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Suzuki GSF650 Service Manual

Other manuals for GSF650: Service Manual

Summary of GSF650

  • Page 1

    Gsf650/s.

  • Page 2: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 fuel system 4 chassis 5 electrical system 6 servicing information 7 foreword this manual contains an introductory description on the suzuki gsf650/s and procedures for its inspection/service and overhaul of its main compo- nents. Othe...

  • Page 3: How To Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 4

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

  • Page 5: General Information

    1 general information 1-1 general information contents country and area codes the following codes stand for the applicable country(-ies) and area(-s). Code country or area e-02 e-19 e-28 england (uk) european markets canada warning/caution/note ..........................................................

  • Page 6: Warning/caution/note

    1-2 general information warning/caution/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ! Indicat...

  • Page 7

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

  • Page 8: Suzuki Gsf650 (2005-Model)

    1-4 general information suzuki gsf650 (2005-model) * difference between photographs and actual motorcycles may exist depending on the markets. Suzuki gsf650s (2005-model) * difference between photographs and actual motorcycles may exist depending on the markets. Serial number location the frame seri...

  • Page 9

    General information 1-5 fuel and oil recommendation fuel (for canada) 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 than 10% ethanol, or less than 5% methanol with ap...

  • Page 10: Break-Ln Procedures

    1-6 general information break-ln procedures during manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “break-in” before subjecting the engine to maximum stresses. The future performa...

  • Page 11: Information Labels

    General information 1-7 information labels no. Label name gsf650 gsf650a gsf650u gsf650ua gsf650s gsf600sa gsf650su gsf650sua 1 information label e-28 e-28 2 fuel caution label e-02 e-02 e-02 e-02 3 screen label 4 warning steering label 5 tire information label 6 general warning label 7 ices canada ...

  • Page 12: Specifications

    1-8 general information specifications dimensions and dry mass overall length....................................................... 2 110 mm overall width ........................................................ 770 mm overall height....................................................... 1085/1 095...

  • Page 13

    General information 1-9 chassis front suspension................................................. Telescopic, coil spring, oil damped rear suspension ................................................. Link type, coil spring, oil damped front suspension stroke ...................................... 13...

  • Page 14: Periodic Maintenance

    2 6 periodic maintenance 2-1 contents periodic maintenance periodic maintenance schedule .......................................................2- 2 periodic maintenance chart .....................................................2- 2 lubrication points ..................................................

  • Page 15

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

  • Page 16

    Periodic maintenance 2-3 lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. 1 brake lever holder and throttle cables 5 gearshift pivot and left footrest pivot 2 brake pedal pivot ...

  • Page 17: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item in the periodic maintenance chart. Valve clearance • remove the fuel tank. ( !4-3) • remove the frame head covers. (gsf650 !5-5) • remove the cowling. (gsf650s !5-5) • remove the...

  • Page 18

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

  • Page 19

    2-6 periodic maintenance spark plugs • remove all of the spark plugs. Note: if it is difficult to remove any of the spark plug caps, pry them up using a screwdriver. # 09930-10121: spark plug wrench set 09900-20803: thickness gauge carbon deposits check to see if there are carbon deposits on the spa...

  • Page 20

    Periodic maintenance 2-7 electrode’s condition check the condition of the electrode. If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged threads, etc. $ spark plug installation $ • insert the spark plugs to the cylinder head by finge...

  • Page 21

    2-8 periodic maintenance air cleaner • remove the fuel tank. ( !4-3) • remove the screws. • remove the air cleaner element 1. • carefully use compressed air to clean the air cleaner element. $ • reinstall the cleaned or new air cleaner element in the reverse order of removal. • when installing the a...

  • Page 22

    Periodic maintenance 2-9 • remove the drain plug from the air cleaner drain hose to allow any water to drain out. Engine oil and oil filter the oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change. Engine oi...

  • Page 23

    2-10 periodic maintenance • start up the engine and allow it to run for several minutes at idling speed. • turn off the engine and wait about three minutes, then check the oil level through the inspection window 3. If the level is below the “l” mark, add oil to the “f” mark. If the level is above th...

  • Page 24

    Periodic maintenance 2-11 fuel line • remove the seat. • remove the fuel tank mounting bolts. ( !4-3) • lift up the fuel tank. Inspect the fuel hoses 1 for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. Engine idle speed note: make this adjustment when the engine...

  • Page 25

    2-12 periodic maintenance carburetor synchronization ( !4-25) pair (air supply) system ( !3-97) fuel filter • lift up the fuel tank. ( !2-10) check the fuel filter 1 for evidence of dirt and contamination. If present, replace the fuel filter with a new one. ( !4-6) clutch cable play • loosen the loc...

  • Page 26

    Periodic maintenance 2-13 drive chain with the transmission in neutral, support the motorcycle using the center-stand and turn the rear wheel slowly by hand. Visu- ally check the drive chain for the possible defects listed below. * loose pins * excessive wear * damaged rollers * improper chain adjus...

  • Page 27

    2-14 periodic maintenance adjusting • loosen or tighten both chain adjuster bolts 1 until there is 20 – 30 mm of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks 2 on both sides of the swingarm and the edge of each chain adjuster must be aligned to...

  • Page 28

    Periodic maintenance 2-15 brakes brake fluid level • keep the motorcycle upright and place the handlebar straight. • check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoirs. • when the brake fluid level is below the lower limit line, replen- ish wit...

  • Page 29

    2-16 periodic maintenance brake pads the extent of brake pad wear can be checked by observing the grooved limit line 1 on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( !5-47) $ brake pedal height • loosen the locknut 1. • turn the push rod 2 until the brake...

  • Page 30

    Periodic maintenance 2-17 air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper. The presence of air is...

  • Page 31

    2-18 periodic maintenance tires tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specific...

  • Page 32

    Periodic maintenance 2-19 front forks inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ( !5-15) rear suspension inspect the rear shock absorbers for oil leakage and check that there is no play in the swin...

  • Page 33

    2-20 periodic maintenance chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-21 for the loca- tions of the following nuts and bolts.) tighten initially at 1 000 km (2 month) and every 6 000 km (24 months) thereafter. Item n·m kgf-m ...

  • Page 34

    Periodic maintenance 2-21.

  • Page 35: Compression Pressure Check

    2-22 periodic maintenance compression pressure check the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should ...

  • Page 36: Oil Pressure Check

    Periodic maintenance 2-23 oil pressure check check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specisfication if the oil pressure is lower or higher than specification, the following causes may be considered. Low oil press...

  • Page 37: Engine

    3 6 engine 3-1 contents engine engine components removable with engine in place ..............3- 2 engine removal and installation ....................................................3- 3 removal ..............................................................................................3- 3 insta...

  • Page 38

    3-2 engine engine components removable with engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. Engine center engine left side engine right side item remova...

  • Page 39

    Engine 3-3 engine removal and installation removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • drain engine oil. ( !2-9) • remove the seat and frame covers. ( !5-4) • remove the frame head covers...

  • Page 40

    3-4 engine • remove the carburetor assembly. ( !4-15) • disconnect the lead wire couplers d to g. D signal generator e side-stand switch f speed sensor g gear position switch • open the clamps. • disconnect the starter motor lead wire 5. • disconnect the generator lead wire 6 and coupler 7. • diseng...

  • Page 41

    Engine 3-5 • loosen the rear axle nut 0 and chain adjusters a to provide additional chain slack. • remove the engine sprocket b. • remove the exhaust pipe bolts. • loosen the muffler connecting bolt c. • remove the muffler mounting bolts d. • remove the muffler assembly. Note: support the muffler as...

  • Page 42

    3-6 engine • remove the oil cooler. • support the engine with a proper jack. • remove the frame down tube f. • remove the engine mounting bolts, nuts and spacer g. • gradually lower the engine..

  • Page 43

    Engine 3-7 installation install the engine in the reverse order of engine removal. • insert the two long bolts from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration. Note: the engine mounting nuts are self-locking. Once the nuts have been remov...

  • Page 44

    3-8 engine • tighten the oil cooler mounting bolts 1 to the specified torque. # oil cooler mounting bolt: 10 n·m (1.0 kgf-m) • tighten the oil cooler hose union bolts 2 to the specified torque. # oil cooler hose union bolt: 28 n·m (2.8 kgf-m) $ note: when installing new exhaust pipe/muffler assembly...

  • Page 45

    Engine 3-9 • apply thread lock super to the driveshaft. % 99000-32030: thread lock super “1303” • tighten the engine sprocket nut 1 to the specified torque. # engine sprocket nut 1: 115 n·m (11.5 kgf-m) • apply a small quantity of thread lock “1342” to the speed sensor rotor bolt. & 99000-32050: thr...

  • Page 46

    3-10 engine • position the carburetor clamps as shown. • after remounting the engine, route the wire harness, cables and hoses properly. ( !7-12 to -19) • install the gearshift lever to the gearshift shaft in the correct position. ( gearshift lever height a standard: 55 mm • tighten the oil drain pl...

  • Page 47

    Engine 3-11 • pour 3.3 l of sf/sg or sh/sj with jaso ma (api) engine oil, with a viscosity rating of 10w-40 (sae), into the engine after overhauling it. • start up the engine and allow it run for several minutes at idle speed and then stop the engine. Wait three minutes and then check that the oil l...

  • Page 48: Engine Disassembly

    3-12 engine engine disassembly $ • remove each pair valve pipe and hose. • remove the oil filter 1 using the special tool. ) 09915-40610: oil filter wrench • remove the oil hoses 2. • remove the cylinder head cover 3. Identify the position of each removed part. Organize the parts in their respective...

  • Page 49

    Engine 3-13 • remove the signal generator cover 4. • remove all of the spark plugs. ) 09930-10121: spark plug wrench set • turn the crankshaft clockwise and align the “t” mark on the signal generator rotor with the center of the pickup coil. Also, position the notches a on the right end of each cams...

  • Page 50

    3-14 engine • remove the cam chain guide a. • remove the cylinder head bolt b. • the cylinder head can be removed after its twelve 14-mm nuts are removed. Note: when loosening the cylinder head nuts, loosen each nut little by little, in descending order, according to the numbers cast on the cylinder...

  • Page 51

    Engine 3-15 • remove the left and right oil pipes 4. • remove the cylinder base nut 5. • firmly grip the cylinder block at both ends and lift it straight up. If the cylinder block does not come off, lightly tap on the finless portions of it using a plastic mallet. $ pistons • scribe the cylinder num...

  • Page 52

    3-16 engine starter motor • remove the starter motor 1. Generator • remove the generator 1. • remove the signal generator rotor 2 using the special tool. • disconnect the oil pressure switch lead wire 3. • remove the signal generator stator (along with the pickup coil) 4 and oil pressure switch 5. C...

