1. DL manuals
  2. Suzuki
  3. Motorcycle
  4. GSF1200 2001
  5. Service Manual

Suzuki GSF1200 2001 Service Manual

Summary of GSF1200 2001

  • Page 1

    9 9 5 0 0 - 3 9 2 0 1 - 0 1 e gsf1200s/gsf1200

  • Page 2: Group Index

    Group index 1 foreword this manual contains an introductory description on the suzuki gsf1200s and procedures for its inspection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the general information section to familiarize yoursel...

  • Page 3: How To Use This Manual

    Collar brake disc (r) bearing (r) spacer bearing (l) brake disc (l) collar front wheel air valve balancer axle shaft brake disc bolt how to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3....

  • Page 4

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply oil. Use e...

  • Page 5: General Information

    General information 1-1 1 general information warning/caution/note ............................................................. 1- 2 general precautions .............................................................. 1- 2 suzuki gsf1200sk1 (2001-model) ............................................ 1-...

  • Page 6: Warning/caution/note

    1-2 general information warning/caution/note 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 mes- sages highlighted by these signal words. ! Indicat...

  • Page 7

    General information 1-3 " * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use...

  • Page 8: Serial Number Location

    1-4 general information suzuki gsf1200sk1 (2001-model) serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are requir...

  • Page 9: Break-In Procedures

    General information 1-5 engine oil use a premium quality 4-stroke motor oil to ensure longer ser- vice life of your motorcycle. Use only oils which are rated sf or sg under the api service classification. The recommended viscosity is sae 10w-40. If an sae 10w-40 motor oil is not available, select an...

  • Page 10: Information Labels

    1-6 general information information labels 10 mm (0.4 in) 10 mm (0.4 in) 10 mm (0.4 in) 10 mm (0.4 in) 28 mm (1.1 in) 28 mm (1.1 in) 10 mm (0.4 in) 10 mm (0.4 in) (e-28 only) (for e-03, 33) 5 mm (0.2 in) document tray (except e-28) (except e-03, 33) (attached on the left frame pipe) (attached on the...

  • Page 11: Specifications

    General information 1-7 specifications dimensions and dry mass overall length ................................................................ 2 070 mm (81.5 in) overall width ................................................................. 765 mm (30.1 in) overall height .............................

  • Page 12

    1-8 general information chassis front suspension .......................................................... Telescopic, coil spring, oil damped, spring pre-load fully adjustable rear suspension ........................................................... Link type, oil damped, coil spring, spring pre...

  • Page 13: Country Or Area Codes

    General information 1-9 code country or area e-02 england (uk) e-03 usa e-19 european markets e-24 australia e-28 canada e-33 california (usa) e-54 israel country or area codes the following codes stand for the applicable country(-ies) and area(-s)..

  • Page 14: Periodic Maintenance

    2 periodic maintenance contents periodic maintenance schedule .............................................. 2- 2 periodic maintenance chart ............................................... 2- 2 lubrication points................................................................... 2- 3 maintenance and...

  • Page 15

    2-2 periodic maintenance periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months, ...

  • Page 16

    Periodic maintenance 2-3 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 17: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item mentioned in the periodic maintenance chart. Valve clearance inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 12 000 km (7 500 miles, 12 months). • remove the seat ...

  • Page 18

    Periodic maintenance 2-5 • insert a thickness gauge between the end of the valve stem and the adjusting screw on the rocker arm. If the clearance is out of specification, hold the locknut with a wrench and use the special tool to adjust the clearance. & 09900-20803: thickness gauge 09917-14910: valv...

  • Page 19

    2-6 periodic maintenance spark plug gap measure the spark plug gap using a thickness gauge. If out of specification, regap the spark plug. % spark plug gap: 0.6 – 0.7 mm (0.024 – 0.028 in) & 09900-20803: thickness gauge electrode’s condition check the condition of the electrode. If it is extremely w...

  • Page 20

    Periodic maintenance 2-7 exhaust pipe bolts and muffler bolts tighten initially at 1 000 km (600 miles, 1 month) and ev- ery 12 000 km (7 500 miles, 12 months) thereafter. • tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque. ) exhaust pipe bolt: 23 n.M (2.3 kgf.M, 16....

  • Page 21

    2-8 periodic maintenance • reinstall the cleaned or new air cleaner element in the re- verse order of removal. • when installing the air cleaner element into the air cleaner case, make sure that the * mark a points up. ' if driving under dusty conditions, clean the air cleaner element more frequentl...

  • Page 22

    Periodic maintenance 2-9 engine oil and oil filter (engine oil) replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (oil filter) replace initially at 1 000 km (600 miles, 1 month) and every 18 000 km (11 000 miles, 18 months) thereafter. The oil ...

  • Page 23

    2-10 periodic maintenance oil filter replacement • drain the engine oil as described in the engine oil replace- ment procedure. • remove the oil filter 1 using the special tool. • apply engine oil lightly to the o-ring of the new oil filter, before installation. • install the new oil filter. Turn it...

  • Page 24

    Periodic maintenance 2-11 engine idle speed inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. Note: make this adjustment when the engine is hot. • start the engine, turn the throttle stop screw and set the en- gine idle speed between 1 100 an...

  • Page 25

    2-12 periodic maintenance 3rd step: • while holding the throttle grip at the fully closed position, slowly turn out the adjuster 3 of the throttle returning cable 2 until resistance is felt. • tighten the locknut 1 while holding the adjuster 3. % throttle cable play a: 2 – 4 mm (0.08 – 0.16 in) + af...

  • Page 26

    Periodic maintenance 2-13 clutch (clutch fluid) inspect every 12 000 km (12 months). Replace fluid every 2 years. (clutch hose) inspect every 6 000 km (6 months). Replace hose every 4 years. Clutch fluid level • keep the motorcycle upright and place the handlebars straight. • check the clutch fluid ...

  • Page 27

    2-14 periodic maintenance drive chain inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. Lubricate every 1 000 km (600 miles). With the transmission in neutral, support the motorcycle using the center-stand and turn the rear wheel slowly by ha...

  • Page 28

    Periodic maintenance 2-15 adjusting • loosen or tighten both chain adjuster bolts 4 until there is 20 – 30 mm (0.8 – 1.2 in) of slack at the middle of the chain be- tween the engine and rear sprockets as shown. The reference marks a on both sides of the swingarm and the edge of each chain adjuster m...

  • Page 29

    2-16 periodic maintenance brakes (brake) inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. (brake hose and brake fluid) inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years. Replace fluid every 2 years. Brake fluid leve...

  • Page 30

    Periodic maintenance 2-17 brake pads the extent of brake pad wear can be checked by observing the grooved limit line 1 on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( $5-44 and -54) ' replace the brake pads as a set, otherwise braking per- formance will be...

  • Page 31

    2-18 periodic maintenance air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper. The presence of air is...

  • Page 32

    Periodic maintenance 2-19 • rear brake: the only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. Tires inspect every 6 000 km (4 000 miles, 6 months). Tire tread condition operating the motorcycle with excessively worn tires will decreas...

  • Page 33

    2-20 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. Cold inflatio...

  • Page 34

    Periodic maintenance 2-21 front forks inspect every 12 000 km (7 500 miles, 12 months). Inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( $5-12) rear suspension inspect every 12 000 km (7 500 miles, 12 m...

  • Page 35

    2-22 periodic maintenance check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-23 for the locations of the following nuts and bolts.) item n.M kgf.M lb-ft 1 steering stem head nut 65 6.5 47.0 2 front fork upper clamp bolt 23 2.3 16.5 3 front fork lower clam...

  • Page 36

    Periodic maintenance 2-23.

  • Page 37: Compression Pressure Check

    2-24 periodic maintenance compression pressure check 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 mainte- nance records kept at your dealership should ...

  • Page 38: Oil Pressure Check

    Periodic maintenance 2-25 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification above 300 kpa (3.0 kgf/cm 2 , 43 psi) below 600 kpa (6.0 kgf/cm 2 , 85 psi) at 3 000 r/min., oil temp. At 60°c (1...

  • Page 39: Engine

    Engine 3-1 3 engine contents engine components removable with engine in place ................................................................................ 3- 2 engine removal and reinstallation ...................................... 3- 3 engine removal ..............................................

  • Page 40

    3-2 engine engine components removable with engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. Engine center see page exhaust pipe/muffler ...............

  • Page 41

    Engine 3-3 engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • remove the seat and frame side covers. ( !5-5 and -6) • remove the fuel tank. ( !4-3) • remov...

  • Page 42

    3-4 engine • disconnect the pair valve hoses 1, 2 and 3. 1 air cleaner hose 2 vacuum hose 3 pair hoses • loosen the respective carburetor clamp screws 4. • disconnect the throttle position sensor lead wire coupler 5. • slightly move the air cleaner box backward. • remove the carburetor assembly by d...

  • Page 43

    Engine 3-5 • remove the two wire clamps. • disconnect the starter motor lead wire 1. • disconnect the generator lead wire 2 and coupler 3. • remove the gearshift lever by removing its mounting bolt. • remove the engine sprocket cover by removing the bolts. • remove the speed sensor rotor 4. • remove...

  • Page 44

    3-6 engine • remove the eight exhaust pipe bolts. • remove the muffler mounting bolts. • remove the exhaust pipe/muffler. • remove the oil cooler hose union bolts 1. • remove the oil cooler by removing the mounting bolts 2..

  • Page 45

    Engine 3-7 • suppport the engine with a proper engine jack. • remove the frame down tube mounting bolts and nuts. • remove the frame down tube 1. • remove the engine mounting bolts, nuts, spacer and brackets. • gradually lower the engine. Note: only for e-28 model; the engine mounting brackets a are...

  • Page 46

    3-8 engine engine reinstallation reinstall the engine in the reverse order of engine removal. • insert the two long bolts from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration. Note: the engine mounting nuts are self-locking. Once the nuts have...

  • Page 47

    Engine 3-9 • tighten the oil cooler mounting bolts to the specified torque. " oil cooler mounting bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) • tighten the oil cooler hose union bolts to the specified torque. " oil cooler hose union bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) $ use a new gasket washer to prevent o...

  • Page 48

    3-10 engine #1 #2 #3 #4 #1 #2 #3 #4 carburetor clamp position (air cleaner side) carburetor clamp position (engine side) l.H r.H • apply thread lock super “1303” to the threads of the driveshaft. % 99000-32030: thread lock super “1303” • tighten the engine sprocket nut 1 to the specified torque. " e...

  • Page 49

    Engine 3-11 • after remounting the engine, route the wire harness, cables and hoses properly. ( !7-12) • tighten the oil drain plug 1 to the specified torque. " oil drain plug: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • install the gearshift lever to the gearshift shaft in the correct position. ' gearshift le...

  • Page 50: Engine Disassembly and

    3-12 engine engine disassembly and reassembly $ identify the position of each removed part. Organize the parts in their respective groups (e.G., intake, exhaust) so that they can be reinstalled in their original positions. Engine disassembly • remove each pair valve pipe and hose. • remove the oil f...

  • Page 51

    Engine 3-13 • remove the signal generator cover 1. ( 09911-73730: 5 mm “t” type hexagon wrench • remove all of the spark plugs. • turn the crankshaft clockwise and align the “t” mark on the signal generator rotor with the center of the pickup coil. Also, position the notches 2 on the right end of ea...

  • Page 52

    3-14 engine • remove the cam chain guide 1. • remove the cylinder head bolt 2. • the cylinder head can be removed when its twelve 10-mm nuts 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 ...

  • Page 53

    Engine 3-15 • remove the left and right oil pipes 1. • remove the cylinder base nut 2. • firmly grip the cylinder block at both ends and lift it straight up. If the cylinder block does not come off, lightly tap on the finless portions of it using a plastic mallet. $ be careful not to damage the fins...

  • Page 54

    3-16 engine • remove the starter motor 1. • remove the generator 2. • remove the signal generator rotor 3 using the special tool. ( 09900-00410: hexagon wrench set • disconnect the oil pressure switch lead wire 4. • remove the signal generator stator (along with the pickup coil) 5 and oil pressure s...

  • Page 55

    Engine 3-17 • remove the clutch pressure plate lifter 1 by removing the circlip. ( 09900-06108: snap ring pliers • after removing the clutch pressure plate lifter, remove the thrust washer 2, bearing 3 and clutch push piece 4, and pull out the clutch push rods, 5 and 6. Note: if it is difficult to p...

