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Suzuki GSF1250 Service Manual

Summary of GSF1250

  • Page 1

    9 9 5 0 0 - 3 9 3 0 0 - 0 1 e printed in japan k7 gsf1250/s/a/sa no.7761 gsf1250/s/a/sa 99500-39300-01e cover14 for ps printing (30 mm) 2006.12.29 top bottom dic216 k7 gsf1250/s/a/sa.

  • Page 2: Foreword

    Foreword this manual contains an introductory description on the suzuki gsf1250/s/a/sa and procedures for its inspec- tion/service and overhaul of its main components. Other information considered as generally known is not included. Read the general information section to familiarize yourself with t...

  • Page 3: Table of Contents

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

  • Page 5: Section 00

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

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions warning / caution / note b718h10000001 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 message...

  • Page 7

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

  • Page 8

    00-3 precautions: • check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc. Clamp • clamp the wire harness at such positions as indicated in “wiring harness routing diagram in section 9a (page 9a-8)”. • bend ...

  • Page 9

    Precautions: 00-4 • be careful not to touch the electrical terminals of the electronic parts (ecm, abs control unit/hu, etc.). The static electricity from your body may damage them. • when disconnecting and connecting the coupler, make sure to turn off the ignition switch, or electronic parts may ge...

  • Page 10

    00-5 precautions: • before measuring voltage at each terminal, check to make sure that battery voltage is 11 v or higher. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis. • never connect any tester (voltmeter, ohmmeter, or whatever) to the electronic unit when its ...

  • Page 11

    Precautions: 00-6 continuity check 1) measure resistance across coupler “b” (between “a” and “c” in figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals “a” and “c”. 2) disconnect the coupler “b” and measure resistance between couplers “a” and “b-1”....

  • Page 12

    00-7 precautions: 3) measure resistance between terminal at one end of circuit (“a” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “a” and “c”. 4) disconnect the connector/coupler included in circuit (coupler “b”) and measure res...

  • Page 13

    Precautions: 00-8 • after using the tester, turn the power off. Special tool : 09900–25008 (multi-circuit tester set) note • when connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them. • use the needle poi...

  • Page 14

    00-9 precautions:.

  • Page 15: Section 0

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

  • Page 16: General Information

    0a-1 general information: general information general information general description symbols b718h10101001 listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. Abbreviations b718h10...

  • Page 17

    General information: 0a-2 fp relay: fuel pump relay g: gen: generator gnd: ground gp switch: gear position switch h: hc: hydrocarbons ho2 sensor: heated oxygen sensor (ho2s) i: iap sensor: intake air pressure sensor (iaps) iat sensor: intake air temperature sensor (iats) ig: ignition isc valve: idle...

  • Page 18

    0a-3 general information: read only memory (rom): rom s: secondary air injection (air): — secondary throttle control system (stcs): stc system (stcs) secondary throttle valve (stv): st valve (stv) secondary throttle valve actuator (stva): stv actuator (stva) t: throttle body (tb): throttle body (tb)...

  • Page 19

    General information: 0a-4 left side suzuki gsf1250sa (2007-model) right side left side vehicle identification number b718h10101004 the frame serial number or v.I.N. (vehicle identification number) “a” is stamped on the right side of the steering head pipe. The engine serial number “b” is located on ...

  • Page 20

    0a-5 general information: engine oil (for other countries) oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of sf/sg or sh/sj in api with ma in jaso. Suzuki recommends the use of sae 10w-40 engine oil. If sae 10w-40 engine oil is no...

  • Page 21

    General information: 0a-6 country and area codes b718h10101008 the following codes stand for the applicable country(-ies) and area(-s). Wire color symbols b718h10101009 code country or area effective frame no. Gsf1250 k7 (e-02) u.K. Js1ch122200100001 – gsf1250 k7 (e-19) e.U. Js1ch122100100001 – gsf1...

  • Page 22

    0a-7 general information: warning, caution and information labels location b718h10101010 7 6 12, 13 9 1 2 8 4 10 3 5 [c] [a] 11 [d] [b] i718h1010016-02 gsf1250/a gsf1250s/sa 1. Noise label — for e-03, 24, 33 2. Information label — for e-03, 28, 33 3. Vacuum hose routing label — for e-33 4. Fuel caut...

  • Page 23

    General information: 0a-8 component location electrical components location b718h10103001 7 7 8 5 6 11 12 13 14 4 1 2 3 10 9 i718h1010014-03 1. Fuel pump relay 6. Fuel level gauge 11. Mode selection switch coupler 2. Starter relay/main fuse 7. Ignition coil/plug cap 12. Isc valve 3. Cooling fan rela...

  • Page 24

    0a-9 general information: 20 21 17 18 19 15 16 16 22 23 24 25 27 26 28 29 30 31 i718h1010015-04 15. Iap sensor (no.1) 21. Turn signal/side-stand relay 27. Gp switch 16. Fuel injector 22. Horn 28. Starter motor 17. Iap/tp/iat sensor 23. Cooling fan 29. Speed sensor 18. Stp sensor 24. Ckp sensor 30. H...

  • Page 25

    General information: 0a-10 specifications specifications (gsf1250/s) b718h10107001 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 130 mm (83.9 in) overall width 790 mm (31.1 in) overall height 1 09...

  • Page 26

    0a-11 general information: chassis electrical capacities item specification remark front suspension telescopic, coil spring, oil damped rear suspension link type, coil spring, oil damped front suspension stroke 130 mm (5.1 in) rear wheel travel 136 mm (5.4 in) steering angle 35 ° (right & left) cast...

  • Page 27

    General information: 0a-12 specifications (gsf1250a/sa) b718h10107002 note these specifications are subject to change without notice. Dimensions and dry mass engine drive train item specification remark overall length 2 130 mm (83.9 in) overall width 790 mm (31.1 in) overall height 1 095 mm (43.1 in...

  • Page 28

    0a-13 general information: chassis electrical capacities item specification remark front suspension telescopic, coil spring, oil damped rear suspension link type, coil spring, oil damped front suspension stroke 130 mm (5.1 in) rear wheel travel 136 mm (5.4 in) steering angle 35 ° (right & left) cast...

  • Page 29

    General information: 0a-14 special tools and equipment special tool b718h10108002 09900–06107 snap ring pliers 09900–06108 snap ring pliers 09900–18740 hexagon socket (24 mm) 09900–20102 vernier calipers (1/20 mm, 200 mm) 09900–20202 micrometer (1/100 mm, 25 – 50 mm) 09900–20204 micrometer (75 – 100...

  • Page 30

    0a-15 general information: 09915–40610 oil filter wrench 09915–40611 oil filter wrench 09915–63311 compression gauge attachment 09915–64512 compression gauge 09915–74521 oil pressure gauge hose 09915–74540 oil pressure gauge attachment 09915–77331 meter (for high pressure) 09916–10911 valve lapper s...

  • Page 31

    General information: 0a-16 09923–74511 bearing remover 09924–84510 bearing installer set 09924–84521 bearing installer set 09930–10121 spark plug wrench set 09930–11920 torx bit (jt40h) 09930–11940 bit holder 09930–11950 torx wrench 09930–30104 rotor remover slide shaft 09930–34970 rotor remover set...

  • Page 32: Maintenance and Lubrication

    0b-1 maintenance and lubrication: general information maintenance and lubrication precautions precautions for maintenance b718h10200001 the “periodic maintenance schedule chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at p...

  • Page 33

    Maintenance and lubrication: 0b-2 lubrication points b718h10205002 proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots and wipe off...

  • Page 34

    0b-3 maintenance and lubrication: repair instructions air cleaner element replacement b718h10206001 replace air cleaner element every 18 000 km (11 000 miles, 36 months) refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. Air cleaner element inspection and cleaning b71...

  • Page 35

    Maintenance and lubrication: 0b-4 exhaust pipe bolt and muffler bolt inspection b718h10206005 tighten exhaust pipe bolts, muffler bolt and nut initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. Check the exhaust pipe bolts, muffler bolts and nut to t...

  • Page 36

    0b-5 maintenance and lubrication: spark plug gap 1) remove the spark plugs. Refer to “ignition coil / plug cap and spark plug removal and installation in section 1h (page 1h-4)”. 2) measure the spark plug gap using a thickness gauge. Adjust the spark plug gap if necessary. Spark plug gap 0.7 – 0.8 m...

  • Page 37

    Maintenance and lubrication: 0b-6 note • the cam must be at positions, “a” or “b”, when checking or adjusting the valve clearance. Clearance readings should not be taken with the cam in any other position than these two positions. • the valve clearance should be taken when each cylinder is at top de...

  • Page 38

    0b-7 maintenance and lubrication: 11) turn the crankshaft clockwise 360 ° (one full rotation) and align the match mark on the crankshaft with the mating surfaces of crankcases. Also, position the notches “e” on the right end of each camshaft as shown. Then, measure the following valve clearances “g”...

  • Page 39

    Maintenance and lubrication: 0b-8 (intake side) i718h1020003-02.

  • Page 40

    0b-9 maintenance and lubrication: (exhaust side) i718h1020004-02.

  • Page 41

    Maintenance and lubrication: 0b-10 6) install the camshafts and cam chain tension adjuster. Refer to “engine top side assembly in section 1d (page 1d-28)”. 7) rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped between the shim and the tappet that could cause a...

  • Page 42

    0b-11 maintenance and lubrication: 3) tighten the oil drain plug (1) to the specified torque. Caution ! Replace the gasket washer with a new one. Tightening torque oil drain plug (a): 23 n·m (2.3 kgf-m, 16.5 lb-ft) 4) pour new oil through the oil filler. When performing an oil change (without oil fi...

  • Page 43

    Maintenance and lubrication: 0b-12 4) install a new oil filter. Turn it by hand until you feel that the oil filter o-ring contacts the oil filter mounting surface. Then, tighten the oil filter two full turns (or to specified torque) using the special tool. Note to properly tighten the oil filter, us...

  • Page 44

    0b-13 maintenance and lubrication: 3) check the engine coolant level by observing the full and lower lines on the engine coolant reservoir tank. If the level is below the lower line, add engine coolant to the full line from the engine coolant reservoir tank filler. 4) reinstall the seat. Engine cool...

  • Page 45

    Maintenance and lubrication: 0b-14 5) slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. 6) add engine coolant up to the thermostat connector inlet. 7) start up the engine and bleed air from the thermostat connector inlet completely. 8) add engine coolant u...

  • Page 46

    0b-15 maintenance and lubrication: 3) inspect the clutch hose for crack, damage or clutch fluid leakage. If it is damaged, replace the clutch hose with a new one. 4) after finishing the clutch hose inspection, reinstall the removed parts. Clutch hose replacement b718h10206014 replace clutch hose eve...

  • Page 47

    Maintenance and lubrication: 0b-16 4) count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Drive chain 20-pitch length service limit: 319.4 mm (12.57 in) 5) after finishing the drive chain ...

  • Page 48

    0b-17 maintenance and lubrication: brake system inspection b718h10206019 inspect brake system initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Inspect brake hose and brake fluid every 6 000 km (4 000 miles, 12 months) warning ! • the brake system of...

  • Page 49

    Maintenance and lubrication: 0b-18 front and rear brake hose inspection 1) remove the seat, right frame cover and fuel tank. (gsf1250a/sa) refer to “exterior parts construction in section 9d (page 9d-2)” and “fuel tank removal and installation in section 1g (page 1g-9)”. 2) inspect the brake hoses a...

  • Page 50

    0b-19 maintenance and lubrication: air bleeding from brake fluid circuit refer to “air bleeding from brake fluid circuit in section 4a (page 4a-8)”. Rear brake light switch adjustment refer to “rear brake light switch inspection and adjustment in section 4a (page 4a-8)”. Tire inspection b718h1020602...

  • Page 51

    Maintenance and lubrication: 0b-20 steering system inspection b718h10206025 inspect steering system initially at 1 000 km (600 miles, 2 months) and every 12 000 km (7 500 miles, 24 months) thereafter. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtighten...

  • Page 52

    0b-21 maintenance and lubrication: chassis bolt and nut inspection b718h10206028 tighten chassis bolt and nut initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. 1. Frame do...

  • Page 53

    Maintenance and lubrication: 0b-22 compression pressure check b718h10206029 refer to “compression pressure check in section 1d (page 1d-3)”. Oil pressure check b718h10206030 refer to “oil pressure check in section 1e (page 1e- 3)”. Sds check b718h10206033 refer to “sds check in section 1a (page 1a-1...

  • Page 54

    0b-23 maintenance and lubrication: specifications tightening torque specifications b718h10207001 note the specified tightening torque is also described in the following. “chassis bolt and nut inspection (page 0b-21)” reference: for the tightening torque of fastener not specified in this section, ref...

  • Page 55: Service Data

    Service data: 0c-1 general information service data specifications service data b718h10307001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) item standard limit valve diam. In. 31 (1.22) — ex. 27 (1.06) — valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.008) — ex. 0.20 – 0....

  • Page 56

    0c-2 service data: cylinder + piston + piston ring unit: mm (in) conrod + crankshaft unit: mm (in) item standard limit compression pressure 1 300 – 1 700 kpa (13 – 17 kgf/cm 2 , 185 – 242 psi) 1 000 kpa (10 kgf/cm 2 , 142 psi) compression pressure difference — 200 kpa (2 kgf/cm 2 , 28 psi) piston-to...

  • Page 57

    Service data: 0c-3 oil pump clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio thermostat + radiator + fan + coolant item standard limit oil pressure (at 60 °c, 140 °f) 100 – 400 kpa (1.0 – 4.0 kgf/cm 2 , 14 – 57 psi) at 3 000 r/min — item standard limit clutch drive plate th...

  • Page 58

    0c-4 service data: injector + fuel pump + fuel pressure regulator fi sensors + secondary throttle valve actuator throttle body item specification note injector resistance 11 – 13 Ω at 20 °c (68 °f) fuel pump discharge amount 166 ml (5.6/5.8 us/lmp oz) and more/10 sec. Fuel pressure regulator operati...

  • Page 59

    Service data: 0c-5 electrical unit: mm wattage unit: w item specification note firing order 1 ⋅ 2 ⋅ 4 ⋅ 3 spark plug type ngk: cr7e denso: u22esr-n gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ckp sensor resistance 90 – 150 Ω ckp sensor peak voltage 2.0 v and more when cran...

  • Page 60

    0c-6 service data: brake + wheel unit: mm (in) tire suspension unit: mm (in) item standard limit rear brake pedal height 50 – 60 (2.0 – 2.4) — brake disc thickness front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) rear 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) brake disc runout — 0.30 (0.012) master cylinder bo...

  • Page 61

    Service data: 0c-7 fuel + oil tightening torque specifications b718h10307002 engine item specification note fuel type use only unleaded gasoline of at least 87 pump octane (r/2 + m/2) or 91 octane or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less th...

  • Page 62

    0c-8 service data: fi system and intake air system cooling system oil pressure switch lead wire bolt 1.5 0.15 1.1 crankcase bolt [m6] (initial) 6 0.6 4.5 (final) 11 1.1 8.0 [m8] (initial) 15 1.5 11.0 (final) 26 2.6 19.0 crankshaft journal bolt [m9] (initial) 18 1.8 13.0 (final) 32 3.2 23.0 oil galle...

  • Page 63

    Service data: 0c-9 chassis item n ⋅m kgf-m lb-ft steering stem head nut 65 6.5 47.0 steering stem nut tighten 45 n ⋅m (4.5 kgf-m, 32.5 ib-ft) then turn back 1/2 – 1/4. 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 ro...

  • Page 64

    0c-10 service data: tightening torque chart for other bolts and nuts not listed in the preceding page, refer to this chart: bolt diameter “a” (mm) conventional or “4” marked bolt “7” marked bolt n ⋅m kgf-m lb-ft n ⋅m kgf-m lb-ft 4 1.5 0.15 1.0 2.3 0.23 1.5 5 3 0.3 2.0 4.5 0.45 3.0 6 5.5 0.55 4.0 10 ...

  • Page 65: Section 1

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

  • Page 66

    1-ii table of contents pair control solenoid valve removal and installation.........................................................1b-6 pair system inspection .....................................1b-6 crankcase breather (pcv) hose inspection.......1b-8 crankcase breather (pcv) hose / cover / separa...

  • Page 67

    Table of contents 1-iii schematic and routing diagram........................ 1e-2 engine lubrication system chart diagram ......... 1e-2 diagnostic information and procedures............ 1e-3 engine lubrication symptom diagnosis ............. 1e-3 oil pressure check ...................................

  • Page 68

    1-iv table of contents ckp sensor removal and installation ................1h-8 engine stop switch inspection............................1h-8 ignition switch inspection....................................1h-9 ignition switch removal and installation.............1h-9 specifications......................

  • Page 69: Precautions

    Precautions: 1-1 engine precautions precautions precautions for engine b718h11000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”..

  • Page 70

    1a-1 engine general information and diagnosis: engine engine general information and diagnosis general description injection timing description b718h11101001 injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on th...

  • Page 71

    Engine general information and diagnosis: 1a-2 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control self-diagnosis function b718h11101002 the self-diagnosis function...

  • Page 72

    1a-3 engine general information and diagnosis: for example: the ignition switch is turned on, and the engine stop switch is turned off. In this case, the speedometer does not receive any signal from the ecm, and the panel indicates “chec”. If chec is indicated, the lcd does not indicate the trouble ...

  • Page 73

    Engine general information and diagnosis: 1a-4 schematic and routing diagram fi system wiring diagram b718h11102001 ckps speedometer fi pa ir control solenoid v alv e fp fp rela y ig coil stv a isc v alv e star ter rela y star ter motor clp s witch m side-stand s witch engine stop s witch side-stand...

  • Page 74

    1a-5 engine general information and diagnosis: terminal alignment of ecm coupler b718h11102002 i718h1110004-02 terminal no. Circuit terminal no. Circuit 1 stva signal (stva, 2a) 31 ckp sensor signal (ckp-) 2 stva signal (stva, 1a) 32 serial data for self-diagnosis 3 evap page control valve [e-33 onl...

  • Page 75

    Engine general information and diagnosis: 1a-6 component location fi system parts location b718h11103001 “a” “b” “c” “d” “e” “f” “h” “i” “j” “g” i718h1110146-04 “a”: ecm “c”: cooling fan relay “e”: isc valve “g”: cooling fan “i”: pair control solenoid valve “b”: to sensor “d”: stv actuator “f”: ho2 ...

  • Page 76

    1a-7 engine general information and diagnosis: diagnostic information and procedures engine symptom diagnosis b718h11104001 condition possible cause correction / reference item engine will not start or is hard to start (compression too low) valve clearance out of adjustment. Adjust. Worn valve guide...

  • Page 77

    Engine general information and diagnosis: 1a-8 engine stalls often (incorrect fuel/air mixture) defective iap sensor or circuit. Repair or replace. Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace. Damaged or cracked vacuum hose. Replace...

  • Page 78

    1a-9 engine general information and diagnosis: engine noisy (noise seems to come from water pump) worn or damaged impeller shaft. Replace. Worn or damaged mechanical seal. Replace. Contact between pump case and impeller. Replace. Too much play on pump shaft bearing. Replace. Engine runs poorly in hi...

  • Page 79

    Engine general information and diagnosis: 1a-10 engine lacks power (defective control circuit or sensor) low fuel pressure. Repair or replace. Defective tp sensor. Replace. Defective iat sensor. Replace. Defective ckp sensor. Replace. Defective gp sensor. Replace. Defective iap sensor. Replace. Defe...

  • Page 80

    1a-11 engine general information and diagnosis: self-diagnostic procedures b718h11104005 use of mode select switch note • do not disconnect coupler from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming dtc (diagnostic trouble code) store...

  • Page 81

    Engine general information and diagnosis: 1a-12 use of sds note • do not disconnect the coupler from ecm, the battery cable from the battery, ecm ground wire harness from the engine or main fuse before confirming dtc (diagnostic trouble code) stored in memory. Such disconnection will erase the memor...

  • Page 82

    1a-13 engine general information and diagnosis: 4) start the engine or crank the engine for more than 4 seconds. 5) check the dtc to determine the malfunction part. Refer to “dtc table (page 1a-18)”. Note • read the dtc (diagnostic trouble code) and show data when trouble (displaying data at the tim...

  • Page 83

    Engine general information and diagnosis: 1a-14 show data when trouble (displaying data at the time of dtc) b718h11104008 use of sds ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is c...

  • Page 84

    1a-15 engine general information and diagnosis: 2) click the drop down button (2), either “failure #1” or “failure #2” can be selected. Sds check b718h11104009 using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by ...

  • Page 85

    Engine general information and diagnosis: 1a-16 sample data sampled from cold starting through warm-up data at 3 000 r/min under no load check the engine r/min. 1 200 r/min. Check the water temperature. 50 ˚c and more check the manifold absolute pressure. Xxx kpa i718h1110149-01 check the manifold a...

  • Page 86

    1a-17 engine general information and diagnosis: data at the time of racing data of intake negative pressure during idling (100 °c) throttle: quick wide open throttle: slowly open secondary throttle valve opens closes in according with the throttle valve opening pair control solenoid valve on off in ...

  • Page 87

    Engine general information and diagnosis: 1a-18 example of trouble three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been sav...

  • Page 88

    1a-19 engine general information and diagnosis: in the lcd (display) panel, the malfunction code is indicated from small code to large code. C26 (p0353) ) (page 1a-73) ignition signal #3 (ig coil #3) for #3 cylinder c27 (p0354) ) (page 1a-73) ignition signal #4 (ig coil #4) for #4 cylinder c28 (p165...

  • Page 89

    Engine general information and diagnosis: 1a-20 fail-safe function table b718h11104003 fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. The engine can start and can run even if th...

  • Page 90

    1a-21 engine general information and diagnosis: fi system troubleshooting b718h11104004 customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate ...

  • Page 91

    Engine general information and diagnosis: 1a-22 visual inspection prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mod...

  • Page 92

    1a-23 engine general information and diagnosis: c17 iap sensor (no.2) the sensor should produce following voltage. 0.5 v ≤ sensor voltage in other than the above range, c17 (p1750) is indicated. Iap sensor (no.2), lead wire/ coupler connection p1750 h sensor voltage is higher than specified value. I...

  • Page 93

    Engine general information and diagnosis: 1a-24 c32/c33 c34/c35 fuel injector ckp sensor (pickup coil) signal is produced, but fuel injector signal is interrupted 4 times or more continuously. In this case, the code c32 (p0201), c33 (p0202), c34 (p0203) or c35 (p0204) is indicated. Primary fuel inje...

  • Page 94

    1a-25 engine general information and diagnosis: dtc “c12” (p0335): ckp sensor circuit malfunction b718h11104011 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnos...

