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  5. Supplementary Service Manual

Suzuki 2006 GSF1200AK6 Supplementary Service Manual

Summary of 2006 GSF1200AK6

  • Page 1

    Gsf1200a /sa use this manual with: gsf1200/s service manual (99500-39280-01e) 9 9 5 0 1 - 3 9 5 7 0 - 0 1 e.

  • Page 2

    Gsf1200ak6/sak6 (’06-model) 1 contents gsf1200ak6/sak6 (’06-model) this manual describes abs service data, abs specifications and abs servicing procedures which differ from those of the gsf1200k6/sk6 (’06-model). Note: • any differences between the gsf1200k6/sk6 (’06-model) and gsf1200ak6/sak6 (’06-...

  • Page 3

    2 gsf1200ak6/sak6 (’06-model) gsf1200ak6/sak6 (’06-model) contents dtc deleting and abs operation check .................................. 34 sds check ............................................................................................. 36 use of sds diagnostic procedures......................

  • Page 4: Specifications

    Gsf1200ak6/sak6 (’06-model) 3 specifications dimensions and dry mass overall length ...................................................... 2 130 mm (83.9 in) overall width ....................................................... 790 mm (31.1 in) overall height ...........................................

  • Page 5

    4 gsf1200ak6/sak6 (’06-model) chassis front suspension ................................................. Telescopic, coil spring, oil damped rear suspension .................................................. Link type, coil spring, oil damped front suspension stroke.....................................

  • Page 6: Introduction

    Gsf1200ak6/sak6 (’06-model) 5 introduction abs (anti-lock brake system) this system not only prevents the wheels from locking while braking, but also provides more stable braking by controlling the wheel speed so as to maximize the friction between the tires and road surface. If the wheels lock up, ...

  • Page 7

    6 gsf1200ak6/sak6 (’06-model) relationship between the slip ratio, side force and the friction between the tire and road surface the relationship between the slip ratio, side force and the friction between the tire and road surface are shown in the following graph. * “side force” is the supporting f...

  • Page 8

    Gsf1200ak6/sak6 (’06-model) 7 abs control cycle in order to understand the abs control cycle, it is necessary to understand the normal control cycle on a well-gripped road. The abs control flows at various wheel speeds and brake fluid pressure changes as shown in the following graph. A when the brak...

  • Page 9

    8 gsf1200ak6/sak6 (’06-model) front and rear wheel speed sensors wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2. Abs control unit abs control unit calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and,...

  • Page 10

    Gsf1200ak6/sak6 (’06-model) 9 abs control unit calculating process the abs controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the abs control unit calculating process. Abs control is performed in one cycle every 10/1 000 sec- onds. In addition...

  • Page 11

    10 gsf1200ak6/sak6 (’06-model) hydraulic unit (hu) the hydraulic unit operates the solenoid valves based upon the signal which is output from the abs control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by oper...

  • Page 12

    Gsf1200ak6/sak6 (’06-model) 11 hydraulic unit solenoid valves (inlet/outlet) the solenoid valves switch the brake fluid circuit to one of three positions (increasing, decreasing and main- taining pressure) according to the signal that is output from the abs control unit. As the abs control unit ener...

  • Page 13

    12 gsf1200ak6/sak6 (’06-model) when operating the abs brake fluid pressure-decreasing mode if the slip ratio exceeds the set value, or if a decrease of brake fluid pressure does not accelerate the wheel to the set speed, high enough for the brake fluid pressure to be maintained constant, the abs wil...

  • Page 14

    Gsf1200ak6/sak6 (’06-model) 13 brake fluid pressure-increasing mode if the accelerating wheel speed exceeds the set value, the abs increases the pressure. At this time, the abs control unit outputs the signal to stop the solenoid valve coils from being energized, opening the inlet valve and closing ...

  • Page 15

    14 gsf1200ak6/sak6 (’06-model) fail-safe function if malfunction occurs in the abs electric system, this sets fail-safe relay off. Consequently, motor relay will be set off and the indicator light on, and no current will be applied to motor solenoid valve inactivating abs and turning abs indicator l...

  • Page 16: Cautions In Servicing

    Gsf1200ak6/sak6 (’06-model) 15 cautions in servicing abs wiring • the abs parts are connected to various lead wires. The cou- pler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly. Make sure that the proper clamps are used and positioned correctly....

