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Suzuki 1200 bandit Service Manual

Summary of 1200 bandit

  • Page 1

    9 9 5 0 0 - 3 9 2 8 0 - 0 1 e printed in japan k6 gsf1200/gsf1200s k6 gsf1200/gsf1200s.

  • Page 2: Foreword

    Foreword this manual contains an introductory description on the suzuki gsf1200/gsf1200s and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with t...

  • Page 3: Table of Contents

    00 0 1 2 3 4 5 6 9 precautions............................................................... 00-i precautions ............................................................ 00-1 general information ................................................... 0-i general information ..............................

  • Page 5: Section 00

    Table of contents 00- i 00 section 00 contents precautions precautions ...............................................00-1 precautions........................................................... 00-1 warning / caution / note..................................... 00-1 general precautions .................

  • Page 6: Precautions

    00-1 precautions: precautions precautions warning / caution / note b649g10000001 please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighte...

  • Page 7

    Precautions: 00-2 • use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. • after reassembling, check parts for tightness and proper operation. • to protect the environment, do not unlawfully dispose of used motor oil, engine cool...

  • Page 8

    00-3 precautions: • check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc. Fuse • when a fuse blows, always investigate the cause, correct it and then replace the fuse. • do not use a fuse of a different cap...

  • Page 9

    Precautions: 00-4 • the abs control unit/hu cannot be disassembled. Replace the whole unit with a new one. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the abs control unit/hu instantly when reverse power is applied. • removin...

  • Page 10

    00-5 precautions: 1) disconnect the negative (–) cable from the battery. 2) check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock if equipped. 3) using a test male terminal, check the female terminals of the circuit ...

  • Page 11

    Precautions: 00-6 3) also, if measured values are as listed below, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “a” and “b”. Voltage between “a” and body ground: approx. 5 v “b” and body ground: approx. 5 v – 2 v voltage drop “c” and body ground: 3...

  • Page 12

    00-7 precautions: using the multi-circuit testers • use the suzuki multi-circuit tester set. • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Special tool (a): 09900–25008 (multi-circuit tester set) using the testers • incorrectly connecting the (...

  • Page 13: Section 0

    Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols .............................................................. 0a-1 abbreviations .....................

  • Page 14: General Information

    0a-1 general information: general information general description symbols b649g10101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Symbol definition torque control required...

  • Page 15

    General information: 0a-2 abbreviations b649g10101002 a: abdc: after bottom dead center abs: anti-lock brake system ac: alternating current acl: air cleaner, air cleaner box api: american petroleum institute atdc: after top dead center a/f: air fuel mixture b: bbdc: before bottom dead center btdc: b...

  • Page 16

    0a-3 general information: vehicle side view b649g10101003 note difference between photographs and actual motorcycles may exist depending on the markets. Suzuki gsf1200 (2006-model) right side left side suzuki gsf1200s (2006-model) right side left side i649g1010008-01 i649g1010009-01 i649g1010005-06 ...

  • Page 17

    General information: 0a-4 vehicle identification number b649g10101004 the frame serial number or v.I.N. (vehicle identification number) “a” is stamped on the right side of the steering head pipe. The engine serial number “b” is located on the right side of the crankcase. These numbers are required e...

  • Page 18

    0a-5 general information: cylinder identification b649g10101008 the four cylinders of this engine are identified as no.1, 2, 3 and no.4 cylinder, as counted from left to right (as viewed by the rider on the seat). Country and area codes b649g10101009 the following codes stand for the applicable coun...

  • Page 19

    General information: 0a-6 warning, caution and information labels location b649g10101011 5 3 7 [a] 1 2 8 [c] 6 [d] [b] 4 4 10 9 i649g1010011-04 gsf1200 gsf1200s 1. Noise label — for e-24 2. Information label — for e-28 3. Fuel caution label for e-02 for e-02, 24 4. Screen label — for e-02, 19, 24, 2...

  • Page 20

    0a-7 general information: component location electrical components location b649g10103001 3 4 2 7 8 5 1 6 i649g1010003-05 1. Ignition coil 3. Handlebar switch (rh) 5. Rear brake light switch 7. Ckp sensor 2. Ignition switch 4. Front brake light switch 6. Throttle position sensor 8. Oil pressure swit...

  • Page 21

    General information: 0a-8 9 10 11 12 17 13 15 16 18 19 21 23 14 22 20 i649g1010004-04 9. Clutch lever position switch 14. Main fuse 19. Generator 10. Handlebar switch (lh) 15. Battery 20. Carburetor heater (for e-02, 19) 11. Fuse box 16. Ignitor 21. Speed sensor 12. Turn signal/side-stand relay 17. ...

  • Page 22

    0a-9 general information: specifications specifications b649g10107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 130 mm (83.9 in) overall width 790 mm (31.1 in) overall height 1 095 mm (43.1 in...

  • Page 23

    General information: 0a-10 chassis electrical capacities item specification remark front suspension telescopic, coil spring, oil damped rear suspension link type, coil spring, oil damped front suspension stroke 130 mm (5.1 in) rear wheel travel 136 mm (5.4 in) caster 35 ° (right & left) trail 25 ° 2...

  • Page 24

    0a-11 general information: special tools and equipment special tools b649g10108001 09900-06106 09900-06107 09900-06108 09900-20102 snap ring pliers snap ring pliers snap ring pliers vernier calipers (1/20 mm, 200 mm) 09900-20202 09900-20204 09900-20205 09900-20508 micrometer (1/100 mm, 25 – 50 mm) m...

  • Page 25

    General information: 0a-12 09913-50121 09913-60910 09913-61510 09913-70210 oil seal remover bearing remover bearing remover bearing installer set 09915-40610 09915-63210 09915-64510 09915-74521 oil filter wrench compression gauge adaptor compression gauge set oil pressure gauge hose 09915-74540 0991...

  • Page 26

    0a-13 general information: 09917-14920 09917-47010 09920-34820 09920-34840 valve adjuster driver vacuum pump gauge clutch pressure plate holder starter clutch holder 09920-53740 09921-20240 09922-22711 09923-73210 clutch sleeve hub holder bearing remover set drive chain cutting and joining tool bear...

  • Page 27: Maintenance and Lubrication

    Maintenance and lubrication: 0b-1 maintenance and lubrication precautions precautions for maintenance b649g10200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and ...

  • Page 28

    0b-2 maintenance and lubrication: scheduled maintenance periodic maintenance schedule chart b649g10205001 note i = inspect and clean, adjust, replace or lubricate as necessary. R = replace t = tighten item interval km 1 000 6 000 12 000 18 000 24 000 mile 600 4 000 7 500 11 000 14 500 months 2 12 24...

  • Page 29

    Maintenance and lubrication: 0b-3 lubrication points b649g10205002 proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off...

  • Page 30

    0b-4 maintenance and lubrication: repair instructions air cleaner element removal and installation b649g10206001 inspect air cleaner element every 6 000 km (4 000 miles, 12 months) replace air cleaner element every 18 000 km (11 000 miles, 36 months) removal 1) remove the fuel tank. Refer to “carbur...

  • Page 31

    Maintenance and lubrication: 0b-5 cleaning carefully use compressed air to clean the air cleaner element. Caution ! Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the outside, dirt will be forced into the pores of the air cleaner element, restri...

  • Page 32

    0b-6 maintenance and lubrication: spark plug inspection and cleaning b649g10206004 refer to “spark plug removal and installation: ”. Inspect spark plug every 6 000 km (4 000 miles, 12 months) replace spark plug every 12 000 km (7 500 miles, 24 months) heat range check spark plug heat range by observ...

  • Page 33

    Maintenance and lubrication: 0b-7 valve clearance inspection and adjustment b649g10206005 inspect valve clearance initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter. Valve clearance adjustment must be checked and adjusted, a) at the time of periodic in...

  • Page 34

    0b-8 maintenance and lubrication: 9) insert the thickness gauge between the valve stem end and adjusting screw on the rocker arm. If the clearance is out of specification, hold the lock-nut with a wrench and use the special tools to adjust the clearance. Caution ! Both the right and left valve clear...

  • Page 35

    Maintenance and lubrication: 0b-9 engine oil and filter replacement b649g10206007 replace engine oil initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. Replace oil filter initially at 1 000 km (600 miles, 2 month) and every 18 000 km (11 000 miles, 36 ...

  • Page 36

    0b-10 maintenance and lubrication: 3) apply engine oil lightly to the o-ring of new oil filter, before installation. Caution ! Only use a genuine suzuki motorcycle oil filter. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and ...

  • Page 37

    Maintenance and lubrication: 0b-11 engine idle speed inspection and adjustment b649g10206011 inspect engine idle speed initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. Note make this adjustment when the engine is hot. Start the engine, turn the throt...

  • Page 38

    0b-12 maintenance and lubrication: clutch hose replacement b649g10206031 refer to “clutch hose removal and installation: in section 5c”. Air bleeding from clutch fluid circuit b649g10206032 refer to “air bleeding from clutch fluid circuit: ”. Clutch fluid replacement b649g10206033 refer to “clutch f...

  • Page 39

    Maintenance and lubrication: 0b-13 drive chain slack adjustment 1) place the motorcycle on its side-stand for accurate adjustment. 2) loosen the axle nut (1). 3) loosen the chain adjuster lock-nuts (2). 4) loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) “a” o...

  • Page 40

    0b-14 maintenance and lubrication: warning ! • the brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never re...

  • Page 41

    Maintenance and lubrication: 0b-15 rear brake hose inspection inspect the brake hose for crack, damage or brake oil leakage. If any defects are found, replace the brake hose with a new one. Brake pedal height inspection and adjustment 1) inspect the brake pedal height “a” between the pedal top face ...

  • Page 42

    0b-16 maintenance and lubrication: caution ! The standard tire fitted on this motorcycle is 120/70 zr17 m/c (58w) for front and 180/55 zr17 m/c (73w) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a suzuki genuine tire. Tire type dunlop •...

  • Page 43

    Maintenance and lubrication: 0b-17 chassis bolt and nut inspection b649g10206022 tighten chassis bolt and nut initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. 1. Steering ...

  • Page 44

    0b-18 maintenance and lubrication: compression pressure check b649g10206023 refer to “compression pressure check: in section 1d”. Oil pressure check b649g10206024 refer to “oil pressure check: in section 1e”. 15. Front axle bolt 21. Air bleeder valve (brake) 16. Front axle pinch bolt : 23 n ⋅m (2.3 ...

  • Page 45

    Maintenance and lubrication: 0b-19 specifications tightening torque specifications b649g10207001 note the specified tightening torque is also described in the following. “chassis bolt and nut inspection: ” reference: for the tightening torque of fastener not specified in this section, refer to “tigh...

  • Page 46: Service Data

    0c-1 service data: service data specifications service data b649g10307003 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diameter in. 28.5 (1.12) — ex. 25 (1.0) — valve clearance (when cold) in. 0.10 – 0.15 (0.004 – 0.006) — ex. 0.18 – 0.23 (0.007 – 0.00...

  • Page 47

    Service data: 0c-2 cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure 1 250 kpa (12.5 kgf/cm 2 , 178 psi) 875 kpa (8.75 kgf/cm 2 , 124 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to-cylinder clearan...

  • Page 48

    0c-3 service data: oil pump clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio carburetor item standard limit oil pump reduction ratio 1.703 (72/46 x 37/34) — oil pressure (at 60 °c, 140 °f) above 300 kpa (3.0 kgf/cm 2 , 43 psi) below 600 kpa (6.0 kgf/cm 2 , 85 psi) at 3 000 ...

  • Page 49

    Service data: 0c-4 electrical unit: mm (in) wattage unit: w item specification note ignition timing 7 ° b.T.D.C. At 1 300 r/min. E-28 7 ° b.T.D.C. At 1 200 r/min. Others firing order 1 ⋅ 2 ⋅ 4 ⋅ 3 spark plug type ngk: jr9b gap 0.6 – 0.7 (0.024 – 0.028) spark performance over 8 (0.3) at 1 atm. Ckp se...

  • Page 50

    0c-5 service data: brake + wheel unit: mm (in) suspension unit: mm (in) item standard limit rear brake pedal height 60 (2.4) — brake disc thickness front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) rear 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) brake disc runout — 0.30 (0.012) master cylinder bore front 15.870 ...

  • Page 51

    Service data: 0c-6 tire fuel + oil item standard limit cold inflation tire pressure (solo/dual riding) front 250 kpa (2.50 kgf/cm 2 , 36 psi) — rear 250 kpa (2.50 kgf/cm 2 , 36 psi) — tire size front 120/70 zr17m/c (58 w) — rear 180/55 zr17m/c (73 w) — tire type front dunlop d218fn — rear dunlop d21...

  • Page 52

    0c-7 service data: tightening torque specifications b649g10307002 engine item n ⋅m kgf–m lb–ft cylinder head cover bolt (10 pcs) 14 1.4 10.0 cylinder head cover plug 15 1.5 11.0 cylinder head cover union bolt 20 2.0 14.5 cylinder head nut [m10] 38 3.8 27.5 cylinder head bolt [m6] 10 1.0 7.0 cylinder...

  • Page 53

    Service data: 0c-8 chassis fuel level gauge mounting bolt 10 1.0 7.0 oil filter 20 2.0 14.5 item n ⋅m kgf–m lb–ft item n ⋅m kgf–m lb–ft steering stem head nut 65 6.5 47.0 steering stem nut tighten 45 n ⋅m (4.5 kgf-m, 32.5 lb-ft) then turn back 1/2 – 1/4. Front fork upper clamp bolt 23 2.3 16.5 front...

  • Page 54

    0c-9 service data: tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf–m lb–ft n ⋅m kgf–m lb–ft 4 1.5 0.15 1.0 2 0.2 1.5 5 3 0.3 2.0 5 0.5 3.5 6 6 0.6 4.5 10 1.0 7.0 8 ...

  • Page 55: Section 1

    Table of contents 1- i 1 section 1 contents engine precautions .................................................1-1 precautions............................................................. 1-1 precautions for engine.......................................... 1-1 engine general information and diagnos...

  • Page 56

    1-ii table of contents oil pressure regulator inspection ......................1e-5 oil pan / oil sump filter cleaning ......................1e-6 oil pressure switch removal and installation ....1e-6 oil pressure switch inspection ...........................1e-7 oil jet (for the cylinder head) remov...

  • Page 57

    Table of contents 1-iii ckp sensor removal and installation................1h-8 engine stop switch inspection .........................1h-10 ignition switch inspection .................................1h-10 ignition switch removal and installation...........1h-10 specifications.........................

  • Page 58: Precautions

    1-1 precautions: precautions precautions precautions for engine b649g11000001 refer to “general precautions: in section 00” and “precautions for electrical circuit service: in section 00”..

  • Page 59

    Engine general information and diagnosis: 1a-1 engine general information and diagnosis diagnostic information and procedures engine symptom diagnosis b649g11104011 condition possible cause correction / reference item engine will not start or is hard to start (compression too low.) worn cylinder. Re...

  • Page 60

    1a-2 engine general information and diagnosis: engine noisy (noise seems to come from transmission.) worn or rubbing gear. Replace. Worn countershaft spline. Replace countershaft. Worn driveshaft spline. Replace driveshaft. Worn or rubbing primary gear. Replace. Worn bearing. Replace. Engine idle po...

