle s frame or directly to the battery negative ve terminal see illustration 14 Battery voltage should be shown on the meter with the ignition switched ON 3 If using a test light or buzzer connect its positive ve probe to the power supply terminal and its negative ve probe to a good earth ground on the motorcycle s frame or directly to the battery negative ve terminal see illustration 15 With the ignition ON the test light should illuminate or the buzzer sound Ora test light note the earth connection to the frame arrow 4 if no voltage is indicated work back towards the fuse continuing to check for voltage When you reach a point where there is voltage you know the problem lies between that point and your last check point Checking the earth ground Earth connections are made either directly to the engine or frame such as sensors neutral switch etc which only have a positive feed or by a separate wire into the earth circuit of the wiring harness Alternatively a short earth wire is sometimes run directly from the component to the motorcycle s frame Corrosion is often the cause of a poor earth connection if total failure is experienced check the security of the main earth lead from the negative ve t
66. n Engage a gear and try rocking the bike back and forth with the clutch lever held against the handlebar If this doesn t work on cable operated clutches hold the clutch lever back against the handlebar with a strong elastic band or cable tie for a couple of hours see illustration 8 Hold clutch lever back against the handlebar with elastic bands or a cable tie if the air intakes or silencer end s were blocked off remove the bung or cover used If the fuel tank was coated with a rust preventative oil or a stabiliser added to the fuel drain and flush the tank and dispose of the fuel sensibly If no action was taken with the fuel tank prior to storage it is advised that the old fuel is disposed of since it will go off over a period of time Refill the fuel tank with fresh fuel Frame and running gear Oil all pivot points and cables Check the tyre pressures They will definitely need inflating if pressures were reduced for storage Lubricate the final drive chain where applicable Remove any protective coating applied to the fork tubes stanchions since this may well destroy the fork seals If the fork tubes weren t protected and have picked up rust spots remove them with very fine abrasive paper and refinish with metal polish Check that both brakes operate correctly Apply each brake hard and check that it s not possible to move the motorcycle forwards then check that the brake frees off
67. n suspect a broken wire Checking for voltage A voltage check can determine whether current is reaching a component Voltage can be checked with a dc voltmeter multimeter set on the dc volts scale test light or buzzer see illustrations 12 and 13 A meter has the advantage of being able to measure actual voltage Fault Finding Equipment ner mis A simple test light can be used for voltage checks A buzzer is useful for voltage checks When using a meter check that its leads are inserted in the correct terminals on the meter red to positive ve black to negative ve Incorrect connections can damage the meter A voltmeter or multimeter set to the dc volts scale should always be connected in parallel across the load Connecting it in series will destroy the meter Voltage checks are made with the ignition ON 1 First identify the relevant wiring circuit by referring to the wiring diagram at the end of this manual If other electrical components share the same power supply ie are fed from the same fuse take note whether they are working correctly this is useful information in deciding where to start checking the circuit Checking for voltage at the rear brake light power supply wire using a meter 2 If using a meter check first that the meter leads are plugged into the correct terminals on the meter see above Set the meter to the dc vo
68. nd All threaded fasteners should be Clean straight have undamaged threads and undamaged corners on the hex head where the spanner fits Develop the habit of replacing all damaged nuts and boits with new ones Rusted nuts and bolts should be treated with a penetrating oil to ease removal and prevent breakage After applying the rust penetrant let it work for a few minutes before trying to loosen the nut or bolt Badly rusted fasteners may have to be chiselled off or removed with a special nut breaker available at tool shops If a bolt or stud breaks off in an assembly it can be drilled out and removed with a special tool called an E Z out or screw extractor Most dealer service departments and motorcycle repair shops can perform this task as well as others such as the repair of threaded holes that have been stripped out Washers should always be replaced exactly as removed Replace any damaged washers with new ones Always use a flat washer between a lock washer and any soft metal surface such as aluminium thin sheet metal or plastic Special locknuts can only be used once or twice before they lose their locking ability and must be replaced Tightening sequences and procedures When threaded fasteners are tightened they are often tightened to a specific torque value torque is basically a twisting force Over tightening the fastener can weaken it and cause it to break while under tightening can cause it to eventually