  • Page 17

    16 gsf1200ak6/sak6 (’06-model) abs control unit/hu • never allow dust or water to contact the abs control unit/hu. • never subject the abs control unit/hu to strong impacts or allow them to be dropped. • the abs control unit/hu cannot be disassembled. Replace the whole unit with a new one. Abs infor...

  • Page 18

    Gsf1200ak6/sak6 (’06-model) 17 tester • use the suzuki multi-circuit tester (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. • since the resistance may differ depending on the tester used and the temperature, the resistance should b...

  • Page 19: Abs Components

    18 gsf1200ak6/sak6 (’06-model) abs components abs components location 1 abs control unit/hu 5 front wheel speed sensor rotor 2 mode selection coupler 6 rear wheel speed sensor 3 sds coupler 7 rear wheel speed sensor rotor 4 front wheel speed sensor sa mp le.

  • Page 20

    Gsf1200ak6/sak6 (’06-model) 19 abs wiring diagram on off lock p off on bl 1 2 45 6 3 12v on off 1 1.Head hi 2.Head lo 3.Abs 4.Ignition 5.Signal 6.Meter 10a 10a 15a 15a 15a 10a ignition switch rear brake light switch fuse bo x br br bl/b bl/b br o/g r r/b r/b r r/b b/bl b/r b/g b b/g b b/bl b/r b/g b...

  • Page 21

    20 gsf1200ak6/sak6 (’06-model) abs unit system diagram batter y ignition ignition abs br ak e light s w itch br ak e light s w itch abs indicator light solenoid batter y + fa il saf e rela y motor rela y ground f ront wheel speed sensor rear wheel speed sensor mode select coupler abs control unit m ...

  • Page 22: Abs Troubleshooting

    Gsf1200ak6/sak6 (’06-model) 21 abs troubleshooting abs troubleshooting description many of the abs malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the abs. Bef...

  • Page 23

    22 gsf1200ak6/sak6 (’06-model) troubleshooting procedure troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. ( !Page 24) 2. Perform the pre-diagnosis inspection. ( !Page 25) 3....

  • Page 24

    Gsf1200ak6/sak6 (’06-model) 23 basic troubleshooting diagram 1. Gather information from the customer. ( !Page 24) 2. Perform the pre-diagnosis inspection. ( !Page 25) 3. Inspect the abs indicator light. ( !Page 28) 6. Inspect the abs components. ( !Page 67) 4. Output the dtcs stored in the abs contr...

  • Page 25

    24 gsf1200ak6/sak6 (’06-model) information gathering to properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without du...

  • Page 26

    Gsf1200ak6/sak6 (’06-model) 25 pre-diagnosis inspection the mechanical and hydraulic components of the brake system should be inspected prior to performing any electrical checks. These inspections may find problems that the abs could not detect; thus, shortening repair time. Brake brake fluid level ...

  • Page 27

    26 gsf1200ak6/sak6 (’06-model) abs component wheel speed sensor – sensor rotor clearance • inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thi...

  • Page 28

    Gsf1200ak6/sak6 (’06-model) 27 • check for continuity between n (b/w) at the coupler and the battery - terminal, also o (b/w) at the coupler and the bat- tery - terminal. " 09900-25008: multi-circuit tester set ( tester knob indication: continuity ()) if there are no continuity, repair the coupler o...

  • Page 29

    28 gsf1200ak6/sak6 (’06-model) abs indicator light inspection step 1 1) check if the abs indicator light lights up when turning the ignition switch to on. Does the abs indicator light up? The abs indicator light lights up step 2 1) ride the motorcycle at more than 10 km/h (6.2 mile/h). Does the abs ...

  • Page 30

    Gsf1200ak6/sak6 (’06-model) 29 step 4 1) turn the ignition switch to off. 2) disconnect the abs control unit coupler. ( !Page 26) 3) turn the ignition switch to on with the abs control unit cou- pler disconnected, measure the voltage between f (o/y) and n (b/w) at the coupler. % normal value: batter...

