Introduction to Your Workshop Manual
This comprehensive workshop manual, published by Haynes Publishing Inc., is designed to guide owners and mechanics through the maintenance, service, and repair procedures for Suzuki GS/GSX550 4-valve Fours 572cc motorcycles produced between 1983 and 1985. It covers a wide range of models, ensuring detailed instructions for your specific motorcycle.
Models covered include:
- 1983 GS550 ED
- 1983 GS/GSX550 ESD
- 1984 GSX550 EE
- 1984 GS/GSX550 ESE
- 1984 GS550 ES3
- 1984 GSX550 EFE
- 1985 GS550 EF
- 1985 GS550 ESF
- 1983 GS550 LD
- 1985 GS550 LF
Image: Front cover of the Haynes Owner's Workshop Manual for Suzuki GS/GSX550 models. The cover features a motorcycle and the manual's title.
Safety Precautions
Always prioritize safety when working on your motorcycle. Before beginning any procedure, ensure the motorcycle is stable and cool. Disconnect the battery when working on electrical components. Use appropriate personal protective equipment (PPE) such as gloves and eye protection. Refer to the manual's dedicated safety section for comprehensive guidelines and warnings specific to various tasks.
Routine Maintenance
This section details all scheduled maintenance tasks necessary to keep your Suzuki GS/GSX550 in optimal condition. It includes step-by-step instructions for:
- Oil and filter changes
- Spark plug inspection and replacement
- Air filter cleaning and replacement
- Chain adjustment and lubrication
- Brake system inspection and fluid replacement
- Tire pressure and wear checks
- Cable lubrication and adjustment
- General fastener torque checks
Following the recommended maintenance schedule is crucial for the longevity and safe operation of your motorcycle.
Engine and Transmission Service
Detailed procedures for servicing the 572cc 4-valve engine and its transmission are provided. This includes:
- Valve clearance adjustment
- Cylinder head removal and installation
- Piston and cylinder inspection
- Crankshaft and connecting rod service
- Clutch component inspection and replacement
- Transmission disassembly, inspection, and reassembly
- Carburetor synchronization and adjustment
Each procedure is accompanied by clear illustrations and specifications to ensure accurate work.
Chassis, Suspension, and Brakes
This section covers the structural and handling components of your motorcycle, including:
- Front fork disassembly, inspection, and oil replacement
- Rear shock absorber removal and inspection
- Steering head bearing adjustment and replacement
- Wheel removal, bearing inspection, and tire replacement guidelines
- Brake caliper service, pad replacement, and bleeding procedures
- Frame inspection and component mounting
Electrical System
Understand and troubleshoot your motorcycle's electrical system with detailed diagrams and instructions for:
- Battery maintenance and charging
- Charging system (alternator/stator, rectifier/regulator) testing
- Ignition system components (coils, CDI) testing
- Lighting and signaling system diagnosis
- Wiring harness inspection and repair
- Fuse box and relay identification
Troubleshooting Common Issues
A dedicated troubleshooting guide helps diagnose common problems based on symptoms. This section provides systematic approaches to identify the root cause of issues such as:
- Engine starting difficulties
- Poor engine performance
- Brake system malfunctions
- Electrical failures
- Unusual noises or vibrations
Follow the diagnostic charts and recommended inspection steps to resolve problems efficiently.
Specifications
This manual includes comprehensive technical specifications essential for proper maintenance and repair. Key data points include:
- Engine displacement and bore/stroke
- Compression ratios
- Ignition timing and spark plug gaps
- Carburetor settings and jet sizes
- Fluid capacities and types (engine oil, fork oil, brake fluid)
- Tire sizes and recommended pressures
- Standard torque specifications for various fasteners
- Electrical component resistances and voltages
Always refer to these specifications to ensure components are within operational tolerances.
Support and Additional Resources
For further assistance or inquiries regarding this workshop manual, please contact Haynes Publishing Inc. This manual is a product of their extensive experience in automotive and motorcycle repair documentation.
Publisher: Haynes
Publication Date: November 1, 1985
Print Length: 200 pages
Language: English
ISBN-10: 1850101337
ISBN-13: 978-1850101338
While this manual provides detailed instructions, professional assistance should be sought for tasks beyond your skill level or if you are unsure about any procedure.