69. ng Check and replace the springs as a set Chapter 2 Engine oil deteriorated Old thin worn out oil will not provide proper lubrication for the plates causing the clutch to drag Replace the oil and filter Chapter 1 Engine oil viscosity too high Using a heavier oil than recommended in Chapter 1 can cause the plates to stick together putting a drag on the engine Change to the correct weight oil Chapter 1 Clutch housing seized on mainshaft Lack of lubrication severe wear or damage can cause the guide to seize on the shaft Overhaul of the clutch and perhaps transmission may be necessary to repair the damage Chapter 2 Clutch release mechanism defective Overhaul the clutch cover components Chapter 2 Loose clutch centre nut Causes drum and centre misalignment putting a drag on the engine Engagement adjustment continually varies Overhaul the clutch assembly Chapter 2 Fault Finding rere17 6 Gear shifting problems Doesn t go into gear or lever doesn t return Clutch not disengaging See above Lj Selector fork s bent or seized Often caused by dropping the machine or from lack of oil Overhaul the transmission Chapter 2 3 Gear s stuck on shaft Most often caused by a lack of lubrication or excessive wear in transmission bearings and bushings Overhaul the transmission Chapter 2 Gear selector drum binding Caused by lubrication failure or excessive wear Replace the drum and bearin
70. o check that the sprocket is securely mounted on the rear wheel hub Check that the chain belt guard is in place v On shaft drive bikes check for oil leaking from the drive unit and fouling the rear tyre Steering v With the front wheel raised off the ground rotate the steering from lock to lock The handlebar or switches must not contact the fuel tank or be close enough to trap the rider s hand Problems can be caused by damaged lock stops on the lower yoke and frame or by the fitting of non standard handlebars v When performing the lock to lock check also ensure that the steering moves freely without drag or notchiness Steering movement can be impaired by poorly routed cables or by overtight head bearings or wom bearings The tester will perform a check of the steering head bearing lower race by mounting the front wheel on a surface plate then performing a lock to lock check with the weight of the machine on the lower bearing see illustration 3 v Grasp the fork sliders lower legs and attempt to push and pull on the forks see illustration 4 Any play in the steering head bearings will be felt Note that in extreme cases wear of the front fork bushes can be misinterpreted for head bearing play Check that the handlebars are securely mounted v Check that the handlebar grip rubbers are secure They should by bonded to the bar left end and to the throttle cable pulley on the right end Front
71. oesn t go into gear or lever doesn t return Jumps out of gear Overshifts DOODOOOOGUO OBOCOODUOO amp g of possible causes starting with the simplest or most obvious and progressing in stages to the most complex Take nothing for granted but above all apply liberal quantities of common sense The main symptom of a fault is given in the text as a major heading below which are listed the various systems or areas which may contain the fault Details of each possible cause for a fault and the remedial action to be taken are given in brief in the paragraphs below each heading Further information should be sought in the relevant Chapter 7 Abnormal engine noise J Knocking or pinging O Piston slap or rattling 1 Valve noise Other noise 8 Abnormal driveline noise J Clutch noise Transmission noise C Final drive noise 9 Abnormal frame and suspension noise Front end noise J Shock absorber noise C Brake noise 10 Oil pressure indicator light comes on C Engine lubrication system L3 Electrical system 11 Excessive exhaust smoke C White smoke O Black smoke DL Brown smoke 12 Poor handling or stability C Handlebar hard to tum CJ Handlebar shakes or vibrates excessively 3 Handlebar pulls to one side 1 Poor shock absorbing qualities 13 Braking problems O Brakes are spongy don t hold L Brake lever or pedal pulsates O Brakes drag 14 Electrical problems C1 Battery dead or weak
72. ommended grade fuel Chapter 3 Spark plug heat range incorrect Uncontrolled detonation indicates that the plug heat range is too hot The plug in effect becomes a glow plug raising cylinder temperatures Install the proper heat range plug Chapter 1 Improper air fuel mixture This will cause the cylinders to run hot and lead to detonation Clogged jets or an air leak can cause this imbalance Chapter 3 Piston slap or rattling C Oylinder to piston clearance excessive Caused by improper assembly Inspect and overhaul top end parts Chapter 2 Connecting rod bent Caused by over revving trying to start a badly flooded engine or from ingesting a foreign object into the combustion chamber Replace the damaged parts Chapter 2 Piston pin or piston pin bore worn or seized from wear or lack of lubrication Replace damaged parts Chapter 2 Piston ring s worn broken or sticking Overhaul the top end Chapter 2 Piston seizure damage Usually from lack of lubrication or overheating Replace the pistons and bore the cylinders as necessary Chapter 2 8 Abnormal driveline noise E C Connecting rod upper or lower end clearance excessive Caused by excessive wear or lack of lubrication Replace worn parts Chapter 2 Vaive noise Incorrect valve clearances Adjust the clearances Chapter 1 Valve spring broken or weak Check and replace weak valve springs Chapter 2 Camshaft or cylinder h
73. ontinuity tester Self powered bleeper or test light which indicates continuity Cp Candlepower Bulb rating common found on US motorcycles Crossply tyre Tyre plies arranged in a criss cross pattern Usually four or six plies used hence 4PR or 6PR in tyre size codes Cush drive Rubber damper segments fitted between the rear wheel and final drive sprocket to absorb transmission shocks see illustration Ses Cush drive rubbers dampen out transmission shocks D Degree disc Calibrated disc for measuring piston position Expressed in degrees Dial gauge Clock type gauge with adapters for measuring runout and piston position Expressed in mm or inches Diaphragm The rubber membrane in a master cylinder or carburettor which seals the upper chamber Diaphragm spring A single sprung plate often used in ciutches Direct current dc Current produced by a dc generator Decarbonisation The process of removing carbon deposits typically from the combustion chamber valves and exhaust port system Detonation Destructive and damaging explosion of fuel air mixture in combustion chamber instead of controlled burning Diode An electrical valve which only allows current to flow in one direction Commonly used in rectifiers and starter interlock systems Disc valve or rotary valve A induction system used on some two stroke engines Double overhead camshaft DOHC An engine that uses two overhead camshafts one for the intake v