  • Page 56

    3-18 engine • remove the clutch diaphragm springs 1, clutch diaphragm spring seat 2 and clutch pressure plate 3. • remove the clutch drive and driven plates along with the clutch sleeve hub. • remove the thrust washer 4. • with the spacer and bearing removed, the primary driven gear (integral with t...

  • Page 57

    Engine 3-19 note: when removing the gearshift cam driven gear, do not lose the gearshifting pawl 3, pin 4 and spring 5. • remove the circlip 6. ( 09900-06107: snap ring pliers • remove the washers 7, oil pump driven gear 8 and pin 9. Note: do not lose the circlip, pin and the washers. • remove the s...

  • Page 58

    3-20 engine • hold the starter clutch assembly using the special tool and then loosen the starter clutch mounting bolt. ( 09920-34840: starter clutch holder note: do not remove the starter clutch mounting bolt at this stage, only loosen it. You will need to use it in conjunction with the special too...

  • Page 59

    Engine 3-21 • remove the countershaft bearing retainer 1. • remove the plug 2. • remove the upper crankcase bolts and nut. • remove the oil pan 3. • remove the shim 4 and o-ring 5. • remove the oil sump filter 6. • remove the oil return pipe 7. • remove the lower crankcase bolts and nut..

  • Page 60

    3-22 engine • remove the main oil gallery plug 1 and o-ring. ( 09900-00410: hexagon wrench set • 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 crank- case off of ...

  • Page 61

    Engine 3-23 • remove the dampers 1 and cam chain tensioner guide 2. • remove the o-rings (3 and 4). Note: * do not remove the crankshaft journal bearings unless abso- lutely necessary. * make a note of where the crankshaft journal bearings are re- moved from so that they can be reinstalled in their ...

  • Page 62

    3-24 engine • unhook the gearshift cam stopper spring 1 from the lower crankcase. • remove the circlip 2 from the gearshift cam, then draw out the gearshift cam 3 from the opposite side. ( 09900-06107: snap ring pliers • remove the circlip 4 and gearshift cam stopper 5. ( 09900-06107: snap ring plie...

  • Page 63

    Engine 3-25 • remove the oil pump 1. ( 09900-00410: hexagon wrench set • remove the o-rings and dowel pins..

  • Page 64

    3-26 engine engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. • install the o-rings (1 and 2) and dowel...

  • Page 65

    Engine 3-27 note: when installing the gearshift cam stopper plate 1, align the pin groove a with the pin b as shown. • install the gearshift cam 2 and its related parts. 3 gearshift cam stopper 4 circlip 5 spring 6 circlip $ always use new circlips (4 4 4 4 4 and 6 6 6 6 6). • position the gearshift...

  • Page 66

    3-28 engine • hold the gearshift forks 1 by hand when installing the gear- shift fork shaft 2. • install the bearing pins 3 and c-rings 4 into the upper crank- case. • install the countershaft assembly 5 and driveshaft assembly 6 into the upper crankcase. Note: * be sure to install the bearing dowel...

  • Page 67

    Engine 3-29 • install the cam chain tensioner guide 1 and the two dampers 2 properly. Note: be sure to face the arrow mark on the damper towards the front and rear, not towards the left and right. • install the o-rings (3 and 4). $ replace the o-rings with new ones to prevent oil leak- age. • before...

  • Page 68

    3-30 engine bond “1207b” should be applied to the following locations. The line of bond.

  • Page 69

    Engine 3-31 • install the right oil pipe a with the bolt 1. • install the copper washers onto bolts 9 and a. • install the two allen bolts at position b. • install the ten crankcase bolts (8 mm). • tighten the crankcase bolts (crankshaft tightening bolts) in as- cending order. Tighten each bolt a li...

  • Page 70

    3-32 engine • install the left oil pipe 1. • install a new o-ring 2 and shim 3. • install a new gasket and the oil sump filter 4. $ replace the gasket and o-ring with new ones to prevent oil leakage. • install a new gasket and the oil pan. Tighten the oil pan bolts to the specified torque. " oil pan...

  • Page 71

    Engine 3-33 • install the oil seal retainer 1 with the four bolts and then bend the tab on the retainer. Note: route the gear position switch lead wire to the inside of the oil seal retainer’s tab a as shown. • remove the grease from the tapered portion of the starter clutch and crankshaft. Use a no...

  • Page 72

    3-34 engine • install the gearshift shaft 5. Note: align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear. • install the washer and fix the gearshift shaft with the circlip. ( 09900-06107: snap ring pliers • install the washer 6, pin 7, oil pump driven g...

  • Page 73

    Engine 3-35 • install the primary driven gear assembly onto the countershaft, and apply engine oil onto the needle bearing and spacer. • install the thrust washer 2 onto the countershaft. • install the generator/oil pump drive gears 1 onto the primary driven gear assembly as shown. • install the spr...

  • Page 74

    3-36 engine no.1: 40 pcs no.2: 48 pcs $ no. 1 and no. 2 drive plates resemble each other very closely in external appearance. Make sure to check the number of facing before installing them. Drive plate no. 1: 40 pcs drive plate no. 2: 48 pcs • put the clutch pressure plate onto the clutch sleeve hub...

  • Page 75

    Engine 3-37 • lock the clutch sleeve hub nut with a center punch. • insert the clutch push rod 1 into the countershaft. • install the clutch push piece 2, bearing 3 and thrust washer 4 to the countershaft. • fix the clutch pressure plate lifter with the circlip. ( 09900-06108: snap ring pliers note:...

  • Page 76

    3-38 engine diaphragm spring holder diaphragm springs 150 n.M (15.0 kgf.M, 108.5 lb-ft).

  • Page 77

    Engine 3-39 • install the oil pressure switch, apply the recommended bond to its thread and tighten it to the specified torque. * 99000-31140: suzuki bond “1207b” " oil pressure switch: 14 n.M (1.4 kgf.M, 10.0 lb-ft) • be sure to fit the slot 4 on the back surface of the signal gen- erator rotor ove...

  • Page 78

    3-40 engine • make sure that the oil jets b in the upper crankcase are not clogged. • install the generator. " generator mounting bolt: 25 n.M (2.5 kgf.M, 18.0 lb-ft) note: apply suzuki super grease “a” to the generator o-ring. & 99000-25010: suzuki super grease “a” $ replace the o-ring with a new o...

  • Page 79

    Engine 3-41 • 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 oil solu- tion to their surfaces. ) 99000-25140: suzuki moly paste • place a cloth beneath the piston, and install the circli...

  • Page 80

    3-42 engine exhaust side • install the new o-rings 2 onto the oil pipes and apply suzuki super grease “a” to the o-rings. • install the right and left oil pipes. $ replace the o-rings 2 with new ones to prevent oil leak- age. & 99000-25010: suzuki super grease “a” • place the cylinder head onto the ...

  • Page 81

    Engine 3-43 • tighten the twelve 10-mm nuts in ascending order and to the specified torque. " cylinder head nut: 38 n.M (3.8 kgf.M, 27.5 lb-ft) • after firmly tightening the twelve 10-mm nuts, install the cylin- der head bolt (6 mm) 1 and tighten it to the specified torque. " cylinder head bolt: 10 ...

  • Page 82

    3-44 engine • the exhaust camshaft sprocket has an arrow marked “1” 1. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • engage the cam chain with the exhaust camshaft sprocket. • the other arrow marked “2” should now be pointing straight up. Star...

  • Page 83

    Engine 3-45 24th pin 1st pin.

  • Page 84

    3-46 engine • each camshaft journal holder is identified with an embossed letter. Install the dowel pins into each cam- shaft journal holder. • fasten the camshafts (in and ex) evenly by tightening the camshaft journal holder bolts sequentially and in a crisscross pattern. Note: damage to the cylind...

  • Page 85

    Engine 3-47 • 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 tensioner. Note: before installing the cam chain tensioner, turn the crankshaft clock- wise to remove any cam chain slack between the crankshaft spr...

  • Page 86

    3-48 engine • before installing the cylinder head cover gasket onto the cylin- der head cover, apply the recommended bond to the groove in the cylinder head cover. • apply the recommended bond to the four camshaft end caps of the gasket as shown. * 99000-31140: suzuki bond “1207b” • place the cylind...

  • Page 87

    Engine 3-49 • install the left and right oil hoses and tighten their mounting bolts to the specified torque. $ replace the o-rings (a and b) with new ones to prevent oil leakage. " oil hose mounting bolt: 10 n.M (1.0 kgf.M, 7.0 lb-ft) • turn the oil filter by hand until you feel that the oil filter ...

  • Page 88: Engine Components Inspection

    3-50 engine engine components inspection and service camshaft/cylinder head inspection and service ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., intake, exhaust, #1 or #2) so that they can be installed in their original loca- tions. Camshafts if t...

  • Page 89

    Engine 3-51 camshaft sprockets the fixed position of each camshaft sprocket is determined by arrow mark “3” for the intake camshaft, and by arrow marks “1” and “2” for the exhaust camshaft, as located in reference to the notch 1 on the right end of each camshaft. Inspect the teeth of each camshaft s...

  • Page 90

    3-52 engine • apply thread lock super “1303” to the threads of the cam- shaft sprocket bolts and then tighten them to the specified torque. & 99000-32030: thread lock super “1303” % camshaft sprocket bolt: 25 n.M (2.5 kgf.M, 18.0 lb-ft) cam chain tensioner the cam chain tensioner is maintained at th...

  • Page 91

    Engine 3-53 cylinder head disassembly • remove the rocker arm shaft set bolt 1 and cylinder head plug 2. " 09900-00410: hexagon wrench set • remove the rocker arm shaft 1, rocker arm 2 and spring 3. Note: to remove the rocker arm shaft, screw a 8-mm bolt into the rocker arm shaft end and then pull o...

  • Page 92

    3-54 engine • remove the valve spring seat. • remove the valve from the combustion chamber side. • remove the oil seal. Cylinder head distortion decarbonize the combustion chambers. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance r...

  • Page 93

    Engine 3-55 10 mm (0.39 in) valve face wear visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face de- creases as the face wears. Measure the valve face t. If it is out of specification replace the valve with a new one. " 09900-2010...

  • Page 94

    3-56 engine valve guide servicing • using the valve guide remover 1, drive the valve guide out toward the intake or exhaust camshaft side. " 09916-44310: valve guide remover/installer note: * discard the removed valve guide subassemblies. * only oversized valve guides are available as replacement pa...

  • Page 95

    Engine 3-57 valve seat width • coat the valve seat uniformly with prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. " 09916-10911: valve lapper set • the ring...

  • Page 96

    3-58 engine • when installing the solid pilot 1, rotate it slightly. Contact area too high and too wide on face of valve • seat the pilot snugly. Install the 45° cutter 2, attachment 3 and t-handle 4. Initial seat cut • using the 45° cutter, descale and clean up the seat. Rotate the cutter one or tw...

  • Page 97

    Engine 3-59 final seat cut • if the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. Note: after cutting the 15° angle, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width. • after the desired seat po...

  • Page 98

    3-60 engine valve seat sealing condition inspection clean and assemble the cylinder head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. ...

  • Page 99

    Engine 3-61 # valve spring tension (in & ex) standard: inner: 53 – 65 n, 5.3 – 6.5 kgf/28 mm (11.7 – 14.3 lbs/1.10 in) outer: 131 – 151 n, 13.1 – 15.1 kgf/31.5 mm (28.9 – 33.3 lbs/1.24 in) rocker arm shaft outside diameter inspection on the sliding surface, take two measurements, at right angle to e...

  • Page 100

    3-62 engine • oil each oil seal 1 and press-fit them into position using the valve guide installer. • install each valve spring seat 2 (for intake side) and 3 (for exhaust side). " 09916-44310: valve guide remover/installer ! Do not reuse the oil seals. • insert the valves with their stems coated wi...

  • Page 101

    Engine 3-63 • 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 1 to wedge between the retainer and the valve stem. Be sure that the rounded lip a of the cotter fi...

  • Page 102

    3-64 engine • when installing the intake pipe bolts, apply a small quantity of thread lock “1342” to these thread. * * * * * 99000-32050: thread lock “1342” ! Use a new o-ring to prevent the joint from sucking in any air. Note: * when replacing the intake pipes, identify the different intake pipes a...

  • Page 103

    Engine 3-65 cylinder block/piston inspection cylinder block distortion check the gasket surface of the cylinder block for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder block. " 09900-20803...

  • Page 104

    3-66 engine piston-to-cylinder clearance subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylin- der and the piston. # piston-to-cylinder clearance service l...