  • Page 31

    30 gsf1200ak6/sak6 (’06-model) step 7 the abs indicator light does not go off 1) turn the ignition switch to off. 2) remove the left frame cover. ( !Gsf1200k6/sk6 9d-5) 3) remove the fuse box mounting bolt. ( !Page 28) 4) open the fuse box and inspect the ignition fuse 1. Ignition fuse: 15 a is the ...

  • Page 32

    Gsf1200ak6/sak6 (’06-model) 31 step 10 1) turn the ignition switch to off. 2) remove the right frame cover. ( !Gsf1200k6/sk6 9d-5) 3) short the mode select coupler terminals (orange – b/w) using the special tool. " 09930-82710: mode select switch 4) check for continuity between c (orange) and n (b/w...

  • Page 33

    32 gsf1200ak6/sak6 (’06-model) dtc (diagnostic trouble code) output connect the special tool to the mode select coupler to output the memorized dtcs on the abs indicator light. • turn the ignition switch to off. • remove the right frame cover. ( !Gsf1200k6/sk6 9d-5) • connect the special tool to the...

  • Page 34

    Gsf1200ak6/sak6 (’06-model) 33 understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the abs indicator light. A number between 1 and 9 is represented by the number of times that the abs indicator light lights up in interval of 0.4 seconds and the se...

  • Page 35

    34 gsf1200ak6/sak6 (’06-model) dtc deleting and abs operation check dtc deleting • connect the special tool to the mode select coupler (o – b/w) and output the dtcs. " 09930-82710: mode select switch • while the dtcs are being output, set the special tool to off. $ • in the dtc deletion mode, switch...

  • Page 36

    Gsf1200ak6/sak6 (’06-model) 35 abs operation check after deleting the dtcs, repeat the code output procedure and make sure that no dtcs remain (the abs indicator light no longer flashes). If any dtcs remain, perform the appropriate procedures, then delete the codes. If dtcs are left stored, con- fus...

  • Page 37

    36 gsf1200ak6/sak6 (’06-model) sds check using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can ...

  • Page 38

    Gsf1200ak6/sak6 (’06-model) 37 use of sds diagnostic procedures * don’t disconnect couplers from abs hu, the battery cable from the battery, abs hu ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such discon- ne...

  • Page 39

    38 gsf1200ak6/sak6 (’06-model) use of sds diagnosis reset proce- dure • after repairing the trouble, turn off the ignition switch and turn on again. • click the abs button 1. • click the “dtc inspection” button 2. • check the dtc. • the previous malfunction history code (past dtc) still remains stor...

  • Page 40

    Gsf1200ak6/sak6 (’06-model) 39 • follow the displayed instructions. • check that both “current dtc” 4 and “past dtc” 5 are deleted (nil). Sa mp le.

  • Page 41

    40 gsf1200ak6/sak6 (’06-model) active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “abs” 1. 4) click “active control” 2. 5) click “abs hu operating” 3. Sa mp le.

  • Page 42

    Gsf1200ak6/sak6 (’06-model) 41 6) it progresses to the next according to the following indication of screens. Return next cancel help return next cancel help sa mp le.

  • Page 43

    42 gsf1200ak6/sak6 (’06-model) note: * if the front wheel is selected, place the motorcycle on the center stand and lift the front wheel off the ground using a jack. * two operators are needed in this work; one should apply a rotational force to the front wheel. Return next cancel help return next c...

  • Page 44

    Gsf1200ak6/sak6 (’06-model) 43 note: * in normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the abs hu operating sound will be heard. * the abs hu motor operates for 6 seconds and then stops automatically. Note: inspect the rear b...

  • Page 45

    44 gsf1200ak6/sak6 (’06-model) dtc table *1 it goes off after running at more than 10 km/h (6.2 mile/h). *2 the wheel speed sensor lead wire is connected to the abs control unit, but a short-circuit or faulty conti- nuity inside the abs control unit caused this dtc to appear, therefore, the abs cont...

  • Page 46

    Gsf1200ak6/sak6 (’06-model) 45 dtc troubleshooting dtc “13” (c1613): wheel speed sensor rotor malfunction (f) step 1 1) inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in...

  • Page 47

    46 gsf1200ak6/sak6 (’06-model) step 4 1) inspect the front tire and wheel. % type: dunlop d218f n 120/70zr17m/c (58w) tire pressure solo riding: 250 kpa (2.50 kgf/cm 2 , 36 psi) dual riding: 250 kpa (2.50 kgf/cm 2 , 36 psi) wheel runout service limit (axial and radial): 2.0 mm (0.08 in) are the fron...