74. op end components will be required 8 Low compression pressure may be due to worn cylinder bores pistons or rings failure of the cylinder head gasket worn valve seals or poor vaive seating 9 To distinguish between cylinder piston wear and valve leakage pour a small quantity of oil into the bore to temporarily seal the piston rings then repeat the compression tests see illustration 3 if the readings show a noticeable increase in pressure this confirms that the cylinder bore piston or rings are worn If however no change is indicated the cylinder head gasket or valves should be examined ee Bores can be temporarily sealed with a squirt of motor oil 10 High compression pressure indicates excessive carbon build up in the combustion chamber and on the piston crown If this is the case the cylinder head should be removed and the deposits removed Note that excessive carbon build up is less likely with the used on modern fuels Checking battery open circuit voltage A never smoke or create any sparks in the vicinity of the battery Never allow the electrolyte to contact your skin or clothing if it does wash it off and seek immediate medical attention Before any electrical fault is investigated the battery should be checked You ll need a dc voltmeter or multimeter to check battery voltage Check that the leads are inserted in the correct terminals on the meter red lead to positive ve black lead
75. printing Test standards are becoming increasingly stringent although there are some exemptions for older vehicles More information about the MOT test can be obtained from the HMSO publications How Safe is your Motorcycle and The MOT Inspection Manual for Motorcycle Testing Many of the checks require that one of the wheels is raised off the ground If the motorcycle doesn t have a centre stand note that an auxiliary stand will be required Additionally the help of an assistant may prove useful Certain exceptions apply to machines under 50 cc machines without a lighting System and Classic bikes if in doubt about any of the requirements listed below seek confirmation from an MOT tester prior to Submitting the motorcycle for the test Check that the frame number is clearly visible If a component is in e borderline condition the HINT tester nas discretion in deciding whether to pass or fail it If the motorcycle presented is clean and evidently well cared for the tester may be more inclined to pass a borderline component than if the motorcycle is scruffy and apparently neglected Lights turn signals horn and reflector v With the ignition on check the operation of the following electrical components Note The electrical components on certain small capacity machines are powered by the generator requiring that the engine is run for this check a Headlight and tail light Check that both illumin
76. pter 6 Brake caliper piston seized in bore Caused by wear or ingestion of dirt past deteriorated seal Chapter 6 Brake pad damaged Pad material separated from backing plate Usually caused by faulty manufacturing process or from contact with chemicals Replace pads Chapter 6 O Pads improperly installed Chapter 6 nere20 Fault Finding 14 Electrical problems Battery dead or weak C Battery faulty Caused by sulphated plates which are shorted Wiring faulty Wiring grounded earthed or connections loose in through sedimentation Also broken battery terminal making only occasional contact Chapter 8 other electrical accessories Regulator rectifier defective Chapter 8 OO 0 UD Battery cables making poor contact Chapter 1 Load excessive Caused by addition of high wattage lights or Ignition main switch defective Switch either grounds earths Cl internally or fails to shut off system Replace the switch Chapter 8 7 Alternator stator coil open or shorted Chapter 8 ignition charging or lighting circuits Chapter 8 Battery overcharged Ci Regulator rectifier defective Overcharging is noticed when battery gets excessively warm Chapter 8 Battery defective Replace battery with a new one Chapter 8 Battery amperage too low wrong type or size Install manufacturer s specified amp hour battery to handle charging load Chapter 8 Fault Finding Equipment Checking
77. r Trail A feature of steering geometry Distance from the steering head axis to the tyre s central contact point Triple clamps The cast components which extend from the steering head and support the fork stanchions or tubes Often called fork yokes Turbocharger A centrifugal device driven by exhaust gases that pressurises the intake air Normally used to increase the power output from a given engine displacement TWI Abbreviation for Tyre Wear Indicator Indicates the location of the tread depth indicator bars on tyres U Universal joint or U joint UJ A double pivoted connection for transmitting power from a driving to a driven shaft through an angle Typically found in shaft drive assemblies Unsprung weight Anything not supported by the bike s suspension ie the wheel tyres brakes final drive and bottom moving part of the suspension V Vacuum gauges Clock type gauges for measuring intake tract vacuum Used for carburettor synchronisation on multi cylinder engines Vaive A device through which the flow of liquid gas or vacuum may be stopped started or regulated by a moveable part that opens shuts or partially obstructs one or more ports or passageways The intake and exhaust valves in the cylinder head are of the poppet type Valve clearance The clearance between the valve tip the end of the valve stem and the rocker arm or tappet follower The valve clearance is measured when the valve is closed The