  • Page 105

    Engine 3-67 oversize piston ring the following two types of oversize piston rings are used. They bear the following identification numbers. 1st 2nd 0.5 mm 50 50 oversize oil ring the following two types of oversize oil rings are available as op- tional parts. They bear the following identification m...

  • Page 106

    3-68 engine arrow mark b • the 1st 1 and 2nd 2 piston rings should be installed with the mark facing up. • first, install a spacer 3 into the oil ring groove and then install the two side rails 4. The spacer and side rails do not have a designated top and bottom. They can be installed in any posi- t...

  • Page 107

    Engine 3-69 spring height clutch inspection clutch diaphragm spring measure the free height of each diaphragm spring with a vernier calipers. If each diaphragm spring height is not within the speci- fied limit, replace it with a new one. " 09900-20102: vernier calipers # clutch spring free height se...

  • Page 108

    3-70 engine clutch release cylinder disassembly • remove the gearshift lever and engine sprocket cover. ( $ 3-5) • remove the clutch hose by removing the union bolt 1. • remove the air bleeder valve 2. • remove the clutch release cylinder by removing the mounting bolts 3 and piston retainer screws 4...

  • Page 109

    Engine 3-71 gearshift linkage inspection gearshift shaft/gearshift arm inspection check the gearshift shaft/gearshift arm for bends or wear. Check the return spring on the gearshift arm for damage or fa- tigue. If any defects are found, replace the defective part(-s). Oil seal inspection inspect the...

  • Page 110

    3-72 engine gearshift shaft hole inspection check the gearshift shaft hole for damage or wear. Gearshift shaft reassembly when installing the gearshift shaft return spring, position the stop- per between the ends of the gearshift shaft return spring..

  • Page 111

    Engine 3-73 transmission inspection and service ! Identify the position of each removed part. Organize the parts in their respective groups (i.E., drive or driven) so that they can be reinstalled in their original positions. Gearshift fork-to-gearshift fork groove clearance measure the gearshift for...

  • Page 112

    3-74 engine disassembly countershaft assembly • remove the left end bearing 1 and oil seal 2. • remove the 5th (top) drive gear circlip 3 from its groove and slide it towards the 3rd drive gear 4. " 09900-06107: snap ring pliers • slide the lock washer 5 towards the 5th (top) drive gear 6, then turn...

  • Page 113

    Engine 3-75 driveshaft assembly • disassemble the driveshaft assembly as shown in the illustra- tion. 1 bearing 5 4th driven gear 2 2nd driven gear 6 low driven gear 3 5th (top) driven gear 7 bearing 4 3rd driven gear reassembly assemble the countershaft and driveshaft assemblies in the re- verse or...

  • Page 114

    3-76 engine driveshaft assembly • align the bushing oil hole 1 with the shaft oil hole 2. • with the lock washer turned in its groove a, align the cutout b of the lock washer with the tab c on the gear bushing. • install the spacer 3 after installing the o-ring 4. Countershaft assembly • align the b...

  • Page 115

    Engine 3-77 ! Install the oil seal as shown in the illustration. 1 left end bearing 2 oil seal 3 2nd drive gear 4 countershaft 1 1st (low) driven gear 2 4th driven gear 3 3rd driven gear 4 5th (top) driven gear 5 2nd driven gear 6 driveshaft 7 countershaft/1st (low) drive gear 8 4th drive gear 9 3rd...

  • Page 116

    3-78 engine.

  • Page 117

    Engine 3-79 conrod/crankshaft inspection 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. " 09900-20602: dial gauge (1/1000 mm) 09900-22403: small bore gauge (18 – 35 ...

  • Page 118

    3-80 engine • remove the conrods and mark them to identify their respective cylinders. • inspect the bearing surfaces for any signs of fusion, pitting, burns, or flaws. If there is any damage, replace them with the specified set of bearings. Conrod-crank pin bearing selection • place the plastigauge...

  • Page 119

    Engine 3-81 • check the corresponding crank pin o.D. Code numbers (“1”, “2” or “3”) 3. Bearing selection table crank pin o.D. 3 code 1 2 3 conrod 1 green black brown i.D. 2 2 black brown yellow conrod i.D. Specification code i.D. Specification 1 41.000 – 41.008 mm (1.6142 – 1.6145 in) 2 41.008 – 41....

  • Page 120

    3-82 engine bearing assembly • when installing the bearings into the bearing cap and conrod, be sure to install the tab 1 first, and then press in the opposite side of the bearing. • apply molybdenum oil solution to the crank pin and bearing surface. ( 99000-25140: suzuki moly paste • when mounting ...

  • Page 121

    Engine 3-83 • mate the lower crankcase with the upper crankcase and tighten the crankshaft bolts to the specified torque and in the proper tightening sequence. % crankcase bolt (initial): 13 n.M (1.3 kgf.M, 9.5 lb-ft) (final): 23 n.M (2.3 kgf.M, 16.5 lb-ft) • remove the lower crankcase and measure t...

  • Page 122

    3-84 engine upper lower crankcase journal i.D. Specification code i.D. Specification a 39.000 – 39.008 mm (1.5354 – 1.5357 in) b 39.008 – 39.016 mm (1.5357 – 1.5361 in) crankshaft journal o.D. Specification code o.D. Specification a 35.992 – 36.000 mm (1.4170 – 1.4173 in) b 35.984 – 35.992 mm (1.416...

  • Page 123

    Engine 3-85 crankshaft thrust clearance adjustment • with the crankshaft’s right-side and left-side thrust bearings inserted into the upper crankcase, measure the thrust clear- ance between the left-side thrust bearing and the crankshaft using the thickness gauge. R: right-side thrust bearing l: lef...

  • Page 124

    3-86 engine left-side thrust bearing selection table clearance before color 1 thrust bearing inserting the left-side (part no.) thickness thrust clearance thrust bearing 2.42 – 2.44 mm black 2.36 – 2.38 mm (0.0953 – 0.0961 in) (12228-48b00-0h0) (0.0929 – 0.0937 in) 2.44 – 2.46 mm orange 2.38 – 2.40 ...

  • Page 125: Engine Lubrication System

    Engine 3-87 engine lubrication system oil pump removal the crankcase must be separated to service the oil pump. The oil pump service requires engine removal and disassembly. Refer to the engine removal and the engine disassembly sec- tions for oil pump removal. ( $3-25) inspection rotate the oil pum...

  • Page 126

    3-88 engine • oil pressure regulator • oil sump filter oil pressure regulator inspection check the operation of the oil pressure regulator by pushing on the piston with an appropriately shaped tool. If the piston does not operate, replace the oil pressure regulator with a new one. Oil sump filter cl...

  • Page 127

    Engine 3-89 oil sump filter/oil pressure regulator installation installation is in the reverse order of removal. Note: refer to the following pages for the details of each step. Install: • oil sump filter note: * when installing the oil sump filter, make sure that the arrow mark a points towards the...

  • Page 128

    3-90 engine oil pressure switch/oil cooler removal after draining the engine oil, remove the oil pressure switch and the oil cooler. Note: refer to the following pages for the details of each step. Drain: • engine oil ( $2-9) remove: • signal generator cover. • oil pressure switch. • oil cooler oil ...

  • Page 129

    Engine 3-91 oil cooler hose inspection inspect the oil cooler hoses for damage and oil leaks. If any de- fects are found, replace the oil cooler hose(-s) with a new one. Oil cooler inspection and cleaning remove any foreign matter that is stuck in the oil cooler fins us- ing compressed air. Inspect ...

  • Page 130

    3-92 engine • signal generator cover ( $3-48) adjust the following item to specification. * engine oil .......................................................... $2-9 oil filter $2-10 oil pressure $2-25 oil jet oil jet (for the cylinder head) removal • the oil jet (for the cylinder head) can be remo...

  • Page 131

    Engine 3-93 oil jet (for piston cooling and the transmission) removal • the oil jet (for piston cooling and the transmission) can be re- moved after separating the crankcase. Remove: • oil jet (for piston cooling) 1 • oil jet (for the transmission) 2 inspection make sure that the oil jets are not cl...

  • Page 132: Oil P

    3-94 engine engine lubrication system chart conr od small end cam chain cylinder head cylinder head countershaft gears clutch pla tes driveshaft gears oil pump oil cooler by-p ass oil sump fil ter driveshaft right side bearing oil p a n regula to r oil fil ter oil jet oil jet oil jets oil jet oil je...

  • Page 133

    Engine 3-95 engine lubrication system.

  • Page 134

    3-96 engine cylinder head cooling system chart.

  • Page 135

    Engine 3-97 cylinder head cooling system.

  • Page 136: Pair (Air Supply) System

    3-98 engine pair (air supply) system pair system removal • remove the fuel tank. ( $4-3) • disconnect all of the pair valve hoses. 1 vacuum hose 2 air cleaner hose 3 pair hose no. 1 4 pair hose no. 2 5 pair hose no. 3 6 pair hose no. 4 • remove the pair valve. • remove the pair pipes from each cylin...

  • Page 137

    Engine 3-99 pair (air supply) system inspection hoses and pipes • inspect the hoses and pipes for wear or damage. • inspect that the hoses and pipes are securely connected. Pair valve • remove the pair valve. ( $3-98) • inspect the pair valve body for damage. Pair valve • inspect that air flows thro...

  • Page 138

    3-100 engine p a ir v alv e clamp no .4 cy . N o .3 cy . N o .2 cy . N o .1 cy . 10 n . M (1.0 kgf . M, 7.0 lb-ft) clamp 10 n . M (1.0 kgf . M, 7.0 lb-ft) v acuum hose t o no .3 carb uretor t o air cleaner bo x pair (air supply) system hose routing.

  • Page 139: Fuel System

    Fuel system 4-1 fuel system contents fuel system ...................................................................................... 4- 2 fuel tank ............................................................................................ 4- 3 removal ..............................................

  • Page 140: Fuel System

    4-2 fuel system fuel tank fuel valve vacuum hose fuel hose fuel vacuum fuel system the fuel system consists of a fuel tank, fuel valve, vacuum hose, fuel hose and carburetor assembly. When there is negative pressure (vacuum) in the combustion chamber, the fuel is able to flow from the fuel tank, thr...

  • Page 141: Fuel Tank

    Fuel system 4-3 fuel tank removal • remove the seat. ( !5-5) • remove the fuel tank mounting bolts 1. • turn the fuel valve knob to the “on” position. • remove the fuel valve knob 2 by removing its mounting screw. • disconnect the vacuum hose 3 and fuel hose 4. " gasoline is highly flammable and exp...

  • Page 142: Fuel Valve

    4-4 fuel system fuel vacuum 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 combu...

  • Page 143

    Fuel system 4-5 removal • remove the fuel tank. ( !4-3) • remove the fuel valve 1. " * gasoline is very explosive. Extreme care must be taken. * the gaskets 2 and o-ring 3 must be replaced with new ones to prevent fuel leakage. Inspection and cleaning if the fuel filter is dirty with sediment or rus...

  • Page 144: Fuel Level Gauge

    4-6 fuel system fuel level gauge removal • remove the fuel tank. ( !4-3) • remove the fuel level gauge 1. " gasoline is very explosive. Extreme care must be taken. Inspection measure the resistance between the lead wire terminals when the float is at the position listed below. $ 09900-25008: multi-c...

  • Page 145: Carburetor

    Fuel system 4-7 carburetor construction 1 top cap 2 o-ring 3 spring 4 jet needle stopper 5 o-ring 6 spring 7 washer 8 e-ring 9 spacer 0 jet needle a diaphragm b piston valve c pilot air jet d starter (enricher) plunger e needle valve assy f float g float pin h needle jet i o-ring j main jet holder k...

  • Page 146

    4-8 fuel system specifications item specification e-02, 19, 24, 54 e-03, 28 carburetor type mikuni bsr36ss ← bore size 36 mm ← i.D. No. 32f0 32f1 idle r/min. 1 200 ± 100 r/min. ← float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ← main jet (m.J.) #100 # jet needle (j.N.) 5c70-3rd 5c71-1st needle jet (n.J....

  • Page 147

    Fuel system 4-9 i.D. No. Location each carburetor has an i.D. Number 1 printed on its body..

  • Page 148

    4-10 fuel system negative pressure 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 t...

  • Page 149

    Fuel system 4-11 air fuel/air mixture fuel 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...

  • Page 150

    4-12 fuel system air fuel/air mixture fuel 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 need...

  • Page 151

    Fuel system 4-13 fuel air fuel/air mixture fuel 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 ...

  • Page 152

    4-14 fuel system removal • remove the fuel tank. ( !4-3) • remove the frame side covers. ( !5-6) • remove the fuel tank bracket bolts 1. • remove the air cleaner box mounting bolts 2. • disconnect the throttle position sensor coupler 3. • loosen the respective carburetor clamp screws. • slightly mov...