  • Page 61: Emission Control Devices

    Emission control devices: 1b-1 emission control devices precautions precautions for emission control devices b649g11200001 refer to “general precautions: in section 00”. General description carburetor system description b649g11201005 gsf1200/s motorcycles are equipped with precision carburetors that...

  • Page 62

    1b-2 emission control devices: crankcase emission control system description b649g11201006 the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion ch...

  • Page 63

    Emission control devices: 1b-3 exhaust emission control system description b649g11201008 the exhaust emission control system is composed of the pair system and three-way catalyst system. The fresh air is drawn into the exhaust port through the pair control valve and pair reed valve. The pair control...

  • Page 64

    1b-4 emission control devices: schematic and routing diagram pair system hose routing diagram b649g11202001 5 2 3 4 1 6 7 7 7 1 2 3 4 1 2 7 6 5 5 “d” “a” “i” “c” “b” “h” “e” “g” “f” i649g1120008-04 1. Pair hose no.1 7. Pair control valve “f”: marking (white) must face front side. 2. Pair hose no.2 “...

  • Page 65

    Emission control devices: 1b-5 repair instructions pair system removal and installation b649g11206001 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation: in section 1g”. 2) disconnect the following parts from the pair valve. • pair hose no.1 (1) • pair hose no.2 (2) • pair...

  • Page 66

    1b-6 emission control devices: pair system inspection b649g11206004 pair hose and pipe 1) remove the fuel tank. Refer to “fuel tank removal and installation: in section 1g”. 2) inspect the hoses and pipes for wear or damage. 3) inspect that the hoses and pipes are properly connected. Refer to “pair ...

  • Page 67

    Emission control devices: 1b-7 b) connect the vacuum pump gauge to the vacuum port of the pair valve as shown. Apply negative pressure slowly to the pair valve and blow into it as shown above. If air does not flow out at the specified pressure, the pair valve is ok. If the pair valve does not functi...

  • Page 68

    1b-8 emission control devices: specifications tightening torque specifications b649g11207001 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications: in section 0c”. Special tools and equipment special tool b649g11208001 fastening pa...

  • Page 69: Engine Mechanical

    Engine mechanical: 1d-1 engine mechanical schematic and routing diagram camshaft and sprocket assembly diagram b649g11402001 24th pin 1st pin i649g1140075-03.

  • Page 70

    1d-2 engine mechanical: diagnostic information and procedures compression pressure check b649g11404001 the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mai...

  • Page 71

    Engine mechanical: 1d-3 repair instructions engine components removable with the engine in place b649g11406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 72

    1d-4 engine mechanical: engine left side engine right side item removal inspection installation engine sprocket cover refer to “engine sprocket removal and installation: in section 3a”. — refer to “engine sprocket removal and installation: in section 3a”. Engine sprocket refer to “engine sprocket re...

  • Page 73

    Engine mechanical: 1d-5 engine assembly removal b649g11406002 before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) drain engine oil. Refer to “engine oil and filter replacement: in section 0b”. 2) remove...

  • Page 74

    1d-6 engine mechanical: 13) remove the wire harness clamp (7). 14) disconnect the gear position switch lead wire couplers (8). 15) disconnect the ckp sensor lead wire coupler (9). 16) open the wire harness clamps. 17) disconnect the starter motor lead wire (10). 18) disconnect the generator lead wir...

  • Page 75

    Engine mechanical: 1d-7 25) loosen the rear axle nut (16) and chain adjusters (17) to provide additional chain slack. 26) remove the engine sprocket (18). 27) remove the muffler, exhaust pipe and exhaust pipe gaskets. Refer to “exhaust pipe / muffler removal and installation: in section 1k”. 28) rem...

  • Page 76

    1d-8 engine mechanical: 33) gradually lower the front side of the engine and remove the engine. Warning ! Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed. 20 20 21 22 19 19 19 20 [a] [a] 20 i649g1140018-04 19. Frame down tube mounting bolt...

  • Page 77

    Engine mechanical: 1d-9 engine assembly installation b649g11406003 reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • insert the two long bolts (1), (2) from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following...

  • Page 78

    1d-10 engine mechanical: • install the oil cooler/oil cooler hoses. Refer to “oil cooler / oil cooler hose removal and installation: in section 1f”. • install the exhaust pipe/muffler. Refer to “exhaust pipe / muffler removal and installation: in section 1k”. • install a new lock washer (8) and appl...

  • Page 79

    Engine mechanical: 1d-11 • position the carburetor clamps as shown. • after remounting the engine, route the wire harness, cables and hoses properly. Refer to “wiring harness routing diagram: in section 9a” and “throttle cable / starter cable routing diagram: in section 1g”. • install the gearshift ...

  • Page 80

    1d-12 engine mechanical: • pour 4.6 l (4.9/4.0 us/lmp qt) of sf/sg or sh/sj with jaso ma engine oil, with a viscosity rating of 10w-40, into the engine after overhauling it. • start up the engine and allow it run for several minutes at idle speed and then stop the engine. Wait three minutes and then...

  • Page 81

    Engine mechanical: 1d-13 cylinder head cover 1) remove the breather cover (1). 2) remove the cylinder head cover (2) from the cylinder head. Camshaft 1) remove the ckp sensor cover (1). 2) remove all of the spark plugs. Refer to “spark plug removal and installation: in section 0b”. Special tool : 09...

  • Page 82

    1d-14 engine mechanical: 2) remove the cylinder head bolt (2). 3) the cylinder head can be removed after its twelve nuts (m10) are removed. Note when loosening the cylinder head nuts, loosen each nut little by little, in descending order, according to the numbers cast on the cylinder head. 4) remove...

  • Page 83

    Engine mechanical: 1d-15 piston 1) scribe the cylinder number on the head of the respective pistons. 2) place a clean rag over the cylinder to prevent any parts from falling into the crankcase. 3) remove the piston pin circlip (1). 4) draw out each piston pin and remove the pistons. 5) remove the cy...

  • Page 84

    1d-16 engine mechanical: oil jet (for the cylinder head) • make sure that the oil jets (1) in the upper crankcase are not clogged. Piston • install the pistons and piston pins in their original cylinders. Refer to the scribe marks on each piston. • before installing the piston pins, apply molybdenum...

  • Page 85

    Engine mechanical: 1d-17 • with pistons #2 and #3 in place, install pistons #1 and #4, and then insert them into the respective cylinders. Note do not overtighten the bands or piston installation into the cylinders will be difficult. Cylinder • tighten the cylinder base nut (1) to the specified torq...

  • Page 86

    1d-18 engine mechanical: • tighten the twelve nuts (m10) in ascending order and to the specified torque. Tightening torque cylinder head nut: 38 n·m (3.8 kgf-m, 27.5 lb-ft) • after firmly tightening the twelve nuts, install the cylinder head bolt (m6) (1) and tighten it to the specified torque. Tigh...

  • Page 87

    Engine mechanical: 1d-19 camshaft note before installing the camshafts onto the cylinder head, apply suzuki moly paste onto the camshaft journals and do not leave any dry spots. Also, apply engine oil onto the camshaft journal holders. M/o: molybdenum oil (molybdenum oil solution) • the exhaust cams...

  • Page 88

    1d-20 engine mechanical: • when the “t” mark on the ckp rotor is aligned with the center of the ckp sensor, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the crankshaft sprocket and the exhaust camshaft sprocket. • the exhaust camshaft sprocket has an arrow m...

  • Page 89

    Engine mechanical: 1d-21 “b” i649g1140073-02 “c” i649g1140074-02 24th pin 1st pin i649g1140075-03.

  • Page 90

    1d-22 engine mechanical: • each camshaft journal holder is identified with an embossed letter and install the dowel pins into each camshaft journal holder. • have the camshaft journal holders seated (in and ex) evenly by tightening the camshaft journal holder bolts sequentially and in a crisscross p...

  • Page 91

    Engine mechanical: 1d-23 cam chain tension adjuster • after removing the spring holder bolt (1) and spring, unlock the ratchet mechanism (2) and push the push rod (3) all the way into the cam chain tension adjuster. Note before installing the cam chain tension adjuster, turn the crankshaft clockwise...

  • Page 92

    1d-24 engine mechanical: • apply a small quantity of thread lock “1342” to the ckp sensor cover bolts. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) • install a new gasket and the ckp sensor cover (1). • install a new gasket washer (2) onto the ckp sensor cover bolt as sho...

  • Page 93

    Engine mechanical: 1d-25 cooling hose • install the left and right cooling hoses and tighten their mounting bolts to the specified torque. Caution ! Replace the o-rings (1) with new ones to prevent oil leakage. Tightening torque cooling hose mounting bolt (a): 10 n·m (1.0 kgf- m, 7.0 lb-ft) pair pip...

  • Page 94

    1d-26 engine mechanical: camshaft runout measure the runout using the dial gauge. Replace the camshaft if the runout exceeds the limit. Special tool (a): 09900–20606 (dial gauge (1/100 mm)) (b): 09900–20701 (magnetic stand) (c): 09900–21304 (v-block (100mm)) camshaft runout (in & ex) service limit: ...

  • Page 95

    Engine mechanical: 1d-27 camshaft journal holder i.D. (in & ex) standard: 22.012 – 22.025 mm (0.8666 – 0.8671 in) special tool (e): 09900–20205 (micrometer (0-25mm)) camshaft journal o.D. (in & ex) standard: 21.959 – 21.980 mm (0.8645 – 0.8654 in) camshaft sprocket inspection b649g11406049 inspect t...

  • Page 96

    1d-28 engine mechanical: 1) apply thread lock super “1303” to the threads of the camshaft sprocket bolts and then tighten them to the specified torque. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) tightening torque camshaft sprocket bolt: 25 n·m (2.5 kgf-m, 18.0 lb-...

  • Page 97

    Engine mechanical: 1d-29 installation install the cam chain guides in the reverse order of removal. Pay attention to the following points: • apply suzuki thread lock super “1303” to thread part and tighten the mounting bolt to the specified torque. : thread lock cement 99000–32030 (thread lock cemen...

  • Page 98

    1d-30 engine mechanical: cylinder head disassembly and assembly b649g11406054 refer to “engine top side disassembly: ”. Refer to “engine top side assembly: ”. Disassembly 1) remove the intake pipes. 2) remove the rocker arm shaft set bolt (1) and cylinder head plug (2). 3) remove the rocker arm shaf...

  • Page 99

    Engine mechanical: 1d-31 assembly 1) locate the plate (1) on the cylinder head of exhaust side. 2) oil each oil seal (2) and press fit them into position using the valve guide installer. Caution ! Do not reuse the oil seals. 3) install each valve spring seat (3) (for intake side) and (4) (for exhaus...

  • Page 100

    1d-32 engine mechanical: 6) install the valve spring retainer, press down the springs using the valve lifter and then install the cotter halves on to the stem end. Then, release the valve lifter to allow the cotter (5) to wedge between the retainer and the valve stem. Be sure that the rounded lip “e...

  • Page 101

    Engine mechanical: 1d-33 11) apply a small quantity of thread lock “1342” to the thread of the intake pipe bolt. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) note • when replacing the intake pipes, identify the different intake pipes according to each i.D. Code (1). (1-32...

  • Page 102

    1d-34 engine mechanical: valve face wear visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve face “a”. If it is out of specification replace the valve with a new one. Special tool : ...

  • Page 103

    Engine mechanical: 1d-35 valve spring free length (in & ex) service limit: inner: 35.0 mm (1.38 in) service limit: outer: 37.8 mm (1.49 in) valve spring tension (in & ex) standard: inner: 53 – 65 n, 5.3 – 6.5 kgf/28.0 mm (11.7 – 14.3 lbs/1.10 in) standard: outer: 131 – 151 n, 13.1 – 15.1 kgf/31.5 mm...

  • Page 104

    1d-36 engine mechanical: 4) check that the transferred red lead (blue) on the valve face is uniform all around and in center of the valve face. If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter. Refer to “valve seat repair: ...

  • Page 105

    Engine mechanical: 1d-37 4) refinish the valve guide holes in the cylinder head using the reamer and handle. Caution ! When refinishing or removing the reamer from the valve guide hole, always turn it clockwise. Special tool (b): 09916–34580 (valve guide reamer (10.8 mm)) (c): 09916–34542 (reamer ha...

  • Page 106

    1d-38 engine mechanical: valve seat repair b649g11406069 the valve seats (1) for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut at 45 °. Caution ! • the valve seat contact area must be inspected after each nut. • do not use lapping compound a...

  • Page 107

    Engine mechanical: 1d-39 piston ring components b649g11406071 piston ring removal and installation b649g11406070 removal 1) draw out the piston pin and remove the piston. Refer to “engine top side disassembly: ”. 2) carefully spread the ring opening with your thumbs and then push up the opposite sid...

  • Page 108

    1d-40 engine mechanical: installation note • when installing the piston ring, be careful not to damage the piston. • do not expand the piston ring excessively since it is apt to be broken down. 1) install the piston rings in the order of the oil ring, second ring and top ring. A) the first member to...

  • Page 109

    Engine mechanical: 1d-41 piston-to-cylinder clearance subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston. Piston-to-cylinder clearance service limit: 0.12 mm (0.0047 in) piston ring-to-...

  • Page 110

    1d-42 engine mechanical: piston pin and pin bore measure the piston pin bore inside diameter using the small bore gauge. If either is out of specification or the difference between these measurement is more than the limits, replace the piston. Special tool (a): 09900–20602 (dial gauge (1/1000mm, 1mm...

  • Page 111

    Engine mechanical: 1d-43 ckp sensor / oil pressure switch 1) remove the ckp sensor component parts (1). Refer to “ckp sensor removal and installation: in section 1h”. 2) disconnect the oil pressure switch lead wire and remove the oil pressure switch (2). Refer to “oil pressure switch removal and ins...

  • Page 112

    1d-44 engine mechanical: 2) remove the washers (2), oil pump driven gear (3) and pin (4). Note be careful not to drop the circlip, pin and washers into the oil pan. Starter clutch 1) remove the starter clutch component parts (1). Refer to “starter clutch removal and installation: in section 1i”. Gea...

  • Page 113

    Engine mechanical: 1d-45 2) remove the plug (2). 3) remove the upper crankcase bolts and nut. 4) remove the oil pan (3). 5) remove the shim (4) and o-ring (5). 6) remove the oil sump filter (6). 7) remove the oil return pipe (7). 8) remove the lower crankcase bolts and nut. 9) remove the main oil ga...

  • Page 114

    1d-46 engine mechanical: 12) make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic mallet to separate the upper and lower crankcase halves and then lift the lower crankcase off of the upper crankcase. Caution ! Do not allow the crankshaft journal bea...

  • Page 115

    Engine mechanical: 1d-47 crankshaft journal bearing / oil jet (for the piston cooling) 1) remove the crankshaft journal bearings. Caution ! • when removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings. • do not touch the bearing surface...

  • Page 116

    1d-48 engine mechanical: 4) unhook the gearshift cam stopper spring (7) from the lower crankcase. 5) remove the snap ring (8) from the gearshift cam, then draw out the gearshift cam (9) from the opposite side. Special tool (a): 09900–06107 (snap ring pliers) 6) remove the snap ring (10) and gearshif...