  • Page 53

    Engine 3-17 • remove the starter clutch cover 2. • hold the starter clutch using the special tool and loosen the clutch spring set bolts in a crisscross pattern. Then, remove the bolts. ) 09920-34810: starter clutch holder • remove the clutch pressure plate 3, clutch drive plates and clutch driven p...

  • Page 54

    3-18 engine • hold the clutch sleeve hub using the special tool and then remove the nut. ) 09920-53740: clutch sleeve hub holder • remove the washer a, washer seat b and clutch sleeve hub c. • remove the thrust washer d. • with the spacer and bearing removed, the primary driven gear assembly is free...

  • Page 55

    Engine 3-19 gearshift • remove the circlip and washer from the gearshift shaft. ) 09900-06107: snap ring pliers • draw out the gearshift shaft 1, and then remove the gearshift cam driven gear 2. Note: when removing the gearshift cam driven gear, do not lose the gearshifting pawl 3, pin 4 and spring ...

  • Page 56

    3-20 engine • hold the starter clutch assembly using the special tool and then loosen the starter clutch mounting bolt. ) 09920-34810: starter clutch holder note: do not remove the starter clutch mounting bolt at this stage, only loosen it. You will need to use it in conjunction with the special too...

  • Page 57

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

  • Page 58

    3-22 engine • remove the lower crankcase bolts and nut. • remove the main oil gallery plug 7 and o-ring. • loosen the crankcase bolts in descending numerical order and then remove them. Note: two allen bolts are located at position a to tighten the crank- shaft. • remove the oil return pipe b. • mak...

  • Page 59

    Engine 3-23 note: if it is difficult to separate the crankcase halves, set the proper bolt and nut to the crankcase by separating the upper and lower crankcase halves, as shown in the illustration. Transmission • remove the crankshaft assembly 1 from the upper crank- case. Note: the crankshaft thrus...

  • Page 60

    3-24 engine • remove the c-rings 9 and bearing pins 0. Note: do not lose the c-rings and bearing pins. • hold the gearshift forks a and draw out the gearshift fork shaft b from the lower crankcase. • unhook the gearshift cam stopper spring c from the lower crankcase. • remove the circlip d from the ...

  • Page 61

    Engine 3-25 • remove the gearshift cam stopper bolt i. Oil pump • remove the oil pump 1. • remove the o-rings and dowel pins. Oil pump inspection............................................... !3-86.

  • Page 62

    3-26 engine engine components inspection and service camshaft/cylinder head inspection and service $ camshafts if the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit. The camshaft runout should be checked. Also, check the cams and j...

  • Page 63

    Engine 3-27 tighten the camshaft journal holder bolts evenly and diagonally to the specified torque. # camshaft journal holder bolt: 10 n·m (1.0 kgf-m) note: do not rotate the camshafts with the plastigauge in place. Remove the camshaft journal holders and measure the width of the compressed plastig...

  • Page 64

    3-28 engine camshaft sprockets the fixed position of each camshaft sprocket is determined by arrow mark “3” for the intake camshaft, and by arrow marks “1” and “2” for the exhaust camshaft, as located in reference to the notch 1 on the right end of each camshaft. Inspect the teeth of each camshaft s...

  • Page 65

    Engine 3-29 cylinder head disassembly • remove the rocker arm shaft set bolt 1 and cylinder head plug 2. • remove the rocker arm shaft 3, rocker arm 4 and spring 5. Note: to remove the rocker arm shaft, screw a 8-mm bolt into the rocker arm shaft end and then pull out the shaft. • using the special ...

  • Page 66

    3-30 engine • remove the valve spring seat. • remove the valve from the combustion chamber side. • remove the oil seal. Cylinder head distortion decarbonize the combustion chambers. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Take clearance r...

  • Page 67

    Engine 3-31 valve face wear visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face wears. Measure the valve face t. If it is out of specification replace the valve with a new one. ) 09900-20102: vernier caliper...

  • Page 68

    3-32 engine • re-finish the valve guide holes in the cylinder head using the reamer and handle. ) 09916-34580: valve guide reamer 09916-34542: valve guide reamer handle • install a ring onto each valve guide. Be sure to use new rings. • oil the stem hole of each valve guide and drive the guide into ...

  • Page 69

    Engine 3-33 • the ring-like dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the fol- lowing specification. ( valve seat width w standard: 0.9 – 1.1 mm if the valve seat is out of specif...

  • Page 70

    3-34 engine • seat the pilot snugly. Install the 45° cutter 2, attachment 3 and t-handle 4. Initial seat cut • using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • measure the valve seat width w after every cut. • if the valve seat is pitted or burned, use the 4...

  • Page 71

    Engine 3-35 final seat cut • if the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. Note: after cutting the 15° angle, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width. • after the desired seat po...

  • Page 72

    3-36 engine valve springs the force of the coil spring keeps the valve seat tight. A weak- ened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and ...

  • Page 73

    Engine 3-37 cylinder head reassembly • locate the plate a on the cylinder head of exhaust side. • oil each oil seal 1 and press-fit them into position using the valve guide installer. • install each valve spring seat 2 (for intake side) and 3 (for exhaust side). ) 09916-44310: valve guide remover/in...

  • Page 74

    3-38 engine • install the valve springs with the smaller pitch a facing the cylinder head. B larger pitch c up d paint mark • install the valve spring retainer, press down the springs using the valve lifter and then install the cotter halves on to the stem end. Then, release the valve lifter to allo...

  • Page 75

    Engine 3-39 intake pipes • when installing the intake pipe, apply suzuki super grease “a” to the o-ring. ' 99000-25010: suzuki super grease “a” • when installing the intake pipe bolts, apply a small quantity of thread lock “1342” to their thread. & 99000-32050: thread lock “1342” $ note: * when repl...

  • Page 76

    3-40 engine ) 09900-20508: cylinder gauge set ( cylinder bore standard: 65.500 – 65.515 mm service limit: 65.615 mm piston diameter measure the piston diameter using the micrometer at 15 mm from the skirt end. If the piston diameter is less than the service limit, replace the piston. ) 09900-20203: ...

  • Page 77

    Engine 3-41 ( piston ring groove width standard: (1st) : 1.01 – 1.03 mm (2nd) : 0.81 – 0.83 mm (oil) : 1.51 – 1.53 mm ( piston ring thickness standard: (1st) : 0.97 – 0.99 mm (2nd) : 0.77 – 0.79 mm piston ring free end gap and piston ring end gap measure the piston ring free end gap using vernier ca...

  • Page 78

    3-42 engine measure the piston pin outside diameter at three positions using the micrometer. If any of the measurements are out of specifica- tion, replace the piston pin. ) 09900-20205: micrometer (0 – 25 mm) ( piston pin o.D. Service limit: 17.980 mm piston ring installation • install the oil ring...

  • Page 79

    Engine 3-43 • position the piston ring gaps as shown. Before inserting each piston into its cylinder, check that the gaps are properly posi- tioned. A exhaust side b intake side 5 2nd ring and lower side rail 6 upper side rail 7 1st ring and spacer note: install the pistons with the “ o” mark facing...

  • Page 80

    3-44 engine clutch driven plates note: wipe off any engine oil from the clutch driven plates using a clean rag. Measure each clutch driven plate for distortion using the thick- ness gauge and surface plate. If a clutch driven plate distortion exceeds the service limit, replace the clutch plates as a...

  • Page 81

    Engine 3-45 starter clutch inspection starter clutch install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction). The starter driven gear should turn smoothly. If excessive resis- tance is felt while turning the starter driv...

  • Page 82

    3-46 engine • install the new oil seal using the special tool. ) 09943-88211: pinion bearing installer $ note: apply suzuki super grease “a” onto the oil seal lip to pre- vent oil seal damage when installing the lower crankcase. ' 99000-25010: suzuki super grease “a” gearshift shaft hole check the g...

  • Page 83

    Engine 3-47 transmission inspection and service $ gearshift fork-to-gearshift fork groove clearance measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. If the clearance exceeds the specification, replace the fork, its respective gear or both. The cl...

  • Page 84

    3-48 engine disassembly countershaft assembly • remove the cap 1, left end bearing 2 and oil seal 3. • remove the 6th (top) drive gear circlip 4 from its groove and slide it towards the 3rd/4th drive gears 5. ) 09900-06107: snap ring pliers • slide the 6th (top) and 2nd drive gears toward the 3rd/4t...

  • Page 85

    Engine 3-49 • remove the 1st (low) driven gear bushing 3, washer and the 5th driven gear 4. • remove the circlip, washer and 4th driven gear 5. • remove the 4th driven gear bushing 6, lock washers, 3rd driven gear 7, 3rd driven gear bushing 8 and washer. • remove the circlip and 6th (top) driven gea...

  • Page 86

    3-50 engine • remove the 2nd driven gear bushing a. • remove the oil seal b..

  • Page 87

    Engine 3-51 reassembly assemble the countershaft and driveshaft assemblies in the reverse order of disassembly. Pay attention to the following points: note: * before installing the gears, rotate the bearing by hand to inspect for abnormal noises and smooth rotation. Replace the bearing if there is a...

  • Page 88

    3-52 engine $ • after installing the 3rd driven gear onto the driveshaft, install lock washer #2 3 onto the driveshaft, and position it so it fits into the groove. • then, fit lock washer #1 4 into lock washer #2 3. $ 1 left end bearing 2 oil seal 3 2nd drive gear 4 countershaft when installing the ...

  • Page 89

    Engine 3-53 # 1 1st (low) driven gear 2 5th driven gear 3 4th driven gear 4 3rd driven gear 5 6th (top) driven gear 6 2nd driven gear 7 driveshaft 8 countershaft/1st (low) drive gear 9 5th drive gear 0 3rd/4th drive gear a 6th (top) drive gear b 2nd drive gear fw d fwd item n·m kgf-m a 115 11.5 b 13...

  • Page 90

    3-54 engine.

  • Page 91

    Engine 3-55 conrod/crankshaft inspection conrod small end i.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. ) 09900-20602: dial gauge (1/1 000 mm) 09900-22403: small bore gauge (18 – 35...

  • Page 92

    3-56 engine • remove the conrods and mark them to identify their respec- tive cylinders. • inspect the bearing surfaces for any signs of fusion, pitting, burns, or flaws. If there is any damage, replace them with the specified set of bearings. Conrod-crank pin bearing selection • place the plastigau...

  • Page 93

    Engine 3-57 • check the corresponding crank pin o.D. Code numbers (“1”, “2” or “3”) 3. Bearing selection table conrod i.D. Specification crank pin o.D. Specification ) 09900-20202: micrometer (25 – 50 mm) bearing thickness specification a color code $ crank pin o.D. 3 code 1 2 3 conrod i.D. 2 1 gree...