  • Page 153

    Fuel system 4-15 disassembly before disassembly, prepare a clean and well lit work place where carburetor components can be laid out neatly and will not get lost. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their r...

  • Page 154

    4-16 fuel system • remove the top cap 1. # do not use compressed air on the carburetor body, be- fore removing the diaphragm; this may damage the dia- phragm. • remove the spring 2 and the piston valve along with its dia- phragm 3. • remove the o-ring 4. • remove the jet needle stopper 5, spring 6, ...

  • Page 155

    Fuel system 4-17 • remove the float pin 1 and then remove the float 2 and needle valve 3. • remove the following parts. 4 main jet 5 needle jet 6 pilot jet 7 pilot screw 8 starter (enricher) jet 9 valve seat note: before removing the pilot screw 7, its setting must be determined. Slowly turn the pil...

  • Page 156

    4-18 fuel system • remove the throttle valve. Pilot screw removal (for with plug type) because harsh cleaning solvents can damage the o-ring seals in the pilot system, the pilot system components should be re- moved before cleaning. • use a 1/8“ size drill bit with a drill-stop to remove the pilot s...

  • Page 157

    Fuel system 4-19 carburetor cleaning " some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • clean all jets with a spray-type carbureto...

  • Page 158

    4-20 fuel system carburetor inspection check the following items for any damage or clogging. * pilot jet * valve seat * main jet * piston valve * main air jet * starter (enricher) jet * pilot air jet * gasket and o-ring * needle jet air bleeding hole * throttle shaft oil seal * float * diaphragm * n...

  • Page 159

    Fuel system 4-21 reassembly reassemble the carburetors in the reverse order of disassembly. Pay attention to the following points. Throttle valve • turn the throttle stop screw and throttle valve synchronizing screw until the throttle valve’s bottom end 1 is aligned with the foremost by-pass port 2 ...

  • Page 160

    4-22 fuel system carburetor heater • apply thermo-grease to the threads and tighten the carburetor heater. (only for e-02) ) 99000-59029: thermo-grease % % % % % carburetor heater: 3 n.M (0.3 kgf.M, 2 lb-ft) carburetor engagement • position the throttle valve control lever 1 between the throttle val...

  • Page 161

    Fuel system 4-23 throttle position sensor positioning install the throttle position sensor as described below. • measure the resistance between the throttle position sen- sor terminals as shown. $ 09900-25008: multi circuit tester set & throttle position sensor resistance : 3.5 – 6.5 kΩ Ω Ω Ω Ω • me...

  • Page 162

    4-24 fuel system throttle cable adjustment (major adjustment) note: minor adjustment can be made by the throttle grip side adjuster. ( !2-11) • remove the fuel tank. ( !4-3) • loosen the lock nut 1 of the throttle returning cable. • turn the returning cable adjuster 2 to obtain proper cable play. • ...

  • Page 163

    Fuel system 4-25 • remove the vacuum inlet cap from the carburetor (for cylinders #1 or #4). • connect one of the carburetor balancer’s rubber hoses to this inlet. $ 09913-13121: carburetor balancer note: if it is difficult to connect the carburetor balancer’s rubber hoses to the vacuum inlets, slig...

  • Page 164

    4-26 fuel system • after balancing the carburetor, set the engine speed by turning the throttle stop screw. Observe the tachometer reading. & engine speed: 1 200 ± 100 r/min carburetor synchronization remove all of the vacuum inlet caps, before synchronizing the carburetors. Connect the carburetor b...

  • Page 165: Chassis

    Chassis 5-1 5 chassis contents exterior parts ...................................................................................................................................... 5- 2 construction ........................................................................................................

  • Page 166: Exterior Parts

    5-2 chassis ( 3.5 kgf . M ) 25.5 lb-ft 35 n . M side co wling (rh) wind screen side co wling (lh) f ront co wling meter panel center co wling co wling br ace side co wling br ac k et (rh) side co wling br ac k et (lh) exterior parts construction.

  • Page 167

    Chassis 5-3 removal cowling and cowling brace (except for gsf1200) • remove the two screws. • remove the rear view mirrors 1 and the front cowling 2. Hooked part • remove the side cowlings 4, left and right. • disconnect the turn signal lead wire coupler. • remove the center cowling 3. • remove the ...

  • Page 168

    5-4 chassis • disconnect the headlight and position light lead wire couplers. • remove the headlight assy 6. (remove the nuts at both left and right sides.) • remove the combination meter 7. ( !6-33) • remove the three screws and the upper panel 8. • remove the wiring harness clamps. • remove the fa...

  • Page 169

    Chassis 5-5 seat • remove the seat 1 by using the ignition key. Document tray • remove the seat. ( ! 5-5) • remove the document tray 1. Frame cover • remove the seat. ( ! 5-5) • remove the passenger grab handle 1. • disconnect the brake light/taillight coupler 2. • remove the frame covers 3, left an...

  • Page 170

    5-6 chassis frame side cover • remove the frame side covers 1, left and right. Remounting remount the cowling, cowling brace, seat and frame covers in the reverse order of removal. Hooked part.

  • Page 171: Front Wheel

    Chassis 5-7 collar brake disc (r) bearing (r) spacer bearing (l) brake disc (l) collar front wheel air valve balancer axle shaft brake disc bolt front wheel construction " item n.M kgf.M lb-ft a 100 10.0 72.5 b 23 2.3 16.5.

  • Page 172

    5-8 chassis 39 n.M (3.9 kgf.M, 28.0 lb-ft) 39 n.M (3.9 kgf.M, 28.0 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 23 n.M (2.3 kgf.M, 16.5 lb-ft) 100 n.M (10.0 kgf.M, 72.5 lb-ft) left right left use old part use old part use old part spacer clearance bearing installer left beari...

  • Page 173

    Chassis 5-9 removal • remove the reflectors. (for e-03, e-28, e-33) • remove the brake caliper mounting bolts 1. • loosen the front axle pinch bolts 2. • loosen the front axle 3. • raise the front wheel off the ground using a jack or wooden block. • remove the front wheel. # do not operate the brake...

  • Page 174

    5-10 chassis • remove the bearing using the special tool. % 09921-20220: bearing remover set # * the removed bearings should be replaced with new ones. * do not stress the brake discs by using wooden block under the wheel. Front axle measure the front axle runout using the dial gauge. If the runout ...

  • Page 175

    Chassis 5-11 remounting remount the front wheel in the reverse order of removal. Pay attention to the following points: • install the front wheel. ' face the arrow mark a on the tire to the direction of wheel rotation, when remounting the wheel. • tighten the front axle 1 to the specified torque. " ...

  • Page 176: Front Fork

    5-12 chassis front fork protecter dust seal oil seal stopper ring oil seal oil seal retainer outer tube slide metal oil lock piece outer tube (r) gasket o-ring spring adjuster collar o-ring spring seat spacer washer spring damper rod (inner rod cylinder) inner tube inner tube slide metal front fork ...

  • Page 177

    Chassis 5-13 removal and disassembly • remove the center cowling. ( ! 5-3) • remove the front wheel. ( ! 5-9) • remove the front fender mounting bolts 1, left and right. • remove the front fender 2. • remove the brake hose clamp bolts 3, left and right. • loosen the front fork upper clamp bolts 4, l...

  • Page 178

    5-14 chassis • remove the front fork cap bolt with spring adjuster 1 by loos- ening the inner rod lock nut. • remove the spring seat 2. • remove the spacer, washer and spring. • invert the fork and stroke it several times to drain out fork oil. • hold the fork inverted for a few minutes to drain oil...

  • Page 179

    Chassis 5-15 • remove the oil seal stopper ring. • remove the damper rod bolt. • remove the inner rod cylinder. • remove the oil seal by slowly pulling out the inner tube. Note: be careful not to damage the inner tube. # the outer and inner tube’s slide metals must be replaced along with the oil sea...

  • Page 180

    5-16 chassis reassembly and remounting reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points: slide metals and oil seal • hold the inner tube vertically, clean the metal groove and install the inner tube slide metal by hand. # do...

  • Page 181

    Chassis 5-17 • insert the inner tube into the outer tube and install the oil seal 1 using the special tool. % 09940-52861: front fork oil seal installer • install the oil seal stopper ring 2. # make sure that the oil seal stopper ring is fitted securely. • install the dust seal 3. Damper rod bolt • ...

  • Page 182

    5-18 chassis fork oil • place the front fork vertically without spring. • compress it fully. • pour specified front fork oil up to the top level of the outer tube. • refill specified front fork oil up to the top level of the outer tube again. Move the outer tube up and down several strokes until bub...

  • Page 183

    Chassis 5-19 fork spring • install the fork spring as shown. Note: the smaller pitch a should face to the bottom of the front fork. Inner rod and lock nut • install the special tool and pull up the inner rod. % 09940-52840: front fork inner rod holder • install the front fork cap. Note: before insta...

  • Page 184

    5-20 chassis • install the front fork protecter. Note: fit the projection of the front fork protecter to the depression of the front fork outer tube. • set the upper surface a of the inner tube at the height c from the upper surface b of the steering stem upper bracket and tighten the front fork low...

  • Page 185

    Chassis 5-21 • install the front fender. Note: face the triangle mark on the front fender plate to front side. • install the front wheel. ( !5-11) • remount the center cowling. ( !5-3) note: before tightening the front axle and front axle pinch bolts, move the front fork up and down four or five tim...

  • Page 186: Steering

    5-22 chassis for e-03, 28, 33 fwd fw d steering construction 1 steering stem upper bracket 2 dust seal 3 steering stem upper bearing set 4 steering stem lower bearing set 5 steering stem 6 dust seal 7 handlebar 8 handlebar balancer 9 handlebar switch assy (l) 0 handlebar switch assy (r) a steering s...

  • Page 187

    Chassis 5-23 • remove the handlebars 1. Note: place the rag on the fuel tank to prevent the fuel tank scratches. • remove the steering stem upper bracket 2. • remove the steering stem nut using the special tool. % 09940-14911: steering stem nut wrench • remove the steering stem lower bracket. Note: ...

  • Page 188

    5-24 chassis • remove the ignition switch 6 using a torx wrench. % 09930-11920: torx bit 09930-11940: bit holder inspection and disassembly inspect the removed parts for the following abnormalities. *handlebar distortion *race wear or damage *bearing wear or damage *abnormal bearing noise *distortio...

  • Page 189

    Chassis 5-25 inner race • press in the lower inner race using the special tool % 09941-74911: steering bearing installer bearings • apply suzuki super grease “a” to the upper and lower bearings and the lip of the dust seals before remounting the steering stem. For usa & 99000-25030: suzuki super gre...

  • Page 190

    5-26 chassis clearance fwd • tighten the steeringstem head nut to the specified torque. " " " " " steering stem head nut: 65 n.M (6.5 kgf.M, 47.0 lb-ft) note: before tightening the steering stem head nut, temporarily install the front forks. Handlebar and front fork • when remounting the front forks...

  • Page 191

    Chassis 5-27 steering tension adjustment check the steering tension as follows • support the motorcycle using a jack and raise the front wheel off the floor 20 – 30 mm (0.8 – 1.2 in). • make sure that the cables and wire harness are properly routed. • with the front wheel pointing straight ahead, at...

  • Page 192: Rear Wheel

    5-28 chassis rear wheel construction " item n.M kgf.M lb-ft a 100 10.0 72.5 b 23 2.3 16.5 c 60 6.0 43.5 1 rear axle 2 brake caliper bracket 3 brake disc 4 collar 5 dust seal 6 bearing (r) 7 spacer 8 bearing (l) 9 retainer 0 cushion a rear sprocket bolt b rear sprocket mounting drum c rear sprocket d...

  • Page 193

    Chassis 5-29 left right spacer clearance bearing installer left right right left ( ) 10.0 kgf.M 72.5 lb-ft 100 n.M ( ) 6.0 kgf.M 43.5 lb-ft 60 n.M ( ) 2.3 kgf.M 16.5 lb-ft 23 n.M ( ) 2.5 kgf.M 18.0 lb-ft 25 n.M (for e-03, e-28, e-33).

  • Page 194

    5-30 chassis removal • support the motorcycle with center stand. • remove the cotter pin. (for e-03, 28, 33) • remove the axle nut 1. • remove the rear axle and disengage the drive chain from the rear sprocket. • remove the rear wheel. # do not operate the brake pedal during or after rear wheel remo...