  • Page 117

    Engine mechanical: 1d-49 oil pump • install the o-rings ((1) and (2)) and dowel pins (3) in the correct position as shown. Caution ! Replace the o-rings with new ones to prevent oil leakage. • apply a small quantity of thread lock “1342” to the oil pump mounting bolts. : thread lock cement 99000–320...

  • Page 118

    1d-50 engine mechanical: • install the gearshift cam (3) and its related parts. – gearshift cam stopper (4) – snap ring (5) – spring (6) – snap ring (7) caution ! Always use new snap rings ((5) and (7)). Special tool (a): 09900–06106 (snap ring pliers) • position the gearshift cam in the neutral pos...

  • Page 119

    Engine mechanical: 1d-51 • install the countershaft assembly (15) and driveshaft assembly (16) into the upper crankcase. Note • be sure to install the bearing dowel pins “c” in their respective positions. • make sure that the countershaft assembly turns freely while holding the driveshaft assembly. ...

  • Page 120

    1d-52 engine mechanical: crankshaft • install the o-rings ((1) and (2)). Caution ! Replace the o-rings with new ones to prevent oil leakage. • before installing the crankshaft assembly, apply molybdenum oil solution to each crankshaft journal bearing. M/o: molybdenum oil (molybdenum oil solution) • ...

  • Page 121

    Engine mechanical: 1d-53 crankcase • clean the mating surfaces of the crankcases. • install the dowel pins in the upper crankcase. • apply a bond to the mating surface of the lower crankcase as follows. : sealant 99000–31140 (suzuki bond 1207b or equivalent) note • make sure that the mating surfaces...

  • Page 122

    1d-54 engine mechanical: • match the upper and lower crankcases. • install the right oil return pipe (1) with the bolt “1”. • install the copper washers onto bolts “9” and “11”. • install the two allen bolts at position “a”. • install the ten crankcase bolts (m8). • tighten the crankcase bolts (cran...

  • Page 123

    Engine mechanical: 1d-55 caution ! Use a new gasket washer to prevent oil leakage. 4 i649g1140349-01 3 5 “b” i649g1140363-01 “c” i649g1140364-01 i649g1140358-01.

  • Page 124

    1d-56 engine mechanical: • install the left oil return pipe (6). • install a new o-ring (7) and shim (8). • install a new gasket and the oil sump filter (9). Caution ! Replace the gasket and o-ring with new ones to prevent oil leakage. • install a new gasket and the oil pan. Caution ! Replace the oi...

  • Page 125

    Engine mechanical: 1d-57 • apply a small quantity of thread lock “1342” to the two screws. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) • install the countershaft bearing retainer (12). Gear position switch • install the gear position switch. Note when installing the gear...

  • Page 126

    1d-58 engine mechanical: oil pump driven gear • install the washer (1), pin (2), oil pump driven gear (3) and washer (4). Gearshift • install each pawl (1) into the gearshift cam driven gear (2). • the large shoulder “a” must face to the outside. • install the cam guide (3) and pawl lifter (4). • ap...

  • Page 127

    Engine mechanical: 1d-59 oil filter • turn the oil filter by hand until you feel that the oil filter o-ring has contacted the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) using the special tool. Note • before installing the oil filter, apply a lig...

  • Page 128

    1d-60 engine mechanical: conrod removal and installation b649g11406060 removal 1) remove the crankshaft assembly from the crankcase. Refer to “engine bottom side disassembly: ”. 2) loosen the bearing cap nuts and tap the bearing cap nut lightly using a plastic mallet to remove the bearing cap. 3) re...

  • Page 129

    Engine mechanical: 1d-61 conrod and crankshaft inspection b649g11406064 refer to “conrod removal and installation: ”. Conrod small end i.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. ...

  • Page 130

    1d-62 engine mechanical: conrod crank pin bearing inspection and selection b649g11406061 refer to “conrod removal and installation: ”. Inspection 1) inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. 2) place the plast...

  • Page 131

    Engine mechanical: 1d-63 2) check the corresponding crank pin o.D. Code numbers ([1], [2] or [3]) “b”. 3) measure the conrod crank pin o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crank pin o.D. Specification special tool (a): 09900–20202 (...

  • Page 132

    1d-64 engine mechanical: crankshaft journal bearing inspection and selection b649g11406062 refer to “engine bottom side disassembly: ”. Refer to “engine bottom side assembly: ”. Inspection 1) inspect each upper and lower crankcase bearing for any damage. 2) install the plastigauge onto each cranksha...

  • Page 133

    Engine mechanical: 1d-65 2) check the corresponding crankshaft journal o.D. Codes ([a], [b] or [c]) “b”, which are stamped on the crankshaft. 3) measure the crankshaft o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crankshaft journal o.D. Spe...

  • Page 134

    1d-66 engine mechanical: crankshaft thrust clearance inspection and selection b649g11406063 refer to “engine bottom side disassembly: ”. Refer to “engine bottom side assembly: ”. Inspection 1) with the crankshaft’s right-side and left-side thrust bearings inserted into the upper crankcase. 2) measur...

  • Page 135

    Engine mechanical: 1d-67 4) select a left-side thrust bearing from the selection table. Note right-side thrust bearing has the same specification as the green (12228-48b00-0e0) of left-side thrust bearing. Left-side thrust bearing selection table 5) after selecting a left-side thrust bearing, instal...

  • Page 136

    1d-68 engine mechanical: specifications service data b649g11407002 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diameter in. 28.5 (1.12) — ex. 25 (1.0) — valve clearance (when cold) in. 0.10 – 0.15 (0.004 – 0.006) — ex. 0.18 – 0.23 (0.007 – 0.009) — va...

  • Page 137

    Engine mechanical: 1d-69 cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure 1 250 kpa (12.5 kgf/cm 2 , 178 psi) 875 kpa (8.75 kgf/cm 2 , 124 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to-cylinder c...

  • Page 138

    1d-70 engine mechanical: tightening torque specifications b649g11407003 note the specified tightening torque is also described in the following. “engine assembly installation: ” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications...

  • Page 139

    Engine mechanical: 1d-71 note required service material is also described in the following. “engine assembly installation: ” special tool b649g11408002 09900–06106 09900–06107 snap ring pliers snap ring pliers ) / ) ) / ) / ) / ) / ) 09900–20102 09900–20202 vernier calipers (1/20 mm, 200 mm) microme...

  • Page 140

    1d-72 engine mechanical: 09900–22302 09900–22403 plastigauge (0.051 - 0.152 mm) small bore gauge (18- 35mm) ) ) / ) / ) 09915–40610 09915–63210 oil filter wrench compression gauge adaptor ) / ) ) 09915–64510 09916–10911 compression gauge set valve lapper set ) ) 09916–14510 09916–14910 valve spring ...

  • Page 141: Engine Lubrication System

    Engine lubrication system: 1e-1 engine lubrication system precautions precautions for engine oil b649g11500001 refer to “fuel and oil recommendation: in section 0a”. Schematic and routing diagram engine lubrication circuit diagram b649g11502002 i649g1150002-01.

  • Page 142

    1e-2 engine lubrication system: engine lubrication system chart diagram b649g11502001 conrod small end cam chain cylinder head cylinder head countershaft gears clutch plates driveshaft gears oil pump oil cooler by-pass oil sump filter driveshaft right side bearing o il pa n regulator oil filter oil ...

  • Page 143

    Engine lubrication system: 1e-3 diagnostic information and procedures engine lubrication symptom diagnosis b649g11504004 oil pressure check b649g11504003 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 144

    1e-4 engine lubrication system: 6) stop the engine and remove the oil pressure gauge and attachment. 7) reinstall the main oil gallery plug and tighten it to the specified torque. Caution ! Use a new o-ring to prevent oil leakage. Tightening torque main oil gallery plug: 40 n·m (4.0 kgf-m, 29.0 lb- ...

  • Page 145

    Engine lubrication system: 1e-5 installation 1) tighten the oil pressure regulator to the specified torque. Tightening torque oil pressure regulator (a): 28 n·m (2.8 kgf-m, 20.0 lb-ft) 2) install the oil sump filter (1). 3) install a new o-ring (2) and shim (3). Caution ! Replace the gasket and o-ri...

  • Page 146

    1e-6 engine lubrication system: 3) install the oil pressure regulator. Refer to “oil pan / oil sump filter / oil pressure regulator removal and installation: ”. Oil pan / oil sump filter cleaning b649g11506025 refer to “oil pan / oil sump filter / oil pressure regulator removal and installation: ”. ...

  • Page 147

    Engine lubrication system: 1e-7 2) connect the oil pressure switch lead wire. Note the suzuki bond should be applied to the groove of the ckp sensor lead wire grommet (1). : sealant 99000–31140 (suzuki bond 1207b or equivalent) 3) install the ckp sensor cover. Refer to “ckp sensor removal and instal...

  • Page 148

    1e-8 engine lubrication system: installation installation is in the reverse order of removal. Pay attention to the following point: note before installing the oil jets, apply a light coat of engine oil to the o-rings. Oil jet inspection b649g11506029 inspect the oil jet in the following procedures: ...

  • Page 149

    Engine lubrication system: 1e-9 specifications service data b649g11507002 oil pump oil tightening torque specifications b649g11507003 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications: in section 0c”. Special tools and equipmen...

  • Page 150: Engine Cooling System

    1f-1 engine cooling system: engine cooling system precautions engine cooling system warning b649g11600001 warning ! To avoid the danger of being burned, do not touch the oil cooling system when the system is hot. Any service on the oil cooling system should be performed when the system is cool. Prec...

  • Page 151

    Engine cooling system: 1f-2 general description engine cooling system description b649g11601005 • to cool the engine, engine oil is jet-sprayed to the combustion chamber area of the cylinder head where temperature is the highest. • oil discharged from the oil pump is sent to the cylinder head cover ...

  • Page 152

    1f-3 engine cooling system: schematic and routing diagram cylinder head cooling system chart diagram b649g11602003 i649g1160002-02.

  • Page 153

    Engine cooling system: 1f-4 diagnostic information and procedures engine cooling symptom diagnosis b649g11604003 condition possible cause correction / reference item engine overheats. Carbon build-up on piston crown. Clean. Insufficient amount of engine oil. Check level and add. Defective oil pump. ...

  • Page 154

    1f-5 engine cooling system: repair instructions engine cooling system components b649g11606037 19 19 19 18 17 16 15 (a) 5, 8 14 13 12 11 10 9 6 6 7 4 2 (a) 5, “a” (a) 1, 3 2 (a) 1, (a) 1, i649g1160027-02 1. Cooling oil hose mounting bolt 9. O-ring 17. Upper oil return pipe (lh) 2. O-ring 10. Gasket ...

  • Page 155

    Engine cooling system: 1f-6 oil cooler and oil cooler hose components b649g11606038 (a) 1, 2 6 3 6 3 (b) 8, (a) 7, 4 5 (a) 7, i649g1160028-01 1. Oil cooler mounting bolt 5. Oil cooler hose (rh) : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Oil cooler 6. Gasket washer : 28 n ⋅m (2.8 kgf-m, 20.0 lb-ft) 3. O-rin...

  • Page 156

    1f-7 engine cooling system: oil cooler and oil cooler hose construction b649g11606028 (a) (b) (a) (a) (a) i649g1160003-04 : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) : apply thread lock “1322” to thread part : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) : do not reuse..

  • Page 157

    Engine cooling system: 1f-8 oil cooler / oil cooler hose removal and installation b649g11606030 removal 1) drain engine oil. Refer to “engine oil and filter replacement: in section 0b”. 2) remove the oil cooler hose union bolts (1) and gasket washers. 3) remove the oil cooler hose bracket bolts, lef...

  • Page 158

    1f-9 engine cooling system: • apply thread lock super “1322” to the oil cooler hose bracket bolts. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) • tighten the oil cooler hose bracket bolts to specified torque. Tightening torque oil cooler hose bracket bolt (c): 10 n·...

  • Page 159

    Engine cooling system: 1f-10 oil pump / oil pressure regulator removal and installation b649g11606031 removal 1) separate the crankcases, upper and lower. Refer to “engine bottom side disassembly: in section 1d”. 2) remove the oil pump (1). 3) remove the o-rings and dowel pins. 4) remove the oil pre...

  • Page 160

    1f-11 engine cooling system: installation install the oil nozzle in the reverse order of removal. Pay attention to the following point: • when installing the cylinder head cover, refer to “engine top side assembly: in section 1d”. Oil return pipe (cylinder side) removal and installation b649g1160603...

  • Page 161

    Engine cooling system: 1f-12 3) remove the oil pressure regulator from the oil pump. 4) check the operation of the oil pressure regulator by pushing on the piston with an appropriately sharped tool. If the piston does nut/operates replace the oil pressure regulator with a new one. 5) install the oil...

  • Page 162

    1f-13 engine cooling system: specifications service data b649g11607002 oil pump oil tightening torque specifications b649g11607003 note the specified tightening torque is also described in the following. “engine cooling system components: ” “oil cooler and oil cooler hose components: ” “oil cooler a...

  • Page 163: Fuel System

    Fuel system: 1g-1 fuel system precautions precautions for fuel system b649g11700001 warning ! Gasoline is highly flammable and explosive. Extreme care must be taken. Keep heat, sparks and flames away from gasoline..

  • Page 164

    1g-2 fuel system: general description i.D. No. Location b649g11701001 each carburetor has an i.D. Number “a” printed on its body. Fuel system description b649g11701002 fuel system the fuel system consists of a fuel tank, fuel filter, fuel valve, vacuum hose, fuel hose and carburetor assembly. When t...

  • Page 165

    Fuel system: 1g-3 fuel valve when the engine is not operating, the fuel valve (1) is kept closed by the tension of the spring (2), which closes the fuel passageway and stops the flow of fuel to the carburetors. When the engine has started, negative pressure (vacuum) “a” is generated in the combustio...

  • Page 166

    1g-4 fuel system: diaphragm and piston operation the carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve (1). The piston valve moves according to the negative pressure present on the downstream side of the venturi “a”....

  • Page 167

    Fuel system: 1g-5 slow system this system supplies fuel during engine operation when the throttle valve (1) is closed or slightly opened. The fuel from the float chamber (2) is metered by the pilot jet (3) where it mixes with air coming in through the pilot air jet (4). This mixture, rich with fuel,...

  • Page 168

    1g-6 fuel system: main system as the throttle valve (1) is opened, engine speed rises and negative pressure in the venturi “a” increases. This causes the piston valve (2) to move upward. The fuel in the float chamber (3) is metered by the main jet (4). The metered fuel enters the needle jet (5), mix...

  • Page 169

    Fuel system: 1g-7 starter (enricher) system pulling the starter (enricher) plunger causes fuel to be drawn into the starter circuit from the float chamber (1). The starter jet (2) meters this fuel. The fuel then flows into the fuel pipe (3) and mixes with the air coming from the float chamber (1). T...

  • Page 170

    1g-8 fuel system: float system the float (1) and needle valve (2) work in conjunction with one another. As the float (1) moves up and down, so does the needle valve (2). When there is a high fuel level in the float chamber (3), the float (1) rises and the needle valve (2) pushes up against the valve...

  • Page 171

    Fuel system: 1g-9 schematic and routing diagram carburetor hose routing diagram b649g11702002 8 9 12 2 4 7 1 3 5 8 11 10 5 - 15 5 - 15 air cleaner side engine side rh lh rh lh 6 i649g1170009-02 1. Fuel hose (connected to the carburetor and fuel valve) 5. Air vent hose (rh) 9. Air cleaner box drain h...