78. r 4 Ignition HT coils defective Chapter 4 Fuel air mixture incorrect LJEI Be Bl Dp rn o Air bleed holes clogged Remove carburettor and blow out all passages Chapter 3 Air filter clogged poorly sealed or missing Chapter 1 Air filter housing poorly sealed Look for cracks holes or loose clamps and replace or repair defective parts Chapter 3 Fuel level too high or too low Check the float height Chapter 3 Carburettor intake manifolds loose Check for cracks breaks tears or loose clamps Replace the rubber intake manifold joints if split or perished Chapter 3 Jet needle incorrectly positioned or wom Check and adjust or replace Chapter 3 Main jet clogged Dirt water or other contaminants can clog the main jets Clean the fuel tap filter the in line filter the float chamber area and the jets and carburettor orifices Chapter 3 Main jet wrong size The standard jetting is for sea level atmospheric pressure and oxygen content Check jet size Chapter 3 Throttle shaft to carburettor body clearance excessive Overhaul carburettors replacing wor parts or complete carburettor if necessary Chapter 3 Compression low m o Spark plugs loose Remove the plugs and inspect their threads Reinstall and tighten to the specified torque Chapter 1 Cylinder head not sufficiently tightened down If the cylinder head is suspected of being loose then there s a chance that the gasket or head is damaged if
79. r damaged Inspect wheels for runout Chapter 6 Handlebar pulls to one side 7 Frame bent Definitely suspect this if the machine has been dropped May or may not be accompanied by cracking near the bend Replace the frame Chapter 5 t Wheels out of alignment Caused by improper location of axle spacers or from bent steering stem or frame Chapter 5 Swingarm bent or twisted Caused by age metal fatigue or impact damage Replace the arm Chapter 5 J Steering stem bent Caused by impact damage or by dropping the motorcycle Replace the steering stem Chapter 5 Fork tube bent Disassemble the forks and replace the damaged parts Chapter 5 L1 Fork oil level uneven Check and add or drain as necessary Chapter 5 Poor shock absorbing qualities Too hard a Fork oil level excessive Chapter 5 b Fork oil viscosity too high Use a lighter oil see the Specifications in Chapter 5 c Fork tube bent Causes a harsh sticking feeling Chapter 5 d Shock shaft or body bent or damaged Chapter 5 e Fork internal damage Chapter 5 f Shock internal damage g Tire pressure too high Chapter 1 C Too soft a Fork or shock oil insufficient and or leaking Chapter 5 b Fork oil level too low Chapter 5 c Fork oil viscosity too light Chapter 5 d Fork springs weak or broken Chapter 5 e Shock internal damage or leakage Chapter 5 a aana Brakes are spongy don t hold Air in brake lin
80. r worn clutch components Overhaul clutch Chapter 2 Timing not advancing Ignition control unit faulty Chapter 4 Engine oil viscosity too high Using a heavier oi than the one recommended in Chapter 1 can damage the oil pump or lubrication system and cause drag on the engine Brakes dragging Usually caused by debris which has entered the brake piston seals or from a warped disc or bent axle Repair as necessary nereie Fault Finding 4 Overheating Firing incorrect LJ Spark plugs fouled defective or worn out Chapter 1 CJ Incorrect spark plugs Chapter 1 3 Faulty ignition HT coils Chapter 4 Fuel air mixture incorrect L Main jet clogged Dirt water and other contaminants can clog the main jets Clean the fuel tap filter the fuel pump in line filter the float chamber area and the jets and carburettor orifices Chapter 3 C Main jet wrong size The standard jetting is for sea level atmospheric pressure and oxygen content Check jet size Chapter 3 Air filter clogged poorly sealed or missing Chapter 1 Air filter housing poorly sealed Look for cracks holes or loose clamps and replace or repair Chapter 3 Fuel level too low Check float height Chapter 3 Carburettor intake manifolds loose Check for cracks breaks tears or loose clamps Replace the rubber intake manifold joints if split or perished Chapter 3 Compression too high J Carbon build up in combustion chamber Use of a fuel
81. recent years many non wax polishes that contain a wide variety of chemicals such as polymers and silicones have been introduced These non wax polishes are usually easier to apply and last longer than conventional waxes and polishes reFee MOT Test Checks About the MOT Test in the UK all vehicles more than three years old are subject to an annual test to ensure that they meet minimum safety requirements A current test certificate must be issued before a machine can be used on public roads and is required before a road fund licence can be issued Riding without a current test certificate will also invalidate your insurance For most owners the MOT test is an annual cause for anxiety and this is largely due to owners not being sure what needs to be checked prior to submitting the motorcycle for testing The simple answer is that a fully roadworthy motorcycle will have no difficulty in passing the test This is a guide to getting your motorcycle through the MOT test Obviously it will not be possible to examine the motorcycle to the same standard as the professional MOT Electrical System tester particularly in view of the equipment required for some of the checks However working through the following procedures will enable you to identify any problem areas before submitting the motorcycle for the test It has only been possible to summarise the test requirements here based on the regulations in force at the time of