  • Page 195

    Chassis 5-31 inspection and disassembly tire ............................................................. ( ! 5-61) rear wheel ............................................. ( ! 5-9) wheel bearing ...................................... ( ! 5-9) rear wheel and its bearing inspection manner is the sam...

  • Page 196

    5-32 chassis rear axle measure the rear axle runout using the dial gauge. If the runout exceeds the service limit, replace the rear axle. % 09900-20606: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm) $ wheel axle runout service limit: 0.25 mm (0.01 in) cushion in...

  • Page 197

    Chassis 5-33 rear sprocket mounting drum bearing and dust seal • install the new bearing and new dust seal using the special tool. % 09913-75520: bearing installer note: apply suzuki super grease “a” to the bearing and dust seal lip before assembling the rear sprocket mounting drum. For usa & 99000-...

  • Page 198: Rear Suspension

    5-34 chassis rear suspension construction " item n.M kgf.M lb-ft a 50 5.0 36.0 b 78 7.8 56.5 c 78 7.8 56.5 d 100 10.0 72.5 e 35 3.5 25.5 1 rear shock absorber 2 rear cushion lever 3 rear cushion lever rod 4 bearing 5 spacer 6 bearing 7 spacer 8 bearing 9 spacer 0 spacer a chain adjuster plate b wash...

  • Page 199

    Chassis 5-35 left side right side 50 n.M ( 5.0 kgf.M ) 36.0 lb-ft 78 n.M ( 7.8 kgf.M ) 56.5 lb-ft 50 n.M ( 5.0 kgf.M ) 36.0 lb-ft 78 n.M ( 7.8 kgf.M ) 56.5 lb-ft 78 n.M ( 7.8 kgf.M ) 56.5 lb-ft 100 n.M ( 10.0 kgf.M ) 72.5 lb-ft.

  • Page 200

    5-36 chassis removal • remove the rear wheel. ( ! 5-30) • remove the drive chain case 1. • remove the rear torque link nut 2. • remove the brake hose union bolt 3. • remove the brake hose from the brake hose guide and hose clamps. # handle brake fluid with care: the fluid reacts chemically with pain...

  • Page 201

    Chassis 5-37 • remove the right and left pivot shaft end caps 6. • remove the swingarm by removing the pivot shaft nut and pivot shaft. • remove the rear shock absorber 7, cushion lever 8, cushion lever rods 9. Inspection and disassembly dust seals and spacers • remove the dust seals, washers and sp...

  • Page 202

    5-38 chassis 09923-73210 09930-30102 • remove the swingarm needle bearings and spacer using the special tools. % 09923-74510: bearing remover 09930-30102: sliding shaft # the removed needle bearings should be replaced with new ones. Swingarm inspect the swingarm for damage. Cushion lever needle bear...

  • Page 203

    Chassis 5-39 pivot shaft measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft. % 09900-20606: dial gauge (1/100 mm) 09900-20701: magnetic stand 09900-21304: v-block set (100 mm) $ swingarm pivot shaft runout service limit: 0.3 mm (0.01...

  • Page 204

    5-40 chassis gas pressure release • mark the drill hole with a center punch. • cover the rear shock absorber with a transparent vinyl bag 1. • hold the rear shock absorber 2 with a vice. • drill a hole with a 3 mm drill bit. ' wear eye protection to protect your eyes from released gas and metal chip...

  • Page 205

    Chassis 5-41 remounting remount the swingarm and rear shock absorber in the reverse order of removal. Pay attention to the following points: • when remount the rear shock absorber and cushion lever, set the index punched mark rearward. • tighten the cushion lever rod mounting nuts 1 and rear shock a...

  • Page 206

    5-42 chassis • tighten the brake hose union bolt 6 to the specified torque. " brake hose union bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) • tighten the rear torque link nut 7 to the specified torque. " rear torque link nut: 35 n.M (3.5 kgf.M, 25.5 lb-ft) rear wheel ( ! 5-33) rear brake bleed air from the ...

  • Page 207: Front Brake

    Chassis 5-43 front brake construction ' * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. * do not use any brake fluid taken from old, used or unsealed containers. Never r...

  • Page 208

    5-44 chassis brake pad replacement • remove the spring 1. • remove the brake pads by removing the clip 2 and pad mount- ing pin 3. # * do not operate the brake lever while dismounting the pads. * replace the brake pads as a set, otherwise braking performance will be adversely affected. • install the...

  • Page 209

    Chassis 5-45 caliper removal and disassembly • remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. Note: place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid. • remove the brake caliper by removi...

  • Page 210

    5-46 chassis • remove the dust seals and piston seals. # do not reuse the dust seals and piston seals to prevent fluid leakage. Caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches or other damage. Brake caliper piston inspect the brake caliper piston surface...

  • Page 211

    Chassis 5-47 • tighten each bolt to the specified torque. " front brake caliper housing bolt 1: 21 n.M (2.1 kgf.M, 15.0 lb-ft) front brake caliper mounting bolt 2: 39 n.M (3.9 kgf.M, 28.0 lb-ft) front brake hose union bolt 3: 23 n.M (2.3 kgf.M, 16.5 lb-ft) note: before remounting the caliper, push t...

  • Page 212

    5-48 chassis brake disc inspection • remove the front and rear wheels. ( ! 5-9 and -30) check the brake disc for damage or cracks. Measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if damage is found. % 09900-20205: micrometer (0 – ...

  • Page 213

    Chassis 5-49 master cylinder removal and disassembly • disconnect the front brake light switch lead wires 1. • place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose. # immediately wipe of...

  • Page 214

    5-50 chassis • pull out the dust boot 1 and remove the circlip 2. % 09900-06108: snap ring pliers • remove the piston/secondary cup, primary cup and spring. 3 secondary cup 4 piston 5 primary cup 6 spring master cylinder inspection master cylinder inspect the master cylinder bore for any scratches o...

  • Page 215

    Chassis 5-51 master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: # * wash the master cylinder components with new brake fluid before reassembly. * do not wipe the brake fluid off ...

  • Page 216

    5-52 chassis • tighten the brake hose union bolt to the specified torque. " brake hose union bolt: 23 n.M (2.3 kgf.M, 16.5 lb-ft) # bleed air from the brake system after reassembling the master cylinder. ( ! 2-18).

  • Page 217: Rear Brake

    Chassis 5-53 rear brake construction ' * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based brake fluids. * do not use any brake fluid taken from old, used or unsealed containers. Never re...

  • Page 218

    5-54 chassis # bleed air from the brake system. ( ! ! ! ! ! 2-18) brake pad replacement • remove the brake pad cover. • remove the clip 1. • remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3. # * do not operate the brake pedal during or after brake pa...

  • Page 219

    Chassis 5-55 brake caliper removal and disassembly • remove the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle. • remove the brake caliper mounting bolts 2 and rear torque link nut 3. Note: slightly loosen the brake caliper housing bolts 4 to facilitate later d...

  • Page 220

    5-56 chassis • place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. # do not use high pressure air to prevent brake caliper piston damage. • remove the dust seals and piston seals. # do not reuse the dust seals and piston seals ...

  • Page 221

    Chassis 5-57 • tighten each bolt to the specified torque. " brake caliper housing bolt 1: 30 n.M (3.0 kgf.M, 21.5 lb-ft) brake caliper mounting bolt 2: 25 n.M (2.5 kgf.M, 18.0 lb-ft) brake hose union bolt 3: 23 n.M (2.3 kgf.M, 16.5 lb-ft) rear torque link nut 4: 35 n.M (3.5 kgf.M, 25.5 lb-ft) master...

  • Page 222

    5-58 chassis • remove the brake hose connector by removing the screw. • remove the o-ring 1. # replace the o-ring with a new one. • pull out the dust boot 2 and remove the circlip 3. % 09900-06108: snap ring pliers • remove the push rod 4, piston/primary cup 5 and spring 6. Master cylinder inspectio...

  • Page 223

    Chassis 5-59 master cylinder reassembly and remounting reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: # * wash the master cylinder components with new brake fluid before reassembly. * do not wipe the brake fluid off ...

  • Page 224: Clutch Master Cylinder

    5-60 chassis 1 piston/cup set 2 clutch hose a master cylinder bolt b union bolt clutch master cylinder construction removal • disconnect the clutch lever position switch lead wires. • place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Unscrew the unio...

  • Page 225: Tire And Wheel

    Chassis 5-61 inspection wheels wipe off any rubber substance or rust from the wheel, and inspect the wheel rim. If any one of the following items are observed, replace the wheel with a new one. * a distortion or crack. * any scratches or flaws in the bead seating area. * wheel runout (axial & radial...

  • Page 226

    5-62 chassis valve installation clean any dust or rust which is around the valve hole 1 and then install the valve in the rim. Note: to properly install the valve 2 into the valve hole, apply a special tire lubricant or neutral soapy liquid to the valve. # be careful not to damage the valve lip a. B...

  • Page 227

    Chassis 5-63 • the tire is designed to have specified rotational direction. # never use oil, grease or gasoline on the tire bead in place of tire lubricant. • when installing the tire, the arrow 1 on the side wall should point the direction of wheel rotation. • align the chalk mark put on the tire a...

  • Page 228: Electrical System

    Electrical system 6-1 6 electrical system contents cautions in servicing ................................................................... 6- 2 location of electrical components ............................... 6- 5 charging system ......................................................................

  • Page 229: Cautions In Servicing

    6-2 electrical system cautions in servicing connectors • when disconnecting a connector, be sure to hold the ter- minals; do not pull the lead wires. • when connecting a connector, push it in so it is firmly attached. • inspect the connector for corrosion, contamination and any breakage in the cover...

  • Page 230

    Electrical system 6-3 battery • the mf battery used in this motorcycle does not require main- tenance (e.G., electrolyte level inspection, distilled water replen- ishing). • during normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced....

  • Page 231

    6-4 electrical system using the multi circuit tester • properly use the multi circuit tester (+) and (-) probes. Im- proper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, m...

  • Page 232

    Electrical system 6-5 location of electrical components 1 turn signal/side-stand relay 2 fuse box 3 ignition switch 4 handlebar switch (r) 5 front brake light switch 6 battery 7 rear brake light switch 8 throttle position sensor 9 signal generator 0 oil pressure switch.

  • Page 233

    6-6 electrical system a clutch lever position switch b handlebar switch (l) c ignition coil d main fuse e starter relay f ignitor g horn h starter motor i generator j speed sensor k side-stand switch l gear position switch m speed sensor rotor.

  • Page 234: Charging System

    Electrical system 6-7 charging system description (generator with ic regulator) the generator features a solid-state regulator that is mounted inside the generator. All regulator com- ponents are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator voltage s...

  • Page 235

    6-8 electrical system troubleshooting no accessories no continuity current leaks check accessories which use excessive amounts of electricity. Accessories are installed no current leaks correct battery overcharges • faulty ic regulator • faulty battery • poor contact of generator lead wire coupler c...

  • Page 236

    Electrical system 6-9 inspection battery current leak inspection • turn the ignition switch to the “off” position. • remove the seat. ( !5-5) • remove the document tray. ( !5-5) • disconnect the battery - lead wire. • connect the multi circuit tester between the battery - ter- minal and the battery ...

  • Page 237: Generator

    6-10 electrical system generator ( item n.M kgf.M lb-ft a 55 5.5 40.0 b 25 2.5 18.0 c 4.5 0.45 3.5 d 2.5 0.25 1.8 e 4.0 0.40 3.0 f 3.7 0.37 2.7 1 generator driven gear 2 damper (4 pcs) 3 damper housing 4 oil seal 5 o-ring 6 spacer 7 generator end housing 8 bearing 9 stud bolt 0 retainer a rotor b be...

  • Page 238

    Electrical system 6-11 removal and disassembly • remove the engine sprocket cover. ( !3-5) • disconnect the generator lead wire 1 and coupler 2. Note: before disconnecting the generator lead wire, disconnect the battery - lead wire. • remove the generator 3. • hold the generator driven gear using a ...

  • Page 239

    6-12 electrical system • remove the brush holder 1 and ic regulator 2. • remove the stator coil lead wires mounting screws 3. • remove the rectifier 4. Note: straighten the stator coil lead wires using long-nose pliers, then remove the rectifier. • remove the generator housing nuts. • separate the g...

  • Page 240

    Electrical system 6-13 • remove the bearing retainer 1. • remove the bearing 2, washer 3 and spacer 4. • remove the oil seal 5. Inspection rotor bearings inspect the rotor bearings for abnormal noise. Also, rotate the rotor bearings by hand and make sure that they rotate smoothly. If there is anythi...

