1985-1986 Suzuki GV1200GL, Madura 1200 Service Manual
Diagnostic procedures and component service for the SUZUKI GV1200GL and Madura 1200. Documents paper handling and control panel diagnostics. Part Number 99500-39041-03E
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Yamaha Models Covered & Key Technical Specifications
Models: Suzuki GV1200GL / Madura 1200
Sub-models / Variants: 1985–1986
Trade Names: Madura 1200
Build Years: 1985–1986
Serial Numbers: V705–100034 (Engine Serial Number)
Technical Data:
- Engine type: Four-stroke, water-cooled, DOHC, TSCC, 82-degree V-four
- Displacement: 1165 cc (71.1 cu. in)
- Compression ratio: 10.5:1
- Transmission: 6-speed constant mesh
- Drive system: Shaft drive
- Fuel system: Mikuni BDS36SS carburetor x4
- Ignition type: Transistorized
- Spark plug: NGK D8EA or NIPPON DENSO X24ES-U
- Battery: 12V 50.4 kC (14 Ah) / 10 HR
- Fuel capacity: 13.0 liters (3.4 US gal)
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Suzuki GV1200GL Madura 1200: Technical Documentation
- Covers 1985–1986 Suzuki GV1200GL Madura 1200, including diagnostic and service procedures for the water-cooled V-4 TSCC engine
- Official Suzuki publication P/N 99500-39041-03E, published October 1990
- Documents 29 chassis bolt and nut torque specifications, engine disassembly sequences, and clutch fluid bleeding methods
- Files include technical diagrams for engine, chassis, and cooling system maintenance
- Delivered as a direct download the moment payment clears
- Indexed PDF search covers every chapter and appendix
- This official service manual is the definitive reference for the Madura 1200 powertrain and chassis service
Engine and Chassis Walkthrough
This factory service publication covers the 1985–1986 Suzuki GV1200GL. The text provides technical descriptions for the V-4 engine, TSCC combustion chamber, liquid-cooling system, and the 6-speed shaft-drive assembly. Major chapters document engine removal, top-end disassembly, crankcase splitting, and transmission gear inspection, along with periodic maintenance schedules for critical wear components and fluids.
Specification Highlights
Engine overhaul requires precise data, such as crankshaft journal oil clearance values documented at 0.020–0.044 mm. Piston-to-cylinder clearance must be kept within the 0.120 mm service limit. Intake valve stem diameter is specified as 5.465–5.480 mm for standard fitment. Spark plug gap is set to 0.6–0.7 mm for optimal ignition performance.
Crankcase bolt tightening follows a specified sequence, with final torque for 10-mm bolts documented at 45–55 Nm (32.5–40.0 lb-ft). Brake fluid level service requires understanding factory maintenance documentation for DOT3 or DOT4 compatibility. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This official 1985–1986 Suzuki GV1200GL Madura 1200 service manual details engine, chassis, electrical, and fuel-injection specifications for the full 1985–1986 model-year range.
Document Reference: Suzuki Motor Corporation, 99500-39041-03E, October 1990
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