  • Page 172

    1g-10 fuel system: fuel tank drain hose and breather hose routing diagram b649g11702005 4 3 1 2 5 6 7 i649g1170010-02 1. Fuel tank drain hose 5. Air cleaner drain hose 2. Fuel tank breather hose no.1 6. Hoses : be careful not to bind the fuel tank drain hose and fuel tank breather hose with the othe...

  • Page 173

    Fuel system: 1g-11 throttle cable / starter cable routing diagram b649g11702004 1 2 3, [c] “a” “b” 3 5 4 3, [c] 3, [c] 1 2 6 7 “a” 3 - 5 mm (0.12 - 0.20 in) 0 mm (0 in) 0 mm (0 in) i649g1170011-06 1. No.1 throttle cable : after connecting the no.1 throttle cable, set the no.1 throttle thread length ...

  • Page 174

    1g-12 fuel system: diagnostic information and procedures carburetor symptom diagnosis b649g11704001 condition possible cause correction / reference item starting difficulty. Clogged starter jet. Clean. Clogged starter jet passage. Clean. Air leaking from joint between starter body and carburetor. Ti...

  • Page 175

    Fuel system: 1g-13 repair instructions fuel tank construction b649g11706018 “a” (a) 1 2, 3, 4 5 i649g1170013-03 1. Fuel valve 5. Rear bracket cushion : be careful not to mistake the assembling position and direction. 2. Gasket washer “a”: apply adhesive agent to the cushion rubber. 3. Gasket : 4.4 n...

  • Page 176

    1g-14 fuel system: fuel tank removal and installation b649g11706019 removal warning ! Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from gasoline. 1) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 2) remove the fuel tank mounting b...

  • Page 177

    Fuel system: 1g-15 • tighten the fuel valve mounting bolts to the specified torque. Tightening torque fuel valve mounting bolt (a): 4.4 n·m (0.44 kgf-m, 3.2 lb-ft) fuel filter inspection and cleaning b649g11706021 inspect and clean the fuel filter in the following procedures: 1) remove the fuel tank...

  • Page 178

    1g-16 fuel system: • set the triangle mark forward and tighten the fuel level gauge mounting bolts securely. Tightening torque fuel level gauge mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) fuel level gauge inspection b649g11706023 refer to “fuel level gauge inspection: in section 9c”. Throttle c...

  • Page 179

    Fuel system: 1g-17 carburetor components b649g11706001 carburetor related parts 1 6 7 3, 2, 3, 1 6 5, 5, 4 4 (b) 8 13 12, [a] 11 10 (a) 9, 5, 5, i649g1170027-02 1. Air vent hose 8. Throttle position sensor : 5.0 n ⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Fuel joint pipe (no.1) 9. Carburetor set shaft : 2.0 n ⋅m...

  • Page 180

    1g-18 fuel system: carburetor parts 1 2 3 6 8 4, 5 7 9 10 12 11 14 13 15 26 25 16 23, 19 22 18, 24 20 21 17 i649g1170077-01 1. Top cap 8. Spacer 15. Needle valve assembly 22. Starter jet 2. Spring 9. Jet needle 16. Float 23. Gasket (o-ring) 3. Jet needle stopper 10. Diaphragm 17. Needle jet 24. Floa...

  • Page 181

    Fuel system: 1g-19 carburetor assembly removal and installation b649g11706002 removal 1) remove the seat and frame covers. Refer to “exterior parts removal and installation: in section 9d”. 2) remove the fuel tank. Refer to “fuel tank removal and installation: ”. 3) remove the air cleaner box mounti...

  • Page 182

    1g-20 fuel system: • after all of the work has been completed, install the carburetor assembly onto the engine and perform the following adjustments. – engine idle speed. Refer to “engine idle speed inspection and adjustment: in section 0b”. – throttle cable play. Refer to “throttle cable play inspe...

  • Page 183

    Fuel system: 1g-21 7) remove the top cap (5). Caution ! Do not use compressed air on the carburetor body, before removing the diaphragm; this may damage the diaphragm. 8) remove the spring (6) and the piston valve along with its diaphragm (7). 9) remove the o-ring (8). 10) remove the jet needle stop...

  • Page 184

    1g-22 fuel system: 13) remove the float chamber (18). 14) remove the carburetor heater (19). (for e-02, 19) 15) remove the o-ring (20). 16) remove the float pin (21) and then remove the float (22) and needle valve (23). 17) remove the following parts. • main jet (24) • needle jet (25) • pilot jet (2...

  • Page 185

    Fuel system: 1g-23 3) carefully drill through the plug (2). 4) thread a self-tapping sheet metal screw into the plug (2). 5) pull on the screw head with pliers to remove the plug. 6) carefully clean any metal shavings from the area. 7) slowly turn the pilot screw clockwise and count the number of tu...

  • Page 186

    1g-24 fuel system: • before installing the top cap, install the new o-ring. Caution ! Replace the o-ring with a new one. • position the throttle valve control lever (1) between the throttle valve synchronizing screw and spring as shown. • apply thin coat of the grease to the fuel joint pipe o- rings...

  • Page 187

    Fuel system: 1g-25 5) measure the float height “a” while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue “a” as necessary to bring the float height “a” to the specified level. Special tool : 09900–20102 (vernire calipers) float height “a” 13.0 ± 1.0 mm (0.51...

  • Page 188

    1g-26 fuel system: 2) clean all circuits of the carburetor thoroughly – not just the perceived problem area. 3) clean the circuits in the carburetor body with a spray-type cleaner and allow each circuit to soak, if necessary, to loosen dirt and varnish. 4) blow the body dry using compressed air. Cau...

  • Page 189

    Fuel system: 1g-27 2) measure the resistance between the terminals “a” to “c” as shown. If the resistance is not within the specified value, replace the tp sensor. Refer to “tp sensor replacement: ”. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) thro...

  • Page 190

    1g-28 fuel system: 6) under above condition, position the tp sensor until resistance is 2.66 – 4.94 k Ω. 7) when the resistance is within specification, tighten the tp sensor mounting screws. Tightening torque tp sensor screw (a): 2.0 n·m (0.2 kgf-m, 1.5 lb- ft) 8) connect the tp sensor coupler. Car...

  • Page 191

    Fuel system: 1g-29 11) check the vacuum of the four cylinders. 12) if the columns of vacuum indicator are not at the same level, adjust the throttle valves synchronizing screws “1”, “2” and “3”. Note during balancing the throttle valves, always set the engine idle speed, using throttle stop screw. A...

  • Page 192

    1g-30 fuel system: specifications service data b649g11707004 carburetor oil tightening torque specifications b649g11707005 note the specified tightening torque is also described in the following. “fuel tank construction: ” “carburetor components: ” reference: for the tightening torque of fastener no...

  • Page 193

    Fuel system: 1g-31 special tools and equipment recommended service material b649g11708001 note required service material is also described in the following. “carburetor components: ” special tool b649g11708002 material suzuki recommended product or specification note grease suzuki super grease a or ...

  • Page 194: Ignition System

    1h-1 ignition system: ignition system schematic and routing diagram ignition system diagram b649g11802001 the fully transistorized ignition system consists of the following components: a ckp sensor (which is made up of the ckp sensor rotor and ckp sensor), ignitor, throttle position sensor, two igni...

  • Page 195

    Ignition system: 1h-2 diagnostic information and procedures ignition system symptom diagnosis b649g11804005 condition possible cause correction / reference item spark plug not sparking damaged spark plug. Replace. Damaged spark plug cap. Replace. Fouled spark plug. Clean or replace. Wet spark plug. ...

  • Page 196

    1h-3 ignition system: no spark or poor spark b649g11804001 troubleshooting note check that the transmission is in neutral and the engine stop switch is in the “run” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step action yes ...

  • Page 197

    Ignition system: 1h-4 repair instructions ignition coil and spark plug cap components b649g11806007 spark plug removal and installation b649g11806017 refer to “spark plug removal and installation: in section 0b”. Spark plug inspection and cleaning b649g11806018 refer to “spark plug inspection and cl...

  • Page 198

    1h-5 ignition system: 4) connect the multi-circuit tester with the peak voltage adaptor as follows. Caution ! Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual. Note do not disconnect the ignition coil primary lead wire. Special tool (a): 099...

  • Page 199

    Ignition system: 1h-6 4) measure the ignition coil resistance in both the primary and secondary windings. If the windings are in sound condition, their resistance should be close to the specified values. Special tool : 09900–25008 (multi-circuit tester set) ignition coil resistance primary: approx. ...

  • Page 200

    1h-7 ignition system: 3) connect the multi-circuit tester with the peak volt adaptor as follows. Caution ! Before using the multi-circuit tester and peak voltage adaptor, refer to the appropriate instruction manual. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication: vol...

  • Page 201

    Ignition system: 1h-8 d) measure the ckp sensor peak voltage in the same manner as on the ignitor coupler. If the peak voltage on the ckp sensor lead wire couplers is within specification, but on the ignitor coupler is out of specification, the wire harness must be replaced. If both peak voltages ar...

  • Page 202

    1h-9 ignition system: 5) disconnect the oil pressure switch lead wire (2). 6) remove the ckp sensor. Refer to “wiring harness routing diagram: in section 9a”. Installation install the ckp sensor in the reverse order of removal. Pay attention to the following points: • install the ckp sensor (1). • b...

  • Page 203

    Ignition system: 1h-10 • apply a small quantity of thread lock “1342” to the ckp sensor cover bolts. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) engine stop switch inspection b649g11806013 inspect the engine stop switch in the following procedures: 1) remove the right fr...

  • Page 204

    1h-11 ignition system: specifications service data b649g11807002 electrical unit: mm (in) tightening torque specifications b649g11807003 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications: in section 0c”. Special tools and equip...

  • Page 205: Starting System

    Starting system: 1i-1 starting system general description starting system diagram b649g11901001 refer to “wire color symbols: in section 0a”. The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-st...

  • Page 206

    1i-2 starting system: the circuit consists of the turn signal/side-stand relay, neutral indicator light and switches. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down. The gear position and side-stan...

  • Page 207

    Starting system: 1i-3 schematic and routing diagram starting system diagram b649g11902001 refer to “wire color symbols: in section 0a”. Component location starting system components location b649g11903001 refer to “electrical components location: in section 0a”. Diagnostic information and procedures...

  • Page 208

    1i-4 starting system: starter motor will not run b649g11904001 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b649g11904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 209

    Starting system: 1i-5 repair instructions starter motor components b649g11906013 3 7 10 (b) 12, 4 5 4 2 1 (a) 11, 13 6 8 9 (c) i649g1190005-03 1. O-ring 6. Armature 11. Starter motor lead wire nut : 6.5 n ⋅m (0.65 kgf-m, 4.7 lb-ft) 2. Housing end (inside) 7. Washer set 12. Starter motor mounting bol...

  • Page 210

    1i-6 starting system: starter motor removal and installation b649g11906001 refer to “electrical components location: in section 0a”. Removal 1) disconnect the battery (–) lead wire. Refer to “battery removal and installation: in section 1j”. 2) remove the cooling hose mounting bolts. 3) disconnect t...

  • Page 211

    Starting system: 1i-7 • install the cooling hose and tighten its mounting bolts to the specified torque. Caution ! Replace the o-ring (1) with a new one to prevent oil leakage. Tightening torque cooling hose mounting bolt (c): 10 n·m (1.0 kgf- m, 7.0 lb-ft) starter motor disassembly and assembly b64...

  • Page 212

    1i-8 starting system: starter motor inspection b649g11906003 refer to “starter motor disassembly and assembly: ”. Carbon brush inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush holder set with a new one. Mea...

  • Page 213

    Starting system: 1i-9 starter relay removal and installation b649g11906014 refer to “electrical components location: in section 0a”. Removal 1) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 2) disconnect the battery (–) lead wire from the battery. 3) disconnect ...

  • Page 214

    1i-10 starting system: 3) measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Special tool (a): 09900–25008 (multi-circuit tester set) starter relay resistance 3 – 6 Ω 4...

  • Page 215

    Starting system: 1i-11 4) connect the side-stand switch coupler. 5) install the left frame cover. Refer to “exterior parts removal and installation: in section 9d”. Turn signal / side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. Side-...

  • Page 216

    1i-12 starting system: 3) check the continuity between blue and black/white lead wires with the transmission in “neutral”. Caution ! When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged. Special tool : 0990...

  • Page 217

    Starting system: 1i-13 4) remove the idle gear shaft (1) and starter idle gear (2). 5) hold the starter clutch assembly using the special tool and then loosen the starter clutch mounting bolt. Special tool (a): 09920–34840 (starter clutch holder) note do not remove the starter clutch mounting bolt a...

  • Page 218

    1i-14 starting system: • install the starter idle gear (1) and its shaft (2). • apply a light coat of suzuki bond to the starter clutch cover gasket mating surface as shown. : sealant 99000–31140 (suzuki bond 1207b or equivalent) • install the dowel pin, new gasket and starter clutch cover, and tigh...

  • Page 219

    Starting system: 1i-15 starter button inspection b649g11906021 inspect the starter button in the following procedures: 1) remove the right frame head cover. (gsf1200) refer to “exterior parts removal and installation: in section 9d”. 2) disconnect the right handlebar switch coupler (1). 3) inspect t...

  • Page 220

    1i-16 starting system: specifications service data b649g11907002 unit: mm (in) tightening torque specifications b649g11907003 note the specified tightening torque is also described in the following. “starter motor components: ” “starter clutch components: ” reference: for the tightening torque of fa...

  • Page 221

    Starting system: 1i-17 special tools and equipment recommended service material b649g11908001 note required service material is also described in the following. “starter motor components: ” “starter clutch components: ” special tool b649g11908002 material suzuki recommended product or specification ...

  • Page 222: Charging System

    1j-1 charging system: charging system general description charging system description (generator with ic regulator) b649g11a01001 the generator features a solid-state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit is attached to...

  • Page 223

    Charging system: 1j-2 component location charging system components location b649g11a03001 refer to “electrical components location: in section 0a”. Diagnostic information and procedures charging system symptom diagnosis b649g11a04009 condition possible cause correction / reference item generator do...

  • Page 224

    1j-3 charging system: battery runs down quickly b649g11a04001 troubleshooting step action yes no 1 check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories. Go to step 2. 2 check the battery for current leakage. Refer to “battery current leaka...

  • Page 225

    Charging system: 1j-4 repair instructions battery current leakage inspection b649g11a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch to the off position. 2) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 3) disco...

  • Page 226

    1j-5 charging system: generator components b649g11a06010 1 3 6 8 11 12 13 14 10 9 15 16 17 18 19 (a) 20, 2, 5, 4, (c) 22, (c) 22, (d) 23, (b) 21, 7 i649g11a0004-07 1. Generator driven gear 9. Stud bolt 17. Ic regulator : 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Damper (4 pcs.) 10. Retainer 18. Brush holde...

  • Page 227

    Charging system: 1j-6 generator removal and installation b649g11a06003 refer to “electrical components location: in section 0a”. Removal 1) disconnect the battery (–) lead wire. Refer to “battery removal and installation: ”. 2) disengage the gearshift lever link by removing bolt. 3) remove the engin...