  • Page 95

    Engine general information and diagnosis: 1a-26 step action yes no 1 1) turn the ignition switch off. 2) check the ckp sensor coupler for loose or poor contacts. If ok, then measure the ckp sensor resistance. 3) disconnect the ckp sensor coupler and measure the resistance. Special tool (a): 09900–25...

  • Page 96

    1a-27 engine general information and diagnosis: 2 1) crank the engine several seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) ckp sensor peak voltage 2.0 v and more ((+...

  • Page 97

    Engine general information and diagnosis: 1a-28 dtc “c13” (p0105-h/l): iap sensor (no.1) circuit malfunction b718h11104012 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal...

  • Page 98

    1a-29 engine general information and diagnosis: c13 for iap sensor no.1 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the iap sensor coupler for lo...

  • Page 99

    Engine general information and diagnosis: 1a-30 p0105-h for iap sensor (no.1) (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the manifold absolute pressure 1 data. Approx. 146 kpa (1.46 kgf/cm 3 , 21 psi) and more ok? Go to step 2. Go to step 4. 2 1) turn the igniti...

  • Page 100

    1a-31 engine general information and diagnosis: 2 4) disconnect the iap sensor (no.1) coupler. 5) check the continuity between the b wire and w/bl wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indica...

  • Page 101

    Engine general information and diagnosis: 1a-32 p0105-l for iap sensor (no.1) (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the manifold absolute pressure 1 data. Approx. –20 kpa (–0.2 kgf/cm 3 , –2.8 psi) and less ok? Go to step 2. Go to step 4. 2 1) turn the igni...

  • Page 102

    1a-33 engine general information and diagnosis: 2 4) disconnect the iap sensor (no.1) coupler. 5) check the continuity between the w/bl wire and ground. Also, check the continuity between the w/bl wire and b/ br wire. If the sound is not heard from the tester, the circuit condition is ok. Special to...

  • Page 103

    Engine general information and diagnosis: 1a-34 3 1) connect the ecm coupler. 2) turn the ignition switch on. 3) measure the input voltage at the b wire and ground with the needle pointed probes. If ok, the measure the input voltage at the b wire and b/ br wire. Special tool (a): 09900–25008 (multi-...

  • Page 104

    1a-35 engine general information and diagnosis: 4 1) turn the ignition switch off. 2) connect the ecm coupler and iap sensor (no.1) coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) start the engine at idle speed and measure the iap sensor (no.1) output voltage at the wire si...

  • Page 105

    Engine general information and diagnosis: 1a-36 5 1) turn the ignition switch off. 2) remove the iap sensor (no.1). Refer to “iap sensor (no.1) removal and installation in section 1c (page 1c- 2)”. 3) connect the vacuum pump gauge to the vacuum port of the iap sensor (no.1). 4) arrange 3 new 1.5 v b...

  • Page 106

    1a-37 engine general information and diagnosis: dtc “c14” (p0120-h/l): tp sensor circuit malfunction b718h11104013 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 107

    Engine general information and diagnosis: 1a-38 c14 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the tp sensor coupler for loose or poor contacts. If ok, then measure the tp sensor input voltage. 3) disconnect the tp sensor coupler. 4) turn the ignition ...

  • Page 108

    1a-39 engine general information and diagnosis: p0120-h (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the throttle position data. Throttle position approx. 125 ° and more ok? Go to step 2. Go to step 4. 2 1) turn the ignition switch off. 2) check the tp sensor coup...

  • Page 109

    Engine general information and diagnosis: 1a-40 2 4) insert the needle pointed probes to the lead wire coupler. 5) check the continuity between the p/b wire and r wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) (b...

  • Page 110

    1a-41 engine general information and diagnosis: p0120-l (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the throttle position data. Throttle position approx. 0 ° ok? Go to step 2. Go to step 4. 2 1) turn the ignition switch off. 2) check the tp sensor coupler for loo...

  • Page 111

    Engine general information and diagnosis: 1a-42 2 5) check the continuity between the p/b wire and ground. Also, check the continuity between the p/b wire and b/br wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) (...

  • Page 112

    1a-43 engine general information and diagnosis: 3 1) connect the ecm coupler. 2) turn the ignition switch on. 3) measure the input voltage at the r wire and ground. If ok, the measure the input voltage at the r and b/br wire. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indic...

  • Page 113

    Engine general information and diagnosis: 1a-44 4 1) turn the ignition switch off. 2) connect the ecm coupler and tp sensor coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) turn the ignition switch on. 5) measure the tp sensor output voltage at the p/b wire and b/br wire by ...

  • Page 114

    1a-45 engine general information and diagnosis: dtc “c15” (p0115-h/l): ect sensor circuit malfunction b718h11104014 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 115

    Engine general information and diagnosis: 1a-46 c15 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then measure the ect sensor input voltage at the wire side coupler. 3) disconnect the coupler and t...

  • Page 116

    1a-47 engine general information and diagnosis: p0115-h (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the engine coolant/oil temperature data. Approx. –30 ° c (–22 ° f) and less ok? Go to step 2. Go to step 3. 1 i718h1110251-01 i718h1110175-01.

  • Page 117

    Engine general information and diagnosis: 1a-48 2 1) turn the ignition switch off. 2) check the ect sensor coupler for loose or poor contacts. If ok, then check the ect sensor lead wire continuity. 3) disconnect the ect coupler. 4) disconnect the ecm coupler. Refer to “ecm removal and installation i...

  • Page 118

    1a-49 engine general information and diagnosis: p0115-l (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the engine coolant/oil temperature data. Approx. 120 ° c (248 ° f) and more ok? Go to step 2. Go to step 3. 2 1) turn the ignition switch off. 2) check the ect sen...

  • Page 119

    Engine general information and diagnosis: 1a-50 2 4) check the continuity between the b/bl wire and ground. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity test ( ) 5) connect the ect s...

  • Page 120

    1a-51 engine general information and diagnosis: 3 1) turn the ignition switch off. 2) connect the ecm coupler. 3) remove the regulator/rectifier. Refer to “regulator / rectifier inspection in section 1j (page 1j-8)”. 4) disconnect the ect sensor coupler. 5) measure the ect sensor resistance. Special...

  • Page 121

    Engine general information and diagnosis: 1a-52 dtc “c17” (p1750-h/l): iap sensor (no.2) circuit malfunction b718h11104030 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal...

  • Page 122

    1a-53 engine general information and diagnosis: note • after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-13)”. • iap sensor (no.2) is incorporated in the tp sensor/iat sensor. C17 for iap sensor no.2 (use of mode select switch) step a...

  • Page 123

    Engine general information and diagnosis: 1a-54 p1750-h for iap sensor no.2 (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the manifold absolute pressure 2 data. Approx. 126 kpa (1.26 kgf/cm 3 , 18 psi) and more ok? Go to step 2. Go to step 4. 2 1) turn the ignition...

  • Page 124

    1a-55 engine general information and diagnosis: 2 6) check the continuity between the r and g/b wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication co...

  • Page 125

    Engine general information and diagnosis: 1a-56 p1750-l for iap sensor no.2 (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the manifold absolute pressure 2 data. Approx. 0 kpa (0 kgf/cm 3 , 0 psi) and less ok? Go to step 2. Go to step 4. 2 1) turn the ignition switc...

  • Page 126

    1a-57 engine general information and diagnosis: 2 3) disconnect the iap sensor (no.2) coupler. 4) insert the needle pointed probes to the lead wire coupler. 5) check the continuity between the g/b wire and ground. Also, check the continuity between the g/b wire and b/ br wire. If the sound is not he...

  • Page 127

    Engine general information and diagnosis: 1a-58 3 1) connect the ecm coupler. 2) turn the ignition switch on. 3) insert the needle pointed probes to the lead wire coupler. 4) measure the input voltage at the r wire and ground with the needle pointed probes. If ok, the measure the input voltage at th...

  • Page 128

    1a-59 engine general information and diagnosis: p1750 for iap sensor no.2 (use of sds) 4 1) turn the ignition switch off. 2) connect the ecm coupler and iap sensor (no.2) coupler. 3) insert the needle pointed probes to the lead wire coupler. 4) starter the engine at idle speed and measure the iap se...

  • Page 129

    Engine general information and diagnosis: 1a-60 dtc “c21” (p0110-h/l): iat sensor circuit malfunction b718h11104015 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the...

  • Page 130

    1a-61 engine general information and diagnosis: c21 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then measure the iat sensor input voltage. 3) disconnect the iat sensor coupler and turn the igniti...

  • Page 131

    Engine general information and diagnosis: 1a-62 p0110-h (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the intake air temperature data. Approx. –30 ° c (–22 ° f) and less ok? Go to step 2. Go to step 3. 1 i718h1110251-01 i718h1110184-02.

  • Page 132

    1a-63 engine general information and diagnosis: 2 1) turn the ignition switch off. 2) check the iat sensor coupler for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 3) disconnect the iat sensor coupler. 4) disconnect the ecm coupler. Refer to “ecm removal and install...

  • Page 133

    Engine general information and diagnosis: 1a-64 p0110-l (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the intake air temperature data. Approx. 125 ° c (257 ° f) and more ok? Go to step 2. Go to step 3. 2 1) turn the ignition switch off. 2) check the iat sensor coup...

  • Page 134

    1a-65 engine general information and diagnosis: 2 4) insert the needle pointed probes to the lead wire coupler. 5) check the continuity between the dg wire and ground. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) (b)...

  • Page 135

    Engine general information and diagnosis: 1a-66 3 1) turn the ignition switch off. 2) disconnect the iat sensor coupler. 3) measure the iat sensor resistance. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) iat sensor resistance approx. 2.56 k Ω at 20 ...

  • Page 136

    1a-67 engine general information and diagnosis: dtc “c23” (p1651-h/l): to sensor circuit malfunction b718h11104016 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ...

  • Page 137

    Engine general information and diagnosis: 1a-68 c23 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the to sensor coupler for loose or poor contacts. If ok, th...

  • Page 138

    1a-69 engine general information and diagnosis: p1651-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the to sensor coupler for loose or poor contacts. If ok, then check th...

  • Page 139

    Engine general information and diagnosis: 1a-70 p1651-l (use of sds) 1 8) check the continuity between the b wire “b” and terminal “22”. Also, check the continuity between b/br wire “c” and terminal “29”. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe...

  • Page 140

    1a-71 engine general information and diagnosis: 1 4) disconnect the to sensor coupler. 5) check the continuity between the b wire “b” and ground. Also, check the continuity between the b wire “b” and b/ br wire “c”. If the sound is not heard from the tester, the circuit condition is ok. Special tool...

  • Page 141

    Engine general information and diagnosis: 1a-72 2 1) connect the ecm coupler and to sensor coupler. 2) dismount the to sensor from its bracket. Refer to “to sensor removal and installation in section 1c (page 1c-3)”. 3) insert the needle pointed probes to the lead wire coupler. 4) turn the ignition ...

  • Page 142

    1a-73 engine general information and diagnosis: dtc “c24” (p0351), “c25” (p0352), “c26” (p0353) or “c27” (p0354): ignition system malfunction b718h11104017 note refer to “no spark or poor spark in section 1h (page 1h-3)” for details. Dtc “c28” (p1655): secondary throttle valve actuator (stva) malfun...

  • Page 143

    Engine general information and diagnosis: 1a-74 step action yes no 1 1) remove the regulator/rectifier. Refer to “regulator / rectifier construction in section 1j (page 1j-8)”. 2) check the stva lead wire coupler for loose or poor contacts. 3) move the air cleaner backward. Refer to “air cleaner ele...

  • Page 144

    1a-75 engine general information and diagnosis: 2 1) turn the ignition switch off. 2) move the throttle body right side. Refer to “throttle body removal and installation in section 1d (page 1d-9)”. 3) disconnect the stva lead wire coupler. 4) check the continuity between each terminal and ground. Sp...

  • Page 145

    Engine general information and diagnosis: 1a-76 active control inspection 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) turn the ignition switch on. 3) click “secondary throttle operating control” (1). 4) click each button (2). At this time, if an operation soun...

  • Page 146

    1a-77 engine general information and diagnosis: dtc “c29” (p1654-h/l): secondary throttle position sensor (stps) circuit malfunction b718h11104019 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not str...

  • Page 147

    Engine general information and diagnosis: 1a-78 c29 (use of mode select switch) step action yes no 1 1) turn the ignition switch off. 2) check the stp sensor coupler for loose or poor contacts. If ok, then measure the stp sensor input voltage. 3) disconnect the stp sensor coupler. 4) turn the igniti...

  • Page 148

    1a-79 engine general information and diagnosis: p1654-h (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the secondary throttle actuator position sensor data. Secondary throttle position approx. 100% and more ok? Go to step 2. Go to step 4. 2 1) turn the ignition swit...

  • Page 149

    Engine general information and diagnosis: 1a-80 2 3) disconnect the stp sensor coupler. 4) check the continuity between the y/w wire and r wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication con...

  • Page 150

    1a-81 engine general information and diagnosis: p1654-l (use of sds) step action yes no 1 1) click the data monitor button (1). 2) check the secondary throttle actuator position sensor data. Secondary throttle position approx. 0% ok? Go to step 2. Go to step 4. 2 1) turn the ignition switch off. 2) ...

  • Page 151

    Engine general information and diagnosis: 1a-82 2 4) check the continuity between the y/w wire and ground. Also, check the continuity between the y/w wire and b/ br wire. If the sound is not heard from the tester, the circuit condition is ok. Special tool (a): 09900–25008 (multi-circuit tester set) ...

  • Page 152

    1a-83 engine general information and diagnosis: 3 1) connect the ecm coupler. 2) disconnect the stp sensor coupler. 3) turn the ignition switch on. 4) measure the input voltage at the r wire and ground. Also, measure the input voltage at the r wire and b/br wire. Special tool (a): 09900–25008 (multi...

  • Page 153

    Engine general information and diagnosis: 1a-84 4 1) turn the ignition switch off. 2) connect the ecm coupler and stp sensor coupler. 3) move the air cleaner box backward. Refer to “throttle body removal and installation in section 1d (page 1d- 9)”. 4) disconnect the stva lead wire coupler. Refer to...

  • Page 154

    1a-85 engine general information and diagnosis: dtc “c31” (p0705): gp switch circuit malfunction b718h11104020 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm ...

  • Page 155

    Engine general information and diagnosis: 1a-86 step action yes no 1 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the gp switch coupler for loose or poor contacts. If ok, then measure the gp sw...

  • Page 156

    1a-87 engine general information and diagnosis: dtc “c32” (p0201), “c33” (p0202), “c34” (p0203) or “c35” (p0204): fuel injector circuit malfunction b718h11104021 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tes...

  • Page 157

    Engine general information and diagnosis: 1a-88 step action yes no 1 1) turn the ignition switch off. 2) lift and support the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the injector coupler for loose or poor contacts. If ok, then measure the injector...

  • Page 158

    1a-89 engine general information and diagnosis: 1 5) if ok, then check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-circuit tester set) injector continuity ∞Ω (infinity) are the resistance and continuity ok? Go to step 2. Replace the injector with a new one. ...

  • Page 159

    Engine general information and diagnosis: 1a-90 2 1) turn the ignition switch on. 2) measure the injector voltage between the y/r wire and ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication voltage ( ) injector voltage battery voltage ((+) terminal: y/r – (–) ter...

  • Page 160

    1a-91 engine general information and diagnosis: dtc “c40” (p0505 / p0506 / p0507): isc valve circuit malfunction b718h11104022 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! • be careful not to disconnect the isc valve coupler at least 5 sec...

  • Page 161

    Engine general information and diagnosis: 1a-92 step action yes no 1 1) turn the ignition switch off. 2) check the isc valve coupler for loose or poor contacts. If ok, then check the isc valve lead wire continuity. 3) disconnect the isc valve coupler and ecm coupler. Refer to “ecm removal and instal...

  • Page 162

    1a-93 engine general information and diagnosis: 2 1) move the throttle body right side. Refer to “throttle body removal and installation in section 1d (page 1d-9)”. 2) disconnect the isc valve coupler. 3) check the continuity between each terminal and ground. Special tool (a): 09900–25008 (multi-cir...

  • Page 163

    Engine general information and diagnosis: 1a-94 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) click the “active control”. 4) click the “isc rpm control” (1). 5) check that t...

  • Page 164

    1a-95 engine general information and diagnosis: check 2 1) click the button (4) and decrease the “spec” (2) to 1 100 rpm slowly. 2) check that the “desired idle speed” (3) is nearly equal to the “spec” (2). At the same time, check that the number of steps (5) in the isc valve position decreases. 3) ...

  • Page 165

    Engine general information and diagnosis: 1a-96 check 4 1) click the button (6) and increase the “spec” (2) to 1 400 rpm. 2) check that the “desired idle speed” (3) is approx. 1 400 rpm. 3) check that the “engine speed” (7) is close to 1 400 rpm. Note be careful not to increase the “spec” to 1 700 r...

  • Page 166

    1a-97 engine general information and diagnosis: dtc “c41” (p0230-h/l): fp relay circuit malfunction b718h11104023 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the e...

  • Page 167

    Engine general information and diagnosis: 1a-98 c41 (use of mode select switch) p0230-h (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the fp relay coupler for loose or poor...

  • Page 168

    1a-99 engine general information and diagnosis: p0230-l (use of sds) step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the fp relay coupler for loose or poor contacts. If ok, then check the...

  • Page 169

    Engine general information and diagnosis: 1a-100 dtc “c41” (p2505): ecm power input signal malfunction b718h11104031 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of th...

  • Page 170

    1a-101 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) check the ecm coupler for loose or poor contacts. If ok, then measure the ecm input voltage. 4) ...

  • Page 171

    Engine general information and diagnosis: 1a-102 dtc “c42” (p1650): ig switch circuit malfunction b718h11104024 detected condition and possible cause troubleshooting note • refer to “ignition switch inspection in section 9c (page 9c-10)” for details. • after repairing the trouble, clear the dtc usin...

  • Page 172

    1a-103 engine general information and diagnosis: troubleshooting (when indicating c44/p0130:) caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing ...

  • Page 173

    Engine general information and diagnosis: 1a-104 1 6) disconnect the ecm coupler. Refer to “ecm removal and installation in section 1c (page 1c-1)”. 7) check the continuity between the w/g wire “a” and terminal “12”. Also, check the continuity between the b/ br wire “b” and terminal “29”. Special to...

  • Page 174

    1a-105 engine general information and diagnosis: 2 1) connect the ecm coupler and ho2 sensor coupler. 2) warm up the engine enough. 3) insert the needle pointed probes to the lead wire coupler. 4) measure the ho2 sensor output voltage between the w/ g wire and b/br wire, when idling condition. Speci...

  • Page 175

    Engine general information and diagnosis: 1a-106 troubleshooting (when indicating c44/p0135:) note after repairing the trouble, clear the dtc using sds tool. Refer to “use of sds diagnosis reset procedures (page 1a-13)”. Step action yes no 1 1) turn the ignition switch off. 2) remove the left frame ...

  • Page 176

    1a-107 engine general information and diagnosis: 2 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on and measure the heater voltage between the w/b wire and ground. If the tester voltage indicates the battery voltage, it i...

  • Page 177

    Engine general information and diagnosis: 1a-108 dtc “c49” (p1656): pair control solenoid valve circuit malfunction b718h11104028 detected condition and possible cause wiring diagram ecm coupler (harness side) troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the t...

  • Page 178

    1a-109 engine general information and diagnosis: step action yes no 1 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) check the pair control solenoid valve coupler for loose or poor contacts. If ok, then measure th...

  • Page 179

    Engine general information and diagnosis: 1a-110 active control inspection 1) set up the sds tool. (refer to sds operation manual for further details.) 2) turn the ignition switch on. 3) click “pair sol operating control” (1). 2 1) turn the ignition switch on. 2) measure the voltage between the o/w ...

  • Page 180

    1a-111 engine general information and diagnosis: 4) click each button (2). At this time, if an operating sound is heard from the pair control solenoid valve, the function is normal. Dtc “c60” (p0480): cooling fan relay circuit malfunction b718h11104029 detected condition and possible cause wiring di...

  • Page 181

    Engine general information and diagnosis: 1a-112 troubleshooting caution ! When using the multi-circuit tester, do not strongly touch the terminal of the ecm coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. Note after repairing the trouble, clear the dtc us...

  • Page 182

    1a-113 engine general information and diagnosis: active control inspection note cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °c (212 °f) after starting the engine. 1) set up the sds tool. (refer to sds operation manual for fur...

  • Page 183

    Engine general information and diagnosis: 1a-114 specifications service data b718h11107001 injector fi sensors item specification note injector resistance 11 – 13 Ω at 20 °c (68 f°) — item specification note ckp sensor resistance 90 – 150 Ω ckp sensor peak voltage 2.0 v and more when cranking iap se...

  • Page 184

    1a-115 engine general information and diagnosis: special tools and equipment special tool b718h11108001 09900–25008 ) (page 1a-66) / ) (page 1a-68) / ) (page 1a-69) / ) (page 1a-70) / ) (page 1a-71) / ) (page 1a-71) / ) (page 1a-72) / ) (page 1a-75) / ) (page 1a-78) / ) (page 1a-80) / ) (page 1a-80)...

  • Page 185: Emission Control Devices

    Emission control devices: 1b-1 engine emission control devices precautions precautions for emission control devices b718h11200001 refer to “general precautions in section 00 (page 00-1)”. General description fuel injection system description b718h11201001 gsf1250 motorcycles are equipped with a fuel...

  • Page 186

    1b-2 emission control devices: crankcase emission control system description b718h11201002 the engine is equipped with a pcv system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion ch...

  • Page 187

    Emission control devices: 1b-3 exhaust emission control system description b718h11201003 the exhaust emission control system is composed of the pair system, ho2 sensor, catalyst system and isc system. The fresh air is drawn into the exhaust port through the pair control solenoid valve and pair reed ...

  • Page 188

    1b-4 emission control devices: schematic and routing diagram pair system hose routing diagram b718h11202001 1 1 2 “a” “a” “a” “b” “b” “b” “c” “c” “ a ” “ a ” “ a ” “ a ” “ a ” i718h1120043-01 1. Pair control solenoid valve “a”: marking (yellow) “c”: to air cleaner box 2. Pair reed valve “b”: marking...

  • Page 189

    Emission control devices: 1b-5 repair instructions heated oxygen sensor (ho2s) removal and installation b718h11206005 removal warning ! Do not remove the ho2 sensor while it is hot. Caution ! • be careful not to expose the ho2 sensor to excessive shock. • do not use an impact wrench when removing or...