82. restricted on certain single shock models due to the location of the shock absorber v With the rear wheel raised off the ground grasp the wheel at the highest point Worn suspension linkage pivots arrows are usually the cause of play in the rear suspension and attempt to pull it up see illustration 8 Any play in the swingarm pivot or suspension linkage bearings will be felt as movement Note Do not confuse play with actual suspension movement Failure to lubricate suspension linkage bearings can lead to bearing failure see illustration 9 Brakes Wheels and Tyres Grasp the swingarm at the ends to check for play in its pivot bearings V With the rear wheel raised off the ground grasp the swingarm ends and attempt to move the swingarm from side to side and forwards and backwards any play indicates wear of the swingarm pivot bearings see illustration 10 Brakes v With the wheel raised off the ground apply the brake then free it off and check that the wheel is about to revolve freely without brake drag v On disc brakes examine the disc itself Check that it is securely mounted and not cracked On disc brakes view the pad material through the caliper mouth and check that the pads are not worn down beyond the limit see illustration 11 WY On drum brakes check that when the brake is applied the angle between the operating lever and cable or rod is not too great see illustration 12 Chec
83. rt components as they can easily mark the gasket sealing surfaces of the parts which must remain smooth If prying is absolutely necessary use a piece of wood but keep in mind that extra clean up will be necessary if the wood splinters After the parts are separated the old gasket must be carefully scraped off and the gasket surfaces cleaned Stubborn gasket material can be soaked with a gasket remover available in aerosol cans to soften it so it can be easily scraped off A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end Copper is recommended because it is usually softer than the surfaces to be scraped which reduces the chance of gouging the part Some gaskets can be removed with a wire brush but regardless of the method used the mating surfaces must be left clean and smooth If for some reason the gasket surface is gouged then a gasket sealant thick enough to fill scratches will have to be used during reassembly of the components For most applications a non drying or semi drying gasket sealant is best Hose removal tips Hose removal precautions closely parallel gasket removal precautions Avoid scratching or gouging the surface that the hose mates against or the connection may leak Because of various chemical reactions the rubber in hoses can bond itself to the metal union that the hose fits over To remove a hose first loosen the hose clamps that secure it to the union T
84. ry black sooty deposits leading to misfire and weak spark Caused by an over rich fuel air mixture faulty choke operation or blocked air filter Overheating A blistered white insulator and glazec electrodes Caused by ignition system fault incorrect fuel or cooling system fault Electrode gap adjustment bend the side electrode using the correct tool PES t Ash deposits Light brown deposits encrusted on the electrodes and insulator leading to misfire and hesitation Caused by excessive amounts of oil in the combustion chamber or poor quality tuel oil Oil fouling Wet oily deposits leading to mistire and weak spark Caused by oil leakage past piston rings or valve guides A stroke engine or excess lubricant 2 stroke engine Worn plug Worn electrodes will cause poor starting in damp or cold weather and will also waste fuel GS500EK 48 cc 1989 GSSODEL A487 cc 1990 GS500EM 487cc 1991 GS500EN 487cc 1992 GS500EP 487cc 1993 GS500ER 487cc 1994 GS500ES 487cc 1995 GS500ET 487cc 1996 GS500EV 487cc 1997 ore 9600 Mlee 12 003 kr orc 2 runths P m wv ep clearly Inkes to 1ncreds at chotes 7 f 231 ard llustratizns acide you through Wd AS each job cy experience level 3 3 ing jobs for beg rrers trough to more diff cull tes s for lhe expert ard give you valuable inside riforma or guch as ways Ol removing carts without using special tao s Suzuki history and GS
85. ry fails to hold a charge it must be renewed Starting procedure if a kickstart is fitted turn the engine over a couple of times with the ignition OFF to distribute oil around the engine If no kickstart is fitted flick the engine kill switch OFF and the ignition ON and crank the engine over a couple of times to work oil around the upper cylinder components If the nature of the ignition system is such that the starter won t work with the kill switch OFF remove the spark plugs fit them back into their caps and earth ground their bodies on the cylinder head Reinstall the spark plugs afterwards Switch the kill switch to RUN operate the choke and start the engine If the engine won t start don t continue cranking the engine not only will this flatten the battery but the starter motor will overheat Switch the ignition off and try again later If the engine refuses to start go through the fault finding procedures in this manual Note f the bike has been in storage for a long time old fuel or a carburettor blockage may be the problem Gum deposits in carburettors can block jets if a carburettor cleaner doesn t prove successful the carburettors must be dismantled for cleaning Once the engine has started check that the lights turn signals and horn work properly Treat the bike gently for the first ride and check all fluid levels on completion Settle the bike back into the maintenance schedule rere12 Fau
86. s 3e1 synchronisation 1 18 Chain cam 2 2 2 11 Chain drive check 0911 cleaning and lubrication 195 freeplay check and adjustment 1 12 guard 793 removal cleaning and installation 5 16 sprockets 5 16 wear and stretch check 1 13 Charging system alternator 8 21 regulator rectifier 8 23 specifications 8 1 tests 8 20 8 23 Chemicals REF 5 Choke cable check and adjustment 19 17 removal and installation 3 13 reFe30 Index Clutch check 1 12 removal inspection and overhaul 2 25 specifications 2e4 switch 8 16 Clutch cable adjustment 1912 removal and installation 2 32 Compression check engine 1 20 REF 20 Connecting rods 2 3 2 56 Control unit ignition 4 4 Conversion factors REF 28 Crankcase inspection and servicing 2 41 separation and reassembly 2 39 Crankshaft removal and main bearings 2 51 specifications 2e3 Cush drive 5 17 Cylinder block 2 2 2 20 Cylinder head disassembly inspection and reassembly 2 17 nut tightness check 1 6 removal and installation 2 15 specifications 292 valve overhaul 2 17 D Dimensions REF 1 Diode 8 16 Disc brake front 6 5 rear 6 10 Drive chain check 0e11 cleaning and lubrication 1e5 freeplay check and adjustment 1 12 guard 7 3 removal cleaning and installation 5 16 sprockets 5 16 wear and stretch check 1 13 E Electrical system alternator
