1985-1986 Suzuki GV1200GL, Madura 1200 Service Manual (P/N 99500-39041-03E)

• Official Suzuki publication detailing diagnostic and service procedures for the 1985–1986 GV1200GL Madura.
• Contains technical diagrams and maintenance protocols for the water-cooled V-4 TSCC engine, chassis, and cooling system.
• Lists 29 specific chassis bolt and nut torque values, alongside detailed engine disassembly sequences and clutch fluid bleeding methods.
• Includes comprehensive electrical system diagrams and fuel-injection specifications for the full model-year range.
• Document Reference: Suzuki Motor Corporation, P/N 99500-39041-03E (published October 1990).

Engine and Chassis Coverage

Workshop professionals know that tackling the Madura powertrain requires exact factory data. This publication breaks down the V-4 engine, TSCC combustion chamber, and liquid-cooling system. It also covers the 6-speed shaft-drive assembly in depth. Major chapters are dedicated to engine removal, top-end disassembly, and crankcase splitting. Need to inspect the transmission gears? The reference material outlines the contents and procedures you will find inside. It maps out periodic maintenance schedules for critical wear components and vital fluids, giving technicians the exact tolerances needed for daily shop work.

Specification Highlights

Rebuilding an engine demands absolute precision. For example, the documentation lists crankshaft journal oil clearance values at 0.020–0.044 mm. Piston-to-cylinder clearance must stay within the strict 0.120 mm service limit. It specifies the intake valve stem diameter as 5.465–5.480 mm for a standard fit, while spark plug gaps are set to 0.6–0.7 mm to ensure optimal ignition.

Crankcase bolt tightening requires a rigid sequence. The text documents the final torque for 10-mm bolts at 45–55 Nm (32.5–40.0 lb-ft). Always prioritize shop safety and consult the complete OEM documentation before starting heavy maintenance, as improper torque application or incorrect DOT3/DOT4 brake fluid handling can compromise vehicle integrity. The data provided here serves as a high-level overview of the manual contents, highlighting the technical depth available for a rebuild.