  • Page 241

    6-14 electrical system p 1 p 2 p 3 p 4 p 1 p 2 p 3 p 4 generator driven gear dampers inspect the generator driven gear dampers for wear and dam- age. If any defects are found, replace the generator driven gear dampers as a set. Note: when installing the generator driven gear dampers, apply suzuki mo...

  • Page 242

    Electrical system 6-15 f b v carbon brushes measure the length of the carbon brushes as shown. If the mea- surement is less then the service limit, replace the carbon brushes with new ones. # 09900-20102: vernier calipers (200 mm) $ brush length service limit: 4.5 mm (0.18 in) ic regulator measure t...

  • Page 243

    6-16 electrical system generator reassembly and remounting reassemble and remount the generator in the reverse order of removal and disassembly. Pay attention to the following points: " the removed oil seal should be replaced with a new one. • apply suzuki super grease “a” to the lip of the oil seal...

  • Page 244

    Electrical system 6-17 note: before reinstalling the slip ring side bearing onto the generator end housing, turn the expander ring and align the expander ring lug with the center of the chamfered edge of the bearing outer race. • tighten the generator housing nuts 1 to the specified torque. ( genera...

  • Page 245: System

    6-18 electrical system y/g o/b b/y b/w bl g o r starter system and side-stand ignition interlock system starter system description the starter system consists of the following components: the starter motor, starter relay, clutch lever posi- tion switch, turn signal/side-stand relay, side-stand switc...

  • Page 246

    Electrical system 6-19 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-sta...

  • Page 247

    6-20 electrical system trouble shooting no click runs the transmission is in neutral. Grasp the clutch lever. Turn on the ignition switch with the engine stop switch in the “run" position. Listen for a click from the starter relay when the starter button is pushed. Clicks no voltage engine does not ...

  • Page 248

    Electrical system 6-21 starter motor removal and disassembly • remove the starter motor. ( !3-16) • disassemble the starter motor, as shown. Starter motor inspection carbon brushes inspect the carbon brushes for abnormal wear, cracks or smooth- ness in the brush holder. If either carbon brush is def...

  • Page 249

    6-22 electrical system commutator inspect the commutator for discoloration, abnormal wear or un- dercut a. If the commutator is abnormally worn, replace the armature. If the commutator surface is discolored, polish it with #400 sand- paper and wipe it using a clean, dry cloth. If there is no undercu...

  • Page 250

    Electrical system 6-23 • apply a small quantity of suzuki moly paste to the armature shaft. ) 99000-25140: suzuki moly paste • align the match mark on the starter motor case with the match mark on the housing end. • apply a small quantity of thread lock “1342” to the starter motor housing bolts. / 9...

  • Page 251

    6-24 electrical system apply 12 volts to terminals a and b and measure for continuity between the positive and negative terminals. If the starter relay clicks and continuity is found, the relay is ok. # 09900-25008: multi circuit tester set * tester knob indication: continuity test (+) " do not appl...

  • Page 252

    Electrical system 6-25 gear position switch the gear position switch coupler is located behind the frame side cover (left side). • remove the frame side cover (left side). ( !5-6) • disconnect the gear position switch coupler and measure the continuity between blue and ground with the transmission i...

  • Page 253

    6-26 electrical system side-stand relay first check the insulation between d and e terminals with the tester. Then apply 12 v to terminals d and c (+ to d and - to c) and check the continuity between d and e. If there is no continuity, replace the turn signal/side-stand relay with a new one. # 09900...

  • Page 254

    Electrical system 6-27 y/w bl y [ ] ignition system (digital ignitor) description the fully transistorized ignition system consists of the following components: a signal generator (which is made up of the signal generator rotor and pickup coil), ignitor (including a 8-bit microcomputer and a 10 mhz ...

  • Page 255

    6-28 electrical system correct incorrect check the ignition system couplers for poor connections. * check that the transmission is in neutral and the engine stop switch is in the “run” position. Grasp the clutch lever. Check that the main fuse is not blown and the battery is fully-charged before dia...

  • Page 256

    Electrical system 6-29 inspection ignition coil primary peak voltage • remove the fuel tank. ( !4-3) • remove all of the spark plug caps and spark plugs. • connect four new spark plugs to each spark plug cap and ground them to the crankcase. Note: make sure that all of the spark plug caps and spark ...

  • Page 257

    6-30 electrical system measure ignition coil primary peak voltage (for #2 and #3 cylinders) in the same manner as for cylinders #1 and #4. Ignition coil (for #2 and #3 cylinders): b/y terminal (+ probe) – ground (- probe) b/y: black with yellow tracer note: do not disconnect the ignition coil primar...

  • Page 258

    Electrical system 6-31 signal generator peak voltage • remove the frame cover. ( !5-5) • remove the frame side cover (left side). ( !5-6) note: make sure that all of the couplers are connected properly and the battery is fully-charged. • disconnect the ignitor coupler 1 at the ignitor. Measure the s...

  • Page 259

    6-32 electrical system peak volt adaptor • remove the frame side cover (left side). ( !5-6) • disconnect the signal generator coupler and connect the multi circuit tester with the peak volt adaptor. Blue terminal (+ probe) – yellow terminal (- probe) • measure the signal generator peak voltage in th...

  • Page 260: Combination Meter

    Electrical system 6-33 combination meter removal • remove the cowling. ( !5-3) • remove the headlight assy. ( !5-4) • disconnect the combination meter couplers 1 and clamps. • remove the combination meter mounting nuts 2. • remove the combination meter 3. Disassembly • disassemble the combination me...

  • Page 261

    6-34 electrical system 1: speedometer 2: tachometer 3: oil - 4: speedometer 5: battery + 6: blank 7: illumination + 8: turn (r) + 9: blank 10: ground (pilot lamp) 11: neutral - 12: high beam + 13: turn (l) + 14: ignition 15: fuel 16: ground (tachometer) 11 10 9 8 7 6 5 4 3 2 1 12 14 13 15 16 high be...

  • Page 262

    Electrical system 6-35 b/r b speedometer inspection if the speedometer, odometer or tripmeter does not function prop- erly, inspect the speed sensor and the coupler connections. If the speed sensor and coupler connections are ok, replace the com- bination meter with a new one. Speed sensor inspectio...

  • Page 263

    6-36 electrical system b/br o/g r/b b/w o/g y/b b/br o/g r/b b/w o/g y/b fuel level meter inspection • remove the fuel tank. ( !4-3) • disconnect the fuel level gauge coupler. ( !4-3) check that the fuel level meter indicates properly when the jumper wire a is connected between the fuel level gauge ...

  • Page 264: Lamps

    Electrical system 6-37 (except for e-03, 24, 28, 33) lamps headlight bulb replacement • disconnect the socket 1. • turn the bulb 2 counterclockwise and remove it. • reassemble the bulb in the reverse order of removal. " if you touch the bulb with your bare hands, clean the bulb with a cloth moistene...

  • Page 265

    6-38 electrical system brake light/taillight and license plate light turn signal lights brake light/taillight bulb: 12 v 21/5 w license plate bulb: 12 v 5 w " if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failu...

  • Page 266: Relays

    Electrical system 6-39 relays starter relay the starter relay is located behind the frame side cover (left side). ( !6-23) turn signal/side-stand relay the turn signal/side-stand relay, which is located under the seat, is composed of the turn signal relay, and the side-stand relay and diode. • remov...

  • Page 267: Switches

    6-40 electrical system ignition switch r o o/y b/w gr br on off lock p lighting switch (except for e-03, 24, 28, 33) o/bl gr o/r y/w off ( 2) ( 3) on ( 4) dimmer switch w y y/w hi ( 5) lo ( 6) turn signal switch lg lbl b l ( 7) push r ( 8) passing light switch (except for e-03, 24, 28, 33) o/r y 2 p...

  • Page 268: Battery

    Electrical system 6-41 battery specifications removal • remove the seat. ( !5-5) • remove the document tray 1. • remove the battery 2. Note: first, disconnect the battery - lead wire a. Remounting remount the battery in the reverse order of removal. Type designation ytx12-bs capacity 12 v, 36 kc (10...

  • Page 269

    6-42 electrical system initial charging filling electrolyte • remove the aluminum tape 1 which seals the battery filler holes 2. • remove the caps 3 from the electrolyte container. Note: * do not remove or pierce the sealed areas 4 of the electrolyte container. * after completely filling the battery...

  • Page 270

    Electrical system 6-43 • after the electrolyte container is completely empty, remove it from the battery and wait about 20 minutes. • insert the caps 1 firmly into the filler holes so that the top of the caps do not protrude above the upper surface of the battery’s top cover. " * the charging system...

  • Page 271

    6-44 electrical system recharging operation • measure the battery voltage using a tester. If the voltage read- ing is less than 12.5 v (dc), recharge the battery with a battery charger. " when recharging the battery, remove the battery from the motorcycle. ( !6-41) note: while recharging, do not rem...

  • Page 272: Servicing Information

    Servicing information 7-1 servicing information 7 contents troubleshooting ........................................................................... 7- 2 engine ............................................................................................. 7- 2 carburetor ..............................

  • Page 273: Troubleshooting

    7-2 servicing information troubleshooting engine complaint symptom and possible causes remedy engine will not start or is hard to start. Compression too low 1. Worn cylinder. 2. Worn piston ring. 3. Worn valve guide or improper valve seating. 4. Loose spark plug. 5. Broken, cracked or damaged piston...

  • Page 274

    Servicing information 7-3 complaint symptom and possible causes remedy engine is noisy. Excessive valve chatter 1. Excessive valve clearance. 2. Weak or broken valve spring. 3. Worn rocker arm or rocker arm shaft. 4. Worn or burnt camshaft journal. Noise seems to come from the piston 1. Worn piston....

  • Page 275

    7-4 servicing information transmission will not shift back. Complaint symptom and possible causes remedy 1. Broken gearshift shaft return spring. 2. Rubbing or stuck gearshift shaft. 3. Worn or distorted gearshift fork. Replace. Repair or replace. Replace. Transmission jumps out of gear. 1. Worn gea...

  • Page 276

    Servicing information 7-5 complaint symptom and possible causes remedy engine lacks power. 1. Insufficient valve clearance. 2. Weak valve spring. 3. Mistimed valves. 4. Worn cylinder. 5. Worn piston ring. 6. Improper valve seating 7. Fouled spark plug. 8. Incorrect spark plug. 9. Clogged carburetor ...

  • Page 277

    7-6 servicing information carburetor complaint symptom and possible causes remedy starting difficulty. 1. Clogged starter jet. 2. Clogged starter jet passage. 3. Air leaking from joint between starter body and car- buretor. 4. Air leaking from carburetor joint or vacuum hose joint. 5. Improperly wor...

  • Page 278

    Servicing information 7-7 front suspension too soft. Complaint symptom and possible causes remedy 1. Weak spring. 2. Insufficient fork oil. Replace. Check level and add. Front suspension too stiff. 1. Excessively viscous fork oil. 2. Excessive fork oil. Replace. Check level and drain. Front suspensi...

  • Page 279

    7-8 servicing information brake drags. Complaint symptom and possible causes remedy 1. Rusty part. 2. Insufficient brake lever or brake pedal pivot lubrication. Clean and lubricate. Lubricate. Electrical complaint symptom and possible causes remedy no sparking or poor sparking. 1. Defective ignition...

  • Page 280

    Servicing information 7-9 battery (mf battery) complaint symptom and possible causes remedy sulfation or spots on surfaces of cell plates. 1. Cracked battery case. 2. Battery has been left in a run-down condition for a long time. Replace the battery. Replace. Battery runs down quickly. 1. Incorrect ...

  • Page 281: Wiring Diagram

    7-10 servicing information off ru n off on push l push r free hi lo push push free on off lock p bl 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off 12v on off 1 sp ta 1 2 3 4 speedometer ignition switch ignition coil side -st and switch fuel level ga uge raer...

  • Page 282

    Servicing information 7-11 for the others push free on off lock p off s on off ru n off on push l push r hi lo push push bl 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off on off 12v on off sp ta 1 2 3 4 1 gear position switch free fuel level ga uge y/b y/b b...

  • Page 283

    7-12 servicing information wire harness, cable and hose routing wire harness routing rear tur n signal (lh) clamp clamp clamp wir ing har ness clamp handle s witch (lh and rh) clamp wir ing har ness tps carb uretor heater (e-02 only) clamp wir ing har ness rear tur n signal (rh) clamp wir ing har ne...

