Suzuki · Suzuki GS air-cooled four (GS400-GS1100 1976-1988)

RE5 (rotary)

Library entry covers 1974-1976

43 factory 39 guideline

Published source

Suzuki RE5A (1976) Owner's Manual, Suzuki part 99011-73601

Factory owner's handbook. Covers 1976 (RE5A).

Open the source

82 items for a 1974 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: None (two-stroke porting)
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1974 Suzuki RE5 (rotary)

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Wash and lubricate drive chain. Factory: Periodic inspection chart p.35: every 300 miles (500 km)

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 2,000 mi

3 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Adjust final drive chain. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Check coolant level

Pre-ride / on the road

Factory

Manual: Inspect coolant level. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Check lights, horn, brake light switches

Pre-ride / on the road

Factory

Manual: Inspect lamps and switches; inspect horn. Factory: Periodic inspection chart p.35: every 2,000 mi (3,000 km)

On the road: every 4,000 mi

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Retighten bolts and nuts. Factory: Periodic inspection chart p.35: initial 750 mi, then every 4,000 mi

Every 1,500 mi or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 2,000 mi or 12 months

1 item

Grease swingarm pivot

Rear suspension and frame

Guideline

Every 2,000 mi

21 items

Adjust engine idle speed

Engine

Factory

Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Change engine oil

Engine

Factory

Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Check tell-tale hole for leakage

Engine

Factory

Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Inspect tachometer and speedometer

Engine

Factory

Factory: Periodic inspection chart p.35: every 2,000 mi (3,000 km)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Clean spark plug; adjust spark plug gap. Factory: Periodic inspection chart p.34: every 2,000 mi (3,000 km)
Clean / inspect air filter

Fuel and air

Factory

Manual: Wash air cleaner element. Factory: Periodic inspection chart p.34: every 2,000 mi (3,000 km)
Check / set ignition timing

Ignition and electrics

Factory

Manual: Check and adjust ignition timing. Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Service battery. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Grease contact breaker shaft

Ignition and electrics

Factory

Factory: Periodic inspection chart p.34: every 2,000 mi (3,000 km)
Lubricate and check automatic advance unit

Ignition and electrics

Factory

Manual: Check ignition timing advance. Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Adjust clutch. Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Change gearbox oil

Primary and gearbox

Factory

Manual: Change transmission oil. Factory: Periodic inspection chart p.34: initial 750 mi, then every 2,000 mi
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Check final driven sprocket wear. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Adjust rear drum brake and rod / cable linkage

Brakes

Factory

Manual: Adjust rear brake pedal. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Check brake pads and discs

Brakes

Factory

Manual: Inspect front brake pads. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Inspect brake fluid level; check brake fluid leakage

Brakes

Factory

Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Inspect rear brake linkage

Brakes

Factory

Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Replace brake linings / skim drums (wear based)

Brakes

Factory

Manual: Check rear brake shoe wear. Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Adjust wheel alignment

Wheels and tires

Factory

Factory: Periodic inspection chart p.35: initial 750 mi, then every 2,000 mi
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Check tire air pressure and tread wear. Factory: Periodic inspection chart p.35: every 2,000 mi (3,000 km)
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Lubricate throttle and clutch cables. Factory: Periodic inspection chart p.34 and lubrication chart p.61: every 2,000 mi

Every 3,000 mi or 12 months

12 items

Check engine mounting bolts and plates

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi

10 items

Check / bleed / adjust oil injection pump cable

Engine

Factory

Manual: Adjust metering oil pump cable. Factory: Periodic inspection chart p.34: initial 750 mi, then every 4,000 mi
Clean oil strainers / mesh screens

Engine

Factory

Manual: Clean engine oil inlet strainer. Factory: Periodic inspection chart p.34: initial 750 mi, then every 4,000 mi
Grease throttle grip

Engine

Factory

Factory: Periodic inspection chart p.34: every 4,000 mi (6,000 km)
Replace oil filter

Engine

Factory

Manual: Replace engine oil filter. Factory: Periodic inspection chart p.34: initial 750 mi, then every 4,000 mi
Replace spark plugs

Engine

Factory

Manual: Replace spark plug. Factory: Periodic inspection chart p.34: every 4,000 mi (6,000 km)
Service fuel system

Fuel and air

Factory

Factory: Periodic inspection chart p.35: initial 750 mi, then every 4,000 mi
Check steering head bearing adjustment

Front end

Factory

Manual: Check steering stem play. Factory: Periodic inspection chart p.35: initial 750 mi, then every 4,000 mi
Repack / replace steering head bearings

Front end

Factory

Manual: Grease steering ball bearings. Factory: Periodic inspection chart p.35: every 4,000 mi (6,000 km)
Grease rear brake rod arm

Brakes

Factory

Factory: Periodic inspection chart p.35: every 4,000 mi (6,000 km)
Lubricate brake cam spindles, check linings and drums

Brakes

Factory

Manual: Grease rear brake cam shaft. Factory: Periodic inspection chart p.35 and lubrication chart p.61: every 4,000 mi

Every 6,000 mi or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

1 item

Check engine breather and oil return

Engine

Guideline

Every 8,000 mi

3 items

Check metering oil pump discharge amount

Engine

Factory

Factory: Periodic inspection chart p.34: every 8,000 mi (12,000 km)
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Factory

Manual: Overhaul carburetor. Factory: Periodic inspection chart p.34: every 8,000 mi (12,000 km)
Replace points and condenser

Ignition and electrics

Factory

Manual: Change contact breaker points. Factory: Periodic inspection chart p.34: every 8,000 mi (12,000 km)

Every 10,000 mi or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 20,000 mi or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

8 items

Inspect coolant hoses and clamps

Engine

Factory

Manual: Change water hoses. Factory: Periodic inspection chart p.35: every two years
Replace coolant

Engine

Factory

Manual: Change coolant. Factory: Periodic inspection chart p.35: every two years
Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Replace fuel lines

Fuel and air

Factory

Manual: Change fuel hoses. Factory: Periodic inspection chart p.35: every two years
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Change front brake rubber parts. Factory: Periodic inspection chart p.35: every two years
Replace brake fluid

Brakes

Guideline

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.