87. s whereas combination switches like the ignition switch have many internal links Study the wiring diagram to ensure that you are connecting across the correct pair of wires Continuity low or no measurable resistance 0 ohms should be indicated with the switch ON and no continuity high resistance with it OFF 3 Note that the polarity of the test probes doesn t matter for continuity checks although care should be taken to follow specific test procedures if a diode or solid state component is being checked 4 A continuity tester or battery and bulb circuit can be used in the same way Connect its probes as described above see illustration 10 The light should come on to indicate continuity in the ON switch position but should extinguish in the OFF position Continuity check of rear brake light switch using a continuity tester Wiring checks Many electrical faults are caused by damaged wiring often due to incorrect routing or chaffing on frame components Loose wet or corroded wire connectors can also be the cause of electrical problems especially in exposed locations 1 A continuity check can be made on a single length of wire by disconnecting it at each end and connecting a meter or continuity tester across both ends of the wire see illustration 11 switch sub harness 2 Continuity low or no resistance 0 ohms should be indicated if the wire is good If no continuity high resistance is show
88. starter motor for a couple of revolutions until the gauge reading stabilises If the starter will not operate with the kill switch OFF turn the ignition switch OFF and refer to the next paragraph 5 install the spark plugs back into their suppressor caps and arrange the plug electrodes so that their metal bodies are earthed grounded against the cylinder head this is essential to prevent damage to the ignition system as the engine is spun over see illustration 2 Position the plugs well away from the plug holes otherwise there is a risk of atomised fuel escaping from the combustion chambers and igniting As a safety precaution cover the top of the valve cover with rag Now turn the ignition switch ON and kill switch ON open the throttle fully and crank the engine over on the starter motor for a couple of revolutions until the gauge reading stabilises All spark plugs must be earthed grounded against the cylinder head 6 After one or two revolutions the pressure should build up to a maximum figure and then stabilise Take a note of this reading and on multi cylinder engines repeat the test on the remaining cylinders 7 The correct pressures are given in Chapter 2 Specifications If the results fall within the specified range and on multi cylinder engines all are relatively equal the engine is in good condition If there is a marked difference between the readings or if the readings are lower than specified inspection of the t
89. steners from a component keep track of their locations Sometimes threading a bolt back in a part or putting the washers and nut back on a stud can prevent mix ups later If nuts and bolts can t be returned to their original locations they should be kept in a compartmented box or a series of small boxes or labelled plastic bags A box of this type is especially helpful when working on assemblies with very small parts such as the carburettors tappets shims etc Whenever wiring looms harnesses or connectors are separated it s a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected Gasket sealing surfaces Gaskets are used to seal the mating surfaces between components and keep lubricants fluids vacuum or pressure contained in an assembly Many times these gaskets are coated with a liquid or paste type gasket sealing compound before assembly Age heat and pressure can sometimes cause the two parts to stick together so tightly that they are very difficult to separate In most cases the part can be loosened by striking it with a soft faced hammer near the mating surfaces A normal hammer can be used if a block of wood is placed between the hammer and the part Do not hammer on cast parts or parts that could be easily damaged With any particularly stubborn part always recheck to make sure that every fastener has been removed Avoid using a screwdriver or bar to pry apa
90. the air filter element Chapter 1 2 Poor running at low speeds weak CL Improper valve clearance This means that the valve is not closing Battery voltage low Check and recharge battery Chapter 8 completely and compression pressure is leaking past the valve Spark plugs fouled defective or worn out Chapter 1 Check and adjust the valve clearances Chapter 1 Spark plug cap or HT wiring defective Chapters 1 and 4 O Cylinder and or piston worn Excessive wear will cause C Spark plug caps not making contact Make sure they are properly compression pressure to leak past the rings This is usually connected accompanied by worn rings as well A top end overhaul is Incorrect spark plugs Wrong type heat range or cap necessary Chapter 2 gt M CEU recite Cena plugs Chapter 1 O Piston rings worn weak broken or sticking Broken or sticking Pulse generator coils defective Chapter 4 piston rings usually indicate a lubrication or carburation problem Ignition HT coils defective Chapter 4 that causes excess carbon deposits or seizures to form on the pistons and rings Top end overhaul is necessary Chapter 2 F uel air mixture incorrect Piston ring to groove clearance excessive This is caused by Pilot screws out of adjustment Chapter 3 excessive wear of the piston ring lands Piston replacement is Pilot jet or air passage clogged Remove and overhaul the necessary Chapter 2 carburettors Chapter 3 in t een 1 Air bleed