  • Page 284

    Servicing information 7-13 star ter motor star ter motor clamp clamp ignitor clamp clamp clamp wir ing har ness star ter rela y signal gener ator side-stand s witch gear position s witch speed sensor speed sensor t o side-stand s witch star ter motor ter minal t o signal gener ator clamp speedometer...

  • Page 285

    7-14 servicing information 30˚ view of a a clamp speed sensor clamp clamp gear position switch lead wire side-stand switch lead wire starter motor lead wire engine oil hose signal generator lead wire engine ground wire generator lead wire engine ground wire must be faced to the inside..

  • Page 286

    Servicing information 7-15 starter cable starter cable clutch hose cable guide cable guide lh cable guide throttle cable no. 1 throttle cable no. 2 throttle cable no. 1 throttle cable no. 2 throttle cable no. 2 throttle cable no. 1 fuel hose 0 mm 0 mm throttle cable no. 2 throttle cable cable protec...

  • Page 287

    7-16 servicing information p air v alv e clamp no .4 cy . No .3 cy . No .2 cy . N o .1 cy . 10 n . M (1.0 kgf . M, 7.0 lb-ft) clamp 10 n . M (1.0 kgf . M, 7.0 lb-ft) v acuum hose t o no .3 carb uretor t o air cleaner bo x pair (air supply) system hose routing.

  • Page 288

    Servicing information 7-17 fuel valve fuel hose clamp clip face the white paint mark to the backward. Carburetor air vent hose fuel hose must be passed between throttle cables. Fuel hose routing.

  • Page 289

    7-18 servicing information clamp clamp clamp note: starter motor lead wire must be passed outside of the clutch hose. Starter motor lead wire cable guide clamp after touching the clutch hose union to the stopper, tighten the union bolt to the specified torque. 35˚ 14 ˚ 35˚ 14 ˚ 42˚ 42˚ 0˚ – 15 ˚ 90 ...

  • Page 290

    Servicing information 7-19 oil hose routing 10 n . M (1.0 kgf . M, 7.0 lb-ft) 10 n . M (1.0 kgf . M, 7.0 lb-ft) 10 n . M (1.0 kgf . M, 7.0 lb-ft) 10 n . M 1.0 kgf . M, 7.0 lb-ft 10 n . M (1.0 kgf . M, 7.0 lb-ft) 23 n . M 2.3 kgf . M, 16.5 lb-ft () ().

  • Page 291

    7-20 servicing information master cylinder throttle cables 42˚ 42˚ 42˚ 21˚ 21˚ 21˚ 5˚ 28˚ 5˚ 28˚ 14˚ 14˚ 14˚ 14˚ 45˚ ± 5 ˚ throttle cable brake hose no. 1 brake hose no. 2 clamp brake caliper after touching the brake hose union to the stopper, tighten the union bolt to the specified torque. After to...

  • Page 292

    Servicing information 7-21 42˚ after touching the brake hose union to the stopper, tighten the union bolt to the specified torque. After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Assemble the clamp as shown. Assemble the clamp as shown. Assemble th...

  • Page 293

    7-22 servicing information f rame f ootrest br ac k e t f rame w asher bolt f ootrest br ac k e t 2.0 mm front footrest bracket set-up.

  • Page 294

    Servicing information 7-23 fuel tank cap fuel tank adhesive agent fuel tank molding 4.4 n.M ( 0.44 kgf.M ) 3.0 lb-ft fuel tank front cushion frame fuel tank side cushion fuel tank bracket 4.0 mm 4.0 mm 3.4 mm fuel valve fuel tank set up.

  • Page 295

    7-24 servicing information l r muffler stay spacer cushion washer washer rh (outside) 29 n.M (2.9 kgf.M, 21.0 lb-ft) 90 90 90 0 10 0 10 90 ignition coil no.1 & no.4 ignition coil no.2 & no.3 clamp high-tension cord no.2 high-tension cord no.4 plug cap plug cap cover high-tension cord routing muffler...

  • Page 296

    Servicing information 7-25 side-stand spring 40 n.M ( 4.0 kgf.M ) 29.0 lb-ft spring center stand spring side-stand springs center stand springs.

  • Page 297

    7-26 servicing information ( 3.5 kgf . M ) 25.5 lb-ft 35 n . M side co wling (rh) wind screen side co wling (lh) f ront co wling meter panel center co wling co wling br ace side co wling br ac k et (rh) side co wling br ac k et (lh) cowling and cowling brace set-up.

  • Page 298

    Servicing information 7-27 f rame side co v er (rh) f rame side co v er (lh) f rame co v e r p assenger g rab handle frame cover and frame side cover set up.

  • Page 299

    7-28 servicing information cushion meter panel meter panel meter panel tape no.1 meter panel tape no.2 view a a cowling cushion and tape side cowling (reverse face) cushion cushion center cowling (reverse face) front cowling (reverse face) 1 mm cushion front cowling tape.

  • Page 300

    Servicing information 7-29 front fender cushion cushion front fender 5 mm 2 mm 2 mm 5 mm 2 mm 2 mm cushion view a a seat support bracket frame seat lock set clamp seat lock cable routing.

  • Page 301

    7-30 servicing information clamp fuel tank dr ain hose clamp fuel tank dr ain hose clamp fuel tank air breather hose fuel tank air breather hose/fuel tank drain hose ! A v oid bending the fuel tank air breather hose to pre vent the stoppag e of fuel flo w . Calif ornia model onl y.

  • Page 302

    Servicing information 7-31 note.

  • Page 303: Special Tools

    7-32 servicing information special tools 09900-00410 hexagon wrench set 09900-06106 snap ring pliers 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09004 impact driver set 09900-20102 vernier calipers (1/20 mm, 200 mm) 09900-20202 micrometer (1/100 mm, 25 – 50 mm) 09900-20204 microm...

  • Page 304

    Servicing information 7-33 09913-75520 bearing installer 09913-75830 bearing remover 09914-25811 “t” type hexagon wrench (6 mm) 09915-40610 oil filter wrench 09915-64510 compression gauge set 09913-10750 (adaptor) 09915-74510 oil pressure gauge 09915-77330 meter (for high pressure) 09915-74540 oil p...

  • Page 305

    7-34 servicing information 09923-74510 bearing remover (20 – 35 mm) 09924-84511 bearing installer set 09925-98221 bearing remover 09930-10121 spark plug wrench set 09930-11920 torx bit 09930-11940 bit holder 09930-30102 sliding shaft 09930-30720 rotor remover 09940-14911 steering stem nut wrench 099...

  • Page 306: Tightening Torque

    Servicing information 7-35 tightening torque 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 16 1.6 11.5 cylinder head nut [m: 10] 38 3.8 27.5 cylinder head bolt [m: 6] 10 1.0 7.0 cylinder head plug 28 2.8 ...

  • Page 307

    7-36 servicing information chassis item n.M kgf.M lb-ft steering stem head nut 65 6.5 47.0 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 23 2.3 16.5 front fork cap bolt 23 2.3 16.5 front fork damper rod bolt 20 2.0 14.5 front axle 100 10.0 72.5 front axle pinch bolt 23 2.3 16.5...

  • Page 308: Tightening Torque Chart

    Servicing information 7-37 tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter conventional or “4” marked bolt “7” marked bolt a (mm) 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....

  • Page 309: Service Data

    7-38 servicing information 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 in. 0.020 – 0.047 clearance (0.0008 – 0.0019) —...

  • Page 310

    Servicing information 7-39 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.58 – 33.62 33.28 (1.3220 – 1.3236) (1.3102) ex. 32.65 – 32.69 32.35 (1.2854 – 1.2870) (1.2736) camshaft journal oil clearance in. & ex. 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) camshaft jour...

  • Page 311

    7-40 servicing information item standard limit piston-ring to piston-ring-groove 1st 0.180 clearance ——— (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) ——— piston ring thickness 1st 0.975 ...

  • Page 312

    Servicing information 7-41 oil pump 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 r/min. Clutch unit: mm (in) item standard limit clutch drive plate thicknes...

  • Page 313

    7-42 servicing information carburetor item specification e-02, 19, 24, 54 e-03, 28 carburetor type mikuni bsr36ss ← bore size 36 mm ← i.D. No. 32f0 32f1 idle r/min. 1 200 ± 100 r/min. ← float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) ← main jet (m.J.) #100 # jet needle (j.N.) 5c70-3rd 5c71-1st needle je...

  • Page 314

    Servicing information 7-43 electrical unit: mm (in) item specification note ignition timing 7° b.T.D.C. At 1 500 r/min. 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. Pickup coil resistance approx. 130 – 200 Ω tester range: (× 10...

  • Page 315

    7-44 servicing information wattage unit: w item specification e-03, 24, 28, 33 the other countries headlight hi 60 + 51 ← lo 51 ← parking or position light 5 brake light/taillight 21/5 × 2 ← turn signal light 21 × 4 ← speedometer light led ← tachometer light led ← turn signal indicator light led × 2...

  • Page 316

    Servicing information 7-45 item standard limit wheel rim runout axial 2.0 ——— (0.08) radial 2.0 ——— (0.08) wheel axle runout front 0.25 ——— (0.010) rear 0.25 ——— (0.010) wheel rim size front 17 × mt3.50 ——— rear 17 × mt5.50 ——— suspension unit: mm (in) item standard limit note front fork stroke 130 ...

  • Page 317

    7-46 servicing information fuel + oil item specification note fuel type fuel tank capacity 19 l including (5.0/4.2 us/lmp gal) e-33 reserve 20 l the other (5.2/4.4 us/lmp gal) countries reserve only 4.4 l (1.2/1.0 us/lmp gal) engine oil type sae 10w/40, api sf or sg engine oil capacity change 3 300 ...

  • Page 318: Gsf1200K1 (2001-Model)

    Gsf1200k1 (2001-model) 8-1 gsf1200k1 (2001-model) specifications ............................................................................. 8- 2 headlight/headlight housing/combination meter ..... 8- 4 wiring diagram ........................................................................... 8- 8...

  • Page 319: Specifications

    8-2 gsf1200k1 (2001-model) specifications dimensions and dry mass overall length ................................................................ * 2 140 mm (84.3 in) overall width ................................................................. 765 mm (30.1 in) overall height ........................

  • Page 320

    Gsf1200k1 (2001-model) 8-3 chassis front suspension .......................................................... Telescopic, coil spring, oil damped, spring pre-load fully adjustable rear suspension ........................................................... Link type, oil damped, coil spring, spring ...

  • Page 321: Headlight/headlight Housing/

    8-4 gsf1200k1 (2001-model) headlight/headlight housing/ combination meter removal • remove the headlight by removing the two screws. • disconnect the socket 1 and coupler 2. • remove the two clamps from the lead wires and disconnect all the lead wire couplers. • remove the headlight housing 3 by rem...

  • Page 322

    Gsf1200k1 (2001-model) 8-5 • remove the combination meter 4 by removing the two bolts. • remove the headlight housing brackets 5 by removing the front forks. ( !5-13) • reassemble and remount the combination meter/headlight housing/headlight in the reverse order of removal and disas- sembly. Combina...

  • Page 323

    8-6 gsf1200k1 (2001-model) headlight/headlight housing disassembly headlight bulb: 12 v 60/55 w position light bulb: 12 v 5 w note: adjust the headlight (vertically and horizontally) after reassembling bulb replacement • remove the headlight by removing the two screws. ( !8-4) • disconnect the socke...

  • Page 324

    Gsf1200k1 (2001-model) 8-7 • unlock the bulb holder spring 3 and pull out the bulb 4. • reassemble the headlight in the reverse order of disassembly. Headlight beam adjustment to adjust the beam horizontally: turn the adjuster 1 clockwise or counterclockwise. To adjust the beam vertically: turn the ...

  • Page 325: Wiring Diagram

    8-8 gsf1200k1 (2001-model) push free on off lock p off s on off ru n off on push l push r free hi lo push push bl 1 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off on off 12v on off sp t a 1 2 3 4 speedometer ignit o r b a tter y st ar ter rela y st ar ter mo...

  • Page 326: Wire Harness Routing

    Gsf1200k1 (2001-model) 8-9 rear tur n signal (lh) clamp clamp wir ing har ness clamp wir ing har ness clamp wir ing har ness tps carb uretor heater (e-02 only) clamp wir ing har ness rear tur n signal (rh) clamp wir ing har ness rear tur n signal (rh) clamp wir ing har ness clamp wir ing har ness t ...

  • Page 327

    8-10 gsf1200k1 (2001-model) t o handle s witch (rh) t o handle s witch (lh) the handle s witch (lh) lead wire m ust be passed abo v e the ignition s witch lead wire . Head light headlight housing f ront tur n signal (lh) wir ing har ness clamp clamp f ront tur n signal handle s witch (rh and lh) spe...