  • Page 94

    3-58 engine bearing assembly • when installing the bearings into the bearing cap and conrod, be sure to install the tab 1 first, and then press in the oppo- site side of the bearing. • apply molybdenum oil solution to the crank pin and bearing surface. + 99000-25140: suzuki moly paste • when mountin...

  • Page 95

    Engine 3-59 • mate the lower crankcase with the upper crankcase and tighten the crankshaft bolts to the specified torque and in the proper tightening sequence. # crankcase bolt (initial) : 13 n·m (1.3 kgf-m) (final) : 23 n·m (2.3 kgf-m) • remove the lower crankcase and measure the width of com- pres...

  • Page 96

    3-60 engine crankcase journal i.D. Specification crankshaft journal o.D. Specification ) 09900-20202: micrometer (25 – 50 mm) bearing thickness specification 1 grooved bearing with oil hole (for lower crankcase) 2 grooved bearing (for upper crankcase) 3 color code crankshaft thrust clearance adjustm...

  • Page 97

    Engine 3-61 note: pull 1 the crankshaft to the left so that there is no clearance on the right-side thrust bearing. ( crankshaft thrust clearance standard: 0.04 – 0.09 mm if the thrust clearance exceeds the standard range, adjust the thrust clearance as follows: • remove the right-side thrust bearin...

  • Page 98

    3-62 engine • after selecting a left-side thrust bearing, install it and then measure the thrust clearance again. Note: the right-side thrust bearing color code 1 and part number are as follows. Green (12228-43414). Crankshaft runout support the crankshaft using v-blocks as shown, with the two end j...

  • Page 99: Engine Reassembly

    Engine 3-63 engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Oil pump • install the o-rings ( 1 and 2) a...

  • Page 100

    3-64 engine • install the gearshift cam 3 and its related parts. 4 gearshift cam stopper 5 circlip 6 spring 7 circlip $ • position the gearshift cam in the neutral position as shown. This will allow the gearshift forks and transmission gears to be installed easily. • install the gearshift forks into...

  • Page 101

    Engine 3-65 • install the bearing pins c and c-rings d into the upper crank- case. • install the countershaft assembly e and driveshaft assembly f into the upper crankcase. Note: * be sure to install the bearing dowel pins g in their respective positions. * install the countershaft end cap in the pr...

  • Page 102

    3-66 engine • install the o-rings ( m and n). $ • before installing the crankshaft assembly, apply molybdenum oil solution to each crankshaft journal bearing. + 99000-25140: suzuki moly paste • install the crankshaft assembly along with the cam chain into the upper crankcase. • insert the right-and ...

  • Page 103

    Engine 3-67 bond “1207b” should be applied to the following locations. The line of bond.

  • Page 104

    3-68 engine • install the right oil pipe a with the bolt 1. • install the copper washers onto bolts 9 and a. • install the two allen bolts at position b. • install the ten crankcase bolts (8 mm). • tighten the crankcase bolts (crankshaft tightening bolts) in ascending order. Tighten each bolt a litt...

  • Page 105

    Engine 3-69 • install the left oil pipe e. • install a new o-ring f and shim g. • install a new gasket and the oil sump filter h. $ • install a new gasket and the oil pan. Tighten the oil pan bolts to the specified torque. # oil pan bolt: 14 n·m (1.4 kgf-m) $ note: install a new gasket washer to the...

  • Page 106

    3-70 engine • install the oil seal retainer 4 with the four bolts and then bend the tab on the retainer. Note: route the gear position switch lead wire to the inside of the oil seal retainers tab a as shown. Starter clutch • remove the grease from the tapered portion of the starter clutch and cranks...

  • Page 107

    Engine 3-71 • install the gearshift shaft 5. Note: align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear. • install the washer and fix the gearshift shaft with the circlip. ) 09900-06107: snap ring pliers oil pump driven gear • install the washer 1, pin...

  • Page 108

    3-72 engine clutch • install the primary driven gear assembly onto the counter- shaft, and apply engine oil onto the needle bearing 1 and spacer 2. • install the thrust washer 3 onto the countershaft. • install the clutch sleeve hub onto the countershaft. • install the washer seat 4, washer 5 and cl...

  • Page 109

    Engine 3-73 • install the clutch push rods ( 9 and 0). Note: apply suzuki super grease “a” to the clutch push rod 7 when installing it. ' 99000-25010: suzuki super grease “a” • install the clutch push piece a, clutch release bearing b and thrust washer c onto the countershaft. • hold the starter clu...

  • Page 110

    3-74 engine • apply a light coat of suzuki bond to the starter clutch cover gasket mating surface c as shown. , 99000-31140: suzuki bond “1207b” • install the dowel pin, a new gasket and the starter clutch cover, and tighten the cover bolts securely. Note: install the gasket washer to the starter cl...

  • Page 111

    Engine 3-75 • pass the signal generator lead wire through the upper crank- case as shown. • install the generator 1. # generator mounting bolt: 26 n·m (2.6 kgf-m) note: apply suzuki super grease “a” to the generator o-ring. ' 99000-25010: suzuki super grease “a” $ • install the starter motor 2. # st...

  • Page 112

    3-76 engine note: before installing the cylinder block stud bolt 7, apply a light coat of the recommended bond to its threads. , 99000-31140: suzuki bond “1207b” # cylinder block stud bolt: 15 n·m (1.5 kgf-m) • make sure that the oil jets 8 in the upper crankcase are not clogged. Pistons • install t...

  • Page 113

    Engine 3-77 • position the piston ring gaps as shown. Before inserting each piston into its cylinder, check that the gaps are properly posi- tioned. B exhaust side c intake side 2 2nd ring and lower side rail 3 upper side rail 4 1st ring and spacer • install each special tool as shown. Some light re...

  • Page 114

    3-78 engine cylinder head • place the cylinder head onto the cylinder block. • cylinder head nuts and washers must be installed in the cor- rect position as shown. A copper washer with normal nut (4 pcs.) b copper washer with cap nut (4 pcs.) c steel washer with normal nut (4 pcs.) • tighten the twe...

  • Page 115

    Engine 3-79 note: before installing the camshafts onto the cylinder head, apply suzuki moly paste onto the camshaft journals d and do not leave any dry spots. Also, apply engine oil onto the camshaft journal holders. + 99000-25140: suzuki moly paste • the exhaust camshaft has the embossed letters “e...

  • Page 116

    3-80 engine • the exhaust camshaft sprocket has an arrow marked “1”. Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head. • engage the cam chain with the exhaust camshaft sprocket. • the other arrow marked “2” should now be pointing straight up. Starti...

  • Page 117

    Engine 3-81 • each camshaft journal holder is identified with an embossed letter. Install the dowel pins into each cam- shaft journal holder. • fasten the camshafts (in and ex) evenly by tightening the camshaft journal holder bolts sequentially and in a crisscross pattern. Note: damage to the cylind...

  • Page 118

    3-82 engine cam chain tensioner adjuster • after removing the spring holder bolt 1 and spring, unlock the ratchet mechanism 2 and push the push rod 3 all the way into the cam chain tensioner adjuster. Note: before installing the cam chain tensioner adjuster, turn the crankshaft clockwise to remove a...

  • Page 119

    Engine 3-83 $ • apply a light coat of the recommended bond to the signal gen- erator gasket mating surface a as shown. , 99000-31140: suzuki bond “1207b” • install a new gasket and the signal generator cover 1. Note: * install the gasket washer onto the signal generator cover bolt b as shown. * appl...

  • Page 120

    3-84 engine • place the cylinder head cover onto the cylinder head. • install the four gaskets onto each cylinder head cover union bolt 1 and apply oil to thread and gasket before tighten them to the specified torque.  cylinder head cover union bolt 1: 20 n·m (2.0 kgf-m) • install the eight gaskets...

  • Page 121

    Engine 3-85 • turn the oil filter by hand until you feel that the oil filter o-ring has contacted the oil filter mounting surface. Then, tighten the oil filter two full turns using the special tool. ) 09915-40610: oil filter wrench note: * before installing the oil filter, apply a light coat of engi...

  • Page 122: Engine Lubrication System

    3-86 engine engine lubrication system oil pump removal the crankcase must be separated to service the oil pump. The oil pump service requires engine removal and disassembly. Refer to the engine removal and engine disassembly sections for oil pump removal. ( !3-25) inspection rotate the oil pump by h...

  • Page 123

    Engine 3-87 • oil pressure regulator • oil sump filter inspection oil pressure regulator check the operation of the oil pressure regulator by pushing on the piston with an appropriately shaped tool. If the piston does not operate, replace the oil pressure regulator with a new one. Cleaning oil sump ...

  • Page 124

    3-88 engine installation installation is in the reverse order of removal. Note: refer to the following pages for the details of each step. Install: • oil sump filter note: do not loose the o-ring 1 and shim 2. • oil pressure regulator # oil pressure regulator: 28 n·m (2.8 kgf-m) • oil pan ( !3-69) •...

  • Page 125

    Engine 3-89 oil pressure switch removal after draining engine oil, remove the oil pressure switch. Note: refer to the following pages for the details of each step. Drain: • engine oil ( !2-9) remove: • signal generator cover • oil pressure switch inspection !6-40 installation installation is in the ...

  • Page 126

    3-90 engine oil cooler inspection and cleaning inspect the oil cooler hoses for damage and oil leaks. If any defects are found, replace the oil cooler hose(-s) with a new one. Inspect the oil cooler for oil leaks. If any defects are found, replace the oil cooler with a new one. If the fins are bent ...

  • Page 127

    Engine 3-91 oil jet oil jet (for the cylinder head) removal • the oil jet (for the cylinder head) can be removed after remov- ing the cylinder block. Note: refer to the following pages for the details of each step. Drain: • engine oil ( !2-9) remove: • cylinder block ( !3-14) • oil jet (for the cyli...

  • Page 128

    3-92 engine installation refer to the cylinder block installation, engine reassembly and engine installation sections. Note: before installing the oil jets, apply a light coat of engine oil to the o-rings..

  • Page 129: Oil P

    Engine 3-93 engine lubrication system chart conr od small end cam chain cylinder head cylinder head countershaft gears clutch pla tes driveshaft gears oil pump oil cooler by-p a ss oil sump fil ter driveshaft right side bearing oil p a n regula tor orifise oil fil ter oil jet oil jet oil jets oil je...

  • Page 130

    3-94 engine engine lubrication system.

  • Page 131: Cylinder Head Cover

    Engine 3-95 cylinder head cooling system chart union bolt union bolt oil pool oil pipe stud bolt stud bolt oil pipe oil pool oil pool oil pool orifice orifice union bolt union bolt oil gallery oil pump oil sump filter cylinder head cover oil pan cylinder head hoses.

  • Page 132

    3-96 engine cylinder head cooling system.