  • Page 190

    1b-6 emission control devices: pair reed valve removal and installation b718h11206008 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) drain engine coolant and remove the thermostat connector. Refer to “thermostat connector / thermostat rem...

  • Page 191

    Emission control devices: 1b-7 2) inspect the hoses for wear or damage. If it is worn or damaged, replace the pair hose with a new one. Refer to “pair system hose routing diagram (page 1b-4)”. 3) reinstall the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. Pair r...

  • Page 192

    1b-8 emission control devices: 4) check the resistance between the terminals of the pair control solenoid valve. Special tool : 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) pair control solenoid valve resistance 18 – 22 Ω at 20 – 30 °c (68 – 86 °f) 5) reinstall the p...

  • Page 193

    Emission control devices: 1b-9 installation installation is in the reverse order of removal. Pay attention to the following points: • apply bond to the mating surface of the breather cover. : sealant 99000–31110 (suzuki bond no.1215 or equivalent) note • make surfaces free from moisture, oil, dust a...

  • Page 194

    1b-10 emission control devices: specifications service data b718h11207001 fi sensors tightening torque specifications b718h11207002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-7)”. Special tools and...

  • Page 195: Engine Electrical Devices

    Engine electrical devices: 1c-1 engine engine electrical devices precautions precautions for engine electrical device b718h11300001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location engine electrica...

  • Page 196

    1c-2 engine electrical devices: iap sensor (no.1) removal and installation b718h11306035 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) disconnect the iap sensor (no.1) coupler (1) and vacuum hose (2). 3) remove the iap sensor (no.1) (3)....

  • Page 197

    Engine electrical devices: 1c-3 ect sensor inspection b718h11306010 refer to “dtc “c15” (p0115-h/l): ect sensor circuit malfunction in section 1a (page 1a-45)”. Inspect the ect sensor in the following procedures: 1) remove the ect sensor. Refer to “ect sensor removal and installation (page 1c-2)”. 2...

  • Page 198

    1c-4 engine electrical devices: stp sensor adjustment b718h11306025 adjust the stp sensor in the following procedures: 1) remove the air cleaner cover and air cleaner element. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 2) disconnect the stva lead wire coupler ...

  • Page 199

    Engine electrical devices: 1c-5 installation 1) remove the air cleaner cover and air cleaner element. Refer to “air cleaner element removal and installation in section 1d (page 1d-6)”. 2) close the secondary throttle valve by finger. 3) with the stv fully closed, install the stp sensor (1) and tight...

  • Page 200

    1c-6 engine electrical devices: isc valve preset and opening initialization b718h11306036 when removing or replacing the isc valve, set the isc valve to the following procedures: 1) turn the ignition switch on. 2) set up the sds tool. (refer to the sds operation manual for further details.) 3) click...

  • Page 201

    Engine electrical devices: 1c-7 specifications service data b718h11307001 fi sensors item specification note ckp sensor resistance 90 – 150 Ω ckp sensor peak voltage 2.0 v and more when cranking iap sensor input voltage (no.1) 4.5 – 5.5 v iap sensor output voltage (no.1) approx. 2.7 v at idle speed ...

  • Page 202

    1c-8 engine electrical devices: tightening torque specifications b718h11307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-7)”. Special tools and equipment recommended service material b718h11308001...

  • Page 203: Engine Mechanical

    Engine mechanical: 1d-1 engine engine mechanical schematic and routing diagram camshaft and sprocket assembly diagram b718h11402001 i718h1140393-01.

  • Page 204

    1d-2 engine mechanical: throttle cable routing diagram b718h11402002 1 2 “a” 4 3 2 1 3 4 5 6 7 “ a ” “ a ” i718h1140308-03 1. Wiring harness 4. Throttle cable no.2 7. Ignition switch lead wire 2. Cable guide (gsf1250s/sa only) 5. Handlebar switch lead wire (l) “a”: 0 mm (0 in) 3. Throttle cable no.1...

  • Page 205

    Engine mechanical: 1d-3 diagnostic information and procedures engine mechanical symptom diagnosis b718h11404002 refer to “engine symptom diagnosis in section 1a (page 1a-7)”. Compression pressure check b718h11404001 the compression pressure reading of a cylinder is a good indicator of its internal c...

  • Page 206

    1d-4 engine mechanical: repair instructions engine components removable with the engine in place b718h11406001 engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each ...

  • Page 207

    Engine mechanical: 1d-5 engine right side engine left side item removal inspection installation clutch cover refer to “clutch removal in section 5c (page 5c-13)”. — refer to “clutch installation in section 5c (page 5c-14)”. Clutch plates refer to “clutch removal in section 5c (page 5c-13)”. Refer to...

  • Page 208

    1d-6 engine mechanical: air cleaner element removal and installation b718h11406034 removal 1) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 2) remove the air cleaner cover screws. 3) remove the air cleaner cover (1). 4) remove the air cleaner element ...

  • Page 209

    Engine mechanical: 1d-7 installation install the throttle cables in the reverse order of removal. Pay attention to the following points: • install the throttle cables as shown in the cable routing diagram. Refer to “throttle cable routing diagram (page 1d-2)”. • check the throttle cable play and pro...

  • Page 210

    1d-8 engine mechanical: throttle body construction b718h11406041 “b” 2 lh lh rh rh upper upper air cleaner side engine side 1 (a) (a) “a” i718h1140314-01 1. Clamp (air cleaner side) : after tighten the clamp band #2, 3 and tighten the clamp band #1, 4. “b”: clamp the drain hose at mark position. 2. ...

  • Page 211

    Engine mechanical: 1d-9 throttle body removal and installation b718h11406042 removal 1) disconnect the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j-12)”. 2) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 3) r...

  • Page 212

    1d-10 engine mechanical: installation install the throttle body in the reverse order of removal. Pay attention to the following points: • connect the throttle pulling cable (1) and throttle returning cable (2) to the throttle cable drum. • tighten the throttle body clamp screws. Refer to “throttle b...

  • Page 213

    Engine mechanical: 1d-11 3) remove the fuel delivery pipe assembly (6). Caution ! Be careful not to twist the fuel delivery pipe’s t-joint (7), when disconnecting the fuel feed hose or removing the fuel delivery pipes, or joint part “a” of the fuel delivery pipe get damage. 4) remove the fuel inject...

  • Page 214

    1d-12 engine mechanical: 9) remove the stp sensor (13). Note prior to disassembly, mark sensor’s original position with a paint or scribe for accurate reinstallation. Special tool : 09930–11950 (torx wrench) caution ! Never remove the iap/tp/iat sensor (14) from the throttle body. Caution ! Never se...

  • Page 215

    Engine mechanical: 1d-13 assembly assemble the throttle body in the reverse order of disassembly. Pay attention to the following points: • apply a thin coat of engine oil to the o-ring. • with the stv fully closed, install the stp sensor (1) and tighten the stp sensor mounting screw to the specified...

  • Page 216

    1d-14 engine mechanical: • apply a thin coat of engine oil to the new cushion seal (2) and the o-ring (3). Caution ! Replace the cushion seal and o-ring with the new ones. • apply a thin coat of engine oil to the new o-rings (4). Caution ! Replace the o-rings with the new ones. • assemble the fuel d...

  • Page 217

    Engine mechanical: 1d-15 • tighten the fuel delivery pipe mounting screws to the specified torque. Tightening torque fuel delivery pipe mounting screw (a): 3.5 n·m ( 0.35 kgf-m, 2.45 lb-ft) throttle body inspection and cleaning b718h11406044 refer to “throttle body disassembly and assembly (page 1d-...

  • Page 218

    1d-16 engine mechanical: 3) connect the respective vacuum tester hoses to each vacuum nipple on the throttle body. 4) start the engine. 5) set up the sds tool. (refer to the sds operation manual for further details.) 6) click “data monitor”. 7) warm up the engine (water temp. More than 80 ° (176 °f)...

  • Page 219

    Engine mechanical: 1d-17 11) check for the synchronization of vacuum from #1 to #4 cylinders. 12) equalize the vacuum of the cylinders by turning each air screw and keep it running at idling speed. Note always set the engine rpm at idle rpm. 13) if the adjustment is not yet correct, remove each air ...

  • Page 220

    1d-18 engine mechanical: 4) remove the fuel tank. Refer to “fuel tank removal and installation in section 1g (page 1g-9)”. 5) drain engine coolant. Refer to “cooling system inspection in section 0b (page 0b-12)”. 6) disconnect the battery (–) lead wire. 7) disconnect the fuel feed hose (1). 8) remov...

  • Page 221

    Engine mechanical: 1d-19 15) disengage the gearshift link arm by removing the bolt. Note mark the gearshift shaft head at which the gearshift link arm slit is set for correct reinstallation. 16) remove the engine sprocket inner cover by removing the bolts. 17) remove the speed sensor rotor (9) while...

  • Page 222

    1d-20 engine mechanical: 23) disconnect the engine ground wire coupler (18) and oil pressure switch coupler (19). 24) disconnect the gp switch coupler (20) and starter motor lead wire (21). 25) support the engine with a proper jack. 26) remove the right engine mounting no.2 bracket (22). 27) remove ...

  • Page 223

    Engine mechanical: 1d-21 engine assembly installation b718h11406003 reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • insert the two mounting bolts from left side, and tighten their nuts. Note the engine mounting nuts are self-locking. Once the nut...

  • Page 224

    1d-22 engine mechanical: • tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration. • apply thread lock super to the driveshaft. : thread lock cement 99000–32030 (thread lock cement super 1303 or equivalent) • tighten the engine sprocket nut to the ...

  • Page 225

    Engine mechanical: 1d-23 • tighten the speed sensor rotor bolt to the specified torque. Tightening torque speed sensor rotor bolt (h): 25 n·m (2.5 kgf-m, 18.0 lb-ft) • before installing the engine sprocket inner cover, apply a small quantity of suzuki super grease to the clutch push rod. : grease 99...

  • Page 226

    1d-24 engine mechanical: engine top side disassembly b718h11406006 caution ! 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. 1) remove the seat (1) and disconnect the batter...

  • Page 227

    Engine mechanical: 1d-25 camshaft 1) remove the right crankshaft cover (1). 2) remove all of the spark plugs. Refer to “ignition coil / plug cap and spark plug removal and installation in section 1h (page 1h-4)”. Special tool : 09930–10121 (spark plug wrench set) 3) turn the crankshaft clockwise and...

  • Page 228

    1d-26 engine mechanical: 8) remove the intake (7) and exhaust camshafts (8). 9) remove the dowel pins. Cylinder head 1) remove the radiator (1). Refer to “radiator / cooling fan motor removal and installation in section 1f (page 1f-5)”. 2) remove the exhaust pipe assembly (2) and muffler. Refer to “...

  • Page 229

    Engine mechanical: 1d-27 cam chain no.1 guide remove the cam chain no.1 guide (1). Cylinder 1) disconnect the water hoses (1). 2) disconnect the ect sensor coupler (2). 3) remove the cylinder (3). Note if the cylinder does not come off easily, lightly tap it using a plastic hammer. 4) remove the cyl...

  • Page 230

    1d-28 engine mechanical: 3) draw out each piston pin (2) and remove the pistons (3). Note scribe the cylinder number on the piston head. Engine top side assembly b718h11406007 assemble the engine top side in the reverse order of disassembly. Pay attention to the following points: piston • when insta...

  • Page 231

    Engine mechanical: 1d-29 • position the piston ring gaps as shown. Before inserting each piston into its cylinder, check that the gaps are properly positioned. Cylinder • install the dowel pins and cylinder gasket (1). Caution ! Replace the cylinder gasket (1) with a new one. • apply molybdenum oil ...

  • Page 232

    1d-30 engine mechanical: cam chain no.1 guide • pull the cam chain out of the cylinder and install the cam chain guide (1). Caution ! Be sure that the cam chain guide (1) is installed properly. Cylinder head • install the dowel pins, o-ring (1) and cylinder head gasket (2). Caution ! Replace the o-r...

  • Page 233

    Engine mechanical: 1d-31 water hose • install the water hoses (1). Refer to “water hose routing diagram in section 1f (page 1f-3)”. Exhaust pipe / muffler • install the exhaust pipe assembly (1), muffler and radiator (2). Refer to “exhaust pipe / muffler removal and installation in section 1k (page ...

  • Page 234

    1d-32 engine mechanical: • the other arrow marked “2” “d” should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” “d”, count out 16 roller pins (from the exhaust camshaft side going towards the intake camshaft side). • engage the 16th roller pin “...

  • Page 235

    Engine mechanical: 1d-33 • install the oil pipe and tighten the mounting bolts to specified torque. Note fit the washer (1) to each oil pipe mounting bolt. Tightening torque oil pipe mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) cam chain tension adjuster • retract the push rod by pushing the sto...

  • Page 236

    1d-34 engine mechanical: • after installing the cam chain tension adjuster, rotate the crankshaft (some turns), and recheck the positions of the camshafts. • be sure to check and adjust the valve clearance. Refer to “valve clearance inspection and adjustment in section 0b (page 0b-5)”. Throttle body...

  • Page 237

    Engine mechanical: 1d-35 • apply suzuki bond to the cam end caps of the gasket as shown. : sealant 99000–31140 (suzuki bond 1207b or equivalent) • apply engine oil to both sides of the gaskets. Caution ! Use the gaskets with new ones to prevent oil leakage. • tighten the cylinder head cover bolts (4...

  • Page 238

    1d-36 engine mechanical: valve clearance inspection and adjustment b718h11406008 refer to “valve clearance inspection and adjustment in section 0b (page 0b-5)”. Camshaft inspection b718h11406009 refer to “engine top side disassembly (page 1d-24)”. Refer to “engine top side assembly (page 1d-28)”. Ca...

  • Page 239

    Engine mechanical: 1d-37 3) install each camshaft journal holder to its original position. Refer to “engine top side assembly (page 1d-28)”. 4) tighten the camshaft journal holder bolts in ascending order of numbers to the specified torque. Refer to “engine top side assembly (page 1d-28)”. Note do n...

  • Page 240

    1d-38 engine mechanical: camshaft sprocket inspection b718h11406010 inspect the camshaft sprocket in the following procedures: 1) remove the intake and exhaust camshafts. Refer to “engine top side disassembly (page 1d-24)”. 2) inspect the teeth of each camshaft sprocket for wear or damage. If they a...

  • Page 241

    Engine mechanical: 1d-39 cam chain tension adjuster inspection b718h11406012 the cam chain tension adjuster is maintained at the proper tension by an automatically adjusted. 1) remove the cam chain tension adjuster. Refer to “engine top side disassembly (page 1d-24)”. 2) check that the push rod slid...

  • Page 242

    1d-40 engine mechanical: cam chain tensioner inspection b718h11406015 inspect the cam chain tensioner in the following procedures: 1) separate the crankcases, upper and lower. Refer to “engine bottom side disassembly (page 1d-53)”. 2) remove the crankshaft assembly from the upper crankcase. Refer to...

  • Page 243

    Engine mechanical: 1d-41 3) remove the valve spring retainer (4) and valve spring (5). 4) pull out the valve (6) from the combustion chamber side. 5) remove the oil seal (7) and spring seat (8). 6) remove the other valves in the same manner as described previously. 7) remove the water outlet pipes (...

  • Page 244

    1d-42 engine mechanical: note • when replacing the intake pipes, identify the different intake pipes according to each i.D. Code “a”. (1-18h0 for cylinder #1 and #4) (2-18h0 for cylinder #2 and #3) • make sure that the “1 up” mark faces up. (for cylinder #1) • make sure that the “4 up” mark faces up...

  • Page 245

    Engine mechanical: 1d-43 • install the valve spring with the small-pitch portion “b” facing cylinder head. • put on the valve spring retainer (2), and using the special tools, press down the spring, fit the cotter halves to the stem end, and release the lifter to allow the cotter halves to wedge in ...

  • Page 246

    1d-44 engine mechanical: cylinder head related parts inspection b718h11406017 refer to “cylinder head disassembly and assembly (page 1d-40)”. Cylinder head distortion 1) decarbonize the combustion chambers. 2) check the gasket surface of the cylinder head for distortion. Use a straightedge and thick...

  • Page 247

    Engine mechanical: 1d-45 valve stem deflection lift the valve about 10 mm (0.39 in) “a” from the valve seat. Measure the valve stem deflection in two directions, “x” and “y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine wh...

  • Page 248

    1d-46 engine mechanical: valve seat width 1) visually check for valve seat width on each valve face. If the valve face has worn abnormally, replace the valve. 2) coat the valve seat with a red lead (prussian blue) and set the valve in place. 3) rotate the valve with light pressure. Special tool (a):...

  • Page 249

    Engine mechanical: 1d-47 valve guide replacement b718h11406018 1) remove the cylinder head. Refer to “engine top side disassembly (page 1d-24)”. 2) remove the valves. Refer to “cylinder head disassembly and assembly (page 1d-40)”. 3) using the valve guide remover, drive the valve guide out toward th...

  • Page 250

    1d-48 engine mechanical: 8) after installing the valve guides, refinish their guiding bores using the reamer. Be sure to clean and oil the guides after reaming. Note • be sure to cool down the cylinder head to ambient air temperature. • insert the reamer from the combustion chamber and always turn t...

  • Page 251

    Engine mechanical: 1d-49 3) remove the water jacket plugs (4). Assembly assembly is in the reverse order of disassembly. Pay attention to the following points: • tighten the water jacket plugs to the specified torque. Caution ! Replace the gaskets with new ones. Tightening torque water jacket plug (...

  • Page 252

    1d-50 engine mechanical: • apply engine oil to o-ring and install the oil jet. • tighten the ect sensor to the specified torque. Caution ! Replace the o-ring and gasket with new ones. Tightening torque ect sensor (b): 18 n·m (1.8 kgf-m, 13.0 lb-ft) cylinder inspection b718h11406020 refer to “engine ...

  • Page 253

    Engine mechanical: 1d-51 piston ring removal and installation b718h11406022 removal 1) draw out the piston pin and remove the piston. Refer to “engine top side disassembly (page 1d-24)”. 2) carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring (2) to r...

  • Page 254

    1d-52 engine mechanical: 2) position the gaps of the three rings and side rails as shown. Before inserting piston into the cylinder, check that the gaps are so located. 3) install the piston and piston pin. Refer to “engine top side assembly (page 1d-28)”. Piston and piston ring inspection b718h1140...

  • Page 255

    Engine mechanical: 1d-53 piston ring free end gap and piston ring end gap measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. If any of the measurements exceed the service lim...

  • Page 256

    1d-54 engine mechanical: 3) remove the water hoses (2) and regulator/rectifier bracket (3). Engine top side disassemble the engine top side (1). Refer to “engine top side disassembly (page 1d-24)”. Starter motor remove the starter motor (1). Clutch remove the clutch component parts (1). Refer to “cl...

  • Page 257

    Engine mechanical: 1d-55 6) remove the pin (8) and washer (9). Note do not drop the pin (8) and washer (9) into the crankcase. 7) remove the oil pump (10). Gearshift system 1) remove the snap ring (1) and washer (2) from the gearshift shaft. Special tool : 09900–06107 (snap ring pliers) 2) remove th...

  • Page 258

    1d-56 engine mechanical: gear position switch remove the gear position switch (1). Crankcase breather cover remove the crankcase breather cover (1) and oil breather separator (2). Oil pressure switch 1) disconnect the oil pressure switch lead wire (1) and remove the oil pressure switch (2). Oil filt...

  • Page 259

    Engine mechanical: 1d-57 oil pressure regulator / oil strainer 1) remove the oil pressure regulator (1). 2) remove the oil strainer (2). 3) remove the o-rings (3). Crank balancer 1) remove the plate (1). 2) remove the balancer shaft arm (2). 3) draw out the balancer shaft (3) and remove the crank ba...

  • Page 260

    1d-58 engine mechanical: 3) loosen the crankcase bolts evenly by shifting the wrench in the descending order of numbers. 4) make sure that all of the bolts are removed. Then, tap the sides of the lower crankcase using a plastic hammer to separate the upper and lower crankcase halves and then lift th...

  • Page 261

    Engine mechanical: 1d-59 transmission remove the transmission component. Refer to “transmission removal in section 5b (page 5b-3)”. Oil jet 1) remove the oil jet (1) (for engine top side) from the upper crankcase. 2) remove the piston cooling oil jets from the upper crankcase. 3) remove the oil gall...

  • Page 262

    1d-60 engine mechanical: note • do not remove the crankshaft journal bearings unless absolutely necessary. • make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions. Oil gallery plug 1) remove the oil gallery plug (1) from the...

  • Page 263

    Engine mechanical: 1d-61 engine mount bushing remove the engine mount bushings (1) if necessary. Engine bottom side assembly b718h11406025 assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: note apply engine oil to each running and sliding par...

  • Page 264

    1d-62 engine mechanical: oil jet • fit the new o-ring (1) to each piston cooling oil jet as shown and apply engine oil to them. Caution ! Use the new o-rings to prevent oil pressure leak. • apply a small quantity of thread lock to the bolts and tighten them to the specified torque. : thread lock cem...

  • Page 265

    Engine mechanical: 1d-63 • before installing the crankshaft assembly, apply engine oil to each crankshaft journal bearing. • install the crankshaft assembly along with the cam chain into the upper crankcase. • insert the right and left-thrust bearings with the oil grooves “a” facing towards the cran...

  • Page 266

    1d-64 engine mechanical: • tighten the other crankcase bolts a little at a time to equalize the pressure. Caution ! Fit new gasket washer to the bolt “a”. Note fit the clamp to the bolt “b”. Tightening torque crankcase bolt (m6) (initial): 6 n·m (0.6 kgf-m, 4.5 lb-ft) crankcase bolt (m6) (final): 11...

  • Page 267

    Engine mechanical: 1d-65 • hold the crankshaft and install the crank balancer assembly. Note align the engraved line “a” on the crank balancer with the triangle mark “b” on the crankcase. • apply engine oil to the balancer shaft and o-ring. Caution ! Replace the o-ring (1) with a new one. • insert t...

  • Page 268

    1d-66 engine mechanical: oil pressure regulator / oil strainer / oil pan • apply suzuki super grease to the o-rings (1) and install them. Caution ! Replace the o-rings (1) with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) • apply suzuki super grease to the o-rings (2) and pre...

  • Page 269

    Engine mechanical: 1d-67 • tighten the oil pan bolts. Caution ! Fit a new gasket washer to the bolt (3). Oil cooler • apply suzuki super grease to the o-ring. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • install the oil cooler to the crank...

  • Page 270

    1d-68 engine mechanical: • connect the oil pressure switch lead wire as shown. Tightening torque oil pressure switch lead wire mounting bolt (a): 1.5 n·m (0.15 kgf-m, 1.1 lb-ft) crankcase breather cover • apply suzuki bond to the mating surface of the breather cover. Note • make surfaces free from m...