  • Page 228

    1j-7 charging system: generator disassembly and assembly b649g11a06011 refer to “generator removal and installation: ”. Disassembly 1) hold the generator driven gear using a vise “a” and two pieces of wood “b” as shown. Then, remove the generator driven gear nut. Caution ! Do not hold the damper hou...

  • Page 229

    Charging system: 1j-8 9) remove the rotor (9) from the generator end housing (10) using a hand press “a” as shown. 10) remove the expander ring. 11) remove the rotor bearing (11) using the special tool. Special tool (b): 09913–60910 (bearing remover) note if there is no abnormal condition the rotor ...

  • Page 230

    1j-9 charging system: • apply a small quantity of thread lock “1342” to the bearing retainer screws and tighten them to the specified torque. : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) tightening torque bearing retainer screw (a): 2.5 n·m (0.25 kgf-m, 1.8 lb-ft) • insta...

  • Page 231

    Charging system: 1j-10 • tighten the generator driven gear nut to the specified torque. Tightening torque generator driven gear nut (c): 55 n·m (5.5 kgf-m, 4.0 lb-ft) note after tightening the generator driven gear nut to the specified torque, stake the nut using a punch. Generator parts inspection ...

  • Page 232

    1j-11 charging system: rotor coil continuity check measure the continuity between the two slip rings (1) on the rotor coil using a tester. If there is no continuity, replace the rotor. Also check that the rotor is properly insulated. Slip rings if the slip rings are dirty, polish them with #400 sand...

  • Page 233

    Charging system: 1j-12 ic regulator measure the voltage between terminal “f” and terminal “b”. If the voltage measured is excessively out of specification, replace the ic regulator. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication diode test ( ) note if the tester read...

  • Page 234

    1j-13 charging system: 3) insert the nozzles of the electrolyte container (3) into the electrolyte filler holes of the battery. 4) hold the electrolyte container firmly so that it does not fall. Note do not allow any of the electrolyte to spill. 5) make sure that air bubbles (4) rise to the top of e...

  • Page 235

    Charging system: 1j-14 charging for initial charging, use the charger specially designed for mf battery. Caution ! • for charging the battery, make sure to use the charger specially designed for mf battery. Otherwise, the battery may be overcharged resulting in shortened service life. • do not remov...

  • Page 236

    1j-15 charging system: battery removal and installation b649g11a06014 refer to “electrical components location: in section 0a”. Removal 1) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 2) disconnect the battery (–) lead wire (1). 3) disconnect the battery (+) le...

  • Page 237

    Charging system: 1j-16 specifications service data b649g11a07001 battery caution ! Never use anything except the specified battery. Generator tightening torque specifications b649g11a07002 note the specified tightening torque is also described in the following. “generator components: ” reference: fo...

  • Page 238

    1j-17 charging system: special tools and equipment recommended service material b649g11a08001 note required service material is also described in the following. “generator components: ” special tool b649g11a08002 material suzuki recommended product or specification note grease suzuki super grease a ...

  • Page 239: Exhaust System

    Exhaust system: 1k-1 exhaust system precautions precautions for exhaust system b649g11b00001 warning ! To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure that ...

  • Page 240

    1k-2 exhaust system: exhaust pipe / muffler removal and installation b649g11b06005 removal 1) loosen the muffler connecting bolt (1). 2) remove the muffler by removing the mounting bolts (2). Note support the muffler to prevent it from falling. 3) remove the exhaust pipe by removing the bolts. Note ...

  • Page 241

    Exhaust system: 1k-3 • tighten the exhaust pipe bolts, muffler connecting bolt and muffler mounting bolts to the specified torque. Tightening torque exhaust pipe bolt (a): 23 n·m (2.3 kgf-m, 16.5 lb- ft) muffler connecting bolt (b): 23 n·m (2.3 kgf-m, 16.5 lb-ft) muffler mounting bolt (c): 23 n·m (2...

  • Page 242

    1k-4 exhaust system: specifications tightening torque specifications b649g11b07001 note the specified tightening torque is also described in the following. “exhaust system construction: ” reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque spec...

  • Page 243: Section 2

    Table of contents 2- i 2 section 2 contents suspension precautions .................................................2-1 precautions............................................................. 2-1 precautions for suspension .................................. 2-1 suspension general diagnosis............

  • Page 244: Precautions

    2-1 precautions: precautions precautions precautions for suspension b649g12000001 refer to “general precautions: in section 00”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque peri...

  • Page 245: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b649g12104009 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defecti...

  • Page 246: Front Suspension

    2b-1 front suspension: front suspension repair instructions front fork components b649g12206001 1 3 5 7 8, (a) 9, (b) 10, 11 13 14 15 19 20 22 21 (b) 16, (a) 18, 6, 12, 4, 2, 17, i649g1220038-04 1. Front fork protector 8. Gasket 15. Spring adjuster 22. Spring 2. Dust seal 9. Damper rod bolt 16. Fron...

  • Page 247

    Front suspension: 2b-2 front fork removal and installation b649g12206002 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation: in section 2d”. Caution ! • make sure that the motorcycle is supported securely. • do not operate the front brake lever with t...

  • Page 248

    2b-3 front suspension: 4) tighten the front fork lower clamp bolts. Tightening torque front fork lower clamp bolt (b): 23 n·m (2.3 kgf- m, 16.5 lb-ft) 5) tighten the front fork upper fork clamp bolt. Tightening torque front fork upper clamp bolt (c): 23 n·m (2.3 kgf- m, 16.5 lb-ft) 6) set the front ...

  • Page 249

    Front suspension: 2b-4 2) remove the spring seat (2). 3) remove the front fork cap bolt with spring adjuster (3) by loosening the inner rod lock-nut (4). 4) remove the spacer (5), washer (6) and spring (7). 5) invert the fork and stroke it several times to drain out fork oil. 6) hold the fork invert...

  • Page 250

    2b-5 front suspension: 12) remove the oil seal by slowly pulling out the inner tube. Note be careful not to damage the inner tube. 13) remove the following parts. • oil seal (13) • oil seal retainer (14) • outer tube slide metal (15) • inner tube slide metal (16) assembly assemble the front fork in ...

  • Page 251

    Front suspension: 2b-6 • install the oil seal stopper ring (4). Caution ! Make sure that the oil seal stopper ring is fitted securely. • install the dust seal (5). Damper rod bolt • insert the inner rod/damper rod (cartridge) (6) and the oil lock piece (7) into the inner tube. • apply thread lock “1...

  • Page 252

    2b-7 front suspension: • refill specified front fork oil up to the top level of the inner tube again. Move the inner tube up and down several strokes until bubbles do not come out from the oil. • keep the front fork vertically and wait 5 – 6 minutes. Note • always keep oil level over the cartridge t...

  • Page 253

    Front suspension: 2b-8 • tighten the lock-nut (2) to the specified torque. Tightening torque inner rod lock-nut (a): 20 n·m (2.0 kgf-m, 14.5 lb- ft) caution ! Use a new o-ring (3) to prevent oil leakage. • apply fork oil lightly to the o-ring (3). : oil 99000–99001–ss8 (suzuki fork oil ss-08 or equi...

  • Page 254

    2b-9 front suspension: specifications service data b649g12207004 front fork unit: mm (in) oil tightening torque specifications b649g12207005 note the specified tightening torque is also described in the following. “front fork components: ” reference: for the tightening torque of fastener not specifi...

  • Page 255

    Front suspension: 2b-10 special tools and equipment recommended service material b649g12208001 note required service material is also described in the following. “front fork components: ” special tool b649g12208002 material suzuki recommended product or specification note oil suzuki fork oil ss-08 o...

  • Page 256: Rear Suspension

    2c-1 rear suspension: rear suspension repair instructions rear suspension components b649g12306001 1 2 (a) 2, 3 (b) 6, 3 (b) 6, (b) 5, 4 7 9 10 8 11 (c) 12, i649g1230043-01 1. Rear shock absorber 6. Cushion rod mounting nut 11. Chain buffer : apply grease to bearing. 2. Rear shock absorber mounting ...

  • Page 257

    Rear suspension: 2c-2 rear suspension assembly construction b649g12306019 ) left right (a) 1, (a) 2, 1 2 3 4 5 6 (b) 4, (b) 5, (b) 3, (c) 6, i649g1230040-04 1. Rear shock absorber mounting nut (upper) 4. Cushion rod (lower) : 50 n ⋅m (5.0 kgf-m 36.0 lb-ft) : apply grease to bearing. 2. Rear shock ab...

  • Page 258

    2c-3 rear suspension: rear shock absorber removal and installation b649g12306002 removal 1) place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the rear shock absorber. 2) remove the left frame cover. Refer to “exterior parts removal and installation: in...

  • Page 259

    Rear suspension: 2c-4 rear suspension adjustment b649g12306005 after installing the rear suspension, adjust the spring pre-load and damping force as follows. Spring pre-load adjustment turn the spring tension ring (1) to the desired position. Note position 1 provides the softest spring tension and p...

  • Page 260

    2c-5 rear suspension: 2) wrap rear shock absorber (1) with a vinyl bag (2) and fix it on a vise as shown. 3) drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas while taking care not to get the vinyl bag entangled with the drill bit. Warning ! •...

  • Page 261

    Rear suspension: 2c-6 cushion lever bearing 1) insert the spacers into bearings. 2) check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a new one. Refer to “cushion lever bearing removal and installation: ”. Cushion lever inspect the cushion lever f...

  • Page 262

    2c-7 rear suspension: installation caution ! The removed bearings must be replaced with new ones. 1) press the bearings into the cushion lever with the special tool. Note when installing the bearing, stamped mark on the bearing must face outside. Special tool (a): 09924–84521 (bearing installer set)...

  • Page 263

    Rear suspension: 2c-8 5) remove the pivot shaft end caps (4), left and right. 6) remove the swingarm by removing the pivot shaft and nut (5). 7) remove the chain buffer (6). 8) remove the cushion rods (7). 9) remove the plate (8). Installation install the swingarm in the reverse order of removal. Pa...

  • Page 264

    2c-9 rear suspension: • tighten the cushion lever, cushion rod lower and rear shock absorber lower mounting nut to the specified torque. Tightening torque cushion rod mounting nut (a): 78 n·m (7.8 kgf-m, 56.5 lb-ft) cushion lever mounting nut (b): 78 n·m (7.8 kgf- m, 56.5 lb-ft) rear shock absorber ...

  • Page 265

    Rear suspension: 2c-10 swingarm inspect the swingarm for damage. If any defect is found, replace the swingarm with a new one. Cushion rod inspect the cushion rods for damage and bend. If any defects are found, replace the cushion rods with new ones. Swingarm pivot shaft measure the swingarm pivot sh...

  • Page 266

    2c-11 rear suspension: installation caution ! The removed bearings must be replaced with new ones. 1) press the swingarm cushion rod bearings with the special tool. Note when installing the bearing, stamped mark on the bearing must face outside. Special tool (a): 09924–84521 (bearing installer set) ...

  • Page 267

    Rear suspension: 2c-12 specifications service data b649g12307002 unit: mm (in) tightening torque specifications b649g12307003 note the specified tightening torque is also described in the following. “rear suspension components: ” “rear suspension assembly construction: ” reference: for the tightenin...

  • Page 268

    2c-13 rear suspension: special tools and equipment recommended service material b649g12308001 note required service material is also described in the following. “rear suspension components: ” “rear suspension assembly construction: ” special tool b649g12308002 material suzuki recommended product or ...

  • Page 269: Wheels and Tires

    Wheels and tires: 2d-1 wheels and tires precautions precautions for wheel and tire b649g12400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. • under-inflated tires make smooth cornering dif...

  • Page 270

    2d-2 wheels and tires: repair instructions front wheel components b649g12406003 (b) 9, 8 (a) 2, 3 5, 4, 10 11 7 6 5, 4, 12, 1 3 (a) 2, i649g1240052-02 1. Front axle 6. Spacer 11. Wheel balancer : apply thread lock to thread part. 2. Brake disc bolt 7. Front wheel 12. Air valve : do not reuse. 3. Bra...

  • Page 271

    Wheels and tires: 2d-3 front wheel assembly construction b649g12406027 left right (b) 2, (a) 1, (b) 2, (a) 1, (c) 3, “ a ” 4, (a) 4, (a) i649g1240050-04 1. Brake disc bolt “a”: clearance : apply grease. 2. Brake caliper mounting bolt : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) : apply thread lock to thread pa...

  • Page 272

    2d-4 wheels and tires: front wheel assembly removal and installation b649g12406005 removal 1) support the motorcycle with a jack or a wooden block. 2) remove the brake calipers. Refer to “front brake caliper removal and installation: in section 4b”. Caution ! Do not operate the brake lever while rem...

  • Page 273

    Wheels and tires: 2d-5 2) install the front wheel with the front axle and tighten the front axle bolt temporarily. Warning ! The directional arrow on the tire should point to the wheel rotation, when remounting the wheel. 3) tighten the brake caliper mounting bolts to the specified torque. Tightenin...

  • Page 274

    2d-6 wheels and tires: front wheel related parts inspection b649g12406019 refer to “front wheel assembly removal and installation: ” tire refer to “tire inspection: in section 0b”. Front brake disc refer to “front brake disc inspection: in section 4b”. Dust seal inspect the dust seal lips for wear o...

  • Page 275

    Wheels and tires: 2d-7 3) remove the bearings (2) using the special tool. Special tool (b): 09921–20240 (bearing remover set) 4) remove the spacer (3). Installation caution ! The removed dust seals and bearings must be replaced with new ones. 1) apply suzuki super grease “a” to the wheel bearings. :...

  • Page 276

    2d-8 wheels and tires: 3) install the dust seals with the special tool. Special tool (b): 09913–70210 (bearing installer set) 4) apply suzuki super grease “a” to the lip of dust seals. : grease 99000–25010 (suzuki super grease a or equivalent) 5) install the front wheel assembly. Refer to “front whe...

  • Page 277

    Wheels and tires: 2d-9 rear wheel components b649g12406004 14 (c) 13 17 18 15 8, 9 16, 7 6 5 (b) 2 (a) [a] [b] 1 4, 3, 12 11, 10, i649g1240053-03 1. Spacer 8. Bearing 15. Rear wheel : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Rear sprocket 9. Spacer 16. Air valve : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Dust s...

  • Page 278

    2d-10 wheels and tires: rear wheel assembly construction b649g12406028 (d) 4, (a) 1, (b) 2, (c) 3, “ a ” left right [a] i649g1240051-04 1. Rear sprocket nut 4. Brake disc bolt : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut “a”: clearance : 100 n ⋅m (10.0 kgf-m, ...

  • Page 279

    Wheels and tires: 2d-11 rear wheel assembly removal and installation b649g12406010 removal 1) support the motorcycle with the center stand. 2) remove the cotter pin. (for e-28) 3) remove the rear axle nut (1) and draw out the rear axle. 4) remove the rear axle and disengage the drive chain from the ...

  • Page 280

    2d-12 wheels and tires: rear wheel related parts inspection b649g12406021 refer to “rear wheel assembly removal and installation: ”. Tire refer to “tire inspection: in section 0b”. Rear brake disc refer to “rear brake disc inspection: in section 4c”. Wheel damper refer to “drive chain related parts ...

  • Page 281

    Wheels and tires: 2d-13 bearing inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to “rear wheel dust seal / bearing / removal and instal...