  • Page 133: Pair (Air Supply) System

    Engine 3-97 pair (air supply) system removal • remove the fuel tank. ( !4-3) • disconnect all of the pair valve hoses. 1 vacuum hose 2 air cleaner hose 3 pair hose no. 1 4 pair hose no. 2 5 pair hose no. 4 6 pair hose no. 3 • remove the pair valve 7. • remove the pair pipes 8 from each cylinder. Ins...

  • Page 134

    3-98 engine reed vavle • remove the pair valve covers. • inspect the reed valves for the carbon deposit. • if the carbon deposit is found in the reed valve, replace the pair valve with a new one. Pair valve • inspect that air flows through the pair valve air inlet port a to the air outlet parts b. •...

  • Page 135

    Engine 3-99 • tighten the pair pipe mounting nuts to the specified torque. # pair pipe mounting nut: 10 n·m (1.0 kgf-m) $ • rout the hoses properly. ( !7-19) use a new gasket 1 to prevent exhaust gas leakage..

  • Page 136: Fuel System

    2 4 6 fuel system 4-1 contents fuel system fuel system ................................................................................................4- 2 fuel tank .....................................................................................................4- 3 removal .......................

  • Page 137: Fuel System

    4-2 fuel system fuel system the fuel system consists of a fuel tank, fuel valve, vacuum hose, fuel filter, fuel hose and carburetor assem- bly. When there is negative pressure (vacuum) in the combustion chamber, the fuel is able to flow from the fuel tank, through the fuel valve and then to the carb...

  • Page 138: Fuel Tank

    Fuel system 4-3 fuel tank removal ! • remove the seat. ( "5-4) • remove the fuel tank mounting bolts. • disconnect the vacuum hose 1, fuel hose 2. • disconnect the fuel tank air breather hose 3 and water drain hose 4. • disconnect the fuel level gauge lead wire coupler 5. • remove the fuel tank. Rem...

  • Page 139: Fuel Valve

    4-4 fuel system fuel valve when the engine is not operating, the fuel valve 1 is kept closed by the tension of the spring 2, which closes the fuel passageway and stops the flow of fuel to the carburetors. When the engine has started, negative pressure (vacuum) a is generated in the combustion chambe...

  • Page 140

    Fuel system 4-5 removal ! • remove the fuel tank. ( "4-3) • remove the fuel valve 1. Inspection and cleaning if the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel fil- ter with compressed air. Installation install the fuel ...

  • Page 141: Fuel Filter

    4-6 fuel system fuel filter removal • remove the fuel tank. ( "4-3) • remove the fuel filter 1. Inspection • if the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Replace the fuel filter if necessary. Installation install the fuel filter ...

  • Page 142: Fuel Level Gauge

    Fuel system 4-7 fuel level gauge removal and installation ! • remove the fuel tank. ( "4-3) • remove the fuel level gauge 1. Install the fuel level gauge in the reverse order of removal. Pay attention to the following points. ! • set the triangle mark forward. Fuel level gauge inspection ........ ( ...

  • Page 143: Carburetor

    4-8 fuel system carburetor construction 1 top cap c float pin m air vent hose 2 spring d starter (enricher) plunger n fuel filter 3 jet needle stopper e gasket (o-ring) o fuel hose 4 jet needle f float chamber p fuel joint pipe no. 1 5 diaphragm/piston valve g drain screw q fuel joint pipe no. 2 6 n...

  • Page 144

    Fuel system 4-9 specifications item specification e-02, 19 e-19 u-type carburetor type keihin cvr32 ← bore size 32.5 ← i.D. No. 38g0 38g2 idle r/min 1 200 ± 100 r/min ← float height 17.0 mm ← main jet (m.J.) #105 (for carburetor #1, 4) #102 (for carburetor #2, 3) ← main air jet (m.A.J.) #50 ← jet ne...

  • Page 145

    4-10 fuel system i.D. No. Location each carburetor has an i.D. Number 1 printed on its body..

  • Page 146

    Fuel system 4-11 diaphragm and piston operation the carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased auto- matically by the piston valve 1. The piston valve moves according to the negative pressure present on the downstream side of the venturi a. Ne...

  • Page 147

    4-12 fuel system slow system this system supplies fuel during engine operation when the throttle valve 1 is closed or slightly opened. The fuel from the float chamber 2 is metered by the slow jet 3 where it mixes with air coming in through the slow air jet 4. This mixture, rich with fuel, then goes ...

  • Page 148

    Fuel system 4-13 main system as the throttle valve 1 is opened, engine speed rises and negative pressure in the venturi a increases. This causes the piston valve 2 to move upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel enters the needle jet 5, mixes with the a...

  • Page 149

    4-14 fuel system starter (enricher) system pulling the starter (enricher) plunger causes fuel to be drawn into the starter circuit from the float chamber 1. The starter jet 2 meters this fuel. The fuel then flows into the fuel pipe 3 and mixes with the air coming from the float chamber 1. The mixtur...

  • Page 150

    Fuel system 4-15 removal • remove the seat and frame covers. ( "5-4) • remove the fuel tank. ( "4-3) • remove the air cleaner box mounting bolts. • disconnect the throttle position sensor coupler 1. • loosen the respective carburetor clamp screws. • move the air cleaner box backward. • disconnect th...

  • Page 151

    4-16 fuel system disassembly before disassembly, prepare a clean and well lit work place where carburetor components can be laid out neatly and will not get lost. Study the service manual carburetor diagram and famil- iarize yourself with component locations and the different fuel circuits and their...

  • Page 152

    Fuel system 4-17 • remove the top cap. # • remove the spring and piston valve assembly 5. • remove the jet needle stopper 6, washer 7, e-ring 8 and jet needle 9 from the piston valve. • remove the float chamber 0. • remove the carburetor heater a. • remove the o-ring b. Do not use compressed air on ...

  • Page 153

    4-18 fuel system • remove the float pin c, float d and needle valve e. • remove the following parts. F main jet g needle jet holder h needle jet i slow jet j starter (enricher) jet k pilot screw note: before removing the pilot screw k, its setting must be deter- mined. Slowly turn the pilot screw cl...

  • Page 154

    Fuel system 4-19 • remove the throttle valve o. Cleaning ! • clean all jets with a spray-type carburetor cleaner and dry them using compressed air. • clean all circuits of the carburetor thoroughly – not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cle...

  • Page 155

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

  • Page 156

    Fuel system 4-21 float height to check the float height, turn the carburetor upside down. Measure the float height a while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue b as necessary to bring the float height a to the specified level. % 09900-20102: verni...

  • Page 157

    4-22 fuel system pilot screw • after cleaning, reinstall the pilot screw to the original setting by turning the screw in until it lightly seats, and then turn it out the same number of turns counted during disassembly. # carburetor engagement • position the throttle valve control lever 1 between the...

  • Page 158

    Fuel system 4-23 throttle position sensor positioning install the throttle position sensor as described below. • measure the resistance between the throttle position sensor terminals. ( "4-21) % 09900-25008: multi circuit tester set ' tester knob indication: resistance (Ω) • measure the resistance b...

  • Page 159

    4-24 fuel system remounting remount the carburetor assembly in the reverse order of removal. Pay attention to the following points. Carburetor clamps position the carburetor clamps as shown. Throttle cable adjustment (major adjustment) note: minor adjustment can be made by the throttle grip side adj...

  • Page 160

    Fuel system 4-25 carburetor synchronization check and adjust the carburetor synchronization among the four carburetors as follows. Use of vacuum balancer gauge calibrating each vacuum gauge • start up the engine and run it in idling condition for warming up. • stop the warmed-up engine. • disconnect...

  • Page 161

    4-26 fuel system • turn the air screw 5 of the carburetor balancer gauge so that the vacuum pressure causes the steel ball 6 to rise to the center line 7 of the tube. • after making sure that the steel ball remains at the center line, disconnect the hose from the vacuum inlet and connect the next ho...

  • Page 162

    Fuel system 4-27 • if the steel balls are not at the same level, adjust the throttle valve synchronizing screws 1, 2 and 3. Adjusting order is as follows. 1 → 2 → 3 • after balancing the carburetor, set the engine speed by turn- ing the throttle stop screw. Observe the tachometer reading. & engine s...

  • Page 163: Chassis

    Chassis 5-1 chassis contents 5 exterior parts ....................................................................................... 5- 3 construction .................................................................................. 5- 3 removal .......................................................

  • Page 164: Chassis

    5-2 chassis chassis contents front brake ............................................................................................. 5-46 construction .................................................................................. 5-46 brake pad replacement ........................................

  • Page 165: Exterior Parts

    Chassis 5-3 exterior parts construction 1 frame head cover 4 upper panel 7 cowling brace 2 cowling body 5 lower panel 8 cowling side bracket 3 wind screen 6 combination meter gsf650 gsf650s.

  • Page 166

    5-4 chassis removal seat • unlock the seat with the ignition key. • remove the front and rear seats as an assembly. Seat height adjustment ................. ( !5-74) luggage box • remove the seat. ( ! Above) • remove the luggage box lid 1. • pull out the starter relay 2. • remove the bolts and lugga...

  • Page 167

    Chassis 5-5 • disconnect the brake light/taillight lead wire coupler 2. • unhook the seat lock cable 3. • remove the seat tail cover. Frame head cover (gsf650) • remove the frame head cover 1 (lh and rh). ": hooked point cowling and cowling brace (gsf650s) • remove the caps. • remove the rear view m...

  • Page 168

    5-6 chassis • disconnect the turn signal lead wire couplers 3. • remove the cowling 4 along with the lower panel 5 and turn signal assemblies. • disconnect the headlight and position light couplers. • remove the headlight assembly 6. • remove the cowling brace 7. Front fender...........................

  • Page 169: Front Wheel

    Chassis 5-7 front wheel construction # 1 front axle 6 bearing (lh) a balancer 2 dust seal 7 brake disc (lh) a front axle 3 brake disc (rh) 8 collar b brake disc bolt 4 bearing (rh) 9 front wheel 5 spacer 0 air bleeder valve item n·m a 65 b 23.

  • Page 170

    5-8 chassis removal • remove the brake calipers 1 (lh and rh). • loosen the front axle pinch bolt 2. • loosen the front axle 3. • raise the front wheel off the ground using a jack or wooden block. • draw out the front axle 3 and remove the front wheel. $ note: after removing the front wheel, fit the...

  • Page 171

    Chassis 5-9 • remove the brake discs. Wheel make sure that the wheel runout (axial and radial) checked as shown do not exceed the service limit. An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings. If bearing replacement fails to reduce ...

  • Page 172

    5-10 chassis reassembly and installation reassembly and installation is in the reverse order of removal and disassembly. Pay attention to the follow- ing points: left use old part use old part use old part spacer clearance bearing installer left bearing (new) left bearing (new) right bearing (new) r...