  • Page 48

    Gsf1200ak6/sak6 (’06-model) 47 dtc “14” (c1614): wheel speed sensor rotor malfunction (r) step 1 1) inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thic...

  • Page 49

    48 gsf1200ak6/sak6 (’06-model) step 4 1) inspect the rear tire and wheel. % type: dunlop d218n 180/55zr17m/c (73w) tire pressure solo riding: 250 kpa (2.50 kgf/cm 2 , 36 psi) dual riding: 250 kpa (2.50 kgf/cm 2 , 36 psi) wheel runout service limit (axial and radial): 2.0 mm (0.08 in) are the rear ti...

  • Page 50

    Gsf1200ak6/sak6 (’06-model) 49 dtc “22” (c1622): abs actuator circuit malfunction (f) step 1 1) raise the front wheel off the ground and support the motorcy- cle with a jack or wooden block. 2) inspect the dragging of the front brake. Is there any dragging in the front brake? Step 2 1) inspect the c...

  • Page 51

    50 gsf1200ak6/sak6 (’06-model) dtc “23” (c1623): abs actuator circuit malfunction (r) step 1 1) support the motorcycle with its center stand. 2) inspect the dragging of the rear brake. Is there any dragging in the rear brake? Step 2 1) inspect the clearance between the rear wheel speed sensor and se...

  • Page 52

    Gsf1200ak6/sak6 (’06-model) 51 dtc “25” (c1625): wheel speed sensor related mulfunction step 1 1) check that the specified tires are installed. Tire type: front: dunlop d218f n 120/70zr17m/c (58w) rear: dunlop d218n 180/55zr17m/c (73w) are the tires ok? Step 2 1) make sure the tire pressure for each...

  • Page 53

    52 gsf1200ak6/sak6 (’06-model) step 4 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thickness gauge 09900-20806: thickness gauge are the clea...

  • Page 54

    Gsf1200ak6/sak6 (’06-model) 53 dtc “35” (c1635): abs motor malfunction step 1 1) inspect if the pump motor makes turning noise by setting the ignition switch to on from off when the vehicle stands still. Does the pump motor make any turning noise? Step 2 1) remove the seat. ( !Gsf1200k6/sk6 9d-5) 2)...

  • Page 55

    54 gsf1200ak6/sak6 (’06-model) dtc “41” (c1641): wheel speed sensor signal malfunction (f) step 1 1) inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: th...

  • Page 56

    Gsf1200ak6/sak6 (’06-model) 55 dtc “42” (c1642): wheel speed sensor circuit open (f) step 1 1) turn the ignition switch to off. 2) remove the right frame head cover. (gsf1200a) ( !Gsf1200k6/sk6 9d-6) 3) remove the left frame cover. ( !Gsf1200k6/sk6 9d-5) 4) remove the fuse box mounting bolt. ( !Page...

  • Page 57

    56 gsf1200ak6/sak6 (’06-model) step 4 1) measure the resistance between b (white) and ground at the front wheel speed sensor coupler. % normal value: ∞ Ω (infinity) * tester knob indication: resistance (Ω) is the resistance between b and ground ok? Step 5 1) check for continuity between b (b/r) on t...

  • Page 58

    Gsf1200ak6/sak6 (’06-model) 57 dtc “43” (c1643): wheel speed sensor circuit short (f) step 1 1) turn the ignition switch to off. 2) remove the left frame cover. ( !Gsf1200k6/sk6 9d-5) 3) remove the fuse box mounting bolt. ( !Page 28) 4) check the abs control unit coupler for loose or poor con- tacts...

  • Page 59

    58 gsf1200ak6/sak6 (’06-model) dtc “44” (c1644): wheel speed sensor signal malfunction (r) step 1 1) inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thi...

  • Page 60

    Gsf1200ak6/sak6 (’06-model) 59 dtc “45” (c1645): wheel speed sensor circuit open (r) step 1 1) turn the ignition switch to off. 2) remove the frame covers, left and right. ( !Gsf1200k6/sk6 9d-5) 3) remove the fuse box mounting bolt. ( !Page 28) 4) check the abs control unit coupler and rear wheel sp...

