Suzuki Gs 150 Repair Manual

• Suzuki Gs 150 Parts Manual
• Suzuki Gs 150 Service Manual Pdf

View and Download Suzuki GS500/F service manual online. GS500/F Motorcycle pdf manual download.

Today i want to share recent problem which i faced when goes for Gujranwala from Lahore. When i was on the way back my bike start missing on low speed. Many times engine goes off and i have to start it. There were many thoughts in my mind, which i will share with you 1) Bike was standing outside home in heavy rain, i thought water goes in carb and that is the cause. 2) Engine oil was needed to be changes.

3) I never goes to mechanic for tuning but that time i thought may be bike need some tuning. 4) I feel throttle cable hard enough. Very next weekend i washed my bike, give lubricant to throttle cables, check and release petrol from carb, wash air filter and bring my bike on the road for try. Unfortunately problem was the same and i was worried about engine performance. Later a thought came in my mind that some time when we pull choke bike starts but for longer period it is not recommended.

Choke increases the petrol quantity and help to start bike in cold. I check choke lever and found that i was pulled somehow. Bring it back to its original position and try it again on road. Problem was just resolved. Now my bike is running fine and i am not worried.

Following are some points you must consider after buying a new bike. 1) Bring your own petrol, minimum of 1.5 litre for initial start. You may go to some petrol pump with this quantity. 2) Charge battery at showroom for at least 30 minutes. Showroom guys charge battery for only 5 to 10 minutes. You will need to charge it after some time.

3) Check engine oil gauge, battery, and engine voice once start your bike. In first try check front and rear brakes as well. 4) Check all lights and indicators. 5) Buy minimum of three duster cloths, if possible, bring them with you as showroom guys use dirty cloth for cleaning bike.

That put some scratches on body. 6) Don't forget to buy Helmet for you security. 7) Buy some good wax for paint and chrome, 'revive all' is good option for seat cover and tyres. 8) Don't wash you bike too early, instead of washing clean it on daily basis with just wet cloth. 9) Run your bike at 40 to 45 km/h till first tunning(1000 km). 10) Change engine oil after first 500 km. 11) Clean air filter as well at the same time.

12) Clean bike chain after 300 to 500, use old tooth brush to remove dust from chain. 13) Don't trust mechanics, they are not trustworthy.

Always get maintenance work in front of your eyes. 14) To safe you mud gaurds from rust, remove them from your bike and fill silicon paste in side spaces and paste silver tape(available at refrigeration shops) underneath.

Don't use so called compound from market. Compound makes mud gaurds rough, ugly looking and black. 15) Always cover your bike at parking/home with parachute cover.

It prevents your bike from dust and rain.

Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2.

Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.

Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank.

(Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted.

Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank.

(Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:.

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections.

Suzuki Gs 150 Parts Manual

The section titles are listed in the GROUP INDEX. Holding the manual as shown at the right will allow you to find the first page of the section easily. The contents are listed on the first page of each section to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40. If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart. BRAKE FLUID Specification and classification: DOT 4 A WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil.

GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.

Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator. LIQUID AMOUNT OF WATER/ENGINE COOLANT Incoming search terms:. REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect negative battery cable.

See BATTERY MAINTENANCE in Service Manual. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual. Remove primary chaincase according to the instructions in the Service Manual. See Figure 2.

Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. Remove the two T-27 TORX screws (2). Unplug the voltage regulator and remove the stator (3).

See VOLTAGE REGULATOR in Service Manual. Disassemble connector 46B (A). See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole.

Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. Pull wires through crankcase hole. INSTALLATION 1. Insert wires through crankcase hole.

See Figure 1. Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal.

Insert wires into connector 46B (A). Mate connector 46. See VOLTAGE REGULATOR in Service Manual.

Is03776 Figure 1. Voltage Regulator 5. See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). Install the rotor (1) on the sprocket shaft. Apply Loctite Threadlocker 262 (red) to sprocket nut threads.

Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). Install primary chaincase according to the instructions in the Service Manual. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual. Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual. REMOVAL Prepare for Service 1.

Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity.

Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1.

Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual.

Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual.

Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1.

O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1. Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in.

(112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase.

Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6.

Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm).

See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown.

Modify Crankcase Incoming search terms:. Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding.

(00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1.

Suzuki Gs 150 Service Manual Pdf

Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6.

Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11.

Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1.

Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced.

Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual.

Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual.

Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit.

Install the compensator bowl with the 12-point screws and lockwashers saved earlier. Install the new wheel to the rear fork.

Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location.

Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed.

Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.

(00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99.

After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:. In order to keep the proper balance on the bike lift, I would suggest that the front wheel be removed first, this is comparatively easier than the rear wheel which will be explained later.

Front wheel removal: Remove the end caps, remove the front axle “Pinch Bolt” front left fork ( item (2) in manual ) remove caliper bolts both (2) both sides (2003 model year) secure calipers, secure wheel from dropping while removing axle from left side. Remove front axle, caution: there are (2) spacers on this axle, left & right, make sure you mark them, as they are both different in shape & in length, & must be re-assembled in same order to provide proper cetrallity of the front wheel with the forks & the brake calipers.both spacers have large flanges which go towards the bearing, the right spacer has (2) flanges, the largest dia.

Goes towards the bearing. ( very important) Now comes the tough part, I had the original stock pipes, so if you have different pipes, or your bike is a different year, (2003) your choices may be different from mine. Remove OEM right side saddlebag, slack off muffler coupling brackets # 8 & # 8a which connect muffler crossover tank to top muffler, this is where the power of the allen socket wrench set will come in handy, they’re pretty tight with the heat,remove top exhaust pipe bracket bolt (item 19 in manual) the top exhaust pipe should now swing down clear of the rear axle. You may be forced to provide more room for the exit and/or re-installation of the rear wheel by removing the bolt which secures the underside mufflet tank on the lower left side of the frame, (item # 13 in manual) then the (2) bolts, ( items # 14 in manual) which will allow the rear muffler body ( lower exhaust pipe ) to be pulled over to the right to provide access for easier rear wheel entry or removal Incoming search terms:. REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. Refer to the service manual and follow the instructions given to remove the main fuse. Remove the outer fairing.

See the service manual. Remove the fairing cap. See the service manual. FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual.

If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T.

4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area.

KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).

Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splashes of DOT 4 brake fluid. Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual. NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box.

See the service manual. The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. Pull the radio or storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage.

Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly.

Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual. Remove the front brake line assembly. NOTES Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available. Remove the front brake master cylinder and clutch lever assemblies from the handlebar. Disconnect the clutch cable from the clutch lever.

See the service manual. Incoming search terms:. Removal of Original Transmission 1. Position motorcycle on a suitable lift. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury.

Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps.

Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem- bly.

Refer to the STARTER REMOVAL in the Service Manual and remove the the starter. See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt. Lift sensor from the transmission case and set aside for later re-installation. Refer to NEUTRAL SWITCH and disconnect the connectors from the neutral switch.

Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing. Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust. See the REAR WHEEL REMOVAL and loosen but, do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission. Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain, remove the oil tank and detach the vent, feed and return lines. Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover. Set the cable aside for later re-installation Incoming search terms:.