  • Page 282

    2d-14 wheels and tires: 2) first install the right wheel bearing, then install the left wheel bearing with the special tools. Special tool (a): 09941–34513 (steering race installer) (b): 09924–84510 (bearing installer set) caution ! The sealed cover of the bearing must face outside. 3) install a new...

  • Page 283

    Wheels and tires: 2d-15 3) remove the valve core. 4) remove the tire using the tire charger. Caution ! For operating procedures, refer to the instructions supplied by the tire changer manufacturer. Note when removing the tire in case of repair or inspection, mark the tire with a chalk to indicate th...

  • Page 284

    2d-16 wheels and tires: 7) when the bead has been fitted properly, install the valve core and adjust the pressure to specification. 8) as necessary, adjust the tire balance. Refer to “wheel balance check and adjustment: ”. Cold inflation tire pressure 9) install the mounting drum to the rear wheel. ...

  • Page 285

    Wheels and tires: 2d-17 2) remove the tire. Refer to “tire removal and installation: ”. 3) remove the air valve (1) from the wheel. Installation install the air valve in the reverse order of removal. Pay attention to the following points: • any dust or rust around the valve hole (2) must be cleaned ...

  • Page 286

    2d-18 wheels and tires: specifications service data b649g12407002 wheel unit: mm (in) tire tightening torque specifications b649g12407003 note the specified tightening torque is also described in the following. “front wheel components: ” “front wheel assembly construction: ” “rear wheel components: ...

  • Page 287

    Wheels and tires: 2d-19 special tools and equipment recommended service material b649g12408001 note required service material is also described in the following. “front wheel components: ” “front wheel assembly construction: ” “rear wheel components: ” “rear wheel assembly construction: ” special to...

  • Page 288

    2d-20 wheels and tires:.

  • Page 289: Section 3

    Table of contents 3- i 3 section 3 contents driveline / axle precautions .................................................3-1 precautions............................................................. 3-1 precautions for driveline / axle ............................. 3-1 drive chain / drive train / dr...

  • Page 290: Precautions

    3-1 precautions: precautions precautions precautions for driveline / axle b649g13000001 refer to “general precautions: in section 00”. Warning ! Never inspect or adjust the drive chain while the engine is running. Caution ! • do not use trichloroethylene, gasoline or any similar solvent. These fluid...

  • Page 291

    Drive chain / drive train / drive shaft: 3a-1 drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b649g13104003 repair instructions drive chain related components b649g13106001 condition possible cause correction / reference item n...

  • Page 292

    3a-2 drive chain / drive train / drive shaft: engine sprocket removal and installation b649g13106008 removal 1) disengage the gearshift lever link by removing the bolt. 2) remove the engine sprocket cover along with the clutch release cylinder and speed sensor. 3) remove the speed sensor rotor (1) b...

  • Page 293

    Drive chain / drive train / drive shaft: 3a-3 • apply a small quantity of thread lock “1342” to the speed sensor rotor bolt (3). : thread lock cement 99000–32050 (thread lock cement 1342 or equivalent) • tighten the speed sensor rotor bolt (3) to the specified torque. Tightening torque speed sensor ...

  • Page 294

    3a-4 drive chain / drive train / drive shaft: installation install the rear sprocket and rear sprocket mounting drum in the reverse order of removal. Pay attention to the following points: • apply grease to the contacting surface between the rear wheel hub and the mounting drum. : grease 99000–25010...

  • Page 295

    Drive chain / drive train / drive shaft: 3a-5 sprocket mounting drum dust seal / bearing removal and installation b649g13106011 removal 1) remove the rear wheel assembly. Refer to “rear wheel assembly removal and installation: in section 2d”. 2) remove the mounting drum from the rear wheel hub. 3) r...

  • Page 296

    3a-6 drive chain / drive train / drive shaft: drive chain replacement b649g13106012 use the special tool in the following procedures, to cut and rejoin the drive chain. Note when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Special tool : 09922–...

  • Page 297

    Drive chain / drive train / drive shaft: 3a-7 6) remove the joint pin (9) of the other side of joint plate. Caution ! Never reuse joint pins, o-rings and plates. Drive chain connecting warning ! Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause sever...

  • Page 298

    3a-8 drive chain / drive train / drive shaft: 8) continue pressing the joint plate until the distance between the two joint plates come to the specification. Joint plate distance specification “a” 21.85 – 22.15 mm (0.860 – 0.872 in) caution ! Should pressing of the joint plate be made excessively be...

  • Page 299

    Drive chain / drive train / drive shaft: 3a-9 specifications service data b649g13107002 drive chain unit: mm (in) tightening torque specifications b649g13107003 note the specified tightening torque is also described in the following. “drive chain related components: ” reference: for the tightening t...

  • Page 300

    3a-10 drive chain / drive train / drive shaft: special tools and equipment recommended service material b649g13108001 note required service material is also described in the following. “drive chain related components: ” special tool b649g13108002 material suzuki recommended product or specification ...

  • Page 301: Section 4

    Table of contents 4- i 4 section 4 contents brake precautions .................................................4-1 precautions............................................................. 4-1 precautions for brake system .............................. 4-1 brake fluid information........................

  • Page 302: Precautions

    4-1 precautions: precautions precautions precautions for brake system b649g14000001 refer to “general precautions: in section 00”. Brake fluid information b649g14000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid...

  • Page 303

    Brake control system and diagnosis: 4a-1 brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b649g14102001 gsf1200 (a) (a) 28 1 1 2 (a) (c) 14 42 (b) (b) (c) (a) 2 42 2 3 3 4 6 5 i649g1410001-04 1. Front brake hose no.1 6: clamp : insert the clamp to the...

  • Page 304

    4a-2 brake control system and diagnosis: gsf1200s (a) 1 2 (a) (c) 14 49 42 (b) (b) (c) (a) 2 42 2 3 6 5 (a) 2 7 i649g1410002-04 1. Front brake hose no.1 6: clamp : insert the clamp to the hole of the front fender fully. 2. Front brake hose no.2 7: front brake hose no.1 : pass the front brake hose no...

  • Page 305

    Brake control system and diagnosis: 4a-3 rear brake hose routing diagram b649g14102002 (a) 42 (a) (b) (a) 28 2 2 1 3 3 3 (d) (c) i649g1410003-05 1. Brake hose clamp : brake hose clamp ends should face forward. : 6 n ⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Brake hose clamp : brake hose clamp ends should face ba...

  • Page 306

    4a-4 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b649g14104001 repair instructions brake pedal height inspection and adjustment b649g14106017 refer to “brake system inspection: in section 0b”. Front brake light switch inspection b649g14106018 ins...

  • Page 307

    Brake control system and diagnosis: 4a-5 rear brake light switch inspection b649g14106019 inspect the rear brake light switch in the following procedures: 1) disconnect the rear brake light switch lead coupler (1). 2) inspect the switch for continuity with a tester. If any abnormality is found, repl...

  • Page 308

    4a-6 brake control system and diagnosis: 4) loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. 5) close the air bleeder valve, pump and squeeze the le...

  • Page 309

    Brake control system and diagnosis: 4a-7 6) loosen the air bleeder valve and pump the brake lever until the old brake fluid flows out of the brake system. 7) close the air bleeder valve and disconnect the clear hose. 8) fill the reservoir with new brake fluid to the upper line of the reservoir. Tigh...

  • Page 310

    4a-8 brake control system and diagnosis: front brake hose removal and installation b649g14106025 removal 1) drain brake fluid. Refer to “brake fluid replacement: ”. 2) remove the front brake hoses as shown in the front brake hose routing diagram. Refer to “front brake hose routing diagram: ”. Instal...

  • Page 311

    Brake control system and diagnosis: 4a-9 front brake master cylinder assembly removal and installation b649g14106028 removal 1) drain brake fluid. Refer to “brake fluid replacement: ”. 2) disconnect the front brake light switch lead coupler (1). 3) place a rag underneath the brake hose union bolt (2...

  • Page 312

    4a-10 brake control system and diagnosis: front master cylinder / brake lever disassembly and assembly b649g14106029 refer to “front brake master cylinder assembly removal and installation: ”. Disassembly 1) remove the brake lever (1) and brake light switch (2). 2) remove the reservoir cap (3), plat...

  • Page 313

    Brake control system and diagnosis: 4a-11 • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • apply suzuki silicone grease to the brake lever pivot bolt. • apply suzuki silicone grease to the contact point between piston and brake leve...

  • Page 314

    4a-12 brake control system and diagnosis: rear brake master cylinder components b649g14106031 rear brake master cylinder assembly removal and installation b649g14106032 removal 1) remove the right frame cover. Refer to “exterior parts removal and installation: in section 9d”. 2) drain brake fluid. R...

  • Page 315

    Brake control system and diagnosis: 4a-13 installation install the rear brake master cylinder in the reverse order of removal. Pay attention to the following points: caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. • tighten the master cylinder mounting bolts...

  • Page 316

    4a-14 brake control system and diagnosis: assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the brake fluid off after washing the comp...

  • Page 317

    Brake control system and diagnosis: 4a-15 specifications service data b649g14107004 brake unit: mm (in) oil tightening torque specifications b649g14107005 note the specified tightening torque is also described in the following. “front brake hose routing diagram: ” “rear brake hose routing diagram: ”...

  • Page 318

    4a-16 brake control system and diagnosis: special tools and equipment recommended service material b649g14108001 note required service material is also described in the following. “front brake master cylinder components: ” “rear brake master cylinder components: ” special tool b649g14108002 material...

  • Page 319: Front Brakes

    Front brakes: 4b-1 front brakes repair instructions front brake components b649g14206011 1, 2, 3, 3, 2, (a) (b) (c) (d) 5 6 (e) 4 i649g1420001-04 1. O-ring 6. Front brake disc : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal : 7.5 n ⋅m (0.75 kgf-m, 5.5 lb-ft) : apply thread lock to thread part. 3. D...

  • Page 320

    4b-2 front brakes: front brake pad inspection b649g14206012 the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement: ”. Caution ! Replace the br...

  • Page 321

    Front brakes: 4b-3 front brake caliper removal and installation b649g14206014 removal 1) drain brake fluid. Refer to “brake fluid replacement: in section 4a”. 2) remove the brake hoses from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle. Note • place a ...

  • Page 322

    4b-4 front brakes: 2) separate the caliper halves to remove the caliper housing bolts. Special tool (a): 09930–11920 (torx bit (jt 40h)) (b): 09930–11940 (bit holder) 3) remove the o-ring. 4) place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed ...

  • Page 323

    Front brakes: 4b-5 • apply the brake fluid to piston seals (1) and dust seals (2). Caution ! • replace the piston seals (1) and dust seals (2) with new ones bf: brake fluid (dot 4) • install the piston seals as shown. • install a new o-ring and reassemble caliper halves. Caution ! Replace the o-ring...

  • Page 324

    4b-6 front brakes: front brake disc removal and installation b649g14206017 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation: in section 2d”. 2) remove the front brake disc. Installation install the front brake disc in the reverse order of removal. P...

  • Page 325

    Front brakes: 4b-7 specifications service data b649g14207004 brake unit: mm (in) oil tightening torque specifications b649g14207005 note the specified tightening torque is also described in the following. “front brake components: ” reference: for the tightening torque of fastener not specified in th...

  • Page 326

    4b-8 front brakes: special tools and equipment recommended service material b649g14208001 note required service material is also described in the following. “front brake components: ” special tool b649g14208002 material suzuki recommended product or specification note brake fluid dot 4 — ) / ) threa...

  • Page 327: Rear Brakes

    Rear brakes: 4c-1 rear brakes repair instructions rear brake components b649g14306011 1 2 4, 3, (a) (b) (c) (d) (e) (f) 6 5 i649g1430001-04 1. Rear caliper bracket : 6.0 n ⋅m (0.6 kgf-m, 4.5 lb-ft) : apply silicone grease to sliding surface. 2. Piston : 27 n ⋅m (2.7 kgf-m, 19.5 lb-ft) : apply thread...

  • Page 328

    4c-2 rear brakes: rear brake pad inspection b649g14306012 the extent of brake pad wear can be checked by observing the grooved limit line “a” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “rear brake pad replacement: ”. Caution ! Replace the brake...

  • Page 329

    Rear brakes: 4c-3 7) install the new brake pads. Note make sure that the detent of the pad is seated onto the retainer on the caliper bracket. 8) tighten the caliper mounting bolt (7) and pad mounting pin (8) to the specified torque. Tightening torque rear brake caliper mounting bolt (a): 22 n·m ( 2...

  • Page 330

    4c-4 rear brakes: 4) pivot the caliper up and remove the caliper from the caliper bracket. Installation install the brake caliper in the reverse order of removal. Pay attention to the following points: • set the caliper to the caliper bracket. • install the brake pads and tighten the caliper mountin...

  • Page 331

    Rear brakes: 4c-5 2) remove the pad spring (3). 3) remove the spacer (4) and rubber boot (5) from the caliper. 4) remove the slide pin (6). 5) place a rag over the piston to prevent it from popping out and then force out the piston using compressed air. Caution ! Do not use high pressure air to prev...

  • Page 332

    4c-6 rear brakes: • apply the brake fluid to piston seal (1) and dust seal (2). Caution ! Replace the piston seal (1) and dust seal (2) with new ones. Bf: brake fluid (dot 4) • install the piston seals as shown. • apply suzuki silicone grease to the inside of the boot. : grease 99000–25100 (suzuki s...

  • Page 333

    Rear brakes: 4c-7 boot and spacer inspect the boots and spacer for damage and wear. If any defects are found, replace them with new ones. Brake pad spring inspect the brake pad springs for damage and excessive bend. If any defects are found, replace them with new ones. Rear brake disc removal and in...

  • Page 334

    4c-8 rear brakes: brake disc runout 1) remove the rear brake caliper. Refer to “rear brake caliper removal and installation: ”. 2) measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (a): 09900–20606 (dial gauge (1/100 mm)) (b): 09900–20701...

  • Page 335

    Rear brakes: 4c-9 specifications service data b649g14307004 brake unit: mm (in) oil tightening torque specifications b649g14307005 note the specified tightening torque is also described in the following. “rear brake components: ” reference: for the tightening torque of fastener not specified in this...

  • Page 336

    4c-10 rear brakes: special tools and equipment recommended service material b649g14308001 note required service material is also described in the following. “rear brake components: ” special tool b649g14308002 material suzuki recommended product or specification note brake fluid dot 4 — ) / ) grease...

  • Page 337: Section 5

    Table of contents 5- i 5 section 5 contents transmission / transaxle precautions .................................................5-1 precautions............................................................. 5-1 precautions for transmission / transaxle............. 5-1 manual transmission...............

  • Page 338: Precautions

    5-1 precautions: precautions precautions precautions for transmission / transaxle b649g15000001 refer to “general precautions: in section 00”..

  • Page 339: Manual Transmission

    Manual transmission: 5b-1 manual transmission diagnostic information and procedures manual transmission symptom diagnosis b649g15204022 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission). Worn or rubbing gear. Replace. Worn countershaft s...

  • Page 340

    5b-2 manual transmission: repair instructions transmission components b649g15206029 transmission removal b649g15206027 1) remove the engine assembly from the frame. Refer to “engine assembly removal: in section 1d”. 2) remove the generator. Refer to “generator removal and installation: in section 1j...