  • Page 61

    60 gsf1200ak6/sak6 (’06-model) step 4 1) measure the resistance between b (white) and ground at the rear wheel speed sensor coupler. % normal value: ∞Ω (infinity) is the resistance between b and ground ok? Step 5 1) check for continuity between 2 (b/y) on the abs control unit coupler and c (b/y) on ...

  • Page 62

    Gsf1200ak6/sak6 (’06-model) 61 dtc “46” (c1646): wheel speed sensor circuit short (r) step 1 1) turn the ignition switch to off. 2) remove the left frame cover. ( !Gsf1200k6/sk6 9d-5) 3) remove the fuse box mounting bolt. ( !Page 28) 4) check the abs control unit coupler for loose or poor con- tacts...

  • Page 63

    62 gsf1200ak6/sak6 (’06-model) dtc “47” (c1647): supply voltage (increased) step 1 1) remove the seat. ( !Gsf1200k6/sk6 9d-5) 2) measure the voltage between the + and - battery terminals using the multi-circuit tester. % battery voltage: 12.0 v and more " 09900-25008: multi-circuit tester set & test...

  • Page 64

    Gsf1200ak6/sak6 (’06-model) 63 step 3 1) turn the ignition switch to off. 2) remove the left frame cover. ( !Gsf1200k6/sk6 9d-5) 3) remove the fuse box mounting bolt. ( !Page 28) 4) check the abs control unit coupler for loose or poor con- tacts. If ok, then disconnect the abs control unit coupler. ...

  • Page 65

    64 gsf1200ak6/sak6 (’06-model) dtc “48” (c1648): supply voltage (decreased) step 1 1) remove the seat. ( !Gsf1200k6/sk6 9d-5) 2) measure the voltage between the + and - battery terminals using the multi-circuit tester. % battery voltage: 12.0 v and more " 09900-25008: multi-circuit tester set & test...

  • Page 66

    Gsf1200ak6/sak6 (’06-model) 65 dtc “55” (c1655): abs control unit malfunction step 1 1) inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) " 09900-20803: thickness ...

  • Page 67

    66 gsf1200ak6/sak6 (’06-model) dtc “61” (c1661): abs solenoid malfunction step 1 1) turn the ignition switch to off. 2) remove the fuse box mounting bolt. ( !Page 28) 3) open the fuse box and inspect the abs fuse 1. Abs fuse: 15 a is the abs fuse ok? $ step 2 1) check the abs control unit coupler fo...

  • Page 68

    Gsf1200ak6/sak6 (’06-model) 67 irreparable malfunctions even though the abs is operating correctly, a dtc is memo- rized in any of the following conditions. • after carrying out dtc deleting and abs operation check ( !Page 34), explain to the customer that the abs is oper- ating correctly. Abs compo...

  • Page 69

    68 gsf1200ak6/sak6 (’06-model) • remove the front wheel speed sensor rotor 2. $ • remove the right frame head cover. (gsf1200) ( !Gsf1200k6/sk6 9d-6) • disconnect the coupler clamp and remove the front wheel speed sensor. Inspection • inspect the wheel speed sensor for damage. • clean the sensor if ...

  • Page 70

    Gsf1200ak6/sak6 (’06-model) 69 • align the recess a on the speed sensor bracket with the stop- per b on the right front fork. • check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. % wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0....

  • Page 71

    70 gsf1200ak6/sak6 (’06-model) front wheel speed sensor right left clearance 26 n.M (2.6 kgf-m, 19.0 lb-ft) 26 n.M (2.6 kgf-m, 19.0 lb-ft) 23 n.M (2.3 kgf-m, 16.5 lb-ft) 23 n.M (2.3 kgf-m, 16.5 lb-ft) 100 n.M (10.0 kgf-m, 72.5 lb-ft) sa mp le.

  • Page 72

    Gsf1200ak6/sak6 (’06-model) 71 rear wheel speed sensor/sensor rotor removal $ • support the motorcycle with its center stand. • remove the rear wheel speed sensor mounting bolts. • remove the rear wheel assembly. ( !Gsf1200k6/sk6 2d-11) # • remove the rear wheel speed sensor rotor 1. $ • remove the ...

