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Suzuki GSX650FA Service Manual

Summary of GSX650FA

  • Page 1

    Top bottom gsx650fak9 supple 99501-36190-01e cover14 09.03.10 (back: 3mm) 5/1 sumi gsx650fa printed in japan k9 k9 9 9 5 0 1 - 3 6 1 9 0 - 0 1 e gsx650f a supplementary service manual supplementary service manual use this manual with: gsf650/a/s/sa gsx650f service manual (99500-36172-01e).

  • Page 2: Foreword

    Foreword this supplementary service manual is a supplement to suzuki gsf650/a/s/sa gsx650f service manual. It has been prepared exclusively for the following applicable model. Applicable model: gsx650fak9 this supplementary service manual describes only service information which differ from that of ...

  • Page 3: Table of Contents

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

  • Page 5: Section 00

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

  • Page 6: Precautions

    00-1 precautions: precautions precautions precautions precautions for abs (gsx650fak9) b917h20000005 abs wiring • the abs parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly. Make sure that the pr...

  • Page 7: 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 8

    0-ii table of contents service data............................................. 0c-1 specifications.......................................................0c-1 service data (gsf650/s/u/suk7) ..................... 0c-* tightening torque list ........................................ 0c-* service data ...

  • Page 9: General Information

    General information: 0a-1 general information general information general description abbreviations (gsx650fak9) b917h20101018 note please refer to the gsf650/sk7 (’07-model) service manual for other abbreviations which are not given in this manual. A: abs: anti-lock brake system vehicle side view (...

  • Page 10

    0a-2 general information: specifications specifications (gsx650fak9) b917h20107007 note • these specifications are subject to change without notice. • any differences between the gsx650fk9 (’09-model) and gsx650fak9 (’09-model) in specifications are indicated an asterisk mark (*). Dimensions and cur...

  • Page 11

    General information: 0a-3 special tools and equipment special tool b917h20108001 09900–20803 thickness gauge 09900–20806 thickness gauge 09900–25008 multi circuit tester set 09900–25009 needle-point probe set 09904–41010 suzuki diagnostic system set 09930–82710 mode select switch 99565–01010–020 cd-...

  • Page 12: Service Data

    0c-1 service data: general information service data specifications service data (gsx650fak9) b917h20307007 note • these specifications are subject to change without notice. • any differences between the gsx650fk9 (’09-model) and gsx650fak9 (’09-model) in service data are indicated an asterisk mark (...

  • Page 13

    Service data: 0c-2 wattage unit: w suspension unit: mm (in) tightening torque list (gsx650fak9) b917h20307008 chassis 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...

  • Page 14

    0c-3 service data:.

  • Page 15: Section 2

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

  • Page 16

    2-ii table of contents front wheel assembly construction (gsx650fak9) .................................................2d-3 rear wheel components (gsx650fak9)..........2d-4 rear wheel assembly construction (gsx650fak9) .................................................2d-5 rear wheel assembly removal...

  • Page 17: Wheels and Tires

    Wheels and tires: 2d-1 suspension wheels and tires precautions precautions for wheel and tire (gsx650fak9) b917h22400002 warning ! • proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. • u...

  • Page 18

    2d-2 wheels and tires: repair instructions front wheel components (gsx650fak9) b917h22406021 fwd fw d (a) 1 3 4 9 (b) 2 11 12 6 4 5 3 10 (b) 2 14 13 5 8 (c) 7 i917h2240001-04 1. Front axle 6. Spacer 11. Tire : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake disc bolt 7. Wheel speed sensor rotor bolt 12. F...

  • Page 19

    Wheels and tires: 2d-3 front wheel assembly construction (gsx650fak9) b917h22406022 left right (b) 2 (a) 1 (a) 4 (c) 3 (b) 2 “ b ” (a) 1 5 “ a ” (d) 6 i917h2240002-01 1. Brake disc bolt 6. Wheel speed sensor rotor bolt : 100 n ⋅m (10.0 kgf-m, 72.5 lbf-ft) 2. Brake caliper mounting bolt “a”: clearanc...

  • Page 20

    2d-4 wheels and tires: rear wheel components (gsx650fak9) b917h22406024 19 1 (c) 6 7 5 18 3 2 17 8 9 16 10 11 12 fwd fw d (a) (b) 15 14 13 6 (d) 4 i917h2240013-01 1. Rear axle 8. Spacer 15. Spacer : 23 n ⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake disc 9. Bearing 16. Air valve : 6.5 n ⋅m (0.65 kgf-m, 4.7 l...

