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- GSX650F
- Supplementary Service Manual
Suzuki GSX650F Supplementary Service Manual
Summary of GSX650F
Page 1
Gsx650f use this manual with: gsf650/s service manual (99500-36170-01e) 9 9 5 0 1 - 3 6 1 8 0 - 0 1 e.
Page 2: Foreword
Foreword this supplementary service manual is a supplement to suzuki gsf650/s service manual. It has been prepared exclusively for the following applicable model. Applicable model: gsx650fk8 this supplementary service manual describes only service information which differ from that of the main man- ...
Page 3: Table of Contents
00 0 1 2 3 4 5 6 9 precautions...............................................................00-* precautions .............................................................00-* general information ................................................... 0-i general information ...............................
Page 5: Section 0
Table of contents 0- i 0 section 0 contents general information general information ................................ 0a-1 general description .............................................0a-1 symbols ...............................................................0a-* abbreviations .....................
Page 6: General Information
0a-1 general information: general information general information general description vehicle side view (gsx650fk8) b817h20101016 note difference between illustration and actual motorcycles may exist depending on the markets. Right side left side country and area codes (gsx650fk8) b817h20101017 the ...
Page 7
General information: 0a-2 warning, caution and information labels location (gsx650fk8) b817h20101018 [a] [b] [c] [d] [e] 1, 11 12, 13 7 2 3 5 4 10 8 9 6 i817h2010003-03 gsx650f gsx650fu 1. Noise label for e-03, 24, 33 — 2. Information label for e-03, 28, 33 — 3. Vacuum hose routing label for e-33 — ...
Page 8
0a-3 general information: specifications specifications (gsx650fk8) b817h20107005 note • these specifications are subject to change without notice. • any differences between the gsf650/sk7 (’07-model) and gsx650fk8 (’08-model) in specifications are indicated an asterisk mark (*). Dimensions and dry ...
Page 9
General information: 0a-4 special tools and equipment special tool b817h20108001 09930–82720 mode select switch.
Page 10: Maintenance and Lubrication
0b-1 maintenance and lubrication: general information maintenance and lubrication scheduled maintenance periodic maintenance schedule chart (gsx650fk8) b817h20205003 note i = inspect and clean, adjust, replace or lubricate as necessary. R = replace. T = tighten. Item interval km 1 000 6 000 12 000 1...
Page 11
Maintenance and lubrication: 0b-2 lubrication points (gsx650fk8) b817h20205004 proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. Note • before lubricating each part, clean off any rusty spots ...
Page 12: Service Data
0c-1 service data: general information service data specifications service data (gsx650fk8) b817h20307007 note • these specifications are subject to change without notice. • any differences between the gsf650/sk7 (’07-model) and gs650fk8 (’08-model) in service data are indicated an asterisk mark (*)...
Page 13
Service data: 0c-2 wattage unit: w tire suspension unit: mm (in) item specification headlight hi * 60 lo * 55 position/parking light * 5 x 2 brake light/taillight 21/5 turn signal light 21 x 4 license plate light 5 speedometer light led tachometer light led turn signal indicator light led x 2 high b...
Page 14
0c-3 service data:.
Page 15: Section 1
Table of contents 1- i 1 section 1 contents engine precautions ................................................. 1-* precautions.............................................................. 1-* precautions for engine........................................... 1-* engine general information and diag...
Page 16
1-ii table of contents pair reed valve removal and installation........ 1b-* pair control solenoid valve removal and installation......................................................... 1b-* pair system inspection ..................................... 1b-* crankcase breather (pcv) hose inspection.....
Page 17
Table of contents 1-iii engine lubrication system ..................... 1e-* precautions............................................................1e-* precautions for engine oil ...................................1e-* schematic and routing diagram.........................1e-* engine lubrication sy...
Page 18
1-iv table of contents repair instructions .............................................. 1h-* ignition coil / plug cap and spark plug removal and installation................................... 1h-* spark plug inspection and cleaning ................... 1h-* ignition coil / plug cap inspection .......
Page 19
Engine general information and diagnosis: 1a-1 engine engine general information and diagnosis general description self-diagnosis function (gsx650fk8) b817h21101003 the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be...