  • Page 341

    Manual transmission: 5b-3 10) remove the oil seal retainer (1) and gear position switch assembly (2). Refer to “gear position switch removal and installation: ”. 11) remove the countershaft bearing retainer (3). 12) remove the plug (4). 13) remove the upper crankcase bolts and nut. 14) remove the oi...

  • Page 342

    5b-4 manual transmission: 20) loosen the crankcase bolts (crankshaft tightening bolts) in descending numerical order and then remove them. Note two allen bolts are located at position “a” to tighten the crankshaft. 21) remove the oil return pipe (11). 22) separate the crankcases, upper and lower. Ca...

  • Page 343

    Manual transmission: 5b-5 26) unhook the gearshift cam stopper spring (18) from the lower crankcase. 27) remove the snap ring (19) from the gearshift cam, then draw out the gearshift cam (20) from the opposite side. Special tool (a): 09900–06107 (snap ring pliers) 28) remove the snap ring (21) and g...

  • Page 344

    5b-6 manual transmission: • install the gearshift cam (2) and its related parts. Caution ! Always use new snap rings ((4) and (6)). Special tool (a): 09900–06107 (snap ring pliers) • position the gearshift cam in the neutral position as shown. Note this will allow the gearshift forks and transmissio...

  • Page 345

    Manual transmission: 5b-7 countershaft and driveshaft • install the bearing pins (1) and c-rings (2) into the upper crankcase. • install the countershaft assembly (3) and driveshaft assembly (4) into the upper crankcase. • install the countershaft end cap in the proper position “a”. Note • be sure t...

  • Page 346

    5b-8 manual transmission: crankcase • apply the suzuki bond to the mating surface of the lower crankcase. : sealant 99000–31140 (suzuki bond 1207b or equivalent) note • make sure that the mating surfaces are free from moisture, oil, dust and other foreign materials. • apply the bond thinly and evenl...

  • Page 347

    Manual transmission: 5b-9 • install the right oil return pipe along with the bolt “1”. • install the copper washers to the bolts “9” and “11”. • install the two allen bolts at position “a”. • install the ten crankcase bolts (m8). • tighten the crankcase bolts (crankshaft tightening bolts) in ascendi...

  • Page 348

    5b-10 manual transmission: caution ! Use a new gasket washer to prevent oil leakage. 2 i649g1520033-02 “b” 3 4 i649g1520032-02 “c” i649g1520034-01 i649g1520031-01.

  • Page 349

    Manual transmission: 5b-11 left oil return pipe and oil sump filter • install the left oil return pipe (1). • install a new o-ring (2) and shim (3). • install a new gasket and the oil sump filter (4). Caution ! Replace the gasket and o-ring with new ones to prevent oil leakage. Oil pan • install a n...

  • Page 350

    5b-12 manual transmission: oil seal retainer • install the oil seal retainer (1) with the four bolts and then bend up the tabs on the retainer. Note route the gear position switch lead wire to the inside of the oil seal retainer’s tab “a” as shown. • install the starter clutch component parts. Refer...

  • Page 351

    Manual transmission: 5b-13 transmission construction b649g15206030 countershaft gear and driveshaft gear disassembly b649g15206031 refer to “transmission removal: ” and “transmission installation: ”. Countershaft gear disassembly caution ! Identify the position of each removed part. Organize the par...

  • Page 352

    5b-14 manual transmission: 2) remove the 5th (top) drive gear snap ring (3) from its groove and slide it towards the 3rd drive gear (4). Special tool : 09900–06107 (snap ring pliers) 3) slide the lock washer (5) towards the 5th (top) drive gear (6), then turn the lock washer (7) and slide it towards...

  • Page 353

    Manual transmission: 5b-15 countershaft gear and driveshaft gear assembly b649g15206040 reassemble the countershaft and driveshaft gears in the reverse order of disassembly. Pay attention to the following points: note when reassembling the transmission gears, attention must be given to the locations...

  • Page 354

    5b-16 manual transmission: countershaft gear assembly • align the bushing oil hole “a” with the shaft oil hole “b”. • with the lock washer (1) turned in its groove “c”, align the cutout “d” of the lock washer (1) with the tab “e” on the lock washer (2). Caution ! Install the oil seal as shown in the...

  • Page 355

    Manual transmission: 5b-17 gearshift fork thickness measure the gearshift fork thickness using the vernier calipers. Special tool (a): 09900–20102 (vernire calipers) gearshift fork thickness standard (no.1, no.2 & no.3): 4.80 – 4.90 mm (0.189 – 0.193 in) gearshift cam bearing inspect the gearshift c...

  • Page 356

    5b-18 manual transmission: 4) disconnect the gear position switch coupler (1). 5) remove the gear position switch. 6) remove the o-ring (2), switch contact (3) and spring (4). Note do not lose the o-ring, switch contact and spring. 7) remove the gear position switch lead wire as shown in the wiring ...

  • Page 357

    Manual transmission: 5b-19 gearshift shaft / gearshift cam driven gear removal and installation b649g15206035 it is unnecessary to remove the engine assembly from the frame when servicing the gearshift linkage. Removal 1) remove the engine sprocket cover. Refer to “engine sprocket removal and instal...

  • Page 358

    5b-20 manual transmission: • fit the springs (1), pins (2) and pawls (3) to the gearshift cam driven gear (4). Note wider side “a” of pawl should be positioned outside. • install the cam guide (5) and pawl lifter (6). • apply a small quantity of thread lock “1342” to the screws. : thread lock cement...

  • Page 359

    Manual transmission: 5b-21 gearshift linkage inspection b649g15206036 refer to “gearshift shaft / gearshift cam driven gear removal and installation: ”. Gearshift shaft (gearshift arm) check the gearshift shaft (gearshift arm) for bends or wear. Check the return spring on the gearshift arm for damag...

  • Page 360

    5b-22 manual transmission: gearshift lever height inspection and adjustment b649g15206039 inspect and adjust the gearshift lever height in the following procedures: 1) inspect the gearshift lever height “a” between the pedal top face and footrest. Adjust the gearshift lever height if necessary. Gear...

  • Page 361

    Manual transmission: 5b-23 specifications service data b649g15207002 transmission + drive chain unit: mm (in) except ratio tightening torque specifications b649g15207003 note the specified tightening torque is also described in the following. “gearshift shaft / gearshift cam driven gear components: ...

  • Page 362

    5b-24 manual transmission: special tools and equipment recommended service material b649g15208001 note required service material is also described in the following. “transmission components: ” “gearshift shaft / gearshift cam driven gear components: ” special tool b649g15208002 material suzuki recom...

  • Page 363: Clutch

    Clutch: 5c-1 clutch precautions precautions for clutch system b649g15300001 refer to “general precautions: in section 00”. Clutch fluid (brake fluid) information b649g15300002 warning ! • this clutch system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types ...

  • Page 364

    5c-2 clutch: schematic and routing diagram clutch hose routing diagram b649g15302001 gsf1200 90 (a) 49 35 21 4 (b) 42 15 (a) 1 4 4 2 5 7 6 2 3 1 i649g1530001-04 1. Clutch hose guide 6. Fixed clamp : align the white paint mark on the clutch hose to the fixed clamp. 2. Stopper : after the clutch hose ...

  • Page 365

    Clutch: 5c-3 gsf1200s 4 90 3 4 2 1 (a) 49 35 21 (b) 42 15 (a) 7 7 8 5 6 4 4 5 10 9 i649g1530002-04 1. Clutch hose 7. Clutch hose clamp : insert the clutch hose clamp end to the hole of the frame fully. 2. Wire harness 8. Clutch hose : pass through the clutch hose between the frame and fuel tank rail...

  • Page 366

    5c-4 clutch: diagnostic information and procedures clutch system symptom diagnosis b649g15304003 repair instructions clutch lever position switch inspection b649g15306007 inspect the clutch lever position switch in the following procedures: 1) disconnect the clutch lever position switch lead wires. ...

  • Page 367

    Clutch: 5c-5 3) attach a pipe to the bleeder valve and insert the free end of the pipe into a receptacle. 4) squeeze and release the clutch lever several times in rapid succession, and squeeze the lever fully without releasing it. 5) loosen the bleeder valve by turning it a quarter of a turn so that...

  • Page 368

    5c-6 clutch: 7) close the air bleeder valve and disconnect a clear hose. 8) fill the reservoir with new fluid to the upper mark of the reservoir. 9) install the reservoir cap. Tightening torque air bleeder valve (clutch) (a): 8 n·m (0.8 kgf-m, 6.0 lb-ft) clutch hose removal and installation b649g153...

  • Page 369

    Clutch: 5c-7 clutch control system components b649g15306013 (c) 4 5 6 [b] [a] 1 (a) 3 (a) 7 (b) 9, 8 2, i649g1530005-03 1. Push rod 7. Push rod : 8 n ⋅m (0.8 kgf-m, 6.0 lb-ft) 2. Piston/cup set 8. Clutch release cylinder set : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 3. Clutch hose 9. Air bleeder : apply brak...

  • Page 370

    5c-8 clutch: clutch master cylinder assembly removal and installation b649g15306016 removal 1) drain clutch fluid. Refer to “clutch fluid replacement: ”. 2) disconnect the clutch lever position switch lead wires (1). 3) place a rag underneath the brake hose union bolt (2) on the master cylinder to c...

  • Page 371

    Clutch: 5c-9 clutch master cylinder / clutch lever disassembly and assembly b649g15306015 refer to “clutch master cylinder assembly removal and installation: ”. Disassembly 1) remove the clutch lever (1) and clutch lever position switch (2). 2) remove the reservoir cap (3), plate (4) and diaphragm (...

  • Page 372

    5c-10 clutch: • apply suzuki silicone grease to the push rod end. : grease 99000–25100 (suzuki silicone grease or equivalent) • when installing the clutch lever position switch, align the projection on the switch with the hole in the master cylinder. • apply suzuki silicone grease to the clutch leve...

  • Page 373

    Clutch: 5c-11 5) remove the engine sprocket cover (3) by removing the bolts. 6) remove the push rod (4). 7) remove the piston retainer (5). 8) remove the air bleeder valve (6). 9) remove the clutch release cylinder (7) by removing the mounting bolts. Installation install the clutch release cylinder ...

  • Page 374

    5c-12 clutch: assembly assemble the clutch cylinder in the reverse order of disassembly. Pay attention to the following points: • wash the cylinder bore and piston with specified brake fluid. Bf: brake fluid (dot 4) caution ! • wash the cylinder components with fresh brake fluid before reassembly. N...

  • Page 375

    Clutch: 5c-13 clutch components b649g15306021 1 2 4 6 7 8 (a) 5, 11 12 10 9 13 14 15 16 17 3, i649g1530062-01 1. Clutch pressure plate lifter 8. No.2 drive plate 15. Clutch sleeve hub 2. Clutch pressure plate 9. No.2 driven plate (1 – 4 pcs) : the no.1 and no.2 driven plats are 9 in total. 16. Prima...

  • Page 376

    5c-14 clutch: clutch assembly diagram b649g15306022 clutch removal b649g15306023 1) drain engine oil. Refer to “engine oil and filter replacement: in section 0b”. 2) remove the clutch cover (1). 3) remove the clutch pressure plate lifter (2) by removing the snap ring. Special tool : 09900–06108 (sna...

  • Page 377

    Clutch: 5c-15 4) remove the thrust washer (3), bearing (4) and clutch push piece (5), and pull out the clutch push rod (6). Note if it is difficult to pull out the push rod (6), use a magnetic hand or wire. 5) hold the clutch pressure plate with the special tool and loosen the clutch sleeve hub nut....

  • Page 378

    5c-16 clutch: 11) remove the spacer and bearing. 12) remove the primary driven gear assembly with the generator/oil pump drive gears. Note if it is difficult to remove the primary driven gear, rotate the crankshaft. 13) remove the thrust washer (13). Clutch installation b649g15306024 1) install the ...

  • Page 379

    Clutch: 5c-17 7) insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order, no.3 drive plate (6) first. Note for drive plate three kinds of the drive plate (no. 1, no. 2 and no. 3) are equipped in the clutch system, they can be distinguished by th...

  • Page 380

    5c-18 clutch: 8) put the clutch pressure plate onto the clutch sleeve hub securely. 9) put the clutch diaphragm spring seat (11) and clutch diaphragm springs (12) onto the clutch pressure plate properly. Note pay attention to the direction of the clutch diaphragm springs. Refer to “clutch assembly d...

  • Page 381

    Clutch: 5c-19 16) fix the clutch pressure plate lifter with the snap ring. Special tool : 09900–06108 (snap ring pliers) note when fitting the circlip, make sure that the sharp edge of the snap ring faces outside. 17) apply a light coat of the suzuki bond “1207b” to the clutch cover gasket mating su...

  • Page 382

    5c-20 clutch: clutch drive and driven plate note wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipers. If the drive plate thickness is found to have reached the limit, replace it with a new one. Special tool (a): 099...

  • Page 383

    Clutch: 5c-21 specifications service data b649g15307004 clutch unit: mm (in) oil tightening torque specifications b649g15307005 note the specified tightening torque is also described in the following. “clutch hose routing diagram: ” “clutch control system components: ” “clutch components: ” “clutch ...

  • Page 384

    5c-22 clutch: special tools and equipment recommended service material b649g15308001 note required service material is also described in the following. “clutch control system components: ” “clutch components: ” special tool b649g15308002 material suzuki recommended product or specification note brak...

  • Page 385: Section 6

    Table of contents 6- i 6 section 6 contents steering precautions .................................................6-1 precautions............................................................. 6-1 precautions for steering ....................................... 6-1 steering general diagnosis.............

  • Page 386: Precautions

    6-1 precautions: precautions precautions precautions for steering b649g16000001 refer to “general precautions: in section 00”..

  • Page 387: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering general diagnosis diagnostic information and procedures steering symptom diagnosis b649g16104003 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted...

  • Page 388: Steering / Handlebar

    6b-1 steering / handlebar: steering / handlebar repair instructions handlebars components b649g16206001 1 4 7 8 4 5 6 1 (b) 3 (a) “a” 2 (b) i649g1620001-04 1. Throttle grip 5. Handle expander “a”: apply handle grip bond. 2. Handlebars 6. Handle balancer expander : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 3. ...

  • Page 389

    Steering / handlebar: 6b-2 handlebars removal and installation b649g16206008 removal 1) remove the following parts from the left handlebar. A) rear view mirror (gsf1200) b) clutch master cylinder/clutch lever (1) caution ! Do not turn the clutch master cylinder upside down. C) left handlebar switch ...

  • Page 390

    6b-3 steering / handlebar: • apply suzuki super grease to the throttle cables and cable pulley. : grease 99000–25010 (suzuki super grease a or equivalent) • insert the projection “c” of the right handlebar switch box into the hole of the handlebars. • install the front brake master cylinder. Refer t...

  • Page 391

    Steering / handlebar: 6b-4 steering components b649g16206010 (a) 1, 2 3 (b) 5, 4 7 7 8 8 (c) 9, 6 15 14 13, 12, 11 10 [a] [a] 15 i649g1620041-01 1. Handlebar holder bolt 8. Rubber seat 15. Headlight housing bracket 2. Handlebar holder (upper) 9. Handlebar holder set nut [a]: for gsf1200 3. Handlebar...

  • Page 392

    6b-5 steering / handlebar: steering removal and installation b649g16206012 removal gsf1200 1) support the motorcycle with a jack or a wooden block. 2) remove the front wheel assembly. Refer to “front wheel assembly removal and installation: in section 2d”. 3) remove the front forks. Refer to “front ...