  • Page 271

    Engine mechanical: 1d-69 water pump • apply suzuki super grease to the o-ring. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • tighten the water pump mounting bolts to the specified torque. Tightening torque water pump mounting bolt (a): 10 n...

  • Page 272

    1d-70 engine mechanical: • install the gearshift cam stopper plate (5). Note align the gearshift cam pin “b” with the gearshift cam stopper plate hole “c”. • apply a small quantity of thread rock to the gearshift cam stopper plate bolt and tighten it to the specified torque. : thread lock cement 990...

  • Page 273

    Engine mechanical: 1d-71 oil pump • install the o-ring to the oil pump and apply suzuki super grease to it. Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • install the oil pump. Note set the oil pump shaft end “a” to the water pump shaft. • t...

  • Page 274

    1d-72 engine mechanical: • install the spacer (7). Clutch • install the clutch component parts (1). Refer to “clutch installation in section 5c (page 5c-14)”. Starter motor • install the starter motor (1). Refer to “starter motor removal and installation in section 1i (page 1i-4)”. Engine top side •...

  • Page 275

    Engine mechanical: 1d-73 disassembly 1) remove the washers (1), bearings (2) and spacer (3) from the crank balancer. 2) remove the balancer gear (4) along with the dampers (5) from the crank balancer. 3) remove the dampers (5) from the balancer gear (4). Assembly assemble the crank balancer in the r...

  • Page 276

    1d-74 engine mechanical: balancer shaft inspect the balancer shaft for wear or damage. Replace the balancer shaft if there is anything unusual. Conrod removal and installation b718h11406026 removal 1) remove the crankshaft assembly from the crankcase. Refer to “engine bottom side disassembly (page 1...

  • Page 277

    Engine mechanical: 1d-75 4) apply engine oil to the conrod cap bolts. 5) tighten the conrod cap bolt by using a 10 mm, 12 point socket wrench in the following two steps. Tightening torque conrod cap bolt: 21 n ⋅m (2.1 kgf-m, 15.0 ib-ft) then turn in 1/4 (90 °) turn. 6) check that the conrod moves sm...

  • Page 278

    1d-76 engine mechanical: crankshaft runout support the crankshaft using v-blocks as shown, with the two end journals resting on the blocks. Set up the dial gauge as shown, and rotate the crankshaft slowly to read the runout. Replace the crankshaft if the runout exceeds the service limit. Special too...

  • Page 279

    Engine mechanical: 1d-77 4) remove the conrod caps and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. If the oil clearance exceeds the service limit, select the specified bearings from the b...

  • Page 280

    1d-78 engine mechanical: 4) select the specified bearings from the bearing selection table. Caution ! The bearings should be replaced as a set. Bearing selection table bearing thickness specification crankshaft journal bearing inspection and selection b718h11406029 refer to “engine bottom side disas...

  • Page 281

    Engine mechanical: 1d-79 2) install the plastigauge onto each crankshaft journal as shown. Special tool (a): 09900–22301 (plastigauge (0.025 – 0.076 mm)) note do not place the plastigauge on the oil hole. 3) mate the lower crankcase with the upper crankcase. 4) tighten the crankshaft journal bolts (...

  • Page 282

    1d-80 engine mechanical: 2) check the corresponding crankshaft journal o.D. Codes ([a], [b] or [c]) “b”, which are stamped on the crankshaft. 3) measure the crankshaft o.D. With the special tool. If any of the measurements are out of specification, replace the crankshaft. Crankshaft journal o.D. Spe...

  • Page 283

    Engine mechanical: 1d-81 2) measure the thrust clearance “a” between the left- side thrust bearing and crankshaft using the thickness gauge. If the thrust clearance exceeds the standard range, adjust the thrust clearance. Note pull the crankshaft to the left (starter clutch side) so that there is no...

  • Page 284

    1d-82 engine mechanical: 4) select a left-side thrust bearing from the selection table. Note right-side thrust bearing has the same specification as the green (12228-17e00-0d0) of left-side thrust bearing. Left-side thrust bearing selection table 5) after selecting a left-side thrust bearing, instal...

  • Page 285

    Engine mechanical: 1d-83 specifications service data b718h11407001 valve + guide unit: mm (in) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit valve diam. In. 31 (1.22) — ex. 27 (1.06) — valve clearance (when cold) in. 0.10 – 0.20 (0.004 – 0.0...

  • Page 286

    1d-84 engine mechanical: conrod + crankshaft unit: mm (in) tightening torque specifications b718h11407002 piston pin bore 18.002 – 18.008 (0.7087 – 0.7090) 18.030 (0.7098) piston pin o.D. 17.996 – 18.000 (0.7085 – 0.7087) 17.980 (0.7079) item standard limit item standard limit conrod small end i.D. ...

  • Page 287

    Engine mechanical: 1d-85 note the specified tightening torque is also described in the following. “throttle body components (page 1d-7)” “throttle body construction (page 1d-8)” “engine assembly installation (page 1d-21)” reference: for the tightening torque of fastener not specified in this section...

  • Page 288

    1d-86 engine mechanical: note required service material is also described in the following. “throttle body components (page 1d-7)” special tool b718h11408002 thread lock cement thread lock cement super 1303 or equivalent p/no.: 99000–32030 ) (page 1d-22) / ) (page 1d-38) / ) (page 1d-70) thread lock...

  • Page 289

    Engine mechanical: 1d-87 09900–20803 09900–21304 thickness gauge v-block (100 mm) ) (page 1d-44) / ) (page 1d-50) / ) (page 1d-52) / ) (page 1d-53) / ) (page 1d-75) / ) (page 1d-81) / ) (page 1d-81) ) (page 1d-36) / ) (page 1d-44) / ) (page 1d-44) / ) (page 1d-76) 09900–22301 09900–22302 plastigauge...

  • Page 290

    1d-88 engine mechanical: 09916–43211 09916–43230 valve guide remover/ installer attachment ) (page 1d-47) / ) (page 1d-47) ) (page 1d-47) 09916–74521 09916–74550 holder body band (piston diam.: 73 – 85 mm) ) (page 1d-29) ) (page 1d-29) 09916–84511 09930–10121 valve adjuster driver spark plug wrench ...

  • Page 291: Engine Lubrication System

    Engine lubrication system: 1e-1 engine engine lubrication system precautions precautions for engine oil b718h11500001 refer to “fuel and oil recommendation in section 0a (page 0a-4)”..

  • Page 292: Main-Gallery

    1e-2 engine lubrication system: schematic and routing diagram engine lubrication system chart diagram b718h11502002 intake camshaft cam chain tension adjuster #1 piston cooling oil jet #1 piston and cylinder wall #1 crank pin bearing crankshaft journal bearing starter driven gear bearing crankshaft ...

  • Page 293

    Engine lubrication system: 1e-3 diagnostic information and procedures engine lubrication symptom diagnosis b718h11504001 oil pressure check b718h11504002 check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Note before checking the oil pr...

  • Page 294

    1e-4 engine lubrication system: 6) stop the engine and remove the oil pressure gauge and attachment. 7) reinstall the main oil gallery plug and tighten it to the specified torque. Caution ! Use a new gasket to oil leakage. Tightening torque main oil gallery plug (m16) (a): 35 n·m (3.5 kgf- m, 25.5 l...

  • Page 295

    Engine lubrication system: 1e-5 6) remove the hose clamp plate (5) from the oil pan. 7) remove the oil gallery plug (6) from the oil pan. 8) remove the o-rings (7), oil pressure regulator (8) and oil strainer (9). Installation installation is in the reverse order of removal. Pay attention to the fol...

  • Page 296

    1e-6 engine lubrication system: • install the oil pressure regulator (1) and oil strainer (2). Note when installing the oil strainer, fit the concave part “a” of the oil strainer onto the convex part “b” of the crankcase. • apply suzuki bond to the mating surface of the oil pan. Note use of suzuki b...

  • Page 297

    Engine lubrication system: 1e-7 oil strainer clean the oil strainer if necessary. Inspect the oil strainer body for damage. If necessary, replace it with a new one. Oil cooler removal and installation b718h11506017 removal 1) drain engine oil and engine coolant. Refer to “engine oil and filter repla...

  • Page 298

    1e-8 engine lubrication system: 3) disconnect the oil pressure switch lead wire. 4) remove the oil pressure switch (1). Installation 1) install the oil pressure switch, apply the suzuki bond to its thread and tighten it to the specified torque. : sealant 99000–31140 (suzuki bond 1207b or equivalent)...

  • Page 299

    Engine lubrication system: 1e-9 installation installation is in the reverse order of removal. Pay attention to the following points: • apply engine oil to the o-ring. Caution ! Use a new o-ring to prevent oil leakage. Oil jet (for cylinder head) removal 1) remove the cylinder. Refer to “engine top s...

  • Page 300

    1e-10 engine lubrication system: • apply a small quantity of thread lock to the bolts and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque piston cooling oil jet bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) oil gallery ...

  • Page 301

    Engine lubrication system: 1e-11 oil pump removal and installation b718h11506016 note do not drop the each parts into the crankcase. Removal 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-10)”. 2) remove the clutch. Refer to “clutch removal in section 5c (pag...

  • Page 302

    1e-12 engine lubrication system: • install the oil pump. Note set the oil pump shaft end “a” to the water pump shaft. • tighten the oil pump mounting bolts to the specified torque. Tightening torque oil pump mounting bolt (a): 10 n·m (1.0 kgf-m, 7.0 lb-ft) • install the washer (1) and pin (2). Note ...

  • Page 303

    Engine lubrication system: 1e-13 oil pump inspection b718h11506014 inspect the oil pump in the following procedures: 1) remove the oil pump. Refer to “oil pump removal and installation (page 1e-11)”. 2) rotate the oil pump by hand and check that it moves smoothly. If it does not move smoothly, repla...

  • Page 304

    1e-14 engine lubrication system: special tools and equipment recommended service material b718h11508001 special tool b718h11508002 material suzuki recommended product or specification note grease suzuki super grease a or equivalent p/no.: 99000–25010 ) (page 1e-5) / )(page 1e- 7) / )(page 1e-11) sea...

  • Page 305: Engine Cooling System

    Engine cooling system: 1f-1 engine engine cooling system precautions precautions for engine cooling system b718h11600001 warning ! • you can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully r...

  • Page 306

    1f-2 engine cooling system: schematic and routing diagram cooling circuit diagram b718h11602004 water pump radiator ect sensor thermostat conneector cylinder head cylinder reservoir tank thermostat oil cooler i718h1160029-03.

  • Page 307

    Engine cooling system: 1f-3 water hose routing diagram b718h11602005 “q” “s” “u” “w” “v” “r” “t” “f” “c” “d” “d” 1 2 “i” “l” 6 6 5 “c” “e” “h” “g” “p” “g” “c” “e” “b” “ a ” 90 90 90 “a” “c” “d” “n” “m” “j” “k” “c” “c” “c” “e” “d” “d” “f” “l” “o” “f” 7 4 “d” “o” 3 7 / “x” “c” i718h1160074-02 1. Jiggl...

  • Page 308

    1f-4 engine cooling system: diagnostic information and procedures engine cooling symptom diagnosis b718h11604001 repair instructions cooling circuit inspection b718h11606012 warning ! • do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. • when...

  • Page 309

    Engine cooling system: 1f-5 radiator cap inspection b718h11606013 inspect the radiator cap in the following procedures: 1) remove the radiator cap. Refer to “cooling circuit inspection (page 1f-4)”. 2) attach the radiator cap (1) to the radiator tester (2) as shown. 3) slowly apply pressure to the r...

  • Page 310

    1f-6 engine cooling system: 4) disconnect the cooling fan motor coupler (2), water bypass hose (3) and radiator outlet hose (4). 5) remove the radiator assembly (5) by removing the bolts. 6) remove the radiator heat shield (6). 7) remove the spacers (7) and mounting bolt. 8) remove the cooling fan m...

  • Page 311

    Engine cooling system: 1f-7 3) any leakage from the connecting section should be corrected by proper tightening. Refer to “water hose routing diagram (page 1f-3)”. 4) after finishing the water hose inspection, reinstall the removed parts. Water hose removal and installation b718h11606016 removal 1) ...

  • Page 312

    1f-8 engine cooling system: 2) inspect the radiator reservoir tank cooling leaks. If any defects are found, replace the radiator reservoir tank with a new one. 3) reinstall the remored parts. Radiator reservoir tank removal and installation b718h11606017 removal 1) remove the seat tail cover. Refer ...

  • Page 313

    Engine cooling system: 1f-9 2) test the cooling fan motor for load current with an ammeter connected as shown in the figure. If the fan motor does not turn, replace the cooling fan assembly with a new one. Refer to “radiator / cooling fan motor removal and installation (page 1f-5)”. Note • when maki...

  • Page 314

    1f-10 engine cooling system: 5) remove the thermostat connector (1) along with bracket (7). 6) remove the bracket (7) from the thermostat connector (1). 7) remove the connector cap (8). 8) remove the thermostat (9). Installation install the thermostat in the reverse order of removal. Pay attention t...

  • Page 315

    Engine cooling system: 1f-11 • connect the water hoses securely. Refer to “water hose routing diagram (page 1f-3)”. • pour engine coolant and bleed air from the cooling circuit. Refer to “cooling system inspection in section 0b (page 0b-12)”. Thermostat inspection b718h11606025 inspect the thermosta...

  • Page 316

    1f-12 engine cooling system: water pump components b718h11606026 water pump construction b718h11606027 2 5 2 4 3 (a) (b) (c) 1 i718h1160062-01 1. Water pump case 4. Mechanical seal : 6 n ⋅m (0.6 kgf-n, 4.5 ib-ft) : apply engine coolant. 2. O-ring 5. Oil seal : 13 n ⋅m (1.3 kgf-n, 9.5 ib-ft) : do not...

  • Page 317

    Engine cooling system: 1f-13 water pump removal and installation b718h11606028 removal note before draining engine oil and engine coolant, inspect engine oil and coolant leakage between the water pump and crankcase. If engine oil is leaking, visually inspect the oil seal and o-ring. If engine coolan...

  • Page 318

    1f-14 engine cooling system: water pump disassembly and assembly b718h11606029 refer to “water pump removal and installation (page 1f-13)”. Disassembly 1) remove the air vent bolt (1) if necessary. 2) remove the water pump case (2). 3) remove the o-ring (3). 4) remove the impeller securing bolt by h...

  • Page 319

    Engine cooling system: 1f-15 assembly 1) install the oil seal with the special tool. Caution ! Replace the oil seal with a new one. Note the stamped mark on the oil seal should face mechanical seal side. Special tool (a): 09913–70210 (bearing installer set) 2) apply a small quantity of the super gre...

  • Page 320

    1f-16 engine cooling system: 6) install the rubber seal (2) into the impeller. 7) after wiping off the oily or greasy matter from the mechanical seal ring (3), install it into the impeller. Note the paint marked side “b” of mechanical seal ring faces the rubber seal. 8) install the washer (4) and se...

  • Page 321

    Engine cooling system: 1f-17 water pump related parts inspection b718h11606030 refer to “water pump disassembly and assembly (page 1f-14)”. Mechanical seal visually inspect the mechanical seal for damage, with particular attention given to the sealing face. Replace the mechanical seal that shows ind...

  • Page 322

    1f-18 engine cooling system: specifications service data b718h11607001 thermostat + radiator + fan + coolant tightening torque specifications b718h11607002 note the specified tightening torque is also described in the following. “water pump components (page 1f-12)” “water pump construction (page 1f-...

  • Page 323

    Engine cooling system: 1f-19 special tools and equipment recommended service material b718h11608001 note required service material is also described in the following. “water pump components (page 1f-12)” “water pump construction (page 1f-12)” special tool b718h11608002 material suzuki recommended pr...

  • Page 324: Fuel System

    1g-1 fuel system: engine fuel system precautions precautions for fuel system b718h11700001 warning ! • keep away from fire or spark. • during disassembling, use care to minimize spillage of gasoline. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Caution ! • to...

  • Page 325

    Fuel system: 1g-2 general description fuel system description b718h11701002 fuel system the fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injectors) and fuel pressure regulator (6). There is no fuel retu...

  • Page 326

    1g-3 fuel system: schematic and routing diagram fuel tank drain hose and breather hose routing diagram b718h11702002 1 2 1 2 “ a ” 4 inside 8 “ b ” “c” 6 7 3 “b” “d” “a” 5 1 i718h1170040-02 1. Fuel tank drain hose 8. Clamp : clamp end should face inside. Tip of clamp should face downward. 2. Fuel ta...

  • Page 327

    Fuel system: 1g-4 diagnostic information and procedures fuel system diagnosis b718h11704001 condition possible cause correction / reference item engine will not start or is hard to start (no fuel reaching the intake manifold) clogged fuel filter or fuel hose. Clean or replace. Defective fuel pump. R...

  • Page 328

    1g-5 fuel system: repair instructions fuel pressure inspection b718h11706042 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel pressure in the following procedures: 1) lift and support the fuel tank. Refer...

  • Page 329

    Fuel system: 1g-6 fuel discharge amount inspection b718h11706028 warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: 1) lift and support the fuel tank. Refer to ...

  • Page 330

    1g-7 fuel system: fuel pump relay inspection b718h11706029 refer to “electrical components location in section 0a (page 0a-8)”. Inspect the fuel pump relay in the following procedures: 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the fue...

  • Page 331

    Fuel system: 1g-8 fuel tank construction b718h11706001 1 3 “a” 2 i718h1170020-03 1. Fuel tank rear cushion : be careful not to mistake the assembling position and direction. 3. Rear bracket cushion : be careful not to mistake the assembling position and direction. 2. Evap pipe cushion (e-33 only) : ...

  • Page 332

    1g-9 fuel system: fuel tank removal and installation b718h11706002 removal warning ! • keep away from fire or spark. • spilled gasoline should be wiped off immediately. • work in a well-ventilated area. 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”....

  • Page 333

    Fuel system: 1g-10 fuel pump components b718h11706033 1 2 3 5 6 7 7 7 (a) 7 fwd fw d 4 i718h1170002-03 1. Vessel 5. Thermistor : apply grease. 2. Fuel mesh filter 6. Fuel level gauge : do not reuse. 3. Fuel pump 7. O-ring : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 4. Fuel pressure regulator assembly : apply e...

  • Page 334

    1g-11 fuel system: fuel pump assembly / fuel level gauge removal and installation b718h11706034 removal warning ! • spilled gasoline should be wiped off immediately. • keep away from fire or spark. • work in a well-ventilated area. 1) remove the fuel tank. Refer to “fuel tank removal and installatio...

  • Page 335

    Fuel system: 1g-12 • apply grease to the o-ring (2). Caution ! Replace the o-ring with a new one. : grease 99000–25010 (suzuki super grease a or equivalent) • when installing the fuel pump assembly, first tighten all the fuel pump mounting bolts lightly and then to the specified torque as shown. Not...

  • Page 336

    1g-13 fuel system: 5) remove the cup cover (6) and fuel pump (7) from the reservoir cup. 6) remove the fuel pressure regulator assembly (8). 7) remove the joint (9). Caution ! Never remove the fuel pressure regulator (10) from the holder. 8) disconnect the lead wire (bi) (11) and remove the fuel lev...

  • Page 337

    Fuel system: 1g-14 • connect all wiring couplers securely so as not to cause contact failure. Fuel mesh filter inspection and cleaning b718h11706036 inspect the fuel mesh filter in the following procedures: 1) remove the fuel mesh filter. Refer to “fuel pump disassembly and assembly (page 1g-12)”. 2...

  • Page 338

    1g-15 fuel system: specifications service data b718h11707001 injector + fuel pump + fuel pressure regulator fuel tightening torque specifications b718h11707002 note the specified tightening torque is also described in the following. “fuel pump components (page 1g-10)” reference: for the tightening t...

  • Page 339

    Fuel system: 1g-16 special tools and equipment recommended service material b718h11708001 note required service material is also described in the following. “fuel pump components (page 1g-10)” special tool b718h11708002 material suzuki recommended product or specification note grease suzuki super gr...

  • Page 340: Ignition System

    1h-1 ignition system: engine ignition system schematic and routing diagram ignition system diagram b718h11802001 refer to “wire color symbols in section 0a (page 0a-6)”. Ignition system components location b718h11802002 refer to “electrical components location in section 0a (page 0a-8)”. #1 #2 #3 #4...

  • Page 341

    Ignition system: 1h-2 diagnostic information and procedures ignition system symptom diagnosis b718h11804001 condition possible cause correction / reference item spark plug not sparking damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defec...

  • Page 342

    1h-3 ignition system: no spark or poor spark b718h11804002 troubleshooting note check that the transmission is in neutral and the engine stop switch is in the “run” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step action yes ...

  • Page 343

    Ignition system: 1h-4 repair instructions ignition coil / plug cap and spark plug removal and installation b718h11806014 removal warning ! The hot engine can burn you. Wait until the engine is cool enough to touch. 1) turn the ignition switch off. 2) remove the fuel tank. Refer to “fuel tank removal...

  • Page 344

    1h-5 ignition system: • install the ignition coil/plug caps and connect their lead wire couplers. Caution ! Do not hit the ignition coil/plug cap with a plastic hammer when installing it. Spark plug inspection and cleaning b718h11806003 refer to “spark plug inspection and cleaning in section 0b (pag...

  • Page 345

    Ignition system: 1h-6 5) insert the needle pointed probe to the lead wire coupler. Note use the special tool, to prevent the rubber of the water proof coupler from damage. 6) connect the multi-circuit tester with the peak voltage adaptor as follows. Caution ! Before using the multi-circuit tester an...

  • Page 346

    1h-7 ignition system: ignition coil / plug cap resistance 1) remove the ignition coil/plug caps. Refer to “ignition coil / plug cap and spark plug removal and installation (page 1h-4)”. 2) measure the ignition coil/plug cap for resistance in both primary and secondary coils. If the resistance is not...

  • Page 347

    Ignition system: 1h-8 3) measure the ckp sensor peak voltage in the following procedure. A) shift the transmission into neutral, turn the ignition switch on and grasp the clutch lever. B) press the starter button and allow the engine to crank for a few seconds, and then measure the ckp sensor peak v...

  • Page 348

    1h-9 ignition system: 4) inspect the engine stop switch for continuity with a tester. If any abnormality is found, replace the right handlebar switch assembly with a new one. Refer to “handlebar removal and installation in section 6b (page 6b-3)”. Special tool : 09900–25008 (multi-circuit tester set...

  • Page 349

    Ignition system: 1h-10 installation install the ignition switch in the reverse order of removal. Pay attention to the following points: • install the ignition switch and new bolts. • tighten each bolt until its head is broken off. Note the spare ignition switch comes equipped with the special bolts,...

