Re: Suzuki GS150R

May be the teflon sleeve disintegrated or it was not routed properly. Don't lube any cable in GS.

Like Rsk said, rust under throttle grip is a common problem. In my bro's Activa, the grip is completely jammed due to corrosion. Use a good, thick, gel-like grease (Castrol Premium Formula Gel or Mobil Delvac) once in a while. WD40 is okay but it won't stay 'in place'.

Replace both with new. Keep the old #2 cable as a spare.

In general, the clutch of a GS150R is hard wearing (+ve) and heavy (-ve). In other vehicles, clutch is much light (+ve) but plates have a shorter life (-ve). Yes, replace clutch wire but route it properly.

Common problem in all GS150Rs. Only thing we can do is to cover that part of wiring harness which rubs against the chassis with some insulation tape.

Re: Suzuki GS150R

Thanks @ashwanth.r and @rsk_kelkar for your guidance and support.

I managed to open handlebar throttle assembly, carburetor end of cables and throttle tube. It was fun and learning experience and here is what I found.

Throttle cable 1 is bit jammed within housing, cable 2 is fine and moves freely within housing.

Lot of rust in throttle tube but there is no friction in it, tube slides freely. Sprayed bit of WD40 on it before reassembling.

I think I also found the origin of problem: the housing of the wire 1 is cracked in the middle at the point where it rubs against the T bar ( not sure about the right word for it, it's where chasis no of the bike is imprinted ) below the handlebar.

So I guess I need to replace throttle wire 1 and hopefully it should be fine after that.

While I was at it I also found similar problem in clutch cable; clutch wire housing is cracked in the middle at the point where it rubs against the T bar. It might be the reason that my clutch feels bit hard, so it might also need replacement.

I see that there are lot of wires ( mostly electric ) which rub against the T bar and it's a matter of time before wear and tear of them also gets an ugly turn. Is there any preventive maintenance for it.

Re: Suzuki GS150R

Thanks for the suggestion. Sure would check it out and post it here.

Re: Suzuki GS150R

This sounds more like the throttle itself is jammed not the cable. Try oiling the throttle or remove it from handle bar and clean.

Re: Suzuki GS150R

Yes, that's the way and it's fun too. Slowly start building a good tools collection.

You can try to push in one cable after another, if that doesn't work - It's easier to remove the fuel tank for better access - don't lean the bike. You just need to undo two bolts and disconnect fuel hose and fuel sensor wire.

Hopefully the replacement of the cables will solve the issue. If the carb is dirty and not cleaned for a long time, the butterfly valve can become sticky and cause such difficulties.

Re: Suzuki GS150R

Thanks @ashwanth.r for your encouraging words. I'm trying to learn basic maintenance stuff of my bike


Thanks for reference of the illustration. Second zip tie contains many other cables and passes through a deep recess under the petrol tank and feels difficult to access. It may be easier to work on this task if the bike is completely leaned over on its Left hand side though I've never seen someone working on the bike like this.

Stock cables ( not changed so far ) are intact ( no fraying ) but the throttle feels jammed on my 2011 25k km GS150r. When I open it, it doesn't close on its own and there is no play. I tried to adjust the play with adjuster nut but there is very little room left for that. I guess it has lost its lubrication.

Re: Suzuki GS150R

Congrats! You have taken your first baby step. For future DIYs, get a basic, good screwdriver set from Taparia.

Yes, cut open these for ease of work. Replace with ties bought from any automotive spares shop or Bajaj SVC.

If you see the illustration on page "7-14" of the manual, it's clear that we don't have to remove the tank for replacing those cables. Why are you changing them? Are they rough/broken ? Don't ever lube any cable in GS150R - I think they all are teflon sleeved cables (incl. clutch and choke).

Re: Suzuki GS150R

Hey guys

With your help and guidance, I changed air filter on my own and I'm quite happy about it.

Tool used: plus screw from the motorcycle toolbox.



Now I want to replace the throttle cables of GS150r. Any guidance on that:

1. I see old throttle cables passing through 2 zip ties. Do I need to open the zip ties?

2. Cables pass though under the petrol tank. Do I need to remove the petrol tank or is it doable without removing it.


Thanks in advance.

Re: Suzuki GS150R

Thank you very much [MENTION=64963]rsk_kelkar[/MENTION], I had been looking for the service manual for a long time.

Re: Suzuki GS150R

You may want to refer to the service manual here. Page 17 and 129.

Re: Suzuki GS150R

Hey guys

Sorry for my novice question. I'm trying to replace air filter of my 2011 GS150r on my own for which I need to remove right side frame cover as mentioned in user manual.

1. How many screws do I need to remove.

2. How do I unhook the frame cover and how much force in which direction do I need to apply without breaking it.

Thank you in advance for your inputs.

Re: Suzuki GS150R

Hello everyone
I need a help from you guys
Need stickers for GS 150
Mumbai
Any contacts from Suzuki would help
Thankyou

Re: Suzuki GS150R

Thanks for sharing the pics/info! RTR 160 2V's strainer plate O-ring can be used (same size). Even my 2012 GS (v1.1 or v2.0 whatever we call it) didn't come with the crush washer. After many cases of SVC personnel and customers demonstrating their bicep power, they added a crush-able gasket there.

Only SGP is best - it's high quality and has that required heaviness. Ask them to order for you. There are atleast 2 versions - one for pre-2012 models with lighter end weights and 2012+ version with heavier bar end weights. Ask the stores guy/any tech in SVC floor if the latest model can be fitted on your model (the holes for aligning the switchgear should match) - if yes, you can use that with Bajaj Pulsar bar end weights.

Don't even think of buying Unicorn's handlebar - it's flimsy/too lightweight to say the least. If nothing works out, I suggest taking a look at either Bajaj Discoverer's 150 or Yamaha SZ-R bar - only those switchgear holes should match.

Re: Suzuki GS150R

Hi , again after completing 4000k.m post engine rebuild, gave it to mechanic for oil change to my usual shell ax7, i usually do it myself but on previous visit the mechanic had advised to change the oil drain plate and bolt as the thread had worn out, during my previous oil change i had noticed broken metal rings inside the oil pan ,(fotos attached) , which the mechanic said were threads from the plate, but i still have my doubts, So any way I personally stayed this time at the garage and had it replaced in front of my eyes,I had never seen the oil strainer before so i requested him to remove and show it to me, it was clean, By t he way I forgot to buy the new O ring and had to reuse the earlier one, Also the small ring/gasket on the drain bolt was missing in my vehicle, might have been misplaced or lost earlier, I sure didnt notice it whenever i changed oil by myself. So when you buy please buy the entire set. doesnt cost much. havent been able to change my handle bar, still searching for the perfect one,

Re: Suzuki GS150R

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