  • Page 21

    Wheels and tires: 2d-5 rear wheel assembly construction (gsx650fak9) b917h22406025 left right (d) 4 (b) 2 (a) 1 (c) 3 “ b ” 5 “ a ” (e) 6 i917h2240014-01 1. Rear sprocket nut 6. Wheel speed sensor rotor bolt : 22 n ⋅m (2.2 kgf-m, 16.0 lbf-ft) 2. Rear axle nut “a”: clearance : 23 n ⋅m (2.3 kgf-m, 16....

  • Page 22

    2d-6 wheels and tires: rear wheel assembly removal and installation (gsx650fak9) b917h22406026 removal 1) remove the rear wheel speed sensor (1) by removing the mounting bolts (2). Refer to “rear wheel speed sensor removal and installation in section 4e in related manual”. 2) loosen the rear axle nu...

  • Page 23

    Wheels and tires: 2d-7 4) tighten the rear axle nut (3) to the specified torque. Tightening torque rear axle nut (a): 100 n·m (10.0 kgf-m, 72.5 lbf- ft) warning ! After remounting the rear wheel, pump the brake pedal several times to check for proper brake operation. 5) install the rear wheel speed ...

  • Page 24

    2d-8 wheels and tires: special tools and equipment recommended service material b917h22408001 note required service material is also described in the following. “front wheel components (gsx650fak9) (page 2d-2)” “front wheel assembly construction (gsx650fak9) (page 2d-3)” “rear wheel components (gsx6...

  • Page 25: Section 4

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

  • Page 26

    4-ii table of contents abs information (gsx650fak9) ........................4e-1 general description .............................................4e-1 wheel speed sensor description ....................... 4e-* abs control unit description .............................. 4e-* hydraulic unit (hu) desc...

  • Page 27

    Brake control system and diagnosis: 4a-1 brake brake control system and diagnosis schematic and routing diagram.

  • Page 28

    4a-2 brake control system and diagnosis: front brake hose routing diagram (gsx650fak9) b917h24102004 6 2 “b” 1 7 1 2 4 (a) (a) (c) 4 “ a ” (a) “a” 8 4 (a) 3 5 (c) (a) “ b ” “ b ” “ g ” “ f ” “ c ” “ c ” “ d ” “ e ” “ f ” “ c ” “ b ” 4 4 4 (b) (b) i917h2410001-04 1. Front brake hose no. 1 : 23 n ⋅m (...

  • Page 29

    Brake control system and diagnosis: 4a-3 rear brake hose routing diagram (gsx650fak9) b917h24102005 “ b ” 3 2 3 2 (a) 1 3 (b) “b” “a” 4 (d) (a) (c) “ a ” 6 “d” “c” 8 (e) 7 6 5 “e” (e) i917h2410002-03 1. Brake hose clamp : brake hose clamp ends should face forward. “c” : pass the rear brake hose no. ...

  • Page 30

    4a-4 brake control system and diagnosis: specifications tightening torque specifications b917h24107002 note the specified tightening torque is described in the following. “front brake hose routing diagram (gsx650fak9) (page 4a-2)” “rear brake hose routing diagram (gsx650fak9) (page 4a-3)” reference:...

  • Page 31: Abs

    Abs: 4e-1 brake abs precautions precautions for abs (gsx650fak9) b917h24500003 refer to “precautions for electrical circuit service in section 00 in related manual”. Abs information (gsx650fak9) b917h24500004 warning ! • be sure to bleed air from the brake fluid circuit when the brake is felt spongy...

  • Page 32

    4e-2 abs: abs operation and abs indicator light the abs indicator light (1) shows the abs operating condition. During normal operation, the abs indicator light lights up when the ignition switch is turned to on and goes off after the motorcycle is ridden at more than 10 km/h (6.2 mile/ h). If a malf...

  • Page 33

    Abs: 4e-3 schematic and routing diagram abs wiring diagram (gsx650fak9) b917h24502005 refer to “wire color symbols in section 0a in related manual”. B/r b/r o/y b/o b/g b/w r r r b/w b/r w/r b/y w/y b/w o b w b w b/y w/r w/b r/bl r/b gr br b/r o o/y w/y b/w b/w br b/g b b/r b/o b/r b/o o/g w/b b/g b...