  • Page 350

    1h-11 ignition system: specifications service data b718h11807001 electrical unit: mm (in) tightening torque specifications b718h11807002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-7)”. Special tool...

  • Page 351: Starting System

    Starting system: 1i-1 engine starting system schematic and routing diagram starting system diagram b718h11902001 refer to “wire color symbols in section 0a (page 0a-6)”. Component location starting system components location b718h11903001 refer to “electrical components location in section 0a (page ...

  • Page 352

    1i-2 starting system: starter motor will not run b718h11904002 note make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting starter motor runs but does not crank the engine b718h11904003 the starter motor runs when the transmission is in neutral, but doe...

  • Page 353

    Starting system: 1i-3 repair instructions starter motor components b718h11906001 (a) 8 7 (a) 1 2 3 5 5 6 4 fwd fw d i718h1190038-03 1. O-ring 5. O-ring : 5 n ⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Housing end (inside) 6. Starter motor case : apply grease to sliding surface. 3. O-ring 7: housing end assembly (...

  • Page 354

    1i-4 starting system: starter motor removal and installation b718h11906002 removal 1) turn the ignition switch off and disconnect the battery (–) lead wire. Refer to “battery removal and installation in section 1j (page 1j-12)”. 2) remove the throttle body. Refer to “throttle body removal and instal...

  • Page 355

    Starting system: 1i-5 • tighten the starter motor mounting bolt (1) with the battery (–) lead wire. Refer to “wiring harness routing diagram in section 9a (page 9a-8)”. Starter motor disassembly and assembly b718h11906003 refer to “starter motor removal and installation (page 1i-4)”. Disassembly dis...

  • Page 356

    1i-6 starting system: starter motor inspection b718h11906004 refer to “starter motor disassembly and assembly (page 1i-5)”. Carbon brush inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the housing end assembly (outs...

  • Page 357

    Starting system: 1i-7 starter relay removal and installation b718h11906005 removal 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) disconnect the battery (–) lead wire from the battery. 4) disconnect the starter re...

  • Page 358

    1i-8 starting system: 3) measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one. Special tool (a): 09900–25008 (multi-circuit tester set) starter relay resistance 3 – 6 Ω 4)...

  • Page 359

    Starting system: 1i-9 5) connect the side-stand switch coupler. 6) install the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 6)”. Turn signal / side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and d...

  • Page 360

    1i-10 starting system: gear position switch 1) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 6)”. 2) disconnect the gear position switch coupler. Caution ! When disconnecting and connecting the gear position switch coupler, make sure to turn o...

  • Page 361

    Starting system: 1i-11 3) remove the idle gear shaft (2) and starter idle gear (3). 4) remove the generator rotor assembly (4). Refer to “generator removal and installation in section 1j (page 1j-4)”. 5) remove the key (5) and starter driven gear (6). 6) hold the generator rotor with the special too...

  • Page 362

    1i-12 starting system: • install the guide (2) to the generator rotor. Note the arrow mark “b” must face to the generator rotor side. • apply thread lock to the bolts, and then tighten them to the specified torque with the special tool. : thread lock cement 99000–32030 (thread lock cement super 1303...

  • Page 363

    Starting system: 1i-13 starter button inspection b718h11906012 inspect the starter button in the following procedures: 1) remove the right frame head cover. (gsf1250/a) refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) disconnect the right handlebar switch coupler (1)....

  • Page 364

    1i-14 starting system: special tools and equipment recommended service material b718h11908001 note required service material is also described in the following. “starter motor components (page 1i-3)” special tool b718h11908002 material suzuki recommended product or specification note grease suzuki s...

  • Page 365: Charging System

    Charging system: 1j-1 engine charging system schematic and routing diagram charging system diagram b718h11a02001 component location charging system components location b718h11a03001 refer to “electrical components location in section 0a (page 0a-8)”. Diagnostic information and procedures charging sy...

  • Page 366

    1j-2 charging system: battery runs down quickly b718h11a04002 troubleshooting battery overcharges faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire coupler. Repair. Battery runs down quickly trouble in charging system. Check the generator, regulator/re...

  • Page 367

    Charging system: 1j-3 repair instructions battery current leakage inspection b718h11a06001 inspect the battery current leakage in the following procedures: 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) disconnect...

  • Page 368

    1j-4 charging system: 2) measure the resistance between the three lead wires. If the resistance is out of specified value, replace the stator with a new one. Also, check that the generator core is insulated properly. Note when making this test, be sure that the battery is in fully charged condition....

  • Page 369

    Charging system: 1j-5 5) remove the generator cover (4). 6) remove the gasket (5) and dowel pins. 7) remove the idle gear shaft (6) and starter idle gear (7). 8) hold the generator rotor with the special tool. Special tool (a): 09930–44530 (rotor holder) 9) loosen the generator rotor bolt. Note when...

  • Page 370

    1j-6 charging system: 12) remove the generator stator (10) along with the ckp sensor (11). Installation install the generator in the reverse order of removal. Pay attention to the following points: • tighten the generator starter set bolts and ckp sensor mounting bolts to the specified torque. Note ...

  • Page 371

    Charging system: 1j-7 • apply bond lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown. : sealant 99000–31140 (suzuki bond no.1207b or equivalent) • install the dowel pins and new gasket (3). Caution ! Use a new gasket to prevent oil leakage. • install ...

  • Page 372

    1j-8 charging system: regulator / rectifier construction b718h11a06013 regulator / rectifier inspection b718h11a06012 inspect the regulator/rectifier in the following procedures: 1) turn the ignition switch off. 2) remove the clamp. 3) disconnect the regulator/rectifier couplers (1). 1 2 3 4 5 (a) (...

  • Page 373

    Charging system: 1j-9 4) measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. Refer to “regulator / rectifier construction (page 1j-8)”. Note if ...

  • Page 374

    1j-10 charging system: 1) remove the aluminum tape (1) which seals the battery filler holes “a”. 2) remove the caps (2) from the electrolyte container. Note • do not remove or pierce the sealed areas “b” of the electrolyte container. • after filling the electrolyte completely, use the removed cap (2...

  • Page 375

    Charging system: 1j-11 6) after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. 7) wait for about 20 minutes. 8) insert the caps (2) into the filler holes, pressing in firmly so that the top of the caps do not protrude above the...

  • Page 376

    1j-12 charging system: 3) after recharging, wait at least 30 minutes and then measure the battery voltage using the multi-circuit tester. If the battery voltage is less than 12.5 v, recharge the battery again. If the battery voltage is still less than 12.5 v after recharging, replace the battery wit...

  • Page 377

    Charging system: 1j-13 specifications service data b718h11a07001 battery caution ! Never use anything except the specified battery. Generator tightening torque specifications b718h11a07002 note the specified tightening torque is also described in the following. “regulator / rectifier construction (p...

  • Page 378

    1j-14 charging system: special tools and equipment recommended service material b718h11a08001 special tool b718h11a08002 material suzuki recommended product or specification note sealant suzuki bond no.1207b or equivalent p/no.: 99000–31140 ) (page 1j-7) 09900–25008 09930–34970 multi-circuit tester ...

  • Page 379: Exhaust System

    Exhaust system: 1k-1 engine exhaust system precautions precautions for exhaust system b718h11b00001 warning ! To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. Caution ! Make sure ...

  • Page 380

    1k-2 exhaust system: repair instructions exhaust system construction b718h11b06001 2 3 (b) 7 (c) 8 (a) 6 (a) 4 (a) 5 1 “a” “b” i718h11b0001-03 1. Exhaust pipes 5. Exhaust pipe mounting bolt “a”: chamfer : 25 n ⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Muffler 6. Muffler connecting bolt “b”: apply exhaust gas se...

  • Page 381

    Exhaust system: 1k-3 exhaust pipe / muffler removal and installation b718h11b06002 removal 1) loosen the muffler connecting bolts (1). 2) remove the muffler (3) by removing the mounting bolt (2) and nut. Note support the muffler to prevent it from falling. 3) remove the radiator. Refer to “radiator ...

  • Page 382

    1k-4 exhaust system: 7) remove the ho2 sensor (6) from the exhaust pipe. Caution ! • be careful not to expose it to an excessive shock. • be careful not to twist or damage the sensor lead wire. Installation installation is in the reverse order of removal. Pay attention to the following points: • tig...

  • Page 383

    Exhaust system: 1k-5 • tighten the exhaust pipe bolts and exhaust pipe mounting bolt to the specified torque. Tightening torque exhaust pipe bolt (a): 23 n·m (2.3 kgf-m, 16.5 lb- ft) exhaust pipe mounting bolt (b): 23 n·m (2.3 kgf- m, 16.5 lb-ft) • route the ho2 sensor lead wire. Refer to “throttle ...

  • Page 384

    1k-6 exhaust system: exhaust system inspection b718h11b06003 inspect the exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition. If any defect is found, replace the exhaust pipe assembly or muffler with a new one. Check the exhaust pipe bolts, muffler connectin...

  • Page 385: Section 2

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

  • Page 386: Precautions

    2-1 precautions: suspension precautions precautions precautions for suspension b718h12000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the...

  • Page 387: Suspension General Diagnosis

    Suspension general diagnosis: 2a-1 suspension suspension general diagnosis diagnostic information and procedures suspension and wheel symptom diagnosis b718h12104001 condition possible cause correction / reference item wobbly front wheel distorted wheel rim. Replace. Worn front wheel bearings. Repla...

  • Page 388: Front Suspension

    2b-1 front suspension: suspension front suspension repair instructions front fork components b718h12206001 1 3 5 7 8 (a) 9 11 13 14 15 19 20 22 21 (b) 16 (a) 18 6 12 4 2 17 fwd (b) 10 i718h1220001-04 1. Front fork protector 10. Front axle pinch bolt 19. Spring seat 2. Dust seal 11. Inner tube 20. Sp...

  • Page 389

    Front suspension: 2b-2 front fork removal and installation b718h12206002 note the right and left front forks are installed symmetrically and therefore the removal procedure for one side is the same as that for the other side. Removal 1) remove the front wheel assembly. Refer to “front wheel assembly...

  • Page 390

    2b-3 front suspension: 2) tighten the front fork cap bolt (2) to the specified torque with the special tool. Tightening torque front fork cap bolt (a): 23 n·m (2.3 kgf-m, 16.5 lb-ft) 3) loosen the lower clamp bolts. 4) set the front fork with the upper surface “t” of the inner tube positioned 1.8 mm...

  • Page 391

    Front suspension: 2b-4 front fork adjustment b718h12206006 turn the adjustment (1) to the desired position. Caution ! Adjust the left and right front forks to the same setting. Std position 3rd groove from top front fork disassembly and assembly b718h12206003 refer to “front fork removal and install...

  • Page 392

    2b-5 front suspension: 8) remove the dust seal (8). 9) remove the oil seal stopper ring (9). 10) remove the damper rod bolt (10). 11) remove the inner rod cylinder (11). 12) remove the oil lock piece (12). 13) remove the oil seal by slowly pulling out the inner tube. Note be careful not to damage th...

  • Page 393

    Front suspension: 2b-6 assembly assemble the front fork in the reverse order of disassembly. Pay attention to the following points: caution ! The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork. Inner tube • install the follow...

  • Page 394

    2b-7 front suspension: damper rod bolt • insert the inner rod/damper rod (cartridge) (6) and the oil lock piece (7) into the inner tube. • apply thread lock to the damper rod bolt and tighten it to the specified torque with a 6-mm hexagon wrench and special tools. Caution ! Use a new gasket to preve...

  • Page 395

    Front suspension: 2b-8 • refill specified front fork oil up to the top level of the inner tube again. Move the inner tube up and down several strokes until bubbles do not come out from the oil. • keep the front fork vertically and wait 5 – 6 minutes. Note • always keep oil level over the cartridge t...

  • Page 396

    2b-9 front suspension: • install the front fork cap (1). Note before installing the front fork cap, turn the inner rod lock-nut (2) completely to the lower position as shown. • tighten the lock-nut (2) to the specified torque. Tightening torque inner rod lock-nut (a): 20 n·m (2.0 kgf-m, 14.5 lb- ft)...

  • Page 397

    Front suspension: 2b-10 fork spring measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. Front fork spring free length service limit: 382 mm (15.0 in.) damper rod move the inner rod by hand to inspect it if operating smoothly. Specifications servic...

  • Page 398

    2b-11 front suspension: special tools and equipment recommended service material b718h12208001 note required service material is also described in the following. “front fork components (page 2b-1)” special tool b718h12208002 material suzuki recommended product or specification note oil suzuki fork o...

  • Page 399: Rear Suspension

    Rear suspension: 2c-1 suspension rear suspension repair instructions rear suspension components b718h12306001 1 (a) 2 3 (b) 6 3 (b) 6 (b) 5 4 7 9 10 11 (a) 2 8 (c) 12 i718h1230001-01 1. Rear shock absorber 7. Chain case : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber mounting nut 8. Swingar...

  • Page 400

    2c-2 rear suspension: rear suspension assembly construction b718h12306002 ) left right (a) 1 (a) 2 1 2 3 4 5 6 (b) 4 (b) 5 (b) 3 (c) 6 i718h1230042-01 1. Rear shock absorber mounting nut (upper) 5. Cushion lever mounting nut : 100 n ⋅m (10.0 kgf-m 72.5 lb-ft) 2. Rear shock absorber mounting nut (low...

  • Page 401

    Rear suspension: 2c-3 rear shock absorber removal and installation b718h12306003 removal 1) place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the rear shock absorber. 2) remove the left frame cover. Refer to “exterior parts removal and installation in ...

  • Page 402

    2c-4 rear suspension: rear shock absorber inspection b718h12306005 inspect the rear shock absorber in the following procedures: 1) remove the rear shock absorber. Refer to “rear shock absorber removal and installation (page 2c- 3)”. 2) inspect the rear shock absorber for damage and oil leakage, and ...

  • Page 403

    Rear suspension: 2c-5 1) mark the drill center at the location “a” using a center punch. 2) wrap rear shock absorber (1) with a vinyl bag (2) and fix it on a vise as shown. 3) drill a 2 – 3 mm (0.08 – 0.12 in.) hole at the marked drill center using a drilling machine and let out gas while taking car...

  • Page 404

    2c-6 rear suspension: cushion lever inspection b718h12306009 refer to “cushion lever removal and installation (page 2c-5)”. Spacer 1) remove the spacers from the cushion lever. 2) inspect the spacers for any flaws or other damage. If any defects are found, replace the spacers with new ones. Cushion ...

  • Page 405

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

  • Page 406

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

  • Page 407

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

  • Page 408

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

  • Page 409

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

  • Page 410

    2c-12 rear suspension: specifications service data b718h12307001 unit: mm (in) tightening torque specifications b718h12307002 note the specified tightening torque is also described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2)” referenc...

  • Page 411

    Rear suspension: 2c-13 special tools and equipment recommended service material b718h12308001 note required service material is also described in the following. “rear suspension components (page 2c-1)” “rear suspension assembly construction (page 2c-2)” special tool b718h12308002 material suzuki rec...

  • Page 412: Wheels and Tires

    2d-1 wheels and tires: suspension wheels and tires precautions precautions for wheel and tire b718h12400001 warning ! • proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. • under-inflated tires make smooth co...

  • Page 413

    Wheels and tires: 2d-2 repair instructions front wheel components b718h12406015 gsf1250/s (b) 9 8 (a) 2 3 5 4 10 11 7 6 5 4 12 1 3 (a) 2 fwd fw d i718h1240050-02 1. Front axle 7. Front wheel : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 8. Collar : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Brake d...

  • Page 414

    2d-3 wheels and tires: gsf1250a/sa 5 4 12 13 7 6 5 4 14 1 3 (a) 2 (a) 2 3 (b) 11 8 9 10 fwd fw d i718h1240001-04 1. Front axle 8. Wheel speed sensor rotor : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 9. Sensor rotor bolt : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Brake disc 10. Wheel speed senso...

  • Page 415

    Wheels and tires: 2d-4 front wheel assembly construction b718h12406002 gsf1250/s left right (b) 2 (a) 1 (b) 2 (a) 1 “ a ” 4 (a) 4 (a) 3 (c) i718h1240044-02 1. Brake disc bolt “a”: clearance : apply grease. 2. Brake caliper mounting bolt : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) : apply thread lock to thread...

  • Page 416

    2d-5 wheels and tires: gsf1250a/sa right left (b) 2 (c) 3 (a) 1 (a) 4 “ a ” “ b ” (a) 4 5 (b) 2 (a) 1 i718h1240002-02 1. Brake disc bolt 5. Front wheel speed sensor : 26 n ⋅m (2.6 kgf-m, 19.0 lb-ft) 2. Brake caliper mounting bolt “a”: clearance : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Front axle bolt ...

  • Page 417

    Wheels and tires: 2d-6 front wheel assembly removal and installation b718h12406003 removal 1) raise the front wheel off the ground and support the motorcycle with a jack or a wooden block. Caution ! Do not carry out the work with the motorcycle resting on the side-stand. Do not support the motorcycl...

  • Page 418

    2d-7 wheels and tires: installation 1) install the collar (1) (gsf1250/s) or front wheel speed sensor bracket (2) (gsf1250a/sa) into the right side of the wheel. Gsf1250/s gsf1250a/sa 2) align the recess “a” on the speed sensor bracket with the stopper “b” on the right front fork. (gsf1250a/sa) 3) i...

  • Page 419

    Wheels and tires: 2d-8 6) tighten two axle pinch bolts on the right fork leg to the specified torque. Tightening torque front axle pinch bolt (b): 23 n·m (2.3 kgf-m, 16.5 lb-ft) 7) move the front fork up and down 4 or 5 times. 8) tighten two axle pinch bolts on the left front fork leg to the specifi...

  • Page 420

    2d-9 wheels and tires: wheel 1) remove the brake pads. Refer to “front brake pad replacement in section 4b (page 4b-2)”. 2) make sure that the wheel runout checked as shown does not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by ...

  • Page 421

    Wheels and tires: 2d-10 installation caution ! The removed dust seals and bearings must be replaced with new ones. 1) apply grease to the wheel bearings. : grease 99000–25010 (suzuki super grease a or equivalent) 2) first install the right wheel bearing, then install the spacer (1) and left wheel be...

  • Page 422

    2d-11 wheels and tires: 3) install the dust seals with the special tool. Special tool (b): 09913–70210 (bearing installer set) 4) apply grease to the lip of dust seals. : grease 99000–25010 (suzuki super grease a or equivalent) 5) install the front wheel speed sensor rotor as the letters “50t” face ...

  • Page 423

    Wheels and tires: 2d-12 rear wheel components b718h12406006 gsf1250/s 14 (c) 13 17 18 15 8 9 16 7 6 5 (b) 2 (a) 1 4 3 12 11 10 i718h1240024-03 1. Spacer 10. Bearing : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear sprocket 11. Dust seal : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Dust seal 12. Collar : 23 n ⋅m ...

  • Page 424

    2d-13 wheels and tires: gsf1250a/sa 16 19 20 17 8 9 18 7 6 5 (b) 2 (a) 1 4 3 11 10 12 14 15 13 (c) i718h1240025-03 1. Spacer 10. Bearing 19. Tire 2. Rear sprocket 11. Dust seal 20. Wheel balancer 3. Dust seal 12. Collar : 100 n ⋅m (10.0 kgf-m, 72.5 lb-ft) 4. Bearing 13. Wheel speed sensor rotor : 60...

  • Page 425

    Wheels and tires: 2d-14 rear wheel assembly construction b718h12406018 gsf1250/s “ a ” (d) 4 (a) 1 (b) 2 left right (c) 3 i718h1240027-03 1. Rear sprocket nut “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut : 60 n ⋅m (6.0 kgf-m, 43.5 lb-ft) : apply grease. 3. Brake caliper mounting...

  • Page 426

    2d-15 wheels and tires: gsf1250a/sa right left (d) 4 (c) 3 (b) 2 “ a ” (a) 1 5 “ b ” i718h1240026-07 1. Rear sprocket nut “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut “b”: 0.3 – 1.5 mm (0.012 – 0.059 in) : apply grease. 3. Brake caliper mounting bolt : 60 n ⋅m (6.0 kgf-m, 43.5 l...

  • Page 427

    Wheels and tires: 2d-16 rear wheel assembly removal and installation b718h12406008 removal 1) support the motorcycle with the center stand. Caution ! Make sure that the motorcycle is supported securely. 2) remove the rear wheel speed sensor by removing the mounting bolts. (gsf1250a/sa) refer to “rea...

  • Page 428

    2d-17 wheels and tires: 5) install the rear wheel speed sensor mounting bolts. (gsf1250a/sa) refer to “rear wheel speed sensor removal and installation in section 4e (page 4e-71)”. 6) check the clearance between the rear wheel speed sensor and sensor rotor. (gsf1250a/sa) refer to “rear wheel speed s...

  • Page 429

    Wheels and tires: 2d-18 bearing inspect the play of the wheel bearings by hand while they are in the wheel. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer to “rear wheel dust seal / bearing removal and installa...

  • Page 430

    2d-19 wheels and tires: 2) first install the right wheel bearing, then install the spacer (1) and left wheel bearing with the special tools. Special tool (a): 09941–34513 (steering race installer) (b): 09924–84510 (bearing installer set) caution ! The sealed cover of the bearing must face outside. 3...

  • Page 431

    Wheels and tires: 2d-20 tire removal and installation b718h12406011 removal the most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation e...

  • Page 432

    2d-21 wheels and tires: 3) bounce the tire several times while rotating. This makes the tire bead expand outward to contact the wheel, thereby facilitating air inflation. 4) install the valve core and inflate the tire. Warning ! • do not inflate the tire to more than 400 kpa (4.0 kgf/cm 2 , 57 psi)....

  • Page 433

    Wheels and tires: 2d-22 air valve inspect the air valve for peeling and damage. If any defect is found, replace the air valve with a new one. Refer to “air valve removal and installation (page 2d- 22)”. Inspect the valve core seal (1) for wear and damage. If any defect is found, replace the valve co...

  • Page 434

    2d-23 wheels and tires: wheel balance check and adjustment b718h12406014 check and adjust the wheel balance in the following procedures: 1) removal the wheel assembly. Refer to “front wheel assembly removal and installation (page 2d-6)” and “rear wheel assembly removal and installation (page 2d-16)”...

  • Page 435

    Wheels and tires: 2d-24 tightening torque specifications b718h12407002 note the specified tightening torque is also described in the following. “front wheel components (page 2d-2)” “front wheel assembly construction (page 2d-4)” “rear wheel components (page 2d-12)” “rear wheel assembly construction ...