  • Page 173

    Chassis 5-11 wheel bearings • apply grease to the bearing before installing. ' 99000-25010: suzuki super grease “a” • install the wheel bearing using the used bearing and special tool. % 09924-84521: bearing installer set $ • make sure that the brake discs are clean and free of any grease. Apply thr...

  • Page 174

    5-12 chassis front axle • tighten the front axle 1 to the specified torque. # front axle: 65 n·m (6.5 kgf-m) note: before tightening the front axle pinch bolt 2, move the front fork up and down four or five times. • tighten the front axle pinch bolt 2 to the specified torque. # front axle pinch bolt...

  • Page 175: Front Fork

    Chassis 5-13 front fork construction ! 1 front fork protector 2 dust seal 3 oil seal stopper ring 4 oil seal 5 oil seal retainer 6 outer tube slide metal 7 oil lock piece 8 outer tube (r) 9 outer tube (l) 0 gasket a ring b cylinder c spring d inner tube e inner tube slide metal f o-ring g spring sea...

  • Page 176

    5-14 chassis removal and disassembly • raise the front wheel off the ground using a jack or wooden block. • remove the brake calipers and front wheel. ( ! 5-8) $ front fender • remove the brake hose clamp bolt 1 (rh). • remove the front fender mounting bolts and plates behind (lh and rh). • disconne...

  • Page 177

    Chassis 5-15 • remove the protector 4. • remove the front fork cap bolt 5, spring seat 6, spacer 7, washer 8 and fork spring 9. ) • invert the front fork and stroke it several times to drain out fork oil. • hold the front fork in the inverted position for a few minutes to allow the fork oil to fully...

  • Page 178

    5-16 chassis • remove the cylinder c and rebound spring d. • remove the oil seal by slowly pulling out the inner tube. Note: be careful not to damage the inner tube. $ • remove the following parts from the inner tube. E oil lock piece f inner tube slide metal g outer tube slide metal h oil seal reta...

  • Page 179

    Chassis 5-17 cylinder ring inspect the cylinder ring for wear or damage. If it is worn or dam- aged, replace it with a new one. Note: the ring should be installed onto the cylinder with its oil passage notches 1 facing downward. Reassembly and installation reassemble and install the front fork in th...

  • Page 180

    5-18 chassis • insert the inner tube into the outer tube and install the oil seal 3 using the special tool. % 09940-52861: front fork oil seal installer • install the oil seal stopper ring 2. $ • install the dust seal 1. Cylinder bolt • apply thread lock “1342” to the cylinder bolt and tighten it to...

  • Page 181

    Chassis 5-19 fork oil • pour the specified fork oil into the inner tube. * 99000-99044-10g: suzuki fork oil #10 & capacity (each leg): 502 ml (gsf650) 507 ml (gsf650s) • move the inner tube up and down several strokes until no more bubbles come out from the oil. • keep the front fork vertically and ...

  • Page 182

    5-20 chassis installation • align the edge of the inner tube with the upper surface of the steering stem upper bracket. • tighten the front fork lower clamp bolts 1. # front fork lower clamp bolt 1: 23 n·m (2.3 kgf-m) • tighten the front fork cap bolt 2 and front fork upper clamp bolt 3. # front for...

  • Page 183: Handlebars And Steering

    Chassis 5-21 handlebars and steering construction # 1 steering stem upper bracket 7 handlebar a steering stem head nut 2 dust seal 8 handlebar spacer b handlebar holder bolt 3 steering stem upper bearing 9 handlebar switch assembly (lh) c front fork upper pinch bolt 4 steering stem lower bearing 0 h...

  • Page 184

    5-22 chassis handlebars removal • remove the following items from the handlebars. 1 rear view mirror 2 left handlebar switch box 3 handlebar balancer 4 grip rubber 5 clutch switch lead wires 6 clutch lever holder/clutch lever 7 rear view mirror 8 brake light switch lead wires 9 front brake master cy...

  • Page 185

    Chassis 5-23 • set the handlebar clamps with their punch marks b forward. • tighten the handlebar clamp bolts. Note: first tighten the handlebar clamp bolts c (front ones) to the specified torque. # handlebar clamp bolt: 23 n·m (2.3 kgf-m) • install the front brake master cylinder. ( !5-56) • apply ...

  • Page 186

    5-24 chassis steering removal (gsf650) • remove the front wheel. ( !5-8) • remove the front forks. ( !5-14) • remove the headlight. ( !6-41) • disconnect the couplers. • remove the headlight housing 1 and bracket 2. • remove the brake hose clamp 3. • remove the combination meter unit 4. • remove the...

  • Page 187

    Chassis 5-25 • remove the dust seal 7 and steering stem upper bearing 8. Removal (gsf650s) • remove the front wheel. ( !5-8) • remove the front forks. ( !5-14) • remove the brake hose clamp 1. • remove the cable guides 2. • remove the ignition switch using the special tools. % 09930-11920: torx bit ...

  • Page 188

    5-26 chassis inspection and disassembly inspect the removed parts for the following abnormalities. * handlebar distortion * distortion of the steering stem * bearing wear or damage * abnormal bearing noise * race wear or damage if any abnormal points are found, replace defective parts with new ones ...

  • Page 189

    Chassis 5-27 inner race • press in the lower inner race using the special tool. % 09941-74911: steering bearing installer bearing • apply suzuki super grease to the bearings, races and dust seals before remounting the steering stem. ' 99000-25010: suzuki super grease “a” steering stem • tighten the ...

  • Page 190

    5-28 chassis • install the ignition switch. % 09930-11920: torx bit jt40h 09930-11940: bit holder , 99000-32050: thread lock super “1322” steering tension adjustment check the steering tension as follows • support the motorcycle using a jack and raise the front wheel off the floor 20 – 30 mm. • make...

  • Page 191: Rear Wheel

    Chassis 5-29 rear wheel construction # 1 chain adjuster plate 9 retainer g rear axle 2 brake caliper bracket 0 wheel damper h rear wheel 3 brake disc a rear sprocket bolt i air valve 4 collar b rear sprocket mounting drum j balancer 5 dust seal c rear sprocket k cotter pin (for e-28) 6 bearing (rh) ...

  • Page 192

    5-30 chassis removal • support the motorcycle with the center stand. • remove the cotter pin. (e-28) • remove the rear axle nut 1. • remove the rear axle and disengage the drive chain from the rear sprocket. • remove the rear wheel. $ • remove the spacer 2 (lh) and collar 3 (rh). • remove the rear s...

  • Page 193

    Chassis 5-31 inspection and disassembly tire ........................................................... ( !2-18, 5-66) wheel ...................................................... ( !5-9) axle shaft............................................. ( !5-9) brake disc .......................................

  • Page 194

    5-32 chassis • remove the sprocket mounting drum bearing and wheel bear- ings using the special tool. % 09921-20240: bearing remover set $ wheel dampers inspect the dampers for wear and damage. Replace the damper if there is anything unusual. • remove the brake disc. Rear sprocket inspect the rear s...

  • Page 195

    Chassis 5-33 reassembly and installation reassembly and installation is in the reverse order of removal and disassembly. Pay attention to the follow- ing points: clearance right light left right spacer clearance bearing installer left right (for e-28) 100 n·m (10.0 kgf-m).

  • Page 196

    5-34 chassis bearings • apply grease to the bearings before installing. ' 99000-25010: suzuki super grease “a” • install new bearing and dust seal to the sprocket mounting drum using the special tool. % 09913-70210: bearing installer set • apply grease to the bearing and dust seal lip. ' 99000-25010...

  • Page 197

    Chassis 5-35 • tighten the rear sprocket nuts to the specified torque. # rear sprocket nut: 50 n·m (5.0 kgf-m) note: the stamped mark a on the rear sprocket should face outside. Wheel • install the rear wheel. ) • adjust the drive chain slack after installing the rear wheel. ( !2-14) • tighten the r...

  • Page 198: Rear Suspension

    5-36 chassis rear suspension construction # 1 rear shock absorber 2 rear cushion lever 3 rear cushion lever rod 4 bearing 5 spacer 6 bearing 7 spacer 8 bearing 9 spacer 0 spacer a spacer b bearing c spacer d pivot shaft e bearing f chain buffer g swingarm h chain cover i chain adjuster j chain adjus...

  • Page 199

    Chassis 5-37 removal • remove the rear wheel. ( !5-30) • remove the drive chain cover 1. • remove the brake hose union bolt 2. • remove the brake hose from the brake hose guide and clamps. $ • remove frame cover (lh). ( !5-4) • remove the rear shock absorber upper mounting bolt/nut 3. • remove the c...

  • Page 200

    5-38 chassis • remove the chain buffer 7, rear shock absorber 8, cushion lever 9 and cushion rods 0. • remove the chain adjusters a. Inspection and disassembly spacers • remove the spacers from the swingarm and cushion lever. • inspect the spacers for any flaws or other damage. If any defects are fo...

  • Page 201

    Chassis 5-39 • remove the swingarm bearings using the special tools. % 1 09923-74510: bearing remover 2 09923-73210: bearing remover 3 09930-30102: sliding shaft $ swingarm inspect the swingarm for damage. Cushion lever bearings insert the spacers into bearings, check the play by moving the spacers ...

  • Page 202

    5-40 chassis cushion lever and cushion rods inspect the cushion lever and cushion rods for damage. Swingarm pivot shaft measure the swingarm pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft. % 09900-20606: dial gauge (1/100 mm) 09900-20701: ma...

  • Page 203

    Chassis 5-41 • press needle bearings into the cushon rod pivot using the special tool. % 09924-84521: steering outer race installer • apply grease to the needle bearings. ' 99000-25010: suzuki super grease “a” cushion lever bearings • press needle bearings into the cushion lever using the special to...

  • Page 204

    5-42 chassis • cover the rear shock absorber with a transparent plastic bag 1. • hold the rear shock absorber 2 with a vice. • mark a hole with a 3 mm drill. ) installation install the swingarm and rear shock absorber in the reverse order of removal. Pay attention to the following points: • when rem...

  • Page 205

    Chassis 5-43 • tighten the cushion lever mounting nut 4 to the specified torque. # cushion lever mounting nut: 78 n·m (7.8 kgf-m) • tighten the rear shock absorber upper mounting nut 5 to the specified torque. # rear shock absorber upper mounting nut: 50 n·m (5.0 kgf-m) rear brake • remount the rear...

  • Page 206

    5-44 chassis left side right side 50 n.M 78 n.M 50 n.M 78 n.M 78 n.M 100 n.M (5.0 kgf-m) (5.0 kgf-m) (7.8 kgf-m) (10.0 kgf-m) (7.8 kgf-m) (7.8 kgf-m).

  • Page 207

    Chassis 5-45 final inspection and adjustment after installing the rear suspension and rear wheel, adjust the following before riding. * drive chain slack.................................( !2-14) * tire pressure.......................................( !2-18) suspension setting after installing the re...