  • Page 73

    72 gsf1200ak6/sak6 (’06-model) inspection • inspect the wheel speed sensor for damage. • clean the sensor if any metal particle or foreign material stuck on it. • check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. Installation in...

  • Page 74

    Gsf1200ak6/sak6 (’06-model) 73 rear wheel speed sensor right left clearance 60 n.M (6.0 kgf-m, 43.5 lb-ft) 100 n.M (10.0 kgf-m, 72.5 lb-ft) 22 n.M (2.2 kgf-m, 16.0 lb-ft) 23 n.M (2.3 kgf-m, 16.5 lb-ft) only for e-28 sa mp le.

  • Page 75

    74 gsf1200ak6/sak6 (’06-model) abs control unit/hu removal # $ • remove the seat. ( !Gsf1200k6/sk6 9d-5) • remove the battery. ( !Gsf1200k6/sk6 1j-15) • remove the starter relay 1 from the battery case 2. • remove the battery case 2. • drain the brake fluid. ( !Gsf1200k6/sk6 4a-6) • loosen the flare...

  • Page 76

    Gsf1200ak6/sak6 (’06-model) 75 • remove the reservoir mounting bolt. ( !Gsf1200k6/sk6 4a-12) • remove the abs control unit/hu by removing the mounting bolts. Installation installation is in the reverse order of removal. Pay attention to the following points. • tighten the brake pipe flare nuts to th...

  • Page 77

    76 gsf1200ak6/sak6 (’06-model) wire harness, hose routing and sensor installation wire harness routing *1 cut the tip of wire clamp after clamping. *5 pass through the lead wire between no.3 and no.4 carburetors. *2 set the plug cap forward. *6 pass through the battery - lead wire inside of the brak...

  • Page 78

    Gsf1200ak6/sak6 (’06-model) 77 *1 cut the tip of wire clamp after clamping. *2 check the adhesive lead wire protection seat when servicing. *3 don’t contact the abs unit wire harness with the abs bracket. Clamp engine mounting br ac k e t t u rn signal (rh) t u rn signal (lh) wir ing har ness no .2 ...

  • Page 79

    78 gsf1200ak6/sak6 (’06-model) front brake hose routing gsf1200a *1 after brake hose union has contacted to the stopper, tighten the union bolt. *3 insert the brake hose clamp to the hole of front fender properly. *2 clamp white paint part of brake pipe. *4 set the clamp with stopper before tighteni...

  • Page 80

    Gsf1200ak6/sak6 (’06-model) 79 gsf1200sa *1 after brake hose union has contacted to the stopper, tighten the union bolt. *3 insert the brake hose clamp to the hole of front fender properly. *2 clamp white paint part of brake pipe. *4 set the clamp with stopper before tightening. Brake pipe b brake h...

  • Page 81

    80 gsf1200ak6/sak6 (’06-model) rear brake hose routing *1 pass through the brake pipe a under the brake pipe b. *4 pass through the brake hose c outside of the brake hose d. *2 set the clamp to the hole of frame before tight- ening. *5 set the clamp to the hole of swingarm before tightening. *3 afte...

  • Page 82

    Gsf1200ak6/sak6 (’06-model) 81 front wheel speed sensor installation gsf1200a *1 pass through the sensor lead wire between brake hose no.2 and brake hose no.2 (l). *4 clamp the sensor lead wire sleeve with the brake hose. *2 pass through the sensor lead wire in front of the brake hose. *5 pass throu...

  • Page 83

    82 gsf1200ak6/sak6 (’06-model) gsf1200sa *1 pass through the sensor lead wire between brake hose no.2 and brake hose no.2 (l). *4 clamp the sensor lead wire sleeve with the brake hose. *2 pass through the sensor lead wire in front of the brake hose. *5 pass through the sensor lead wire inside of the...

  • Page 84

    Gsf1200ak6/sak6 (’06-model) 83 rear wheel speed sensor installation *1 after the clamp has contacted to the stopper, tighten the bolt. *4 pass through the sensor lead wire on the brake hose. *2 clamp sensor lead wire with white tape matched green paint of brake hose. *5 pass through the sensor lead ...

  • Page 85: Special Tools

    84 gsf1200ak6/sak6 (’06-model) special tools note: when order the special tool, please confirm whether it is available or not. Tightening torque 09900-20602 dial gauge 09900-20701 magnetic stand 09900-20803 09900-20806 thickness gauge 09900-20805 tire depth gauge 09900-25008 multi-circuit tester set...