  • Page 436

    2d-25 wheels and tires: 09913–50121 09913–70210 oil seal remover bearing installer set ) (page 2d-9) / )(page 2d- 18) ) (page 2d-11) / ) (page 2d-19) 09921–20240 09924–84510 bearing remover set bearing installer set ) (page 2d-9) / )(page 2d- 18) ) (page 2d-10) / ) (page 2d-19) 09941–34513 steering ...

  • Page 437: Section 3

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

  • Page 438: Precautions

    3-1 precautions: driveline / axle precautions precautions precautions for driveline / axle b718h13000001 refer to “general precautions in section 00 (page 00-1)”. Warning ! Never inspect or adjust the drive chain while the engine is running. Caution ! • do not use trichloroethylene, gasoline or such...

  • Page 439

    Drive chain / drive train / drive shaft: 3a-1 driveline / axle drive chain / drive train / drive shaft diagnostic information and procedures drive chain and sprocket symptom diagnosis b718h13104001 repair instructions drive chain related components b718h13106001 condition possible cause correction /...

  • Page 440

    3a-2 drive chain / drive train / drive shaft: engine sprocket removal and installation b718h13106002 removal 1) support the motorcycle with the center stand. 2) remove the engine sprocket outer cover (1). 3) remove the regulator/rectifier bracket mounting bolts. 4) disengage the gearshift link arm (...

  • Page 441

    Drive chain / drive train / drive shaft: 3a-3 10) loosen the rear axle nut (8). 11) loosen the chain adjusters (9) to provide additional chain slack. 12) remove the engine sprocket (10). Installation install the engine sprocket in the reverse order of removal. Pay attention to the following points: ...

  • Page 442

    3a-4 drive chain / drive train / drive shaft: • fit the gearshift link arm to the gearshift shaft so that the gearshift lever is located at height “a” above the footrest. Gearshift lever height “a” standard: 45 – 55 mm (1.8 – 2.2 in) • adjust the drive chain slack. Refer to “drive chain inspection a...

  • Page 443

    Drive chain / drive train / drive shaft: 3a-5 • tighten the rear sprocket nuts to the specified torque. Tightening torque rear sprocket nut (a): 60 n·m (6.0 kgf-m, 43.5 lb- ft) • install the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-16)”. Driv...

  • Page 444

    3a-6 drive chain / drive train / drive shaft: sprocket mounting drum dust seal / bearing removal and installation b718h13106005 removal 1) remove the rear sprocket mounting drum assembly from the rear wheel hub. Refer to “rear sprocket / rear sprocket mounting drum removal and installation (page 3a-...

  • Page 445

    Drive chain / drive train / drive shaft: 3a-7 4) install the rear sprocket mounting drum. 5) install the rear sprocket mounting drum assembly to rear wheel hub. Refer to “rear sprocket / rear sprocket mounting drum removal and installation (page 3a-4)”. 6) install the rear wheel assembly. Refer to “...

  • Page 446

    3a-8 drive chain / drive train / drive shaft: 6) remove the joint pin (9) of the other side of joint plate. Caution ! Never reuse joint pins, o-rings and plates. Drive chain connecting warning ! Do not use joint clip type of drive chain. The joint clip may have a chance to drop which may cause sever...

  • Page 447

    Drive chain / drive train / drive shaft: 3a-9 5) set the drive chain on the tool as illustrated and turn in the adjuster bolt (5) to secure the wedge holder and wedge pin (4). 6) turn in the pressure bolt [a] (6) and align two joint pins (11) properly with the respective holes of the joint plate (10...

  • Page 448

    3a-10 drive chain / drive train / drive shaft: 3) adjust the drive chain slack, after connecting it. Refer to “drive chain inspection and adjustment in section 0b (page 0b-15)”. Specifications service data b718h13107001 drive chain unit: mm (in) tightening torque specifications b718h13107002 note th...

  • Page 449

    Drive chain / drive train / drive shaft: 3a-11 special tools and equipment recommended service material b718h13108001 note required service material is also described in the following. “drive chain related components (page 3a-1)” special tool b718h13108002 material suzuki recommended product or spec...

  • Page 450

    3a-12 drive chain / drive train / drive shaft:.

  • Page 451: Section 4

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

  • Page 452

    4-ii table of contents abs control unit description ..............................4e-2 hydraulic unit (hu) description ..........................4e-4 self-diagnosis function and abs indicator light description ...............................................4e-5 fail-safe function description...........

  • Page 453: Precautions

    Precautions: 4-1 brake precautions precautions precautions for brake system b718h14000001 refer to “general precautions in section 00 (page 00-1)”. Brake fluid information b718h14000002 warning ! • this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix differe...

  • Page 454

    4a-1 brake control system and diagnosis: brake brake control system and diagnosis schematic and routing diagram front brake hose routing diagram b718h14102001 gsf1250 28 1 1 5 (a) 3 (a) 3 4 2 6 5 42 2 14 42 (a) (b) (c) 2 4 (a) 3 (b) 3 i718h1410001-04 1. Front brake hose no.1 6: clamp : insert the cl...

  • Page 455

    Brake control system and diagnosis: 4a-2 gsf1250s 49 7 3 (a) 3 (a) 1 5 4 1 5 2 4 3 14 42 42 (b) (a) (c) (c) (b) 2 3 (a) 2 6 i718h1410002-05 1. Front brake hose no.1 6: clamp : insert the clamp to the hole of the front fender fully. 2. Front brake hose no.2 7: front brake hose no.1 : pass the front b...

  • Page 456

    4a-3 brake control system and diagnosis: gsf1250a 1 2 “a” “b” 4 3 3 (c) (a) 5 “c” 28 42 42 14 14 49 14 14 21 42 49 14 (b) (a) 5 7 (b) (a) 5 6 1 2 5 5 (a) i718h1410003-07 1. Brake hose no.1 (abs) “a”: clamp white paint part of brake hose. 2. Brake hose no.2 (abs) “b”: white paint 3. Rubber cushion “c...

  • Page 457

    Brake control system and diagnosis: 4a-4 gsf1250sa 1 2 “a” 3 3 4 “b” (c) 10 5 6 7 8 (a) 49 42 “c” 42 (b) (a) 8 1 2 42 14 (a) 8 9 (b) 21 21 14 42 49 14 49 5 (a) 5 i718h1410004-05 1. Brake hose no.1 (abs) 9. Clamp :after positioning the clamp with the stopper, tighten the clamp bolt. 2. Brake hose no....

  • Page 458

    4a-5 brake control system and diagnosis: rear brake hose routing diagram b718h14102002 gsf1250/s (b) (a) (c) (d) 28 3 4 “b” 1 42 3 2 (a) 2 “a” i718h1410062-03 1. Brake hose clamp : brake hose clamp ends should face forward. “b”: white paint 2. Brake hose clamp : brake hose clamp ends should face bac...

  • Page 459

    Brake control system and diagnosis: 4a-6 gsf1250a/sa (c) (b) (a) 3 (d) 28 2 14 (a) 3 5 “b” 1 “a” 4 i718h1410005-03 1. Brake hose clamp : brake hose clamp ends should face forward. “b” : white paint 2. Brake hose clamp : brake hose clamp ends should face backward. : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 3:...

  • Page 460

    4a-7 brake control system and diagnosis: diagnostic information and procedures brake symptom diagnosis b718h14104001 repair instructions brake pedal height inspection and adjustment b718h14106001 refer to “brake system inspection in section 0b (page 0b-17)”. Front brake light switch inspection b718h...

  • Page 461

    Brake control system and diagnosis: 4a-8 2) inspect the switch for continuity with a tester. If any abnormality is found, replace the front brake light switch with a new one. Refer to “front brake master cylinder / brake lever disassembly and assembly (page 4a-15)”. Special tool : 09900–25008 (multi...

  • Page 462

    4a-9 brake control system and diagnosis: front brake 1) fill the master cylinder reservoir to the top of the inspection window. Place the reservoir cap to prevent dirt from entering. 2) attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle. 3) squeeze and rele...

  • Page 463

    Brake control system and diagnosis: 4a-10 rear brake bleed air from the rear brake system as the same manner of front brake. Note the only difference of bleeding operation from the front brake is that the rear master cylinder is actuated by a pedal. Tightening torque air bleeder valve (rear brake): ...

  • Page 464

    4a-11 brake control system and diagnosis: 7) close the air bleeder valve and disconnect the clear hose. Tightening torque air bleeder valve (front brake) (a): 7.5 n·m (0.75 kgf-m, 5.5 lb-ft) 8) fill the reservoir with brake fluid to the upper mark of the reservoir. 9) install the reservoir cap. Rear...

  • Page 465

    Brake control system and diagnosis: 4a-12 8) close the air bleeder valve and disconnect the clear hose. Tightening torque air bleeder valve (rear brake) (a): 6.0 n·m (0.6 kgf-m, 4.5 lb-ft) 9) fill the reservoir with brake fluid to the upper mark of the reservoir. Front brake hose removal and install...

  • Page 466

    4a-13 brake control system and diagnosis: rear brake hose removal and installation b718h14106019 gsf1250/s removal 1) remove the right frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) drain brake fluid. Refer to “brake fluid replacement (page 4a-10)”. 3) ...

  • Page 467

    Brake control system and diagnosis: 4a-14 front brake master cylinder components b718h14106011 front brake master cylinder assembly removal and installation b718h14106012 removal 1) drain brake fluid. Refer to “brake fluid replacement (page 4a-10)”. 2) disconnect the front brake light switch lead co...

  • Page 468

    4a-15 brake control system and diagnosis: installation install the front brake master cylinder in the reverse order of removal. Pay attention to the following points: • when installing the master cylinder (1) onto the handlebars (2), align the master cylinder holder’s mating surface “a” with the pun...

  • Page 469

    Brake control system and diagnosis: 4a-16 2) remove the reservoir cap (3), plate (4) and diaphragm (5). 3) pull out the dust boot (6) and remove the snap ring (7). Special tool : 09900–06108 (snap ring pliers) 4) remove the following parts from the master cylinder. • piston (8) • secondary cup (9) •...

  • Page 470

    4a-17 brake control system and diagnosis: • apply grease to the brake lever pivot bolt. • apply grease to the contact point between piston and brake lever. : grease 99000–25100 (suzuki silicone grease or equivalent) • tighten the pivot bolt and lock-nut to the specified torque. Tightening torque bra...

  • Page 471

    Brake control system and diagnosis: 4a-18 rear brake master cylinder components b718h14106015 rear brake master cylinder assembly removal and installation b718h14106016 removal 1) remove the right frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) drain bra...

  • Page 472

    4a-19 brake control system and diagnosis: 4) place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. 5) remove the brake hose union bolt (2) and disconnect the brake hose. 6) loosen the lock-nut (3). 7) remove the master cylinder mounting bolts (4)...

  • Page 473

    Brake control system and diagnosis: 4a-20 assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the brake fluid off after washing the comp...

  • Page 474

    4a-21 brake control system and diagnosis: specifications service data b718h14107001 brake unit: mm (in) oil tightening torque specifications b718h14107002 note the specified tightening torque is also described in the following. “front brake hose routing diagram (page 4a-1)” “rear brake hose routing ...

  • Page 475

    Brake control system and diagnosis: 4a-22 special tools and equipment recommended service material b718h14108001 note required service material is also described in the following. “front brake master cylinder components (page 4a-14)” “rear brake master cylinder components (page 4a-18)” special tool ...

  • Page 476: Front Brakes

    4b-1 front brakes: brake front brakes repair instructions front brake components b718h14206001 1, 2, 3, 3, 2, (a) (b) (c) (d) 5 6 (e) 4 i649g1420001-05 1. O-ring 6. Front brake disc : 23 n ⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal : 7.5 n ⋅m (0.75 kgf-m, 5.5 lb-ft) : apply thread lock to thread part...

  • Page 477

    Front brakes: 4b-2 front brake pad inspection b718h14206002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “front brake pad replacement (page 4b-2)”. Caution ! Re...

  • Page 478

    4b-3 front brakes: 5) tighten the pad mounting pin to the specified torque. Tightening torque front brake pad mounting pin (a): 16 n·m (1.6 kgf-m, 11.5 lb-ft) note after replacing the brake pads, pump the brake lever several times to check for proper brake operation and then check the brake fluid le...

  • Page 479

    Front brakes: 4b-4 • check the brake fluid leakage and brake operation. Warning ! Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. Front brake caliper disassembly and assembly b718h14206005 re...

  • Page 480

    4b-5 front brakes: assembly assemble the caliper in the reverse order of disassembly. Pay attention to the following points: • wash the caliper bores and pistons with specified brake fluid. Particularly wash the dust seal grooves and piston seal grooves. Bf: brake fluid (dot 4) caution ! • wash the ...

  • Page 481

    Front brakes: 4b-6 • temporarily tighten the brake caliper housing bolts. Caution ! After installing the brake caliper to the front fork, tighten the brake caliper housing bolts to the specified torque. Refer to “front brake caliper removal and installation (page 4b- 3)”. Special tool (a): 09930–119...

  • Page 482

    4b-7 front brakes: front brake disc removal and installation b718h14206007 removal 1) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-6)”. 2) remove the front brake disc. Installation install the front brake disc in the reverse order of...

  • Page 483

    Front brakes: 4b-8 specifications service data b718h14207001 brake unit: mm (in) oil tightening torque specifications b718h14207002 note the specified tightening torque is also described in the following. “front brake components (page 4b-1)” reference: for the tightening torque of fastener not speci...

  • Page 484

    4b-9 front brakes: special tools and equipment recommended service material b718h14208001 note required service material is also described in the following. “front brake components (page 4b-1)” special tool b718h14208002 material suzuki recommended product or specification note brake fluid dot 4 — )...

  • Page 485: Rear Brakes

    Rear brakes: 4c-1 brake rear brakes repair instructions rear brake components b718h14306001 1 2 4, 3, (a) (b) (c) (d) (e) (f) 6 5 i649g1430001-05 1. Rear caliper bracket : 6.0 n ⋅m (0.6 kgf-m, 4.5 lb-ft) : apply silicone grease to sliding surface. 2. Piston : 27 n ⋅m (2.7 kgf-m, 19.5 lb-ft) : apply ...

  • Page 486

    4c-2 rear brakes: rear brake pad inspection b718h14306002 the extent of brake pads wear can be checked by observing the grooved limit line “a” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “rear brake pad replacement (page 4c-2)”. Caution ! Repla...

  • Page 487

    Rear brakes: 4c-3 5) clean up the caliper, especially around the caliper piston. 6) assemble the new brake pad (4), insulator (5) and shim (6). Caution ! Replace the brake pads as a set, otherwise braking performance will be adversely affected. 7) install the new brake pads. Note make sure that the ...

  • Page 488

    4c-4 rear brakes: rear brake caliper removal and installation b718h14306004 removal 1) drain brake fluid. Refer to “brake fluid replacement in section 4a (page 4a-10)”. 2) remove the brake hose from the caliper by removing the union bolt (1) and catch the brake fluid in a suitable receptacle. Note •...

  • Page 489

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

  • Page 490

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

  • Page 491

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

  • Page 492

    4c-8 rear brakes: brake disc runout 1) dismount the rear brake caliper. Refer to “rear brake caliper removal and installation (page 4c- 4)”. 2) measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (a): 09900–20607 (dial gauge (1/100 mm, 10 m...

  • Page 493

    Rear brakes: 4c-9 special tools and equipment recommended service material b718h14308001 note required service material is also described in the following. “rear brake components (page 4c-1)” special tool b718h14308002 material suzuki recommended product or specification note brake fluid dot 4 — ) (...

  • Page 494: Abs

    4e-1 abs: brake abs precautions precautions for abs b718h14500001 refer to “precautions for electrical circuit service in section 00 (page 00-2)”. Abs information b718h14500002 warning ! • be sure to bleed air from the brake fluid circuit when the brake is felt spongy or when a brake relating part i...

  • Page 495

    Abs: 4e-2 abs control unit description b718h14501002 abs control unit (1) calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to hydraulic unit (hu) (2). This abs control unit/hu can ...

  • Page 496

    4e-3 abs: abs control unit calculating process the abs controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the abs control unit calculating process. Abs control is performed in one cycle every 10/1 000 seconds. In addition, if a malfunction is ...

  • Page 497

    Abs: 4e-4 hydraulic unit (hu) description b718h14501003 the hydraulic unit operates the solenoid valves based upon the signal which is output from the abs control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by...

  • Page 498

    4e-5 abs: self-diagnosis function and abs indicator light description b718h14501006 the abs control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of...

  • Page 499

    Abs: 4e-6 stored dtcs (diagnostic trouble codes) as for the diagnostic trouble code, the code of the first malfunction occurred during one ignition on period will be stored. Pay attention to the fact that even though there may occur several malfunctions in one on-period, only one code will be stored...

  • Page 500

    4e-7 abs: schematic and routing diagram abs wiring diagram b718h14502001 refer to “wire color symbols in section 0a (page 0a-6)”. B/r b/r o/y b/o b/g b/w r r r b/w b/r w/r b/y w/y b/w o b w b w b/y w/r w/b r/bl r/b gr br b/r o o/y w/y b/w b/w br b/g b b/r b/o b/r b/o o/g w/b b/g b r r/b gr b/w b b/w...

  • Page 501

    Abs: 4e-8 abs unit diagram b718h14502002 refer to “wire color symbols in section 0a (page 0a-6)”. Batter y ignition ignition abs br ak e light s witch br ak e light s witch abs indicator light solenoid batter y (+) f ail saf e rela y motor rela y ground fr o n t wheel speed sensor rear wheel speed s...

  • Page 502

    4e-9 abs: front wheel speed sensor routing diagram b718h14502003 gsf1250a 1 2 3 5 7 6 “a” “b” “e” “i” “g” 4 “c” “d” “f” “h” 8 i718h1450022-03 1. Clamp 7: clamp : clamp the sensor lead wire at the white marking. “e”: clamp the sensor lead wire sleeve with the brake hose. 2. Guide 8. Front wheel speed...

  • Page 503

    Abs: 4e-10 gsf1250sa 1 2 3 5 7 6 “a” “b” “e” “i” “g” 4 “c” “d” “f” “h” 8 i718h1450023-03 1. Clamp 7: clamp : clamp the sensor lead wire at the white marking. “e”: clamp the sensor lead wire sleeve with the brake hose. 2. Guide 8. Front wheel speed sensor “f”: pass through the sensor lead wire outsid...

  • Page 504

    4e-11 abs: rear wheel speed sensor routing diagram b718h14502004 1 2 2 2 2 3 “a” “d” “e” “f” “g” 4 “ a ” “c” “b” i718h1450118-03 1. Rear wheel speed sensor “a”: outside mark “e”: pass through the sensor lead wire on the brake hose. 2. Brake hose no.2 “b”: after the clamp has contacted to the stopper...

  • Page 505

    Abs: 4e-12 component location abs components location b718h14503001 2 1 3 5 4 6 7 i718h1450119-02 1. Abs control unit/hu 4. Front wheel speed sensor 7. Rear wheel speed sensor rotor 2. Mode select coupler 5. Front wheel speed sensor rotor 3. Sds coupler 6. Rear wheel speed sensor.

  • Page 506

    4e-13 abs: diagnostic information and procedures abs troubleshooting b718h14504001 many of the abs malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the abs. Bef...

  • Page 507

    Abs: 4e-14 example: customer problem inspection form note this form is a standard sample. The form should be modified according to conditions and characteristic of each market. User name: model: vin: date of issue: date reg. Date of problem: mileage: problem symptoms abs operation past malfunctions ...

  • Page 508

    4e-15 abs: pre-diagnosis inspection b718h14504019 the mechanical and hydraulic components of the brake system should be inspected prior to performing any electrical checks. These inspections may find problems that the abs could not detect; thus, shortening repair time. Brake brake fluid level check ...

  • Page 509

    Abs: 4e-16 abs component wheel speed sensor – sensor rotor clearance inspection inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. Special tool (a): 09900–20803 (thickness gauge) (b): 09900–20806 (thickness gauge) wheel speed sensor – sens...

  • Page 510

    4e-17 abs: 7) check for continuity between “24” (b/w) at the coupler and the battery (–) terminal, also “25” (b/w) at the coupler and the battery (–) terminal. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness end) abs in...

  • Page 511

    Abs: 4e-18 3 (the abs indicator light does not light up) 1) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the fuse box (1) by removing the mounting bolt. 3) open the fuse box and inspect the ignition fuse (2). Caution ! If a fuse...

  • Page 512

    4e-19 abs: 4 1) turn the ignition switch off. 2) disconnect the abs control unit coupler. Refer to “abs control unit coupler disconnect and connect (page 4e- 70)”. 3) turn the ignition switch on with the abs control unit coupler disconnected, measure the voltage between “16” (o/y) and “24” (b/w) at ...

  • Page 513

    Abs: 4e-20 6 1) turn the ignition switch off. 2) check for continuity between “24” (b/w) at the coupler and body ground, also “25” (b/w) at the coupler and body ground. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness en...

  • Page 514

    4e-21 abs: 8 1) turn the ignition switch off. 2) disconnect the abs control unit coupler. Refer to “abs control unit coupler disconnect and connect (page 4e- 70)” 3) turn the ignition switch on with the abs control unit coupler disconnected, measure the voltage between “16” (o/y) and “24” (b/w) at t...

  • Page 515

    Abs: 4e-22 10 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) short the mode select coupler terminals (o – b/w) using the special tool. Special tool (a): 09930–82710 (mode select switch) 4) check for co...

  • Page 516

    4e-23 abs: dtc (diagnostic trouble code) output b718h14504021 note • even through the abs is operating correctly, a dtc is memorized in any of the following conditions. – if the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated. – previous malfunctions we...

  • Page 517

    Abs: 4e-24 understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the abs indicator light. A number between 1 and 9 is represented by the number of times that the abs indicator light lights up in interval of 0.4 seconds and the separation between the...

  • Page 518

    4e-25 abs: 1) remove the right frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) set up the sds tool. (refer to the sds operation manual for further details.) special tool (a): 09904–41010 (sds set) (b): 99565–01010–010 (cd-rom ver.10) 3) read the dtc (dia...

  • Page 519

    Abs: 4e-26 3) while the dtcs are being output, set the special tool to off. Caution ! The dtc deletion mode starts 12.5 seconds after the switch is set to off. 4) in the dtc deletion mode, switch the abs test switch from off to on three times, each time leaving it at on for more than 1 second. Dtc d...

  • Page 520

    4e-27 abs: use of sds 1) remove the right frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) after repairing the trouble, turn off the ignition switch and turn on again. 3) set up the sds tool. (refer to the sds operation manual for further details.) specia...