  • Page 34

    4e-4 abs: rear wheel speed sensor routing diagram (gsx650fak9) b917h24502008 1 2 2 2 3 “a” “d” “e” “f” 4 “ a ” “c” “b” 2 “d” 5 2 “g” i917h2450045-01 1. Rear wheel speed sensor “c”: clamp speed sensor lead wire with white tape matched green paint of brake hose. 2. Rear brake hose no. 2 “d”: pass the ...

  • Page 35

    Abs: 4e-5 component location abs components location (gsx650fak9) b917h24503002 2 1 6 7 5 4 3 i917h2450007-03 1. Abs control unit/hu 3. Sds coupler 5. Front wheel speed sensor rotor 7. Rear wheel speed sensor rotor 2. Mode select coupler 4. Front wheel speed sensor 6. Rear wheel speed sensor.

  • Page 36

    4e-6 abs: diagnostic information and procedures abs indicator light inspection (gsx650fak9) b917h24504027 wiring diagram refer to “abs unit diagram in related manual”. Troubleshooting step action yes no 1 1) check if the abs indicator light (1) lights up when turning the ignition switch on. Does the...

  • Page 37

    Abs: 4e-7 3 (the abs indicator light does not light up) 1) remove the left frame cover. Refer to “exterior parts removal and installation (gsf650/s/a/sak7) in section 9d in related manual”. 2) remove the fuse box (1) by removing the mounting bolt (2). 3) open the fuse box and inspect the ignition fu...

  • Page 38

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

  • Page 39

    Abs: 4e-9 6 1) turn the ignition switch off. 2) check for continuity between “24” (b/w) at the coupler and body ground, also “25” (b/w) at the coupler and body ground. Special tool (a): 09900–25008 (multi circuit tester set) tester knob indication continuity ( ) abs control unit/hu coupler (harness ...

  • Page 40

    4e-10 abs: 8 1) turn the ignition switch off. 2) disconnect the abs control unit/hu coupler. Refer to “abs control unit coupler disconnect and connect in related manual” 3) turn the ignition switch on with the abs control unit/hu coupler disconnected, measure the voltage between “16” (o/y) and “24” ...

  • Page 41

    Abs: 4e-11 10 1) turn the ignition switch off. 2) remove the left frame cover. Refer to “exterior parts removal and installation (gsf650/s/a/sak7) in section 9d in related manual”. 3) short the mode select coupler terminals (o – b/w) using the special tool. Special tool (a): 09930–82710 (mode select...

  • Page 42

    4e-12 abs: dtc (diagnostic trouble code) output (gsx650fak9) b917h24504028 note • even through the abs is operating correctly, a dtc is memorized in any of the following conditions. – if the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated. – previous ma...

  • Page 43

    Abs: 4e-13 understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the abs indicator light. A number between 1 and 9 is represented by the number of times that the abs indicator light lights up in interval of 0.4 seconds and the separation between the...

  • Page 44

    4e-14 abs: use of sds note • don’t disconnect couplers from abs control unit/hu, the battery cable from the battery, abs control unit/hu ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will er...

  • Page 45

    Abs: 4e-15 dtc “55” (c1655): abs control unit malfunction (gsx650fak9) b917h24504047 troubleshooting note after repairing the trouble, clear the dtc using sds tool. Refer to “dtc (diagnostic trouble code) deleting in related manual”. Possible cause faulty abs control unit/hu step action yes no 1 1) ...

  • Page 46

    4e-16 abs: 2 1) inspect both of the wheel speed sensor rotors for damage and check that no foreign objects are caught in the rotor openings. Are the rotors ok? Go to step 3. Clean or replace the sensor rotor. 3 1) check that the front and rear wheel speed sensors are mounted securely. Are the sensor...

  • Page 47

    Abs: 4e-17 repair instructions front wheel speed sensor rotor removal and installation (gsx650fak9) b917h24506011 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • do not hit the front wheel speed sensor rotor when dism...

  • Page 48

    4e-18 abs: rear wheel speed sensor rotor removal and installation (gsx650fak9) b917h24506012 caution ! • the abs is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. • do not hit the rear wheel speed sensor rotor when dismounting the rear wheel...