91. the buming of excess fuel present in the exhaust gases by routing fresh air into the exhaust ports Q Quartz halogen bulb Tungsten filament surrounded by a halogen gas Typically used for the headlight see illustration Filaments Dip shield e Quartz envelope __ Quartz halogen headlight bulb construction R Rack and pinion A pinion gear on the end of a shaft that mates with a rack think of a geared wheel opened up and laid flat Sometimes used in clutch operating systems Radial play Up and down movement about a shaft Radial ply tyres Tyre plies run across the tyre from bead to bead and around the circumference of the tyre Less resistant to tread distortion than other tyre types Radiator A liquid to air heat transfer device designed to reduce the temperature of the coolant in a liquid cooled engine Rake A feature of steering geometry the angle of the steering head in relation to the vertical see illustration Steering geometry Rebore Providing a new working surface to the cylinder bore by boring out the old surface Necessitates the use of oversize piston and rings Rebound damping A means of controlling the oscillation of a suspension unit spring after it has been compressed Resists the spring s natural tendency to bounce back after being compressed Rectifier Device for converting the ac output of an altemator into dc for battery charging Reed valve An induc
92. the problem has persisted for any length of time The head bolts should be tightened to the proper torque in the correct sequence Chapter 2 Improper valve clearance This means that the valve is not closing completely and compression pressure is leaking past the valve Check and adjust the valve clearances Chapter 1 Cylinder and or piston worn Excessive wear will cause compression pressure to leak past the rings This is usually accompanied by worn rings as well A top end overhaul is necessary Chapter 2 Piston rings worn weak broken or sticking Broken or sticking piston rings usually indicate a lubrication or carburation problem that causes excess carbon deposits or seizures to form on the pistons and rings Top end overhaul is necessary Chapter 2 t o Piston ring to groove clearance excessive This is caused by excessive wear of the piston ring lands Piston replacement is necessary Chapter 2 Cylinder head gasket damaged If the head is allowed to become loose or if excessive carbon build up on the piston crown and combustion chamber causes extremely high compression the head gasket may leak Retorquing the head is not always sufficient to restore the seal so gasket replacement is necessary Chapter 2 Cylinder head warped This is caused by overheating or improperly tightened head bolts Machine shop resurfacing or head replacement is necessary Chapter 2 Valve spring broken or weak Caused by component fail
93. tion system commonly used on two stroke engines Regulator Device for maintaining the charging voltage from the generator or alternator within a specified range Relay A electrical device used to switch heavy current on and off by using a low current auxiliary circuit Resistance Measured in ohms An electrical component s ability to pass electrical current RON Research Octane Number A measure of a fuel s resistance to knock rpm revolutions per minute Runout The amount of wobble in and out movement of a wheel or shaft as it s rotated The amount a shaft rotates out of true The out of round condition of a rotating part S SAE Society of Automotive Engineers A standard for the viscosity of a fluid Sealant A liquid or paste used to prevent leakage at a joint Sometimes used in conjunction with a gasket Service limit Term for the point where a component is no longer useable and must be renewed Shaft drive A method of transmitting drive from the transmission to the rear wheel Shell bearings Plain bearings consisting of two shell halves Most often used as big end and main bearings in a four stroke engine Often called bearing inserts Shim Thin spacer commonly used to adjust the clearance or relative positions between two parts For example shims inserted into or under tappets or followers to control valve clearances Clearance is adjusted by changing the thickness of the shim Short circuit An electri
94. tion used to locate a gear to a shaft Often used to locate the alternator rotor on the crankshaft Wrist pin Another name for gudgeon or piston pin Rer Conversion Factors Length distance Inches in Feet ft Miles Volume capacity Cubic inches cu in in Imperial pints Imp pt Imperial quarts Imp at Imperial quarts Imp qt US quarts US qt Imperial gallons Imp gal Imperial gallons Imp gal US gallons US gal Mass weight Ounces oz Pounds Ib Force Ounces force ozf oz Pounds force Ibf Ib Newtons N Pressure Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibf in Ib in Pounds force per square inch psi Ibt in b in Pounds force per square inch psi Ibf in Ib in Kilopascals kPa Millibar mbar Millibar mbar Millibar mbar Millibar mbar Millimetres of mercury mmHg Inches of water inH O x25 4 x 0 305 x 1 609 x X OX OX X X xx x x X x x x on y 16 387 0 568 1 137 1 201 0 946 4 546 1 201 3 785 Hou H MW HW HOH 28 35 0 454 ou 0 278 4 448 0 1 uon H 0 070 0 068 0 069 6 895 0 01 100 0 0145 0 75 0 401 0 535 0 036 Torque moment of force Pounds force inches Ibf in Ib in Pounds force inches Ibf in Ib in Pounds force inches lbf in Ib in Pounds force feet Ibf ft Ib ft Pounds force feet Ibf ft Ib ft
95. to side whilst observing the test light or meter When the test light comes on buzzer sounds or meter shows voltage you have found the cause of the short It will usually shown up as damaged or burned insulation 4 Note that the same test can be performed on each component in the circuit even the Switch ner24 Technical Terms Explained A ABS Anti lock braking system A system usually electronically controlled that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheel which is about to skid Aftermarket Components suitable for the motorcycle but not produced by the motorcycle manufacturer Allen key A hexagonal wrench which fits into a recessed hexagonal hole Alternating current ac Current produced by an alternator Requires converting to direct current by a rectifier for charging purposes Alternator Converts mechanical energy from the engine into electrical energy to charge the battery and power the electrical system Ampere amp A unit of measurement for the flow of electrical current Current Volts Ohms Ampere hour Ah Measure of battery capacity Angle tightening A torque expressed in degrees Often follows a conventional tightening torque for cylinder head or main bearing fasteners see illustration bo caa ps D Angie tightening cylinder head bolts Antifreeze A substance usually ethylene glycol mixed with water and added to the cooling system to prevent fre