  • Page 86: Service Data

    Gsf1200ak6/sak6 (’06-model) 85 service data valve + guide 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) — valve-guide to valve-stem clearance in. 0.020 – 0.047 (0.0008 – ...

  • Page 87

    86 gsf1200ak6/sak6 (’06-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 33.58 – 33.62 (1.3220 – 1.3236) 33.28 (1.3102) ex. 32.65 – 32.69 (1.2854 – 1.2870) 32.35 (1.2736) camshaft journal oil clearance in. & ex. 0.032 – 0....

  • Page 88

    Gsf1200ak6/sak6 (’06-model) 87 conrod + crankshaft unit: mm (in) item standard limit piston-ring to piston-ring-groove clearance 1st — 0.180 (0.007) 2nd — 0.150 (0.006) piston ring groove width 1st 1.01 – 1.03 (0.040 – 0.041) — 2nd 1.01 – 1.03 (0.040 – 0.041) — oil 2.01 – 2.03 (0.079 – 0.080) — pist...

  • Page 89

    88 gsf1200ak6/sak6 (’06-model) oil pump clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio item standard limit oil pump reduction ratio 1.703 (72/46 × 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 90

    Gsf1200ak6/sak6 (’06-model) 89 carburetor electrical unit: mm (in) item specification e-02, 19, 24 e-28 carburetor type mikuni bsr36 ← bore size 36 mm (1.42 in) ← i.D. No. 49g0 49g1 idle r/min 1 200 ± 100 r/min 1 300 ± 100 r/min float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ← main jet (m.J.) # ← jet n...

  • Page 91

    90 gsf1200ak6/sak6 (’06-model) wattage unit: w item specification note battery type designation ft12a-bs capacity 12 v 36.0 kc (10 ah)/10 hr standard electrolyte s.G. 1.320 at 20 °c (68 °f) fuse size headlight hi 10 a lo 10 a ignition 15 a signal 15 a meter 10 a main 30 a abs * 15 a abs motor * 20 a...

  • Page 92

    Gsf1200ak6/sak6 (’06-model) 91 brake + wheel 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 – 15.913 (0.6...

  • Page 93

    92 gsf1200ak6/sak6 (’06-model) suspension unit: mm (in) tire item standard limit front fork stroke 130 (5.1) — front fork inner tube o.D. 43 (1.69) — front fork spring free length 391.5 (15.41) 383 (15.08) front fork oil level 110 (4.2) — front fork spring adjuster 3rd groove from top — rear shock a...

  • Page 94

    Gsf1200ak6/sak6 (’06-model) 93 fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyi tertiary butyi ether), less than 10% ethanol, or less than 5% methanol w...

  • Page 95

    Wiring diagram gsf1200a push free on off lock p off run off on push l push r hi lo push on off push b l 1 2 4 5 6 3 on off on off 12v on off 1 2 3 4 1 1.Head hi 2.Head lo 3.Abs 4.Ignition 5.Signal 6.Meter 10a 10a 15a 15a 15a 10a free b : black bl : blue br : brown dbr : dark brown dg : dark green g ...

  • Page 96

    Gsf1200sa (e-02, 19) push free on off lock p off run off on push l push r hi lo push on off push b l 1 2 4 5 6 3 on off on off 12v on off 1 2 3 4 1 1.Head hi 2.Head lo 3.Abs 4.Ignition 5.Signal 6.Meter 10a 10a 15a 15a 15a 10a free b : black bl : blue br : brown dbr : dark brown dg : dark green g : g...

  • Page 97

    Gsf1200sa (e-24, 28) push free on off lock p off run off on push l push r hi lo push on off push b l 1 2 4 5 6 3 on off 12v on off 1 2 3 4 1 1.Head hi 2.Head lo 3.Abs 4.Ignition 5.Signal 6.Meter 10a 10a 15a 15a 15a 10a free b : black bl : blue br : brown dbr : dark brown dg : dark green g : green lg...

  • Page 98

    Prepared by february, 2006 part no. 99501-39570-01e printed in japan 96 sa mp le.

  • Page 99

    Printed in japan k6.