  • Page 521

    Abs: 4e-28 8) follow the displayed instructions. 9) check that both “current dtc” (4) and “past dtc” (5) are deleted (nil). 10) close the sds tool and turn the ignition switch off. 11) disconnect the sds tool and install the left frame cover. 12) ride the motorcycle at more than 30 km/h (18.6 mile/h...

  • Page 522

    4e-29 abs: sds check b718h14504023 using sds, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealer. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compare...

  • Page 523

    Abs: 4e-30 active control inspection b718h14504024 1) remove the right frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) set up the sds tool. (refer to the sds operation manual for further details.) 3) click “abs” (1). 4) click “active control” (2). 5) cli...

  • Page 524

    4e-31 abs: 6) click “next” according to the screen indication. Note skip this screen as this vehicle is not equipped with parking brake. Return next cancel help return next cancel help i718h1450060-02 return next cancel help i718h1450121-01.

  • Page 525

    Abs: 4e-32 note • if the front wheel is selected, place the motorcycle on the center stand and lift the front wheel off the ground using a jack. • two operators are needed in this work; one should apply a rotational force to the front wheel. Note • in normal cases, the front brake lever feels a reac...

  • Page 526

    4e-33 abs: note • inspect the rear brake in the same manner of front brake. • if the abs does not function, the cause may lie in the abs control unit/hu. • in checking the rear brake at the time of pressure reduction drive (4/7), “brake lever” appears on the screen. This is because the present scree...

  • Page 527

    Abs: 4e-34 dtc table b718h14504002 * 1 : it goes off after running at more than 10 km/h (6.2 mile/h). * 2 : the wheel speed sensor lead wire is connected to the abs control unit, but a short-circuit or faulty continuity inside the abs control unit caused this dtc to appear, therefore, the abs contro...

  • Page 528

    4e-35 abs: caution ! When disconnecting couplers and turning the ignition switch on, disconnect the abs control unit coupler in order to prevent a dtc from being stored. Each time a resistance is measured, the ignition switch should be set to off. Dtc “13” (c1613): wheel speed sensor rotor malfuncti...

  • Page 529

    Abs: 4e-36 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to step 4. Tighten the mounting bolts or replace the bracket if necessary. 4 1) inspect the front tire and wheel. Tire type and size dunlop d218ft 120/70zr17m/c (58w) cold inflation tire p...

  • Page 530

    4e-37 abs: dtc “14” (c1614): wheel speed sensor rotor malfunction (r) b718h14504004 troubleshooting possible cause • rear wheel speed sensor rotor distortion • faulty rear wheel speed sensor or wiring discontinuity, etc. Step action yes no 1 1) inspect the clearance between the rear wheel speed sens...

  • Page 531

    Abs: 4e-38 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to step 4. Tighten the mounting bolts or replace the bracket if necessary. 4 1) inspect the rear tire and wheel. Tire type and size dunlop d218n 180/55zr17m/c (73w) cold inflation tire pres...

  • Page 532

    4e-39 abs: dtc “22” (c1622): abs actuator circuit malfunction (f) b718h14504005 troubleshooting possible cause • wire harness discontinuity • front wheel locking, etc. Step action yes no 1 1) raise the front wheel off the ground and support the motorcycle with a jack or wooden block. 2) inspect the ...

  • Page 533

    Abs: 4e-40 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Replace the abs control unit/hu. Tighten the mounting bolts or replace the bracket if necessary. Step action yes no i718h1450066-01.

  • Page 534

    4e-41 abs: dtc “23” (c1623): abs actuator circuit malfunction (r) b718h14504006 troubleshooting possible cause • wire harness discontinuity • rear wheel locking, etc. Step action yes no 1 1) support the motorcycle with its center stand. 2) inspect the dragging of the rear brake. Is there any draggin...

  • Page 535

    Abs: 4e-42 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Replace the abs control unit/hu. Tighten the mounting bolts or replace the bracket if necessary. Step action yes no i718h1450068-01.

  • Page 536

    4e-43 abs: dtc “25” (c1625): wheel speed sensor related malfunction b718h14504007 troubleshooting possible cause • incorrect tire size, poor tire pressure • deformed wheel, etc. Step action yes no 1 1) check that the specified tires are installed. Tire type and size front: dunlop d218ft 120/70zr17m/...

  • Page 537

    Abs: 4e-44 3 1) inspect both wheel speed sensor rotors for damage and check that no foreign objects are caught in the rotor openings. Are the rotors ok? Go to step 4. Clean or replace the rotor. 4 1) inspect the clearances of the front and rear wheel speed sensor – sensor rotor using the thickness g...

  • Page 538

    4e-45 abs: dtc “35” (c1635): abs motor malfunction b718h14504008 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • faulty hu motor • faulty wiring, etc. Step action yes no 1 1) inspect if the pump motor makes turning noise by setting the ignition switch to on f...

  • Page 539

    Abs: 4e-46 3 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) remove the fuse box mounting bolt. Refer to “abs control unit coupler disconnect and connect (page 4e- 70)”. 4) check the abs control unit co...

  • Page 540

    4e-47 abs: dtc “41” (c1641): wheel speed sensor signal malfunction (f) b718h14504009 troubleshooting possible cause • poor contact in the front wheel speed sensor coupler • faulty front wheel speed sensor, etc. Step action yes no 1 1) inspect the clearance between the front wheel speed sensor and se...

  • Page 541

    Abs: 4e-48 3 1) check that the front wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to dtc “42” (c1642). (refer to “dtc “42” (c1642): wheel speed sensor circuit open (f) (page 4e- 49)”.) tighten the mounting bolts or replace the bracket if necessary. Step action yes no i7...

  • Page 542

    4e-49 abs: dtc “42” (c1642): wheel speed sensor circuit open (f) b718h14504010 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • poor contact in the front wheel speed sensor coupler • faulty front wheel speed sensor, etc. Step action yes no 1 1) turn the igniti...

  • Page 543

    Abs: 4e-50 2 1) disconnect the front wheel speed sensor coupler. 2) measure the resistance between “a” (black) and ground at the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) normal value (“a” – ground) ∞Ω (infinity)...

  • Page 544

    4e-51 abs: 4 1) measure the resistance between “b” (white) and ground at the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) normal value (“b” – ground) ∞Ω (infinity) is the resistance between “b” and ground ok? Inspec...

  • Page 545

    Abs: 4e-52 6 1) check for continuity between “3” (w/r) on the abs control unit coupler and “d” (w/r) on the front wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication continuity test ( ) normal value (...

  • Page 546

    4e-53 abs: dtc “43” (c1643): wheel speed sensor circuit short (f) b718h14504011 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • poor contact in the front wheel speed sensor coupler • faulty front wheel speed sensor, etc. Step action yes no 1 1) turn the ignit...

  • Page 547

    Abs: 4e-54 2 1) check for continuity between “2” (b/y) and “3” (w/r) at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness end) is there continuity between “2” and “3”? • inspect the wire harness. (faulty sens...

  • Page 548

    4e-55 abs: dtc “44” (c1644): wheel speed sensor signal malfunction (r) b718h14504012 troubleshooting possible cause • poor contact in the rear wheel speed sensor coupler • faulty rear wheel speed sensor, etc. Step action yes no 1 1) inspect the clearance between the rear wheel speed sensor and senso...

  • Page 549

    Abs: 4e-56 3 1) check that the rear wheel speed sensor is mounted securely. Is the sensor mounted securely? Go to dtc “45” (c1645). (refer to “dtc “45” (c1645): wheel speed sensor circuit open (r) (page 4e- 57)”.) tighten the mounting bolts or replace the bracket if necessary. Step action yes no i71...

  • Page 550

    4e-57 abs: dtc “45” (c1645): wheel speed sensor circuit open (r) b718h14504013 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • poor contact in the rear wheel speed sensor coupler • faulty rear wheel speed sensor, etc. Step action yes no 1 1) turn the ignition...

  • Page 551

    Abs: 4e-58 2 1) disconnect the rear wheel speed sensor coupler. 2) measure the resistance between “a” (black) and ground at the rear wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) normal value (“a” – ground) ∞Ω (infinity) i...

  • Page 552

    4e-59 abs: 4 1) measure the resistance between “b” (white) and ground at the rear wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication resistance ( Ω) normal value (“b” – ground) ∞Ω (infinity) is the resistance between “b” and ground ok? Inspect...

  • Page 553

    Abs: 4e-60 6 1) check the continuity between “18” (w/y) on the abs control unit coupler and “d” (w/y) on the rear wheel speed sensor coupler. Special tool (a): 09900–25008 (multi-circuit tester set) (b): 09900–25009 (needle pointed probe set) tester knob indication continuity test ( ) normal value (...

  • Page 554

    4e-61 abs: dtc “46” (c1646): wheel speed sensor circuit short (r) b718h14504014 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • poor contact in the rear wheel speed sensor coupler • faulty rear wheel speed sensor, etc. Step action yes no 1 1) turn the ignitio...

  • Page 555

    Abs: 4e-62 2 1) check for continuity between “12” (b/r) and “18” (w/y) at the coupler. Special tool (a): 09900–25008 (multi-circuit tester set) tester knob indication continuity ( ) abs control unit coupler (harness end) is there continuity between “12” and “18”? • inspect the wire harness. (faulty ...

  • Page 556

    4e-63 abs: dtc “47” (c1647): supply voltage (increased) b718h14504015 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • faulty regulator/rectifier • faulty abs control unit • faulty wire harness, etc. Step action yes no 1 1) remove the seat. Refer to “exterior ...

  • Page 557

    Abs: 4e-64 3 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) remove the fuse box mounting bolt. Refer to “abs control unit coupler disconnect and connect (page 4e- 70)”. 4) check the abs control unit co...

  • Page 558

    4e-65 abs: dtc “48” (c1648): supply voltage (decreased) b718h14504016 wiring diagram refer to “abs unit diagram (page 4e-8)”. Troubleshooting possible cause • faulty generator or regulator/rectifier • faulty abs control unit • faulty wire harness, etc. Step action yes no 1 1) remove the seat. Refer ...

  • Page 559

    Abs: 4e-66 3 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) remove the fuse box mounting bolt. Refer to “abs control unit coupler disconnect and connect (page 4e- 70)”. 4) check the abs control unit co...

  • Page 560

    4e-67 abs: dtc “55” (c1655): abs control unit malfunction b718h14504017 troubleshooting possible cause faulty abs control unit step action yes no 1 1) inspect the clearances of the front and rear wheel speed sensor – sensor rotor using the thickness gauge. Special tool (a): 09900–20803 (thickness ga...

  • Page 561

    Abs: 4e-68 3 1) check that the front and rear wheel speed sensors are mounted securely. Are the sensors mounted securely? Go to step 4. Tighten the mounting bolts or replace the bracket if necessary. 4 1) delete dtcs and repeat the code output procedure. Refer to “dtc (diagnostic trouble code) delet...

  • Page 562

    4e-69 abs: dtc “61” (c1661): abs solenoid malfunction b718h14504018 troubleshooting possible cause faulty solenoid valve or relay step action yes no 1 1) turn the ignition switch off. 2) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 3) inspect the abs...

  • Page 563

    Abs: 4e-70 repair instructions abs control unit coupler disconnect and connect b718h14506003 disconnect 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 6)”. 3) remove the fuse box mounting bolt (1). 4) disconn...

  • Page 564

    4e-71 abs: front wheel speed sensor removal and installation b718h14506004 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • the wheel speed sensor cannot be disassembled. Removal 1) turn the ignition switch off. 2) rem...

  • Page 565

    Abs: 4e-72 3) disconnect the rear wheel speed sensor coupler (1). 4) remove the rear wheel speed sensor mounting bolts. 5) remove the rear wheel speed sensor as shown in the rear wheel speed sensor routing diagram. Refer to “rear wheel speed sensor routing diagram (page 4e-11)”. Installation refer t...

  • Page 566

    4e-73 abs: installation refer to “wheel speed sensor and sensor rotor inspection (page 4e-74)”. Install the front wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: • install the wheel speed sensor rotor as the letters “50t” face outside. • install the f...

  • Page 567

    Abs: 4e-74 • install the rear wheel assembly. Refer to “rear wheel assembly removal and installation in section 2d (page 2d-16)”. • check the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. Special tool (a): 09900–20803 (thickness gauge) (b): 09900–20806 (th...

  • Page 568

    4e-75 abs: 1) remove the seat and frame covers. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the battery (1). Refer to “battery removal and installation in section 1j (page 1j-12)”. 3) remove the starter relay (2) from the battery case. 4) remove the coolin...

  • Page 569

    Abs: 4e-76 specifications tightening torque specifications b718h14507001 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-7)”. Special tools and equipment special tool b718h14508001 fastening part tighte...

  • Page 570

    4e-77 abs: 09900–25008 09900–25009 multi-circuit tester set needle pointed probe set ) (page 4e-15) / ) (page 4e-17) / ) (page 4e-19) / ) (page 4e-19) / ) (page 4e-20) / ) (page 4e-21) / ) (page 4e-21) / ) (page 4e-22) / ) (page 4e-46) / ) (page 4e-49) / ) (page 4e-50) / ) (page 4e-50) / ) (page 4e-...

  • Page 571: Section 5

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

  • Page 572: Precautions

    5-1 precautions: transmission / transaxle precautions precautions precautions for transmission / transaxle b718h15000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 573: Manual Transmission

    Manual transmission: 5b-1 transmission / transaxle manual transmission diagnostic information and procedures manual transmission symptom diagnosis b718h15204001 condition possible cause correction / reference item engine is noisy (noise seems to come from the transmission). Worn or rubbing gear. Rep...

  • Page 574

    5b-2 manual transmission: repair instructions transmission components b718h15206001 1 2 3 4 5 6 7 8 9 10 11 12 19 17 16 18 13 15 14 i718h1520076-02 1. 1st driven gear 9. 5th drive gear 17. Gearshift cam plate 2. 5th driven gear 10. 3rd/4th drive gear 18. Gear position switch 3. 4th driven gear 11. 6...

  • Page 575

    Manual transmission: 5b-3 transmission removal b718h15206002 1) remove the engine assembly from the frame. Refer to “engine assembly removal in section 1d (page 1d-17)”. 2) disassemble the engine top side (1). Refer to “engine top side disassembly in section 1d (page 1d-24)”. 3) separate the upper a...

  • Page 576

    5b-4 manual transmission: 4) remove the no.3 gearshift fork (5). Countershaft assembly 1) remove the bearing retainer (1). 2) by using suitable size bolts (2), pull out the countershaft assembly (3). Bearing / oil seal 1) remove the oil seal retainer (1) and oil seal (2). 2) remove the countershaft ...

  • Page 577

    Manual transmission: 5b-5 transmission installation b718h15206003 install the transmission in the reverse order of removal. Pay attention to the following points: bearing / oil seal caution ! Replace the removed oil seal, bearings and snap ring with new ones. • install the bearings (1), (2) with the...

  • Page 578

    5b-6 manual transmission: countershaft assembly • apply grease to the o-rings. Caution ! Replace the o-rings (1) with new ones. : grease 99000–25010 (suzuki super grease a or equivalent) • align the punch marks “a” on the countershaft bearing housing and bearing retainer. • apply a small quantity of...

  • Page 579

    Manual transmission: 5b-7 • apply thread lock to the screws and tighten them to the specified torque. : thread lock cement 99000–32110 (thread lock cement super 1322 or equivalent) tightening torque gearshift fork shaft retainer screw (a): 10 n·m ( 1.0 kgf-m, 7.0 lb-ft) gearshift cam retainer screw ...

  • Page 580

    5b-8 manual transmission: transmission construction b718h15206004 1 2 3 3 3 3 3 3 “ a ” i718h1520071-04 1. Counter shaft 2. Drive shaft 3. Snap ring :assemble snap ring with sharp edge side out. “a”: 0.2 mm (0.008 in).

  • Page 581

    Manual transmission: 5b-9 countershaft gear / driveshaft gear disassembly and assembly b718h15206005 refer to “transmission removal (page 5b-3)” and “transmission installation (page 5b-5)”. Disassembly caution ! Identify the position of each removed part. Organize the parts in their respective group...

  • Page 582

    5b-10 manual transmission: assembly note when reassembling the transmission gears, attention must be given to the locations and positions of washers and snap rings. The cross sectional view shows the correct position of the gears, bushings, washers and snap rings. Refer to “transmission construction...

  • Page 583

    Manual transmission: 5b-11 • when installing the gear bushing onto the driveshaft, align the shaft oil hole “a” with the bushing oil hole “b”. Countershaft • install the countershaft bearing into the housing, using the special tool. Caution ! Never reuse countershaft bearing. Special tool (a): 09913...

  • Page 584

    5b-12 manual transmission: transmission related parts inspection b718h15206007 refer to “transmission removal (page 5b-3)”, “transmission installation (page 5b-5)” and “countershaft gear / driveshaft gear disassembly and assembly (page 5b-9)”. Gearshift fork to groove clearance note the clearance fo...

  • Page 585

    Manual transmission: 5b-13 4) disconnect the gear position switch coupler (1). 5) remove the gear position switch (2). Installation install the gear position switch in the reverse order of removal. Pay attention to the following points: • apply grease to the o-ring. Caution ! Replace the o-ring with...

  • Page 586

    5b-14 manual transmission: gearshift lever removal and installation b718h15206017 removal 1) place the motorcycle on the center stand. 2) remove the gearshift lever as shown in the gearshift lever construction. Refer to “gearshift lever construction (page 5b-13)”. Installation 1) install the gearshi...

  • Page 587

    Manual transmission: 5b-15 gearshift construction b718h15206015 gearshift shaft / gearshift cam plate removal and installation b718h15206011 removal 1) remove the engine sprocket outer cover. Refer to “engine sprocket removal and installation in section 3a (page 3a-2)”. 2) disengage the gearshift li...

  • Page 588

    5b-16 manual transmission: 7) remove the gearshift cam plate bolt (11) and gearshift cam plate (12). 8) remove the gearshift cam stopper (13). 9) remove the gearshift arm stopper (14). Installation install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to ...

  • Page 589

    Manual transmission: 5b-17 • check the gearshift cam stopper moves smoothly. • locate the gearshift cam in the neutral position. • install the gearshift cam stopper plate (5). Note align the gearshift cam pin “b” with the gearshift cam stopper plate hole “c”. • apply a small quantity of thread lock ...

  • Page 590

    5b-18 manual transmission: • install the gearshift shaft assembly (6) and washers (7) as shown. Note pinch the gearshift arm stopper (8) with return spring ends “f”. • install a new snap ring (10). Special tool : 09900–06107 (snap ring pliers) • after installing the gearshift lever, check the gearsh...

  • Page 591

    Manual transmission: 5b-19 gearshift shaft oil seal / bearing removal and installation b718h15206013 removal 1) remove the gearshift shaft. Refer to “gearshift shaft / gearshift cam plate removal and installation (page 5b-15)”. 2) remove the gearshift shaft oil seal (1). 3) remove the bearings (2), ...

  • Page 592

    5b-20 manual transmission: specifications service data b718h15207001 transmission + drive chain unit: mm (in) except ratio tightening torque specifications b718h15207002 note the specified tightening torque is also described in the following. “gearshift lever construction (page 5b-13)” “gearshift sh...

  • Page 593

    Manual transmission: 5b-21 special tools and equipment recommended service material b718h15208001 note required service material is also described in the following. “transmission components (page 5b-2)” “gearshift lever construction (page 5b-13)” “gearshift shaft / gearshift cam plate components (pa...

  • Page 594: Clutch

    5c-1 clutch: transmission / transaxle clutch precautions precautions for clutch system b718h15300001 refer to “general precautions in section 00 (page 00-1)”. Clutch fluid (brake fluid) information b718h15300002 warning ! • this clutch system is filled with an ethylene glycol-based dot 4 brake fluid...

  • Page 595

    Clutch: 5c-2 schematic and routing diagram clutch hose routing diagram b718h15302001 1 3 2 5 6 7 8 (a) 35 21 49 4 1 2 10 9 “a” “b” “c” “d” 8 (a) 30 i718h1530005-05 1. Wiring harness 9. Clutch hose no.3 clamp : after positioning the clamp with stopper, tighten the bolt. 2. Clutch hose 10. Grommet : i...

  • Page 596

    5c-3 clutch: diagnostic information and procedures clutch system symptom diagnosis b718h15304001 repair instructions clutch lever position switch inspection b718h15306001 inspect the clutch lever position switch in the following procedures: 1) disconnect the clutch lever position switch lead wires. ...

  • Page 597

    Clutch: 5c-4 air bleeding from clutch fluid circuit b718h15306004 caution ! Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc. The clutch fluid circuit may be purged of air in the following manner: 1) keep the motorcycle upright and place the handl...

  • Page 598

    5c-5 clutch: 6) connect a clear hose to the air bleeder valve and insert the other end of hose into a receptacle. 7) loosen the air bleeder valve and pump the clutch lever until old clutch fluid flows out of the bleeder system. 8) close the air bleeder valve and disconnect a clear hose. Tightening t...

  • Page 599

    Clutch: 5c-6 clutch control system components b718h15306007 5 6 4 2 1 [a] [b] (a) 3 (a) (b) 9 7 8 i718h1530065-02 1. Push rod 7. Push rod : 6 n ⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Piston/cup set 8. Clutch release cylinder set : apply brake fluid. 3. Clutch hose 9. Air bleeder : apply grease. 4. Reservoir c...

  • Page 600

    5c-7 clutch: clutch master cylinder assembly removal and installation b718h15306008 removal 1) drain clutch fluid. Refer to “clutch fluid replacement (page 5c-4)”. 2) disconnect the clutch lever position switch lead wires (1). 3) place a rag under the clutch hose union bolt (2) on the master cylinde...

  • Page 601

    Clutch: 5c-8 • after setting the clutch hose union to the stopper, tighten the union bolt to the specified torque. Caution ! The seal washers should be replaced with the new ones to prevent fluid leakage. Tightening torque clutch hose union bolt (b): 23 n·m (2.3 kgf-m, 16.5 lb-ft) • bleed air from t...

  • Page 602

    5c-9 clutch: assembly assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: caution ! • wash the master cylinder components with new brake fluid before reassembly. • do not wipe the clutch fluid off after washing the components. • when washing the c...

  • Page 603

    Clutch: 5c-10 clutch master cylinder parts inspection b718h15306010 refer to “clutch master cylinder / clutch lever disassembly and assembly (page 5c-8)”. Master cylinder inspect the master cylinder bore for any scratches or other damage. Piston inspect the piston surface for any scratches or other ...

  • Page 604

    5c-11 clutch: clutch push rod (left) inspection b718h15306019 inspect the push rod in the following procedures: 1) remove the clutch push rod. Refer to “clutch release cylinder / push rod removal and installation (page 5c-10)”. 2) inspect the push rod for wear or bend. If any defects are found, repl...

