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Manuals and User Guides for Suzuki GSF1250. We have 2 Suzuki GSF1250 manuals available for free PDF download: Service Manual, Owner’s Manual

• Page 1
  9 9 5 0 0 — 3 9 3 0 0 — 0 1 E…
• Page 2
  FOREWORD This manual contains an introductory description on the SUZUKI GSF1250/S/A/SA and procedures for its inspec- tion/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.
• Page 3
  TABLE OF CONTENTS Precautions…………… 00-i Precautions …………00-1 General Information ……….. 0-i General Information ……….0A-1 Maintenance and Lubrication ……… 0B-1 Service Data…………0C-1 Engine …………….. 1-i Precautions ………….. 1-1 Engine General Information and Diagnosis … 1A-1 Emission Control Devices ……..1B-1 Engine Electrical Devices……..1C-1 Engine Mechanical……….1D-1 Engine Lubrication System ……..
• Page 5
  Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ……….00-1 General Precautions ……….. 00-1 Precautions for Electrical Circuit Service …. 00-2 Precautions…………00-1 Warning / Caution / Note……..00-1…
• Page 6
  CAUTION Indicates a potential hazard that could result • If parts replacement is necessary, replace in death or injury. the parts with Suzuki Genuine Parts or their equivalent. CAUTION • When removing parts that are to be reused, keep them arranged in an orderly manner…
• Page 7
  Precautions: 00-2 • Use a torque wrench to tighten fasteners • Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber •…
• Page 8
  00-3 Precautions: Switch • Check the male connector for bend and female connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. prevent damage. ECM / ABS control unit / HU / Various sensors •…
• Page 9
  Precautions: 00-4 • Be careful not to touch the electrical terminals of the electronic parts (ECM, ABS control unit/HU, etc.). The static electricity from your body may damage them. I649G1000005-02 Battery • Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the I310G1000008-01 components of the FI and ABS systems instantly •…
• Page 10
  00-5 Precautions: • Before measuring voltage at each terminal, check to 1) Disconnect the negative (–) cable from the battery. make sure that battery voltage is 11 V or higher. 2) Check each connector/coupler at both ends of the Terminal voltage check with a low battery voltage will circuit being checked for loose connection.
• Page 11
  Precautions: 00-6 Continuity check 3) Also, if measured values are as listed following, a resistance (abnormality) exists which causes the 1) Measure resistance across coupler “B” (between “A” voltage drop in the circuit between terminals “A” and and “C” in figure). “B”.
• Page 12
  3) Measure resistance between terminal at one end of Using The Multi-Circuit Testers circuit (“A” terminal in figure) and body ground. If • Use the Suzuki multi-circuit tester set. continuity is indicated, there is a short circuit to • Use well-charged batteries in the tester.
• Page 13
  Precautions: 00-8 • After using the tester, turn the power off. Special tool : 09900–25008 (Multi-circuit tester set) I649G1000002-02 NOTE • When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them.
• Page 14
  00-9 Precautions:…
• Page 15
  Symbols ………….. 0A-1 Evaporative Emission Control System Abbreviations …………0A-1 Inspection (E-33 Only) ……..0B-10 SAE-to-Former SUZUKI Term ……0A-2 Engine Oil and Filter Replacement ….0B-10 Vehicle Side View ……….0A-3 Throttle Cable Play Inspection and Vehicle Identification Number ……0A-4 Adjustment …………0B-12…

• Page 16: General Information

  Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.

• Page 17
  J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, Programmable Read Only Memory (PROM): — as well as their former SUZUKI names. Pulsed Secondary Air Injection (PAIR): Pulse Air Ex. SAE term (Abbreviation): Former SUZUKI term…
• Page 18
  Volume Air Flow (VAF): Air Flow I718H1010003-01 Left Side Vehicle Side View B718H10101003 NOTE Difference between illustration and actual motorcycles may exist depending on the markets. SUZUKI GSF1250 (2007-model) Right Side I718H1010004-02 SUZUKI GSF1250A (2007-model) Right Side I718H1010001-01 Left Side I718H1010005-01 I718H1010002-02…

• Page 19: Vehicle Identification Number

  PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart.