  • Page 208: Front Brake

    5-46 chassis front brake construction # 1 master cylinder reservoir cap 8 brake hose #2 e brake caliper pistons 2 reservoir cap plate 9 brake pads f brake caliper 3 diaphragm 0 brake pad mounting pin g brake caliper holder 4 piston/cup set a clip a master cylinder holder bolt 5 master cylinder holde...

  • Page 209

    Chassis 5-47 ) $ brake pad replacement • remove the brake caliper. $ • remove the brake pads by removing the clip 1 and brake pad mounting pin 2. $ • install new brake pads. ) * this brake system is filled with an ethylene glycol-based dot 4 brake fluid. Do not use or mix different types of fluid, s...

  • Page 210

    5-48 chassis • tighten the brake caliper mounting bolts to the specified torque. # brake caliper mounting bolt: 39 n·m (3.9 kgf-m) ) brake fluid replacement • place the motorcycle on a level surface and keep the handle- bars straight. • remove the brake fluid reservoir cap and diaphragm. • suck up t...

  • Page 211

    Chassis 5-49 brake caliper removal and disassembly • drain brake fluid. ( !5-48) • disconnect the brake hose from the brake caliper by remov- ing the brake hose union bolt 1. Note: place a rag underneath the union bolt to catch any spilt of brake fluid. • remove the brake caliper by removing the bra...

  • Page 212

    5-50 chassis brake caliper inspection brake caliper inspect the brake caliper cylinder wall for nicks, scratches and other damage. If any damage is found, replace the caliper with a new one. Caliper pistons inspect the caliper pistons for scratches and other damage. If any damage is found, replace t...

  • Page 213

    Chassis 5-51 brake caliper reassembly and installation reassemble and install the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: • wash the caliper bores and pistons with the specified brake fluid. Particularly wash the dust seal grooves and pis...

  • Page 214

    5-52 chassis • tighten the brake caliper mounting bolts 1 to the specified torque. # brake caliper mounting bolt: 39 n·m (3.9 kgf-m) note: before remounting the brake caliper, push the brake caliper pis- tons all the way into the caliper. • after setting the brake hose union between the stopper, tig...

  • Page 215

    Chassis 5-53 master cylinder removal and disassembly • drain brake fluid. ( !5-48) • disconnect the front brake light switch lead wires 1. • place a rag underneath the brake hose union bolt 2 on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt 2 and disconnect the...

  • Page 216

    5-54 chassis • pull out the dust boot 8 and remove the snap ring 9. % 09900-06108: snap ring pliers • remove the piston/secondary cup, primary cup and spring. 0 secondary cup a piston b primary cup c spring master cylinder inspection master cylinder inspect the master cylinder bore for any scratches...

  • Page 217

    Chassis 5-55 master cylinder reassembly and installation reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: $ - specification and classification: dot 4 • when installing the brake light switch, align the projection on th...

  • Page 218

    5-56 chassis • when installing the master cylinder onto the handlebar, align the master cylinder holder’s mating surface a with the punch mark b on the handlebar and tighten the upper holder bolt first. A mating surface b punch mark c master cylinder d handlebar e upper holder bolt f clearance # mas...

  • Page 219: Rear Brake

    Chassis 5-57 rear brake construction # 1 brake caliper 9 reservoir g dust boot 2 brake caliper pistons 0 brake hose connector a air bleeder valve 3 piston seals a o-ring b brake caliper mounting bolt 4 dust seals b brake hose c brake caliper housing bolt 5 brake pads c master cylinder d brake hose u...

  • Page 220

    5-58 chassis ) $ brake pad replacement • remove the brake pads by removing the brake pad mounting pin 1 and spring 2. $ note: before installing pads, apply suzuki pbc grease or equiva- lent grease to the shim contact surface of caliper pistons. 99000-25110: suzuki pbc grease • install new brake pads...

  • Page 221

    Chassis 5-59 brake fluid replacement • place the motorcycle on a level surface. • remove the frame cover (rh). ( !5-4) • remove the brake fluid reservoir cap and diaphragm. • suck up the old brake fluid as much as possible. • fill the reservoir with new brake fluid. - specification and classificatio...

  • Page 222

    5-60 chassis brake caliper removal and disassembly • drain brake fluid. ( !5-59) • slightly loosen the brake caliper housing bolts 1 to facilitate later disassembly before removing the brake caliper. • disconnect the brake hose from the brake caliper by remov- ing the brake hose union bolt 2. Note: ...

  • Page 223

    Chassis 5-61 • place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. $ • remove the dust seals and piston seals. $ brake caliper inspection brake caliper...........................................( !5-50) brake caliper pistons .....

  • Page 224

    5-62 chassis piston seal • install the piston seals as shown in the illustration. • install the pistons to the caliper. 1 dust seal 2 piston seal 3 caliper note: before installing pads, apply suzuki pbc grease or equiva- lent grease to the shim contact surface of caliper pistons. 99000-25110: suzuki...

  • Page 225

    Chassis 5-63 master cylinder removal and disassembly • remove the frame cover (rh). ( !5-4) • drain brake fluid. ( !5-59) • remove the reservoir mounting bolt 1. • place a rag underneath the brake hose union bolt 2 on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bo...

  • Page 226

    5-64 chassis • remove the push rod 0, piston/primary cup a and spring b. Master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or other dam- age. Piston inspect the piston surface for any scratches or other damage. Rubber parts inspect the primary/secondary cu...

  • Page 227

    Chassis 5-65 • tighten the master cylinder mounting bolts 1 to the specified torque. • tighten the locknut 2 to the specified torque. • after setting the brake hose union to the stopper, tighten the union bolt 3 to the specified torque. # master cylinder mounting bolt 1: 25 n·m (2.5 kgf-m) master cy...

  • Page 228: Tire And Wheel

    5-66 chassis tire and wheel tire 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 efficient as well as functional. For...

  • Page 229

    Chassis 5-67 valve inspect the valve after the tire is removed from the rim. Replace the valve with a new one if the seal a rubber is peeling or has damage. Note: if the external appearance of the valve shows no abnormal con- dition, removing of the valve is not necessary. If the seal has abnormal d...

  • Page 230

    5-68 chassis tire • apply tire lubricant to the tire bead. • when installing the tire onto the wheel, observe the following points. $ • when installing the tire, the arrow a on the side wall should point to the direction of wheel rotation. • align the chalk mark put on the tire at the time of remova...

  • Page 231

    Chassis 5-69 • in this condition, check the “rim line” b cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire comp...

  • Page 232: Drive Chain

    5-70 chassis drive chain use the special tool in the following procedures, to cut and rejoin the drive chain. % 09922-22711: drive chain cutting and joining tool set note: when using the special tool, apply a small quantity of grease to the threaded parts of the special tool. Cutting • set up the sp...

  • Page 233

    Chassis 5-71 • place the drive chain link being disjointed on the holder part 8 of the tool. • turn in both the adjuster bolt 6 and pressure bolt “a” 3 so that each of their end hole fits over the chain joint pin properly. • tighten the pressure bolt “a” 3 with the bar. • turn in the pressure bolt “...

  • Page 234

    5-72 chassis • apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 0. Note: when positioning the joint plate 0 on the tool, its stamp mark must face the joint plate holder 3 side. • set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to...

  • Page 235

    Chassis 5-73 • stake the joint pin by turning (approximately 7/8 turn) the pressure bolt “a” 3 with the bar until the pin end diameter becomes the specified dimension. & pin end diameter specification d $ • adjust the drive chain, after connecting it. ( !2-14) rk 5.45 – 5.85 mm * after joining of th...

  • Page 236: Riding Position Adjustment

    5-74 chassis riding position adjustment seat height adjustment • remove the seat assembly. ( !5-4) • remove the dampers. • remove the front seat. • adjust the position of bracket 1. A: for low (normal) position b: for high position • reinstall the front seat and set the position of bracket 2. A: for...

  • Page 237

    Chassis 5-75 • install the dampers. Note: dampers are used in two ways. Pay attention to the direction of dampers when installing them. A: for low (normal) position b: for high position $ handlebar height adjustment • remove the cable guides. (gsf650s) • remove the handlebar holder nuts and handleba...

  • Page 238: Electrical System

    Electrical system 6-1 electrical system contents 6 cautions in servicing ...........................................................................6- 3 connector .........................................................................................6- 3 coupler ......................................

  • Page 239: Electrical System

    6-2 electrical system electrical system contents combination meter ............................................................................... 6-36 removal ............................................................................................. 6-36 disassembly ................................

  • Page 240: Cautions In Servicing

    Electrical system 6-3 cautions in servicing connector • when disconnecting a connector, be sure to hold the termi- nals; do not pull the lead wires. • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its ...

  • Page 241

    6-4 electrical system semi-conductor equipped part • be careful not to drop the part with a semi-conductor built in such as ignitor. • when inspecting this part, follow inspection instruction strictly. Neglecting proper procedure may cause damage to this part. Battery • the mf battery used in this m...

  • Page 242

    Electrical system 6-5 using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 243

    6-6 electrical system location of electrical components 1 ignition coil 5 rear brake light switch 2 ignition switch 6 throttle position sensor 3 handlebar switch (rh) 7 signal generator 4 front brake light switch 8 oil pressure switch.

  • Page 244

    Electrical system 6-7 9 clutch lever position switch d main fuse i generator 0 handlebar switch (lh) e battery j speed sensor a fuse box f ignitor k speed sensor rotor b turn signal/side-stand relay g horn l gear position switch c starter relay h starter motor m side-stand switch.

  • Page 245: Charging System

    6-8 electrical system charging system description (generator with ic regulator) the generator features a solid-state regulator that is mounted inside the generator. All regulator compo- nents are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator volt- age...

  • Page 246

    Electrical system 6-9 troubleshooting battery runs down quickly step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leakage. ( !6-11) is the battery for current leakage ok? Step 3 1) measure the charging vol...

  • Page 247

    6-10 electrical system step 7 1) inspect wirings. Is the wirings ok? Battery overcharges • faulty regulator/rectifier • faulty battery • poor contact of generator lead wire coupler yes faulty battery no • short circuit of wire harness • poor contact of couplers.

  • Page 248

    Electrical system 6-11 inspection battery current leakage • turn the ignition switch to the off position. • remove the seat. ( !5-4) • remove the luggage box. ( !5-4) • disconnect the battery - lead wire. • measure the current between - battery terminal and the - battery lead wire using the multi-ci...

  • Page 249: Generator

    6-12 electrical system generator ( 1 generator driven gear 9 stud bolt g ic regulator 2 damper (4 pcs.) 0 retainer h brush holder 3 damper housing a rotor i generator end cover 4 oil seal b bearing cover #2 a generator driven gear nut 5 o-ring c slip ring side bearing b generator mounting bolt 6 spa...