Page 20
1a-2 engine general information and diagnosis: dealer mode the defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on lcd (display) panel. Malfunction means that the ecm does not receive sig...
Page 21
Engine general information and diagnosis: 1a-3 3) start the engine or crank the engine for more than 4 seconds. 4) turn the special tool’s switch on. 5) check the dtc to determine the malfunction part. Refer to “dtc table in related manual”. Special tool (a): 09930–82720 (mode select switch) 6) afte...
Page 22: Engine Mechanical
1d-1 engine mechanical: engine engine mechanical schematic and routing diagram throttle cable routing diagram (gsx650fk8) b817h21402003 “a” 2 3 4 2 1 5 6 7 3 4 “ a ” “ a ” i817h2140001-01 1. Wiring harness 4. Throttle cable no. 2 7. Ignition switch lead wire 2. Cable guide 5. Handlebar switch lead w...
Page 23: Section 6
Table of contents 6- i 6 section 6 contents steering precautions ................................................. 6-* precautions.............................................................. 6-* precautions for steering ........................................ 6-* steering general diagnosis..........
Page 24: Steering / Handlebar
6b-1 steering / handlebar: steering steering / handlebar repair instructions handlebar construction (gsx650fk8) b817h26206012 special tools and equipment recommended service material b817h26208003 note required service material is also described in the following. “handlebar construction (gsx650fk8) ...
Page 25: Section 9
Table of contents 9- i 9 section 9 contents body and accessories precautions ................................................. 9-* precautions.............................................................. 9-* precautions for electrical system .......................... 9-* component location ..........
Page 26
9-ii table of contents horn inspection ................................................... 9c-* horn removal and installation ............................ 9c-* combination meter components (gsx650fk8) ...................................................9c-2 combination meter removal and installation ...
Page 27: Wiring Systems
Wiring systems: 9a-1 body and accessories wiring systems schematic and routing diagram wiring diagram (gsx650fk8) b817h29102007 refer to “wire color symbols in section 0a in related manual”..
Page 28
9a-2 wiring systems: for e-02, 19 m engine st op switch fuel pump st ar ter butt o n fr ont brake switch handleb ar switch (r) ignition switch speed sensor side st and switch free push brake light switch ignition coil #1 pa ir solenoid fa n rela y fa n m o to r ho2 sensor ect sensor to sensor fuel p...
Page 29
Wiring systems: 9a-3 for e-03, 24, 28 m engine st op switch fuel pump st ar ter butt o n fr ont brake switch handleb ar switch (r) ignition switch speed sensor side st and switch free push brake light switch ignition coil #1 pa ir solenoid fa n rela y fa n mo to r ho2 sensor ect sensor gp switch to ...
Page 30
9a-4 wiring systems: wiring harness routing diagram (gsx650fk8) b817h29102008 2 4 “c” “a” “b” 3 3 3 1 i817h2910903-02 1. Evap purge control valve (e-33 only) “a”: pass the evap purge control valve lead wire lower the clutch hose (e-33 only). 2. Wiring harness no. 1 “b”: do not make slacked lead wire...
Page 31: Lighting Systems
Lighting systems: 9b-1 body and accessories lighting systems repair instructions headlight components (gsx650fk8) b817h29206024 fwd fw d 1 3 4 4 3 2 i817h2920001-01 1. Headlight low beam bulb (12 v 55 w, h7) 3. Position light bulb (12 v 5 w x 2) 2. Headlight high beam bulb (12 v 60 w, hb3) 4. Bulb c...
Page 32
9b-2 lighting systems: headlight removal and installation (gsx650fk8) b817h29206025 removal 1) remove the body cowling assembly. Refer to “exterior parts removal and installation (gsx650fk8) in section 9d (page 9d-5)”. 2) remove the headlight assembly (1). Installation installation is in the reverse...
Page 33
Lighting systems: 9b-3 3) replace the high beam bulb (3). 4) reinstall the removed parts. Position light 1) remove the combination meter assembly. Refer to “combination meter removal and installation (gsx650fk8) in section 9c (page 9c-2)”. 2) remove the upper panel. Refer to “exterior parts removal ...