  • Page 328: Front Brake Hose Routing

    Gsf1200k1 (2001-model) 8-11 master cylinder throttle cables 28˚ 14˚ 14˚ 21˚ 21˚ 14˚ 5˚ 28˚ 5˚ 28˚ 14˚ 14˚ 14˚ 14˚ 45˚ ± 5˚ throttle cables brake hose no. 1 fwd brake hose no. 2 clamp brake caliper after touching the brake hose union to the stopper, tighten the union bolt to the specified torque. Aft...

  • Page 329: Service Data

    8-12 gsf1200k1 (2001-model) 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 in. 0.020 – 0.047 clearance (0.00...

  • Page 330

    Gsf1200k1 (2001-model) 8-13 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.58 – 33.62 33.28 (1.3220 – 1.3236) (1.3102) ex. 32.65 – 32.69 32.35 (1.2854 – 1.2870) (1.2736) camshaft journal oil clearance in. & ex. 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) camshaft jou...

  • Page 331

    8-14 gsf1200k1 (2001-model) item standard limit piston-ring to piston-ring-groove 1st 0.180 clearance ——— (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) ——— piston ring thickness 1st 0.975...

  • Page 332

    Gsf1200k1 (2001-model) 8-15 oil pump 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 r/min. Clutch unit: mm (in) item standard limit clutch drive plate thickne...

  • Page 333

    8-16 gsf1200k1 (2001-model) carburetor item specification e-02, 19 carburetor type mikuni bsr36ss bore size 36 mm i.D. No. 32f0 idle r/min. 1 200 ± 100 r/min. Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) main jet (m.J.) #100 jet needle (j.N.) 5c70-3rd needle jet (n.J.) p-0m throttle valve (th. V.) #1...

  • Page 334

    Gsf1200k1 (2001-model) 8-17 electrical unit: mm (in) item specification note ignition timing 7° b.T.D.C. At 1 500 r/min. 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. Pickup coil resistance approx. 130 – 200 Ω tester range: (× 1...

  • Page 335

    8-18 gsf1200k1 (2001-model) wattage unit: w item specification headlight hi *60 lo *55 parking or position light 5 brake light/taillight 21/5 × 2 turn signal light 21 × 4 speedometer light led tachometer light led turn signal indicator light led × 2 high beam indicator light led neutral position ind...

  • Page 336

    Gsf1200k1 (2001-model) 8-19 item standard limit wheel rim runout axial 2.0 ——— (0.08) radial 2.0 ——— (0.08) wheel axle runout front 0.25 ——— (0.010) rear 0.25 ——— (0.010) wheel rim size front 17 × mt3.50 ——— rear 17 × mt5.50 ——— suspension unit: mm (in) item standard limit note front fork stroke 130...

  • Page 337

    8-20 gsf1200k1 (2001-model) fuel + oil item specification note fuel type fuel tank capacity including 20 l reserve (5.3/4.4 us/lmp gal) reserve only 4.4 l (1.2/1.0 us/lmp gal) engine oil type sae 10w/40, api sf or sg engine oil capacity change 3 300 ml (3.5/2.9 us/lmp qt) filter 3 500 ml change (3.7...

  • Page 338: Gsf1200K2/sk2 (’02-Model)

    Gsf1200k2/sk2 (’02-model) 9-1 gsf1200k2/sk2 (’02-model) specifications ............................................................................. 9- 2 service data (gsf1200s) ............................................................ 9- 4 service data (gsf1200) ....................................

  • Page 339: Specifications

    9-2 gsf1200k2/sk2 (’02-model) specifications gsf1200/gsf1200s dimensions and dry mass overall length .......................................................... 2 070 mm (81.5 in) ..... Gsf1200s 2 140 mm (84.3 in) ..... Gsf1200 overall width ..............................................................

  • Page 340

    Gsf1200k2/sk2 (’02-model) 9-3 chassis front suspension .................................................... Telescopic, coil spring, oil damped rear suspension ..................................................... Link type, coil spring, oil damped front fork stroke ....................................

  • Page 341: Service Data (Gsf1200S)

    9-4 gsf1200k2/sk2 (’02-model) service data (gsf1200s) 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 in. 0.020 – 0.047 cl...

  • Page 342

    Gsf1200k2/sk2 (’02-model) 9-5 camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.58 – 33.62 33.28 (1.3220 – 1.3236) (1.3102) ex. 32.65 – 32.69 32.35 (1.2854 – 1.2870) (1.2736) camshaft journal oil clearance in. & ex. 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) camshaft j...

  • Page 343

    9-6 gsf1200k2/sk2 (’02-model) item standard limit piston-ring to piston-ring-groove 1st 0.180 clearance ——— (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) ——— piston ring thickness 1st 0.9...

  • Page 344

    Gsf1200k2/sk2 (’02-model) 9-7 oil pump 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 r/min. Clutch unit: mm (in) item standard limit clutch drive plate thick...

  • Page 345

    9-8 gsf1200k2/sk2 (’02-model) carburetor item specification e-02, 19, 24, 54 e-03, 28 carburetor type mikuni bsr36ss ← bore size 36 mm ← i.D. No. 32f0 32f1 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.) #100 # jet needle (j.N.) 5c70-3r...

  • Page 346

    Gsf1200k2/sk2 (’02-model) 9-9 electrical unit: mm (in) item specification note ignition timing 7° b.T.D.C. At 1 200 r/min. 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. Pickup coil resistance approx. 130 – 200 Ω tester range: (×...

  • Page 347

    9-10 gsf1200k2/sk2 (’02-model) wattage unit: w item specification e-03, 24, 28, 33 the other countries headlight hi 60 + 51 ← lo 51 ← parking or position light 5 brake light/taillight 21/5 × 2 ← turn signal light 21 × 4 ← speedometer light led ← tachometer light led ← turn signal indicator light led...

  • Page 348

    Gsf1200k2/sk2 (’02-model) 9-11 item standard limit wheel rim runout axial 2.0 ——— (0.08) radial 2.0 ——— (0.08) wheel axle runout front 0.25 ——— (0.010) rear 0.25 ——— (0.010) wheel rim size front 17 × mt3.50, 17 m/c × mt3.50 ——— rear 17 × mt5.50, 17 m/c × mt5.50 ——— suspension unit: mm (in) item stan...

  • Page 349

    9-12 gsf1200k2/sk2 (’02-model) fuel + oil item specification note fuel type fuel tank capacity 19 l including (5.0/4.2 us/lmp gal) e-33 reserve 20 l the other (5.2/4.4 us/lmp gal) countries reserve only 4.4 l (1.2/1.0 us/lmp gal) engine oil type sae 10w/40, api sf or sg engine oil capacity change 3 ...

  • Page 350: Service Data (Gsf1200)

    Gsf1200k2/sk2 (’02-model) 9-13 service data (gsf1200) 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 in. 0.020 – 0.047 cl...

  • Page 351

    9-14 gsf1200k2/sk2 (’02-model) camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.58 – 33.62 33.28 (1.3220 – 1.3236) (1.3102) ex. 32.65 – 32.69 32.35 (1.2854 – 1.2870) (1.2736) camshaft journal oil clearance in. & ex. 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) camshaft ...

  • Page 352

    Gsf1200k2/sk2 (’02-model) 9-15 item standard limit piston-ring to piston-ring-groove 1st 0.180 clearance ——— (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) ——— piston ring thickness 1st 0....

  • Page 353

    9-16 gsf1200k2/sk2 (’02-model) oil pump 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 r/min. Clutch unit: mm (in) item standard limit clutch drive plate thic...

  • Page 354

    Gsf1200k2/sk2 (’02-model) 9-17 carburetor item specification e-02, 19 carburetor type mikuni bsr36ss bore size 36 mm i.D. No. 32f0 idle r/min. 1 200 ± 100 r/min. Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) main jet (m.J.) #100 jet needle (j.N.) 5c70-3rd needle jet (n.J.) p-0m throttle valve (th. V.)...

  • Page 355

    9-18 gsf1200k2/sk2 (’02-model) electrical unit: mm (in) item specification note ignition timing 7° b.T.D.C. At 1 200 r/min. 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. Pickup coil resistance approx. 130 – 200 Ω tester range: (...

  • Page 356

    Gsf1200k2/sk2 (’02-model) 9-19 item specification note fuse size headlight hi 15 a lo 15 a turn signal 15 a ignition 10 a meter 10 a main 30 a wattage unit: w item specification e-03, 33 e-02, 19 headlight hi 60 ← lo 55 ← parking or position light 5 brake light/taillight 21/5 × 2 ← turn signal light...

  • Page 357

    9-20 gsf1200k2/sk2 (’02-model) item standard limit brake caliper cylinder bore leading 24.000 – 24.076 front (0.9449 – 0.9479) ——— trailing 27.000 – 27.076 (1.0630 – 1.0660) ——— rear 38.180 – 38.256 (1.5031 – 1.5061) ——— brake caliper piston diameter leading 23.925 – 23.975 front (0.9419 – 0.9439) —...

  • Page 358

    Gsf1200k2/sk2 (’02-model) 9-21 tire item standard limit cold inflation tire pressure front 250 kpa (solo/dual riding) (2.50 kgf/cm 2 , 36 psi) ——— rear 250 kpa (2.50 kgf/cm 2 , 36 psi) ——— tire size front 120/70 zr17 (58w), ——— 120/70 zr17 m/c (58w) rear 180/55 zr17 (73w), ——— 180/55 zr17 m/c (73w) ...

  • Page 359: Wiring Diagram

    9-22 gsf1200k2/sk2 (’02-model) push free on off lock p off s on off ru n off on push l push r hi lo push push bl 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off on off 12v on off sp ta 1 2 3 4 1 gear position switch free fuel level ga uge y/b y/b b/w b/w y/b ...

  • Page 360: (For E-24)

    Gsf1200k2/sk2 (’02-model) 9-23 off ru n off on push push free on off lock bl 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off 12v on off 1 sp ta 1 2 3 4 speedometer ignition switch ignition coil side -st and switch fuel level ga uge rear brake light switch ign...

  • Page 361: (For E-03, 28, 33)

    9-24 gsf1200k2/sk2 (’02-model) off ru n off on push l push r free hi lo push push free on off lock p bl 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off 12v on off 1 sp ta 1 2 3 4 speedometer ignition switch ignition coil side -st and switch fuel level ga uge ...

  • Page 362: Wiring Diagram

    Gsf1200k2/sk2 (’02-model) 9-25 push free on off lock p off s on off ru n off on push l push r free hi lo push push bl 1 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off on off 12v on off sp t a 1 2 3 4 speedometer ignit o r b a tter y st ar ter rela y st ar te...

  • Page 363: (For E-03, 33)

    9-26 gsf1200k2/sk2 (’02-model) push free on off lock p off ru n off on push l push r free hi lo push bl 1 1 2 34 5 1. Head hi 15a 2. Head lo 15a 3. Ignition 10a 4. Signal 15a 5. Meter 10a on off 12v on off sp t a 1 2 3 4 speedometer ignit or b a tter y st ar ter rela y st ar ter mo t o r 1: main 30a...

  • Page 364

    Gsf1200k2/sk2 (’02-model) 9-27 wire harness routing (gsf1200s) ignition coil ther mo s witch clamp clamp neutr al s witch side-stand s witch wir ing har ness wir ing har ness clamp rear tur n signal (lh) clamp t o cdi unit t o rear tur n signal (lh) clamp wir ing har ness rear tur n signal (rh) clam...

  • Page 365

    9-28 gsf1200k2/sk2 (’02-model) wire harness routing (gsf1200) ignition coil ther mo s witch clamp clamp neutr al s witch side-stand s witch wir ing har ness wir ing har ness clamp rear tur n signal (lh) clamp t o cdi unit t o rear tur n signal (lh) clamp wir ing har ness rear tur n signal (rh) clamp...

  • Page 366

    Gsf1200k2/sk2 (’02-model) 9-29 star ter motor clamp signal gener ator side-stand s witch neutr al s witch speed sensor clamp signal gener ator side-stand s witch neutr al s witch star ter rela y clamp wir ing har ness cdi unit clamp neutr al s witch side-stand s witch wir ing har ness star ter motor...

  • Page 367

    Prepared by 2nd ed. February, 2002 1st ed. April, 2000 part no. 99500-39201-01e printed in japan 372.

  • Page 368: Gsf1200S/gsf1200

    Gsf1200s/gsf1200 printed in japan k1 k2.