96. trument bulbs 8 92 8 11 check and replacement 8 11 drive cables 8 9 L Legal checks 0 12 Lubricants general REF 5 recommended 1 2 Lubrication engine transmission 0 10 1 2 1 10 drive chain 1 5 stands levers pivots and cables 1 19 Main and connecting rod bearings 2 51 Main fuel cock 394 Maintenance schedule 1 3 Maintenance techniques REFe4 Master cylinder front 6 6 rear 6 11 Mirrors 7 1 MOT test checks REF 6 Mudguard front 7 2 Neutral light bulb switch 8 2 8 11 8 14 O Oil engine transmission change 1910 filter 1 10 level 0 10 type viscosity and capacity 1 2 Oil fork change 1 20 type viscosity and capacity 1 2 5 1 Oil pan sump 2 37 Oil pressure check 1 21 Oil pressure regulator 2 37 Oil pressure switch 8 12 Oil pump 2 33 Oil strainer 2 37 P Pads brake 1 13 6 2 6 7 Piston rings 2 3 2 24 Pistons 2 3 2 22 Plug gap and type 1 1 Pre ride checks 0 10 Pulse generator coils 4 1 4 3 R Rear brake caliper 6 9 checks 1 14 disc 6 10 fluid level check 0 11 master cylinder 6 11 pad check 1 13 pad replacement 6 7 Rear suspension checks 1 16 bearing lubrication 1921 linkage 5012 shock absorber 5 12 specifications 5 1 Rear view mirrors 7 1 Rear wheel bearings 1 19 6 16 coupling rubber dampers 5 17 removal and installation 6 15 REFe32 Index
97. type Oil is rated not only according to viscosity but also according to type Some oils are not rated high enough for use in this engine Check the Specifications section and change to the correct oil Chapter 1 t Wor oil pump or clogged oil passages Check oil pump and clean passages Chapter 2 Miscellaneous causes Engine cooling fins clogged with debris L Modification to exhaust system Most aftermarket exhaust Systems cause the engine to run leaner which make them run hotter When installing an accessory exhaust system always rejet the carburettors Clutch slipping Cable freeplay insufficient Check and adjust cable Chapter 1 L Friction plates worn or warped Overhaul the clutch assembly Chapter 2 C Plain plates warped Chapter 2 Clutch springs broken or weak Old or heat damaged from slipping clutch springs should be replaced with new ones Chapter 2 O Clutch release mechanism defective Replace any defective parts Chapter 2 O Clutch centre or housing unevenly worn This causes improper engagement of the plates Replace the damaged or worn parts Chapter 2 Clutch not disengaging completely Cable freeplay excessive Check and adjust cable Chapter 1 Clutch plates warped or damaged This will cause clutch drag which in turn will cause the machine to creep Overhaul the clutch assembly Chapter 2 Clutch spring tension uneven Usually caused by a sagged or broken spri
98. ure or wear the springs must be replaced Chapter 2 Valve not seating properly This is caused by a bent valve from over revving or improper valve adjustment burned valve or seat improper carburation or an accumulation of carbon deposits on the seat from carburation or lubrication problems The valves must be cleaned and or replaced and the seats serviced if possible Chapter 2 Knocking or pinging a Carbon build up in combustion chamber Use of a fuel additive that will dissolve the adhesive bonding the carbon particles to the crown and chamber is the easiest way to remove the build up Otherwise the cylinder head will have to be removed and decarbonized Chapter 2 Incorrect or poor quality fuel Old or improper grades of fuel can cause detonation This causes the piston to rattle thus the knocking or pinging sound Drain old fuel and always use the recommended fuel grade Chapter 3 Spark plug heat range incorrect Uncontrolled detonation indicates the plug heat range is too hot The plug in effect becomes a glow plug raising cylinder temperatures Install the proper heat range plug Chapter 1 Improper air fuel mixture This will cause the cylinder to run hot which leads to detonation Clogged jets or an air leak can cause this imbalance Chapter 3 Miscellaneous causes o au go n Throttle valve doesn t open fully Adjust the throttle grip freeplay Chapter 1 Clutch slipping May be caused by loose o
99. wheel mounted on a surface plate for steering head bearing lower race check Hold the front brake on and pump the front forks up and down to check operation Checking the steering head bearings for freeplay d P Inspect the area around the fork dust seal for oil leakage arrow Front suspension v With the motorcycle off the stand hold the front brake on and pump the front forks up and down see illustration 5 Check that they are adequately damped v Inspect the area above and around the front fork oil seals see illustration 6 There should be no sign of oil on the fork tube stanchion nor leaking down the slider lower leg On models so equipped check that there is no oil leaking from the anti dive units v On models with swingarm front suspension check that there is no freeplay in the linkage when moved from side to side Rear suspension v With the motorcycle off the stand and an assistant supporting the motorcycle by its handlebars bounce the rear suspension see illustration 7 Check that the suspension components do not foul on any of the cycle parts and check that the shock absorber s provide adequate damping Bounce the rear of the motorcycle to check rear suspension operation reres MOT Test Checks Checking for rear suspension linkage play v Visually inspect the shock absorber s and check that there is no sign of oil leakage from its damper This is somewhat

GS500E SERVICE MANUAL

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