  • Page 605

    Clutch: 5c-12 clutch components b718h15306014 7 7 7 7 7 7 4 4 4 4 4 4 5 6 / 7 (b) 1 2 (a) 3 4 6 / 7 8 9 10 11 i718h1530067-03 1. Clutch pressure plate 6. No.1 driven plate (0 – 2 pcs) : the no.1 and no.2 driven plates are 8 in total. 11. Primary driven gear assembly 2. Clutch push piece 7. No.2 driv...

  • Page 606

    5c-13 clutch: clutch removal b718h15306016 1) drain engine oil. Refer to “engine oil and filter replacement in section 0b (page 0b-10)”. 2) remove the clutch cover (1). 3) remove the gasket (2) and dowel pins. 4) remove the clutch spring set bolts, clutch springs and pressure plate (3). Note loosen ...

  • Page 607

    Clutch: 5c-14 8) remove the clutch push rod (11). Note if it is difficult to pull out the push rod (11), use a magnetic hand or a wire. 9) unlock the clutch sleeve hub nut. 10) hold the clutch sleeve hub with the special tools. Special tool (a): 09920–53740 (clutch sleeve hub holder) : 09920–31020 (...

  • Page 608

    5c-15 clutch: 2) install the spacers (2) and bearing (3), and apply engine oil to them. 3) install the thrust washer (4). 4) install the clutch sleeve hub (5), washer (6) and spring washer (7) note the conical curve side of spring washer (7) faces outside. 5) hold the clutch sleeve hub with the spec...

  • Page 609

    Clutch: 5c-16 9) install the clutch push piece (9), bearing (10) and thrust washer (11) to the countershaft. Note thrust washer (11) is located between the pressure plate and bearing (10). 10) install the spring washer seat (12) and spring washer (13) onto the clutch sleeve hub correctly. 11) insert...

  • Page 610

    5c-17 clutch: note for driven plate two kinds of the driven plate (no.1 and no.2) are equipped in the clutch system, they can be distinguished by the thickness. The no.1 and no.2 driven plates are 8 in total. The driven plate no.2 should be used within 2 pcs. The driven plate no.2 should be installe...

  • Page 611

    Clutch: 5c-18 clutch parts inspection b718h15306018 refer to “clutch removal (page 5c-13)” and “clutch installation (page 5c-14)”. Clutch drive and driven plate note wipe off the engine oil from the drive and driven plates with a clean rag. Measure the thickness of drive plates with a vernier calipe...

  • Page 612

    5c-19 clutch: push rod (right) inspect the push rod for wear and damage. If any defects are found, replace the push rod with a new one. Clutch sleeve hub and primary driven gear assembly inspect the slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutc...

  • Page 613

    Clutch: 5c-20 special tools and equipment recommended service material b718h15308001 note required service material is also described in the following. “clutch control system components (page 5c-6)” “clutch components (page 5c-12)” special tool b718h15308002 material suzuki recommended product or sp...

  • Page 614

    5c-21 clutch:.

  • Page 615: Section 6

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

  • Page 616: Precautions

    6-1 precautions: steering precautions precautions precautions for steering b718h16000001 refer to “general precautions in section 00 (page 00-1)”..

  • Page 617: Steering General Diagnosis

    Steering general diagnosis: 6a-1 steering steering general diagnosis diagnostic information and procedures steering symptom diagnosis b718h16104001 condition possible cause correction / reference item heavy steering over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. ...

  • Page 618: Steering / Handlebar

    6b-1 steering / handlebar: steering steering / handlebar repair instructions handlebar components b718h16206001 4 5 1 (b) 3 (a) “a” 2 (b) 6 1 4 8 7 i718h1620037-01 1. Throttle grip 5. Handle expander “a”: apply handle grip bond. 2. Handlebars 6. Handle balancer expander : 23 n ⋅m (2.3 kgf-m, 16.5 lb...

  • Page 619

    Steering / handlebar: 6b-2 handlebar construction b718h16206013 (a) (a) (a) “b” (a) “b” “ a ” “ a ” “ a ” “a” 1 “a” 2 “a” 3 “a” (b) fwd i718h1620040-01 1. Clutch master cylinder “a”: punch mark : 10 n ⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Front brake master cylinder “b”: up mark : 23 n ⋅m (2.3 kgf-m, 16.5 lb...

  • Page 620

    6b-3 steering / handlebar: handlebar removal and installation b718h16206002 removal 1) remove the following parts from the left handlebar. A) rear view mirror (gsf1250/a) b) clutch master cylinder/clutch lever (1) caution ! Do not turn the clutch master cylinder upside down. C) left handlebar switch...

  • Page 621

    Steering / handlebar: 6b-4 • apply suzuki super grease to the end of the throttle cables and cable pulley. : grease 99000–25010 (suzuki super grease a or equivalent) • insert the projection “c” of the right handlebar switch box into the hole of the handlebars. • install the front brake master cylind...

  • Page 622

    6b-5 steering / handlebar: steering components b718h16206004 (a) 1 2 3 (b) 5 4 7 7 8 8 (c) 9 6 16 14 15 13 12 11 10 [a] [a] 16 i718h1620019-04 1. Handlebar holder bolt 8. Rubber seat 15. Lower seal 2. Handlebar holder (upper) 9. Handlebar holder set nut 16. Headlight housing bracket 3. Handlebars 10...

  • Page 623

    Steering / handlebar: 6b-6 steering removal and installation b718h16206005 removal gsf1250/a 1) support the motorcycle with a jack or a wooden block. 2) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-6)”. 3) remove the front forks. Ref...

  • Page 624

    6b-7 steering / handlebar: gsf1250s/sa 1) support the motorcycle with a jack or a wooden block. 2) remove the front wheel assembly. Refer to “front wheel assembly removal and installation in section 2d (page 2d-6)”. 3) remove the brake hose clamp bolt (gsf1250s) or brake hose joint bolt (1) (gsf1250...

  • Page 625

    Steering / handlebar: 6b-8 installation install the steering in the reverse order of removal. Pay attention to the following points: bearing • apply suzuki super grease to the bearings, races and dust seals before remounting the steering stem. : grease 99000–25010 (suzuki super grease a or equivalen...

  • Page 626

    6b-9 steering / handlebar: handlebars • tighten the handlebar holder set nuts to the specified torque. Tightening torque handlebar holder set nut (a): 45 n·m (4.5 kgf-m, 32.5 lb-ft) inspection after installation • check the steering tension. Refer to “steering tension adjustment (page 6b-10)”. Steer...

  • Page 627

    Steering / handlebar: 6b-10 3) remove the steering stem lower bearing and inner race using a chisel. 4) remove the steering stem upper and lower bearing races using the special tools. Special tool (a): 09941–54911 (bearing outer race remover) (b): 09941–74911 (steering bearing installer) installatio...

  • Page 628

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

  • Page 629

    Steering / handlebar: 6b-12 special tools and equipment recommended service material b718h16208001 note required service material is also described in the following. “steering components (page 6b-5)” special tool b718h16208002 material suzuki recommended product or specification note grease suzuki s...

  • Page 630

    6b-13 steering / handlebar:.

  • Page 631: Section 9

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

  • Page 632

    9-ii table of contents engine sprocket outer cover cushion construction ......................................................9d-5 fastener removal and installation......................9d-5 exterior parts removal and installation ..............9d-6 seat height adjustment ..............................

  • Page 633: Precautions

    Precautions: 9-1 body and accessories precautions precautions precautions for electrical system b718h19000001 refer to “general precautions in section 00 (page 00-1)” and “precautions for electrical circuit service in section 00 (page 00-2)”. Component location electrical components location b718h19...

  • Page 634: Wiring Systems

    9a-1 wiring systems: body and accessories wiring systems schematic and routing diagram wiring diagram (gsf1250) b718h19102001 refer to “wire color symbols in section 0a (page 0a-6)”..

  • Page 635

    Wiring systems: 9a-2 for e-02, 19 b/r b/w b b/r b/o g/b b/w b/g br/b b/y bl/b b/r b/r r dbr dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g/b dbr dg b/w b/y g b/w y b/w b/w b/w w/r b/y b/bl bl bl/w bl/b bl/g w/y lg g w/bl b gr/w gr/b gr...

  • Page 636

    9a-3 wiring systems: wiring diagram (gsf1250s) b718h19102004 refer to “wire color symbols in section 0a (page 0a-6)”. For e-02, 19 b/r b/w b b/r b/o g/b b/w b/g br/b b/y bl/b b/r b/r r g/b dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g...

  • Page 637

    Wiring systems: 9a-4 for e-03, 24, 28 b/r b/w b b/y bl/b b/r b/r r g/b dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g/b dg b/w b/y g b/w y b/w b/w b/w w/r b/y b/bl bl bl/w bl/b bl/g w/y lg g w/bl b gr/w gr/b gr/y gr/r w/b b/g y/b bl/y ...

  • Page 638

    9a-5 wiring systems: wiring diagram (gsf1250a) b718h19102005 refer to “wire color symbols in section 0a (page 0a-6)”. For e-02, 19 b/r b/w b b/y bl/b b/r b/r r dbr dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g/b dbr dg b/w b/y g b/w y...

  • Page 639

    Wiring systems: 9a-6 wiring diagram (gsf1250sa) b718h19102006 refer to “wire color symbols in section 0a (page 0a-6)”. For e-02, 19 b/r b/w b b/y bl/b b/r b/r r g/b dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g/b dg b/w b/y g b/w y b/...

  • Page 640

    9a-7 wiring systems: for e-03, 24, 28 b/r b/w b b/y bl/b b/r b/r r g/b dg y w r/bl o/y b/o b/g r o/r bl/b bl g o/y b/bl br/b b/br b/bl b/g b/br b g/b dbr dg b/w b/y b/bl b/g b/br b g/b dg b/w b/y g b/w y b/w b/w b/w w/r b/y b/bl bl bl/w bl/b bl/g w/y lg g w/bl b gr/w gr/b gr/y gr/r w/b b/g y/b bl/y ...

  • Page 641

    Wiring systems: 9a-8 wiring harness routing diagram b718h19102003 6 1 5 “b” “c” “a” 2 3 7 4 “ a ” “a” “a” 8 9 11 10 12 i718h1910910-05 1. Battery 9. Brake hose (abs) (gsf1250a/sa only) 2. Evap purge control valve (e-33 only) 10. Rear wheel speed sensor coupler (gsf1250a/sa only) 3. Clamp (gsf1250/a ...

  • Page 642

    9a-9 wiring systems: [a] [b] 9 10 11 13 12 14 “b” 15 16 “ a ” 8 5 6 7 1 “a” 3 4 (a) 2 i718h1910916-01 1. Clamp : clamp the speed sensor lead wire and ho2 sensor lead wire. 12. Turn signal lead wire (rh) 2. Side-stand switch 13. Turn signal lead wire (lh) 3. Ho2 sensor coupler 14. Clamp : clamp the r...

  • Page 643

    Wiring systems: 9a-10 1 (d) “ a ” “ a ” “ b ” (c) 2 (a) (a) (b) 3 3 (c) (e) 4 i718h1910913-02 1. Oil pressure lead wire : be careful not to slacken the oil pressure lead wire. : 6.5 n ⋅m (0.65 kgf-m, 4.7 lb-ft) 2. Generator cover : 1.5 n ⋅m (0.15 kgf-m, 1.0 lb-ft) 3. Clamp : push the clamp inside af...

  • Page 644

    9a-11 wiring systems: specifications service data b718h19107001 electrical tightening torque specifications b718h19107002 note the specified tightening torque is also described in the following. “wiring harness routing diagram (page 9a-8)” reference: for the tightening torque of fastener not specifi...

  • Page 645: Lighting Systems

    Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components b718h19206001 gsf1250/a gsf1250s/sa 4 3 2 1 5 i718h1920047-02 1. Headlight rim 3. Headlight bulb (12 v 60/55 w, h4) 5. Position light bulb (12 v 5 w) 2. Headlight unit 4. Headlight housing 3 4 4 1 2...

  • Page 646

    9b-2 lighting systems: headlight removal and installation b718h19206024 gsf1250/a removal 1) removal the headlight mounting screws. 2) disconnect the headlight coupler (1) and position light coupler (2). 3) remove the front brake hose clamp bolt (3) (gsf1250) or front brake hose joint mounting bolt ...

  • Page 647

    Lighting systems: 9b-3 gsf1250s/sa removal 1) remove the cowling. Refer to “exterior parts removal and installation in section 9d (page 9d- 6)”. 2) disconnect the headlight and position light couplers. 3) remove the headlight assembly. Installation installation is in the reverse order of removal. Pa...

  • Page 648

    9b-4 lighting systems: 6) reassemble the headlight. 7) install the headlight assembly so that the hook “a” on the headlight bezel engages with “b” of the housing. Gsf1250s/sa 1) remove the combination meter assembly. Refer to “combination meter removal and installation in section 9c (page 9c-4)”. 2)...

  • Page 649

    Lighting systems: 9b-5 headlight beam adjustment b718h19206026 gsf1250/a adjust the headlight beam, both horizontally and vertically. Note to adjust the headlight beam, adjust the beam horizontally first, then vertically. Gsf1250s/sa 1) insert 5 mm hexagon wrench as shown and adjust the low and high...

  • Page 650

    9b-6 lighting systems: rear combination light construction b718h19206006 rear combination light removal and installation b718h19206007 removal 1) remove the seat tail cover. Refer to “exterior parts removal and installation in section 9d (page 9d- 6)”. 2) remove the rear combination light (1) from t...

  • Page 651

    Lighting systems: 9b-7 brake light bulb / taillight bulb replacement b718h19206008 caution ! When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. 1) remove the seat. Refer to “exterior parts removal and inst...

  • Page 652

    9b-8 lighting systems: license plate light removal and installation b718h19206010 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the tool set (1) and disconnect the license plate light coupler (2). 3) remove the license plate light...

  • Page 653

    Lighting systems: 9b-9 turn signal light components b718h19206012 front turn signal light removal and installation b718h19206013 gsf1250/a removal 1) remove the headlight housing. Refer to “headlight removal and installation (page 9b-2)”. 2) remove the front turn signal light (1) by removing the nut...

  • Page 654

    9b-10 lighting systems: rear turn signal light removal and installation b718h19206014 removal 1) remove the seat. Refer to “exterior parts removal and installation in section 9d (page 9d-6)”. 2) remove the tool set (1) and disconnect the turn signal light coupler (rh: black, lh: gray) (2). 3) remove...

  • Page 655

    Lighting systems: 9b-11 turn signal / side-stand relay inspection b718h19206017 refer to “electrical components location in section 0a (page 0a-8)”. Note make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If th...

  • Page 656

    9b-12 lighting systems: 3) inspect the turn signal switch for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebar removal and installation in section 6b (page 6b-3)”. Special tool : 09900–25008 (multi-circuit tester se...

  • Page 657

    Lighting systems: 9b-13 specifications service data b718h19207001 wattage unit: w tightening torque specifications b718h19207002 note the specified tightening torque is also described in the following. “rear combination light construction (page 9b-6)” “reflex refractor construction (page 9b-10)” ref...

  • Page 658

    9c-1 combination meter / fuel meter / horn: body and accessories combination meter / fuel meter / horn general description combination meter system description b718h19301001 this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting diode). The...

  • Page 659

    Combination meter / fuel meter / horn: 9c-2 repair instructions combination meter components b718h19306001 gsf1250/a 1 2 3 4 5 fwd fw d i718h1930046-03 1. Upper case 2. Combination meter 3. Lower case 4. Cover 5. Bracket.

  • Page 660

    9c-3 combination meter / fuel meter / horn: gsf1250s/sa 1 2 3 i718h1930047-02 1. Upper case 2. Combination meter 3. Lower case.

  • Page 661

    Combination meter / fuel meter / horn: 9c-4 combination meter removal and installation b718h19306002 gsf1250/a removal 1) remove the combination meter mounting bolts. 2) remove the headlight. Refer to “headlight removal and installation in section 9b (page 9b-2)”. 3) disconnect the combination meter...

  • Page 662

    9c-5 combination meter / fuel meter / horn: combination meter inspection b718h19306004 led inspection check that the leds (fi indicator light, abs indicator (gsf1250a/sa only), oil pressure, engine coolant temperature indicator light and meter panel illumination) immediately light up when the igniti...

  • Page 663

    Combination meter / fuel meter / horn: 9c-6 2) connect the variable resistor (2) between the terminals. 3) turn the ignition switch on. 4) check the led operations when the resistance is adjusted to the specified values. If either one or all indications are abnormal, replace the combination meter wi...

  • Page 664

    9c-7 combination meter / fuel meter / horn: 5) turn the ignition switch on. 6) check the display of fuel level indicator (lcd) as shown. If any abnormality is found, replace the combination meter with a new one. Refer to “combination meter removal and installation (page 9c-4)”. Note it takes approx....

  • Page 665

    Combination meter / fuel meter / horn: 9c-8 fuel level gauge inspection b718h19306006 inspect the fuel level gauge in the following procedures: 1) remove the fuel level gauge. Refer to “fuel pump assembly / fuel level gauge removal and installation in section 1g (page 1g-11)”. 2) measure the resista...

  • Page 666

    9c-9 combination meter / fuel meter / horn: installation install the speed sensor in the reverse order of removal. Pay attention to the following points: • tighten the speed sensor mounting bolt to the specified torque. Tightening torque speed sensor bolt (a): 6.5 n·m (0.65 kgf-m, 4.7 lb- ft) • rout...

  • Page 667

    Combination meter / fuel meter / horn: 9c-10 2) turn the ignition switch on. 3) check if the oil pressure indicator (led) will light up when grounding the lead wire (1). If the oil pressure indicator does not light up, replace the combination meter unit with a new one after checking the connection o...

  • Page 668

    9c-11 combination meter / fuel meter / horn: 3) inspect the horn button for continuity with a tester. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “handlebar removal and installation in section 6b (page 6b-3)”. Special tool : 09900–25008 (multi-cir...

  • Page 669

    Combination meter / fuel meter / horn: 9c-12 specifications service data b718h19307001 wattage unit: w tightening torque specifications b718h19307002 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque specifications in section 0c (page 0c-7)”....

  • Page 670: Exterior Parts

    9d-1 exterior parts: body and accessories exterior parts schematic and routing diagram seat lock cable routing diagram b718h19402001 1 2 3 4 i718h1940028-01 1. Screw 2. Seat lock cable 3. Seat lock 4. Plate.

  • Page 671

    Exterior parts: 9d-2 repair instructions exterior parts construction b718h19406006 gsf1250/a 2 3 3 1 1 i718h1940033-01 1. Frame head cover 2. Headlight housing cover 3. Headlight housing stay.

  • Page 672

    9d-3 exterior parts: gsf1250s/sa 6 5 2 3 1 4 7 8 i718h1940026-02 1. Cowling body 3. Cowling brace 5. Upper panel 7. Head pipe 2. Wind screen 4. Lower panel 6. Meter panel lid 8. Bolt (except e-33).

  • Page 673

    Exterior parts: 9d-4 front fender construction b718h19406007 frame cover cushion construction b718h19406002 1 2 3 2 1 fw d i718h1940029-01 1. Front fender 2. Fender plate nut 3. Front fork 1 2 2 i718h1940030-01 1. Frame cover 2. Cushion : clean an adhesive surface before adhering the tape cushion..

  • Page 674

    9d-5 exterior parts: engine sprocket outer cover cushion construction b718h19406008 fastener removal and installation b718h19406003 removal 1) depress the head of fastener center piece (1). 2) pull out the fastener (2). Installation 1) let the center piece stick out toward the head so that the pawls...

  • Page 675

    Exterior parts: 9d-6 2) insert the fastener into the installation hole. Note to prevent the pawl “a” from damage, insert the fastener all the way into the installation hole. 3) push in the head of center piece until it becomes flush with the fastener outside face. Exterior parts removal and installa...

  • Page 676

    9d-7 exterior parts: 5) disconnect the brake light/taillight lead wire coupler (2). 6) unhook the seat lock cable (3). Refer to “seat lock cable routing diagram (page 9d-1)”. 7) remove the seat tail cover (4). Installation install the seat tail cover and pillion rider handle in the reverse order of ...

  • Page 677

    Exterior parts: 9d-8 4) remove the wind screen (2) and upper panel (3). 5) remove the turn signal lights (4), left and right. Refer to “front turn signal light removal and installation in section 9b (page 9b-9)”. 6) remove the cowling (5) along with the lower panel (6). 7) remove the lower panel (6)...

  • Page 678

    9d-9 exterior parts: seat height adjustment b718h19406005 adjust the seat height in the following procedures: 1) remove the seat assembly. Refer to “exterior parts removal and installation (page 9d-6)”. 2) remove the seat height adjusting dampers. 3) remove the front seat from the rear seat. 4) adju...

  • Page 679: Body Structure

    Body structure: 9e-1 body and accessories body structure repair instructions body frame construction b718h19506001 engine mounting bracket bushing replacement b718h19506002 replace the engine mounting bracket bushing if necessary, as shown in the body frame construction. Refer to “body frame constru...

  • Page 680

    9e-2 body structure: engine mount bushing replacement b718h19506003 replace the engine mount bushing if necessary, as shown in the body frame construction. Refer to “body frame construction (page 9e-1)”. Front footrest bracket construction b718h19506005 gsf1250/s gsf1250a/sa 3 3 2 1 (a) 4 i718h19500...

  • Page 681

    Body structure: 9e-3 side-stand construction b718h19506006 1. Side-stand : 50 n ⋅m (5.0 kgf-m, 36.0 lb-ft) : apply grease to sliding surface. 2. Spring : 40 n ⋅m (4.0 kgf-m, 29.0 lb-ft) (b) (a) 2 1 i718h1950005-05.

  • Page 682

    9e-4 body structure: side-stand removal and installation b718h19506007 removal 1) support the motorcycle with the center stand. 2) remove the side-stand as shown in the side-stand construction. Refer to “side-stand construction (page 9e-3)”. Installation install the side-stand as shown in the side-s...

  • Page 683

    Body structure: 9e-5 specifications tightening torque specifications b718h19507001 note the specified tightening torque is also described in the following. “body frame construction (page 9e-1)” “front footrest bracket construction (page 9e-2)” “side-stand construction (page 9e-3)” reference: for the...

  • Page 684

    Prepared by december, 2006 part no. 99500-39300-01e printed in japan 684.

  • Page 685

    9 9 5 0 0 - 3 9 3 0 0 - 0 1 e printed in japan k7 g sf 12 50 /s /a /s a no.7761 gsf1250/s/a/sa 99500-39300-01e cover14 for ps printing (30 mm) 2006.12.29 top bottom dic216 k 7 gsf1250/s/a/sa.