  • Page 250

    Electrical system 6-13 removal and disassembly • disconnect the battery - lead wire. ( !6-11) • remove the engine sprocket cover 1. • disconnect the generator lead wire 2 and coupler 3. • remove the generator. • hold the generator driven gear using a vise 4 and two pieces of wood 5 as shown. Then, r...

  • Page 251

    6-14 electrical system • remove the brush holder 8 and ic regulator 9. • remove the stator coil lead wires mounting screws 0. • remove the rectifier a. Note: straighten the stator coil lead wires using long-nose pliers, then remove the rectifier. • remove the generator housing nuts. • separate the g...

  • Page 252

    Electrical system 6-15 • remove the bearing retainer g. • remove the bearing h, washer i and spacer j. • remove the oil seal k. Inspection rotor bearings inspect the rotor bearings for abnormal noise. Also, rotate the rotor bearings by hand and make sure that they rotate smoothly. If there is anythi...

  • Page 253

    6-16 electrical system generator driven gear dampers inspect the generator driven gear dampers for wear and dam- age. If any defects are found, replace the generator driven gear dampers as a set. Note: when installing the generator driven gear dampers, apply suzuki moly paste to the damper surface. ...

  • Page 254

    Electrical system 6-17 carbon brushes measure the length of the carbon brushes as shown. If the mea- surement is less then the service limit, replace the carbon brushes with new ones. $ brush length service limit: 4.5 mm " 09900-20102: vernier calipers (200 mm) rectifier measure the voltage among th...

  • Page 255

    6-18 electrical system generator reassembly and remounting reassemble and remount the generator in the reverse order of removal and disassembly. Pay attention to the following points: # • apply suzuki super grease “a” to the lip of the oil seal. . 99000-25010: suzuki super grease “a” • apply a small...

  • Page 256

    Electrical system 6-19 note: before reinstalling the slip ring side bearing onto the generator end housing, turn the expander ring and align the expander ring lug with the center of the chamfered edge of the bearing outer race. • tighten the generator housing nuts 1 to the specified torque. ( genera...

  • Page 257: System

    6-20 electrical system starter system and side-stand ignition interlock system starter system description the starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, gear position switch, st...

  • Page 258

    Electrical system 6-21 the circuit consists of the turn signal/side-stand relay, neutral indicator light and switches. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side- stand is either up or down. The gear position and side-st...

  • Page 259

    6-22 electrical system troubleshooting starter motor will not run step 1 1) shift the transmission into neutral. Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “run” position and listen for a click from the starter relay when the starter button is pushed. Is a...

  • Page 260

    Electrical system 6-23 starter motor removal and disassembly • remove the starter motor. • disassemble the starter motor as shown. ( 1 o-ring 5 starter motor case 9 brush spring 2 housing end (inside) 6 armature 0 housing end (outside) 3 o-ring 7 brush 4 o-ring 8 brush holder item n·m kgf-m a 3 0.3 ...

  • Page 261

    6-24 electrical system starter motor inspection carbon brushes inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any damages are found, replace the brush assembly with a new one. Commutator iinspect the commutator for discoloration, abnormal wear or undercut a. If ...

  • Page 262

    Electrical system 6-25 • apply suzuki super grease “a” to the oil seal lip. . 99000-25010: suzuki super grease “a” • apply a small quantity of suzuki moly paste to the arma- ture shaft. ) 99000-25140: suzuki moly paste • align the marks on the housing ends with the marks on the starter motor case. •...

  • Page 263

    6-26 electrical system starter relay inspection • remove the seat. ( !5-4) • pull out the starter relay and remove the luggage box. ( !5-4) • disconnect the battery - lead wire from the battery. ( !6-11) • remove the starter relay cover 1. • disconnect the starter motor lead wire 2, battery + lead w...

  • Page 264

    Electrical system 6-27 side-stand/ignition interlock system part inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Gear po...

  • Page 265

    6-28 electrical system turn signal/side-stand relay the turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • remove the frame cover (lh). ( !5-4) • remove the turn signal/side-stand relay 1. First check the insulation between d and e terminals with the mul...

  • Page 266

    Electrical system 6-29 ignition system (digital ignitor) description the fully transistorized ignition system consists of the following components: a signal generator (which is made up of the signal generator rotor and pickup coil), ignitor, throttle position sensor, two ignition coils and four spar...

  • Page 267

    6-30 electrical system troubleshooting no spark or poor spark 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 1 1) check the ignition...

  • Page 268

    Electrical system 6-31 step 6 1) measure the signal generator peak voltage and its resistance. ( !6-33 to -35) note: the signal generator peak voltage inspection is applicable only with the multi-circuit tester and peak volt adaptor. Is the peak voltage and resistance ok? Yes • faulty ignitor • poor...

  • Page 269

    6-32 electrical system inspection ignition coil primary peak voltage • remove the fuel tank. ( !4-3) • disconnect all the spark plug caps. • connect four new spark plugs to each spark plug cap and ground them on the cylinder. Note: be sure that all the spark plugs are connected properly and the batt...

  • Page 270

    Electrical system 6-33 measure ignition coil primary peak voltage (for #2 and #3 cylin- ders) in the same manner as for cylinders #1 and #4. Ignition coil (for #2 and #3 cylinders): b/y terminal – ground ( + probe) ( - probe) note: do not disconnect the ignition coil primary lead wire. $ ignition co...

  • Page 271

    6-34 electrical system • shift the transmission into neutral, turn the ignition switch to the “on” position and grasp the clutch lever. • press the starter button and allow the engine to crank for a few seconds, and then measure the signal generator peak voltage. • repeat the above procedure a few t...

  • Page 272

    Electrical system 6-35 pickup coil resistance • remove the side frame cover and disconnect the signal gen- erator coupler. ( !6-34) • measure the resistance between the lead wires and ground. If the resistance is not within the specified value, the signal gen- erator stator must be replaced. $ picku...

  • Page 273: Combination Meter

    6-36 electrical system combination meter removal gsf650 • remove the headlight. ( !6-41) • disconnect the couplers and remove the headlight housing 1. • remove the combination meter unit 2. Gsf650s • remove the combination meter unit. ( !5-5) disassembly • disassemble the combination meter unit as f...

  • Page 274

    Electrical system 6-37 speedometer tachometer high beam oil neutral turn signal (r) adjust select turn signal (l) 11 10 9 8 7 16 15 14 13 12 1 2 3 4 5 6 1: power source of speed sensor 2: tachometer 3: oil - 4: speed sensor signal 5: battery + 6: blank 7: blank 8: lg : turn (r) 9: blank 10: blank 11...

  • Page 275

    6-38 electrical system inspection led (light emitting diode) • check that the leds (oil pressure indicator light and meter panel illumination) immediately light up when the ignition switch is turned to on. • check that other leds (neutral indicator light, high-beam indicator light and turn signal in...

  • Page 276

    Electrical system 6-39 • replace the 180 Ω resister b with a 5 Ω one c. • the fuel level indicator is operating correctly if the lcd bars increase to five (full) when the ignition switch is turned to on. • if either test detects a malfunctioning fuel level indicator, replace the combination meter un...

  • Page 277

    6-40 electrical system • connect a 12 v battery (between b and b/w), 10 k Ω resistor (between b/r and b) and multi-circuit tester (tester + probe to b and tester - probe to b/r) as shown. " 09900-25008: multi circuit tester set ' tester knob indication: voltage (&) • move a screwdriver back and fort...

  • Page 278: Lamps

    Electrical system 6-41 lamps headlight gsf650 headlight bulb 1: 12 v 60/55 w position light bulb 2: 12 v 5 w headlight beam adjustment • adjust the headlight beam, both horizontally and vertically. A: horizontal adjuster b: vertical adjuster note: to adjust the headlight beam, adjust the beam horizo...

  • Page 279

    6-42 electrical system • disconnect the headlight coupler 1 and position light coupler 2. • remove the position light socket 3. • remove the socket cover 4. • remove the headlight bulb 5 by unhooking the bulb holder spring 6. # • install the headlight assembly so that the hook a on the headlight bez...

  • Page 280

    Electrical system 6-43 gsf650s headlight bulb 1: 12 v 55 w × 2 position light bulb 2: 12 v 5 w × 2 headlight beam adjustment • insert 5 mm hexagon wrench as shown and adjust the low and hi headlight beam horizontally. A: horizontal adjuster (for both low and hi beam) note: to adjust the headlight be...

  • Page 281

    6-44 electrical system bulb replacement • remove the combination meter unit. ( !5-5) • remove the position light sockets 1. • disconnect the headlight (low) coupler 2 and remove the rubber boot 3. • remove the headlight bulb (low) 4 by unhooking the bulb holder spring 5. # • remove the headlight bul...

  • Page 282

    Electrical system 6-45 brake light/taillight and license plate light brake light/taillight bulb 1: 12 v 21/5 w # turn signal lights turn signal light bulb: 12 v 21 w × 4 # if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent prematu...

  • Page 283: Relays

    6-46 electrical system relays turn signal/side-stand relay the turn signal/side-stand relay, which is located under the seat, is composed of the turn signal relay, and the side-stand relay and diode. Removal • remove the turn signal/side-stand relay 1. ( !6-28) inspection before removing the turn si...

  • Page 284: Switches

    Electrical system 6-47 switches ignition switch removal and installation gsf650 • remove the right frame head cover. ( !5-5) • disconnect the ignition switch coupler 1. • remove the headlight housing. ( !6-36) • remove the ignition switch using the special tools. " 09930-11920: torx bit jt40h 09930-...

  • Page 285

    6-48 electrical system inspection inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Turn signal light switch dimmer switch front brake light switch rear brake light switch position color position color w y o lg lbl ...

  • Page 286: Battery

    Electrical system 6-49 battery specifications a anode plates e stopper b separator (fiberglass plate) f filter c cathode plates g terminal d upper cover breather h safety valve initial charging filling electrolyte • remove the aluminum tape 1 which seals the battery filler holes 2. Note: when fillin...

  • Page 287

    6-50 electrical system • make sure that air bubbles 6 are coming up each electrolyte container, and leave in this position for about more than 20 minutes. Note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the contai...

  • Page 288

    Electrical system 6-51 servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 289: Servicing Information

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

  • Page 290: Troubleshooting

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

  • Page 291

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

  • Page 292

    7-4 servicing information complaint symptom and possible causes remedy transmission jumps out of gear. 1. Worn gear. 2. Worn or distorted gearshift fork. 3. Weakened gearshift stopper spring. 4. Worn gearshift pawl. Replace. Replace. Replace. Replace. Engine idles poorly. 1. Valve clearance out of a...