Page 34
9b-4 lighting systems: reflex refractor construction (gsx650fk8) b817h29206028 specifications service data (gsx650fk8) b817h29207003 wattage unit: w tightening torque specifications b817h29207004 note the specified tightening torque is also described in the following. “reflex refractor construction ...
Page 35
Combination meter / fuel meter / horn: 9c-1 body and accessories combination meter / fuel meter / horn general description combination meter system description (gsx650fk8) b817h29301002 this combination meter mainly consists of the stepping motor, lcd (liquid crystal display) and led (light emitting...
Page 36
9c-2 combination meter / fuel meter / horn: repair instructions combination meter components (gsx650fk8) b817h29306019 combination meter removal and installation (gsx650fk8) b817h29306020 removal 1) remove the screws (1) and pull out the combination meter assembly (2) from the upper panel. 2) discon...
Page 37
Combination meter / fuel meter / horn: 9c-3 installation install the combination meter in the reverse order of removal. Note fix the boot of the combination meter coupler properly. Combination meter disassembly and assembly (gsx650fk8) b817h29306021 refer to “combination meter removal and installati...
Page 38
9c-4 combination meter / fuel meter / horn: 2) with the adjuster switch (1) pressed, turn the ignition switch on. 3) release the adjuster switch (1), 3 to 5 seconds after turning the ignition switch on. 4) press the adjuster switch (1) twice (within 1 second). → reset 5) pointer will return to the s...
Page 39
Combination meter / fuel meter / horn: 9c-5 oil pressure indicator inspection (gsx650fk8) b817h29306024 inspect the oil pressure indicator in the following procedures: note before inspecting the oil pressure switch, check if the engine oil level is correct. Refer to “engine oil and filter replacemen...
Page 40
9c-6 combination meter / fuel meter / horn: specifications service data (gsx650fk8) b817h29307003 wattage unit: w item specification speedometer light led tachometer light led turn signal indicator light led x 2 high beam indicator light led neutral position indicator light led oil pressure/engine c...
Page 41: Exterior Parts
Exterior parts: 9d-1 body and accessories exterior parts repair instructions cowling construction (gsx650fk8) b817h29406011 1 2 3 4 5 6 i817h2940014-03 1. Under cowling (r) 3. Cushion 5. Upper panel 2. Body cowling 4. Windscreen 6. Under cowling (l).
Page 42
9d-2 exterior parts: under cowl construction (gsx650fk8) b817h29406012 under cowl bracket cushion attachment (gsx650fk8) b817h29406013 “c” “b” “a” “a” “d” “c” 1 1 i817h2940021-01 1. Heat shield “a”: max. 5 mm (0.19 in) “c”: 55 mm (2.17 in) 2. Cushion “b”: 0 – 1 mm (0 – 0.039 in) “d”: 3 mm (0.12 in) ...
Page 43
Exterior parts: 9d-3 under cowl protector cushion attachment (gsx650fk8) b817h29406014 upper panel cushion attachment (gsx650fk8) b817h29406015 1 “a” i817h2940017-01 1. Cushion “a”: 85 mm (3.35 in) 1 “a” i817h2940018-01 1. Panel cushion “a”: 5 mm (0.19 in).
Page 44
9d-4 exterior parts: windscreen cushion attachment (gsx650fk8) b817h29406016 intake net cover construction attachment (gsx650fk8) b817h29406017 2 2 1 i817h2940019-01 1. Cushion 2. Tape 1 i817h2940020-01 1. Cover cushion.
Page 45
Exterior parts: 9d-5 exterior parts removal and installation (gsx650fk8) b817h29406010 under cowling refer to “exterior parts removal and installation in related manual”. Removal 1) remove the fasteners (1). 2) disconnect the turn signal light couplers (2), left and right. 3) remove the left under c...
Page 46
9d-6 exterior parts: upper panel removal 1) remove the combination meter assembly. Refer to “combination meter removal and installation (gsx650fk8) in section 9c (page 9c-2)”. 2) remove the upper panel (1). Installation install the under panel in the reverse order of removal. Body cowling removal 1)...
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Prepared by september, 2007 part no. 99501-36180-01e printed in japan 48.
Page 48
Printed in japan k8.