  • Page 393

    Steering / handlebar: 6b-6 14) remove the steering stem nut using the special tool. Note when loosening the stem nuts, hold the steering stem lower bracket to prevent it from falling. Special tool (c): 09940–14911 (steering stem nut wrench) 15) remove the steering stem lower bracket. 16) remove the ...

  • Page 394

    6b-7 steering / handlebar: 8) remove the steering stem head nut and washer. 9) remove the steering stem upper bracket (3). 10) remove the steering stem nut using the special tool. Note when loosening the stem nuts, hold the steering stem lower bracket to prevent it from falling. Special tool (c): 09...

  • Page 395

    Steering / handlebar: 6b-8 • turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings seat properly. • loosen the steering stem nut 1/4 – 1/2 turn “a”. Note this adjustment will vary from motorcycle to motorcycle. Steering stem upper bracke...

  • Page 396

    6b-9 steering / handlebar: steering related parts inspection b649g16206013 refer to “steering removal and installation: ”. Inspect the removed parts for the following abnormalities. • distortion of the steering stem • bearing wear or damage • abnormal bearing noise • race wear or damage • rubber sea...

  • Page 397

    Steering / handlebar: 6b-10 installation install the steering stem bearings in the reverse order of removal. Pay attention to the following points: caution ! The removed bearings and races should be replaced with new ones. Outer race • press in the upper and lower outer races using the special tool....

  • Page 398

    6b-11 steering / handlebar: 4) do the same on the other grip end. 5) if the initial force read on the scale when the handlebar starts turning is either to heavy or too light, adjust it till it satisfies the specification. A) first, loosen the front fork upper and lower clamp bolts, steering stem hea...

  • Page 399

    Steering / handlebar: 6b-12 specifications tightening torque specifications b649g16207001 note the specified tightening torque is also described in the following. “handlebars components: ” “steering components: ” reference: for the tightening torque of fastener not specified in this section, refer t...

  • Page 400

    6b-13 steering / handlebar: special tools and equipment recommended service material b649g16208001 note required service material is also described in the following. “steering components: ” special tool b649g16208002 material suzuki recommended product or specification note grease suzuki super greas...

  • Page 401: Section 9

    Table of contents 9- i 9 section 9 contents body and accessories precautions .................................................9-1 precautions............................................................. 9-1 precautions for electrical system ......................... 9-1 component location .............

  • Page 402

    9-ii table of contents center stand construction..................................9e-4 center stand removal and installation...............9e-4 specifications.......................................................9e-5 tightening torque specifications........................9e-5 special tools and equ...

  • Page 403: Precautions

    Precautions: 9-1 precautions precautions precautions for electrical system b649g19000001 refer to “general precautions: in section 00” and “precautions for electrical circuit service: in section 00”. Component location electrical components location b649g19003001 refer to “electrical components loca...

  • Page 404: Wiring Systems

    9a-1 wiring systems: wiring systems schematic and routing diagram wiring diagram b649g19102004 refer to “wire color symbols: in section 0a”..

  • Page 405

    Wiring systems: 9a-2 gsf1200 (for e02, 19) off ru n off on push free push on off off on on off 1 push hi lo off on push 12 4 35 free l push r 14 23 on off lock p r : turn signal indica t o r light (r) l : turn signal indica t o r light (l) h : hi-beam indica t o r light n : neutral indica t o r ligh...

  • Page 406

    9a-3 wiring systems: gsf1200s (for e-02, 19) off ru n off on push free push on off off on on off 1 push hi lo off on push 12 4 35 free l push r 14 23 on off lock p r : turn signal indica t o r light (r) l : turn signal indica t o r light (l) h : hi-beam indica t o r light n : neutral indica t o r li...

  • Page 407

    Wiring systems: 9a-4 gsf1200s (for e-24, 28) off ru n off on push free push on off on off 1 push hi lo off on push 12 4 35 free l push r 14 23 on off lock p r : turn signal indica t o r light (r) l : turn signal indica t o r light (l) h : hi-beam indica t o r light n : neutral indica t o r light f :...

  • Page 408

    9a-5 wiring systems: wiring harness routing diagram b649g19102001 6 7 8 5 4 3 1 11 10 13 13 12 2 9 15 14 16 17 18 8 “a” i649g1910904-05 1. Battery 8. Throttle cables 15. Speed sensor switch coupler 2. Ignitor unit 9. Starter cable 16. Thermo-switch (for e02, 19) 3. Ignition coil 10. Tps 17. Carburet...

  • Page 409

    Wiring systems: 9a-6 8 1 2 (a) 3 4 5 [a] [b] “ b ” “ a ” 6 7 4 5 i649g1910905-05 1. Starter relay 6. Ckp sensor lead/side-stand lead/gear position lead/starter motor lead/ speed sensor lead/wiring harness [a]: for gsf1200/gsf1200a 2. Side-stand switch 7. Starter motor lead/clutch hose [b]: for gsf12...

  • Page 410

    9a-7 wiring systems: specifications service data b649g19107002 electrical tightening torque specifications b649g19107003 note the specified tightening torque is also described in the following. “wiring harness routing diagram: ” reference: for the tightening torque of fastener not specified in this ...

  • Page 411: Lighting Systems

    Lighting systems: 9b-1 lighting systems repair instructions headlight components b649g19206001 gsf1200 gsf1200s 4 3 2 1 5 i649g1920001-02 1. Headlight rim 4. Headlight housing 2. Headlight unit 5. Position light bulb (12 v 5 w) 3. Headlight bulb (12 v 60/55 w, h4) 1 3 2 3 i649g1920002-03 1. Headligh...

  • Page 412

    9b-2 lighting systems: headlight removal and installation b649g19206014 removal gsf1200 1) removal the headlight mounting screws. 2) disconnect the headlight coupler (1) and position light coupler (2). 3) disconnect the respective couplers and remove the headlight housing. Gsf1200s 1) remove the cow...

  • Page 413

    Lighting systems: 9b-3 2) disconnect the headlight coupler (1) and position light coupler (2). 3) remove the position light socket (3) and replace the position light bulb. 4) remove the bulb socket rubber cap (4). 5) replace the headlight bulb (6) by unhooking the bulb holder spring (5). 6) reassemb...

  • Page 414

    9b-4 lighting systems: 4) replace the headlight bulb (low beam) (4) by unhooking the bulb holder spring (5). 5) replace the headlight bulb (high beam) in the same way as that of the low beam one. 6) reinstall the removed parts. Headlight beam adjustment b649g19206003 gsf1200 adjust the headlight bea...

  • Page 415

    Lighting systems: 9b-5 rear combination light components b649g19206004 rear combination light construction b649g19206015 1 2 i649g1920017-02 1. Brake light/taillight bulb (12 v 21/5 w) 2. Lens (a) 2 3 1 i649g1920018-01 1. Seat tail cover 3. Rear combination light 2. Cushion : 2.0 n ⋅m (0.2 kgf-m, 1....

  • Page 416

    9b-6 lighting systems: rear combination light removal and installation b649g19206016 removal 1) remove the seat tail cover. Refer to “exterior parts removal and installation: in section 9d”. 2) remove the rear combination light (1) from the seat tail cover. Installation install the rear combination ...

  • Page 417

    Lighting systems: 9b-7 license plate light components b649g19206018 license plate light removal and installation b649g19206019 removal 1) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 2) remove the tool set (1) and disconnect the license plate light coupler (2)....

  • Page 418

    9b-8 lighting systems: turn signal light components b649g19206021 front turn signal light removal and installation b649g19206022 removal gsf1200 1) remove the headlight housing. Refer to “headlight removal and installation: ”. 2) remove the front turn signal light (1) by removing the nut. Gsf1200s 1...

  • Page 419

    Lighting systems: 9b-9 rear turn signal light removal and installation b649g19206023 removal 1) remove the seat. Refer to “exterior parts removal and installation: in section 9d”. 2) remove the tool set (1) and disconnect the turn signal light coupler (2). 3) remove the turn signal light (3) by remo...

  • Page 420

    9b-10 lighting systems: reflex refrector construction (for e-24, 28) b649g19206025 turn signal / side-stand relay inspection b649g19206026 refer to “electrical components location: in section 0a”. Note make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, che...

  • Page 421

    Lighting systems: 9b-11 hazard switch inspection b649g19206028 inspect the hazard switch in the following procedures: 1) remove the right frame head cover. (gsf1200) refer to “exterior parts removal and installation: in section 9d”. 2) disconnect the left handlebar switch coupler (1). 3) inspect the...

  • Page 422

    9b-12 lighting systems: 4) after finishing the passing light switch inspection, reinstall the removed parts. Dimmer switch inspection b649g19206031 inspect the dimmer switch in the following procedures: 1) remove the right frame head cover. (gsf1200) refer to “exterior parts removal and installation...

  • Page 423

    Lighting systems: 9b-13 specifications service data b649g19207002 wattage unit: w tightening torque specifications b649g19207003 note the specified tightening torque is also described in the following. “rear combination light construction: ” “reflex refrector construction (for e-24, 28): ” reference...

  • Page 424

    9c-1 combination meter / fuel meter / horn: combination meter / fuel meter / horn repair instructions combination meter components b649g19306014 gsf1200 1 2 3 5 4 fwd fw d i649g1930001-04 1. Upper case assembly 3. Lower case 5. Bracket 2. Combination meter 4. Cover.

  • Page 425

    Combination meter / fuel meter / horn: 9c-2 gsf1200s 1 2 3 i649g1930002-02 1. Upper case assembly 2. Combination meter 3. Lower case.

  • Page 426

    9c-3 combination meter / fuel meter / horn: combination meter removal and installation b649g19306001 removal gsf1200 1) remove the headlight. Refer to “headlight removal and installation: in section 9b”. 2) disconnect the respective couplers and remove the headlight housing (1). 3) remove the combin...

  • Page 427

    Combination meter / fuel meter / horn: 9c-4 combination meter led check b649g19306015 check that the leds (oil pressure indicator light and meter panel illumination) immediately light up when the ignition switch is turned to on. Check that other leds (neutral indicator light, high- beam indicator li...

  • Page 428

    9c-5 combination meter / fuel meter / horn: 7) replace the 180 Ω resister “b” with a 5 Ω one “c”. 8) the fuel level indicator is operating correctly if the lcd bars increase to five (full) when the ignition switch is turned to on. If either test detects a malfunctioning fuel level indicator, replace...

  • Page 429

    Combination meter / fuel meter / horn: 9c-6 speed sensor inspection b649g19306020 inspect the speed sensor in the following procedures: 1) remove the speed sensor. Refer to “speed sensor removal and installation: ”. 2) connect a 12 v battery (between b and b/w), 10 k Ω resistor (between b/r and b) a...

  • Page 430

    9c-7 combination meter / fuel meter / horn: oil pressure switch removal and installation b649g19306022 refer to “oil pressure switch removal and installation: in section 1e”. Ignition switch inspection b649g19306023 inspect the ignition switch in the following procedures: 1) remove the right frame h...

  • Page 431

    Combination meter / fuel meter / horn: 9c-8 3) inspect the horn button for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebars removal and installation: in section 6b”. Special tool : 09900–25008 (multi-circuit tester...

  • Page 432

    9c-9 combination meter / fuel meter / horn: specifications service data b649g19307001 wattage unit: w special tools and equipment recommended service material b649g19308001 special tool b649g19308002 item specification gsf1200 gsf1200s speedometer light led ← tachometer light led ← turn signal indic...

  • Page 433: Exterior Parts

    Exterior parts: 9d-1 exterior parts schematic and routing diagram seat lock cable routing diagram b649g19402002 1 2 3 4 i649g1940001-01 1. Screw 3. Seat lock 2. Seat lock cable 4. Plate.

  • Page 434

    9d-2 exterior parts: repair instructions exterior parts construction b649g19406001 gsf1200 2 3 3 1 1 i649g1940002-02 1. Frame head cover 2. Headlight housing cover 3. Headlight housing stay.

  • Page 435

    Exterior parts: 9d-3 gsf1200s 2 5 6 3 7 4 1 i649g1940003-05 1. Cowling body 3. Cowling brace 5. Upper panel 7. Head pipe 2. Wind screen 4. Lower panel 6. Meter panel lid.

  • Page 436

    9d-4 exterior parts: frame cover cushion construction b649g19406002 1 2 4 2 1 fwd fw d 3 3 “a” i649g1940031-02 1. Front fender 3. Washer “a”: before installing the front fender, apply an adhesive agent to the inside of the washer to prevent it from falling. 2. Fender plate nut 4. Front fork 2 1 2 i6...

  • Page 437

    Exterior parts: 9d-5 fastener removal and installation b649g19406003 removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls “a” close. 2) insert the fastener into the installation hole. ...

  • Page 438

    9d-6 exterior parts: installation install the frame covers in the reverse order of removal. Pillion rider handle and seat tail cover removal 1) remove the seat. 2) remove the frame covers. 3) remove the pillion rider handle (1). 4) remove the fasteners. Refer to “fastener removal and installation: ”...

  • Page 439

    Exterior parts: 9d-7 3) remove the combination meter assembly (1). Refer to “combination meter removal and installation: in section 9c”. 4) remove the wind screen (2) and upper panel (3). 5) disconnect the turn signal lead wire couplers and remove the turn signal lights (4), left and right. Refer to...

  • Page 440

    9d-8 exterior parts: installation install the cowling and cowling brace in the reverse order of removal. Pay attention to the following point: • after installing, be sure to inspect the headlight beam. Refer to “headlight beam adjustment: in section 9b”. Front fender refer to “front fork removal and...

  • Page 441: Body Structure

    Body structure: 9e-1 body structure repair instructions body frame construction b649g19506007 engine mounting bracket bushing replacement b649g19506008 replace the engine mounting bracket bushing if necessary, as shown in the body frame construction. Refer to “body frame construction: ”. Engine moun...

  • Page 442

    9e-2 body structure: battery protector construction b649g19506001 “ a ” “ a ” 1 1 fwd 2 1 i649g1950001-01 1. Protector 2. Battery “a”: 50 mm (1.97 in).

  • Page 443

    Body structure: 9e-3 front footrest bracket construction b649g19506002 side-stand construction b649g19506003 1 2 3 3 (a) 4, i649g1950002-02 1. Frame 3. Washer : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Footrest bracket 4. Bolt 1. Side-stand : 40 n ⋅m (4.0 kgf-m, 29.0 lb-ft) 2. Spring : apply grease to sli...

  • Page 444

    9e-4 body structure: side-stand removal and installation b649g19506004 removal 1) support the motorcycle with the center stand. 2) remove the side-stand as shown in the side-stand construction. Refer to “side-stand construction: ”. Installation install the side-stand as shown in the side-stand const...

  • Page 445

    Body structure: 9e-5 specifications tightening torque specifications b649g19507001 note the specified tightening torque is also described in the following. “body frame construction: ” “front footrest bracket construction: ” “side-stand construction: ” reference: for the tightening torque of fastener...

  • Page 446

    Prepared by december, 2005 part no. 99500-39280-01e printed in japan 448.

  • Page 447

    9 9 5 0 0 - 3 9 2 8 0 - 0 1 e printed in japan k6 gsf1200/gsf1200s k6 gsf1200/gsf1200s.