  • Page 293

    Servicing information 7-5 complaint symptom and possible causes remedy engine overheats. 1. Carbon build-up on piston crown. 2. Insufficient amount of engine oil. 3. Defective oil pump. 4. Clogged oil circuit. 5. Float chamber fuel level too low. 6. Air leakage from intake pipe. 7. Incorrect engine ...

  • Page 294

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

  • Page 295

    Servicing information 7-7 brakes complaint symptom and possible causes remedy rear wheel wobbles. 1. Distorted wheel rim. 2. Worn rear wheel bearing. 3. Defective or incorrect tire. 4. Worn swingarm bearing. 5. Worn rear suspension bush. 6. Loose rear suspension fastener. Replace. Replace. Replace. ...

  • Page 296

    7-8 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking. 1. Defective ignition coil. 2. Defective spark plug. 3. Defective signal generator. 4. Defective ignitor. Replace. Replace. Replace. Replace. Spark plug is wet or quickly becomes fouled wi...

  • Page 297

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

  • Page 298: Wiring Diagram

    7-10 servicing information wiring diagram gsf650 push free on off lock p off ru n off on push l push r hi lo push on off push bl 1 2 34 5 on off on off 12v on off 12 3 4 1 1.Head hi 2.Head lo 3.Ignition 4.Signal 5.Meter 10a 10a 15a 15a 10a free speedometer ignition switch ignition coil side-st and s...

  • Page 299

    Servicing information 7-11 gsf650s push free on off lock p off ru n off on push l push r hi lo push push bl 1 2 34 5 on off on off 12v on off 12 3 4 1 1.Head hi 2.Head lo 3.Ignition 4.Signal 5.Meter 10a 10a 15a 15a 10a free on off lg b/w lg b/w w b/w w b/w y b/w y b/w b b/w b b/w b b/w b b/w b b/w b...

  • Page 300

    7-12 servicing information wire harness, cable and hose routing wire harness routing set the label f a ce of ignitor under side . T aping clamp neutr a l s w itch coupler clamp clamp ther mo s w itch wir ing har ness (except e-02,19) t ube: under side clamp ther mo s w itch clutch cab le star ter ca...

  • Page 301

    Servicing information 7-13 clamp t u rn lh and rh speedometer clamp wir ing har ness wir ing har ness no . 2 clamp t u rn signal (rh) t u rn signal (lh) 10 mm ices label (e-28 only) guide ignition s w itch handle s w itch (lh) 14 n·m (1.4 kgf-m) 14 n·m (1.4 kgf-m) clamp wir ing har ness speed sensor...

  • Page 302

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

  • Page 303

    Servicing information 7-15 cable routing (gsf650) clutch cable starter cable pass through the starter cable left side of the pipe. Trottle cable no. 1 pass through the cables under the hoses. Pass through the starter cable over the throttle cables. Pass through the clutch cable behind the #1 carbure...

  • Page 304

    7-16 servicing information cable routing (gsf650s) trottle cable no. 1 trottle cable no. 2 pass through the cables under the hoses. Pass through the starter cable over the throttle cables. Pass through the clutch cable behind the #1 carburetor and #2 carburetor. Pass through the starter cable left s...

  • Page 305

    Servicing information 7-17 carburetor hose routing strainer air vent hose air vent hose vacuum hose breather hose apply heat sink. 3 n·m (0.3 kgf-m) for e-02, 19 only carburetor clamp position right side air cleaner side left right engine side left right 0 – 10˚ fuel hose wiring harness.

  • Page 306

    7-18 servicing information fuel tank drain hose routing breather hose no. 1 drain hose breather hose no. 3 breather hose no. 2 clamp air cleaner drain hose.

  • Page 307

    Servicing information 7-19 pair (air supply) system hose routing tighten the valve and bracket together. Be careful not to touch the hoses and cables. Matching mark matching mark #3 #4 matching mark matching mark insert firmly set expansion side to the carburetor. Pass through the air cleaner hose i...

  • Page 308

    7-20 servicing information front brake hose routing 28˚ after the brake hose union touching to the stopper, tighten the union bolt. After the brake hose union touching to the stopper, tighten the union bolt. After positioning the clamp with the stopper, tighten the bolt. After positioning the clamp ...

  • Page 309

    Servicing information 7-21 rear brake hose routing 42˚ after the brake hose union touching to the stopper, tighten the union bolt. Face the clamp backward face the clamp forward after the brake hose union touching to the stopper, tighten the union bolt. White marking insert firmly pass through the h...

  • Page 310: Ignition Coil Installation

    7-22 servicing information ignition coil installation spark plug cap installation frame #4 #1 #3 #2 fw d fwd plug cap plug cap cover fwd fwd.

  • Page 311: Fuel Tank Set Up

    Servicing information 7-23 fuel tank set up apply adesive agent to the cushion rubber. Be careful for assembling direction. 4.4 n·m (0.44 kgf-m).

  • Page 312: Muffler Mounting

    7-24 servicing information front footrest bracket set-up muffler mounting footrest bracket washer bolt washer frame apply permatex 1372. Muffler connector chamfer 23 n·m (2.3 kgf-m) 23 n·m (2.3 kgf-m).

  • Page 313: Side-Stand Springs

    Servicing information 7-25 side-stand springs center stand springs side-stand spring 40 n·m (4.0 kgf-m) spring center stand spring.

  • Page 314: Exterior Parts Construction

    7-26 servicing information exterior parts construction 1 cowling body 4 lower panel 7 frame 2 wind screen 5 upper panel 3 cowling brace 6 meter panel lid.

  • Page 315: Frame Cover Cushion

    Servicing information 7-27 frame cover cushion seat lock cable routing cushion cushion screw plate seat lock cable seat lock.

  • Page 316: Taillight Installaion

    7-28 servicing information taillight installaion reflex refrector installation seat tail cover tail lamp 2.0 n·m (0.2 kgf-m) cusion reflex refrector 1.8 n·m (0.18 kgf-m) rear fender.

  • Page 317

    Servicing information 7-29 battery protector installation protector protector battery protector 50 mm 50 mm.

  • Page 318: Special Tools

    7-30 servicing information special tools 09900-00410 hexagon wrench set 09900-06106 snap ring pliers 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09004 impact driver set 09900-20102 vernier calipers (1/20 mm, 200 mm) 09900-20202 micrometer (1/100 mm, 25 – 50 mm) 09900-20203 microm...

  • Page 319

    Servicing information 7-31 09913-75520 bearing installer 09913-75830 bearing remover 09940-34520 t-handle 09940-34531 attachment (a) 09914-25811 “t” type hexagon wrench (6 mm) 09915-40610 oil filter wrench 09915-64510 compression gauge set 09913-10750 (adaptor) 09915-74510 oil pressure gauge 09915-7...

  • Page 320

    7-32 servicing information note: when ordering a special tool, please confirm whether it is available or not. 09922-22711 drive chain cutting and joining tool set 09923-73210 bearing remover 09923-74510 bearing remover (20 – 35 mm) 09924-84510 bearing installer set 09925-98221 bearing remover 09930-...

  • Page 321: Tightening Torque

    Servicing information 7-33 tightening torque engine item n·m kgf-m cylinder head cover bolt (10 pcs.) 14 1.4 cylinder head cover plug 15 1.5 cylinder head cover union bolt 20 2.0 cylinder head nut [m: 10] 37 3.7 cylinder head bolt [m: 6] 10 1.0 cylinder head plug 28 2.8 cylinder base nut 9 0.9 cylin...

  • Page 322

    7-34 servicing information chassis item n·m kgf-m spark plug 11 1.1 cam chain guide mounting bolt 10 1.0 item n·m kgf-m steering stem head nut 65 6.5 front fork upper clamp bolt 23 2.3 front fork lower clamp bolt 23 2.3 front fork cap bolt 23 2.3 front fork cylinder bolt 30 3.0 front axle 65 6.5 fro...

  • Page 323

    Servicing information 7-35 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 n·m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9...

  • Page 324: Service Data

    7-36 servicing information service data valve + guide unit: mm camshaft + cylinder head unit: mm item standard limit valve diameter in. 23 — ex. 20 — valve clearance (when cold) in. 0.10 – 0.15 — ex. 0.18 – 0.23 — valve-guide to valve-stem clearance in. 0.020 – 0.047 — ex. 0.040 – 0.067 — valve stem...

  • Page 325

    Servicing information 7-37 cylinder + piston + piston ring unit: mm conrod + crankshaft unit: mm item standard limit compression pressure 1 000 – 1 500 kpa (10 – 15 kgf/cm 2 ) 800 kpa (8 kgf/cm 2 ) compression pressure difference — 200 kpa (2 kgf/cm 2 ) piston-to-cylinder clearance 0.015 – 0.025 0.1...

  • Page 326

    7-38 servicing information oil pump clutch unit: mm transmission + drive chain unit: mm except ratio item standard limit oil pump reduction ratio 1.898 (75/43 × 37/34) — oil pressure (at 60 °c, 140 °f) above 300 kpa (3.0 kgf/cm 2 ) below 600 kpa (6.0 kgf/cm 2 ) at 3 000 r/min. — item standard limit ...

  • Page 327

    Servicing information 7-39 carburetor item specification e-02, 19 e-19 u-type carburetor type keihin cvr32 ← bore size 32.5 ← i.D. No. 38g0 38g2 idle r/min 1 200 ± 100 r/min ← float height 17.0 mm ← main jet (m.J.) #105 (for carburetor #1, 4) #102 (for carburetor #2, 3) ← main air jet (m.A.J.) #50 ←...

  • Page 328

    7-40 servicing information electrical unit: mm item specification note ignition timing 10° b.T.D.C. At 1 200 r/min. Firing order 1•2•4•3 spark plug type ngk: cr8ek denso: u24etr gap 0.6 – 0.7 spark performance over 8 at 1 atm. Pickup coil resistance approx. 135 – 200 Ω tester range: (× 100 Ω) signal...

  • Page 329

    Servicing information 7-41 wattage unit: w brake + wheel unit: mm item specification gsf650 gsf650s headlight hi 60 55 lo 55 ← position light 5 5 × 2 brake light/taillight 21/5 × 2 ← turn signal light 21 × 4 ← speedometer light led ← tachometer light led ← turn signal indicator light led × 2 ← high ...

  • Page 330

    7-42 servicing information suspension unit: mm tire item standard limit note front fork stroke 130 — front fork inner tube o.D. 41 — front fork spring free length 344.3 (gsf650) 338.9 (gsf650s) 337 (gsf650) 332 (gsf650s) front fork oil level 108 (gsf650) 104 (gsf650s) — rear wheel travel 126 — swing...

  • Page 331

    Servicing information 7-43 fuel + oil item specification note fuel type used only unleaded gasoline of at least 87 pump octane or 91 octane (r/2 + m/2) or higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with...

  • Page 332

    Prepared by november, 2004 part no. 99500-36150-01e printed in japan 340

  • Page 333

    Printed in japan k5.