  • Page 49

    Abs: 4e-19 specifications tightening torque specifications b917h24507001 reference: for the tightening torque of fastener not specified in this section, refer to “tightening torque list in section 0c in related manual”. Special tools and equipment special tool b917h24508001 fastening part tightening...

  • Page 50

    4e-20 abs:.

  • Page 51: Section 5

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

  • Page 52: Clutch

    5c-1 clutch: transmission / transaxle clutch schematic and routing diagram clutch hose routing diagram (gsx650fak9) b917h25302002 1 3 2 5 6 7 8 (a) 4 2 9 “a” “b” “c” “d” 8 (a) 10 1 “ d ” “ b ” “ c ” “ a ” i917h2530001-04 1. Wiring harness “a”: pass the wiring harness through upper the clutch hose no...

  • Page 53

    Clutch: 5c-2 specifications tightening torque specifications b917h25307002 note the specified tightening torque is described in the following. “clutch hose routing diagram (gsx650fak9) (page 5c-1)” reference: for the tightening torque of fastener not specified in this section, refer to “tightening t...

  • Page 54

    5c-3 clutch:.

  • Page 55: 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 56

    9-ii table of contents engine coolant temperature removal and installation......................................................... 9c-* fuel level indicator inspection ........................... 9c-* fuel level indicator switch (thermistor) inspection..................................................

  • Page 57: Wiring Systems

    Wiring systems: 9a-1 body and accessories wiring systems schematic and routing diagram wiring diagram (gsx650fak9) b917h29102009 refer to “wire color symbols in section 0a in related manual”..

  • Page 58

    9a-2 wiring systems: for e-02, 19 m engine stop switch fuel pump st ar ter butt on fr ont brake switch handleb ar switch (r) speed sensor side st and switch free push brake light switch ignition coil #1 ignition coil #2 pa ir ecm solenoi d f a n rela y f a n mo t o r ho2 sensor ect abs valve fuse (1...

  • Page 59

    Wiring systems: 9a-3 for e-03, 24, 28 m engine stop switch fuel pump st ar ter butt o n fr ont brake switch handleb ar switch (r ) speed sensor side st and switch free push brake light switch ignition coil #1 ignition coil #2 pa ir ecm solenoid f a n rela y f a n mo t o r ho2 sensor ect sensor gp sw...

  • Page 60

    9a-4 wiring systems: for e-33 m engine stop switch fuel pump st ar ter butt o n fr ont brake switch handleb ar switch (r) speed sensor side st and switch free push brake light switch ignition coil #1 ignition coil #2 pair solenoid f a n rel ay f a n mo t o r ho2 sensor ect sensor to sensor fuel pump...

  • Page 61

    Wiring systems: 9a-5 wiring harness routing diagram (gsx650fak9) b917h29102008 4 1 3 “b” “c” “a” 5 5 2 “ a ” “a” “a” 6 7 10 9 11 8 “e” “d” 12 i917h2910901-07 1. Battery 10. Clamp : clamp the handle switch lead wires, ignition switch lead wire and front wheel speed sensor lead wire (abs). 2. Clamp : ...

  • Page 62

    9a-6 wiring systems: 12 “b” 13 14 “ a ” 8 5 6 6 6 1 “a” 3 4 (a) 2 7 6 11 9 10 7 i917h2910902-02 1. Clamp : clamp the speed sensor lead wire and ho2 sensor lead wire. 10. Headlight high beam bulb cap 2. Side-stand switch 11. Horn lead wire 3. Ho2 sensor coupler 12. Clamp : clamp the regulator/rectifi...

  • Page 63

    Wiring systems: 9a-7 specifications service data (gsx650fak9) b917h2910s004 electrical tightening torque specifications b917h2910s005 note the specified tightening torque is described in the following. “wiring harness routing diagram (gsx650fak9) (page 9a-5)” reference: for the tightening torque of ...

  • Page 64

    Prepared by march, 2009 part no. 99501-36190-01e printed in japan 64.

  • Page 65: Gsx650Fa

    Top bottom gsx650fak9 supple 99501-36190-01e cover14 09.03.10 (back: 3mm) 5/1 sumi gsx650fa printed in japan k9 k9 9 9 5 0 1 - 3 6 1 9 0 - 0 1 e gsx650f a supplementary service manual supplementary service manual use this manual with: gsf650/a/s/sa gsx650f service manual (99500-36172-01e).