• Page 20: Cylinder Identification

  3 250 ml (3.4/2.9 US/Imp qt) oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. For engine coolant mixture information, refer to “Engine If SAE 10W-40 engine oil is not available, select an Coolant Description in Section 1F (Page 1F-1)”.

• Page 21
  General Information: 0A-6 Country and Area Codes B718H10101008 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSF1250 K7 (E-02) U.K. JS1CH122200100001 – GSF1250 K7 (E-19) E.U. JS1CH122100100001 – GSF1250S K7 (E-02) U.K.
• Page 22
  0A-7 General Information: Warning, Caution and Information Labels Location B718H10101010 12, 13 I718H1010016-02 GSF1250/A GSF1250S/SA 1. Noise label — For E-03, 24, 33 2. Information label — For E-03, 28, 33 3. Vacuum hose routing label — For E-33 4. Fuel caution label…
• Page 23
  General Information: 0A-8 Component Location Electrical Components Location B718H10103001 I718H1010014-03 1. Fuel pump relay 6. Fuel level gauge 11. Mode selection switch coupler 2. Starter relay/Main fuse 7. Ignition coil/plug cap 12. ISC valve 3. Cooling fan relay 8. PAIR control solenoid valve 13.
• Page 24
  0A-9 General Information: I718H1010015-04 15. IAP sensor (No.1) 21. Turn signal/side-stand relay 27. GP switch 16. Fuel injector 22. Horn 28. Starter motor 17. IAP/TP/IAT sensor 23. Cooling fan 29. Speed sensor 18. STP sensor 24. CKP sensor 30. HO2 sensor 19.
• Page 25
  General Information: 0A-10 Specifications Specifications (GSF1250/S) B718H10107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 130 mm (83.9 in) Overall width 790 mm (31.1 in) 1 095 mm (43.1 in)
• Page 26
  Generator Three-phase A.C. generator Main fuse 30 A Fuse 10/10/15/15/10/15 A 12 V 60/55 W (H4) GSF1250 Headlight 12 V 55 W (H7) + 12 V 55 W (H7) GSF1250S 12 V 5 W GSF1250 Position light 12 V 5 W x 2…
• Page 27
  General Information: 0A-12 Specifications (GSF1250A/SA) B718H10107002 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 130 mm (83.9 in) Overall width 790 mm (31.1 in) 1 095 mm (43.1 in) GSF1250A Overall height 1 235 mm (48.6 in)
• Page 28
  0A-13 General Information: Chassis Item Specification Remark Front suspension Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 130 mm (5.1 in) Rear wheel travel 136 mm (5.4 in) Steering angle 35° (right & left) Caster 25°…
• Page 29
  General Information: 0A-14 Special Tools and Equipment Special Tool B718H10108002 09900–06107 09900–06108 09900–18740 09900–20102 09900–20202 Snap ring pliers Snap ring pliers Hexagon socket (24 Vernier calipers (1/20 Micrometer (1/100 mm, 200 mm) mm, 25 – 50 mm) 09900–20204 09900–20205 09900–20530 09900–20602 09900–20605 Micrometer (75 –…
• Page 30
  0A-15 General Information: 09915–40610 09915–40611 09915–63311 09915–64512 09915–74521 Oil filter wrench Oil filter wrench Compression gauge Compression gauge Oil pressure gauge attachment hose 09915–74540 09915–77331 09916–10911 09916–14510 09916–14521 Oil pressure gauge Meter (for high Valve lapper set Valve spring Valve spring attachment pressure) compressor…
• Page 31
  General Information: 0A-16 09923–74511 09924–84510 09924–84521 09930–10121 09930–11920 Bearing remover Bearing installer set Bearing installer set Spark plug wrench set Torx bit (JT40H) 09930–11940 09930–11950 09930–30104 09930–34970 09930–44530 Bit holder Torx wrench Rotor remover slide Rotor remover set Rotor holder shaft 09930–82710 09930–82720…

• Page 32: Maintenance And Lubrication

  0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B718H10200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

• Page 33: Lubrication Points

  Maintenance and Lubrication: 0B-2 Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months — Brake fluid Replace every 2 years. Tires — Steering — — Front forks —…

• Page 34
  0B-3 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Replacement Cleaning B718H10206001 1) Remove the air cleaner element. Refer to “Air Replace air cleaner element Cleaner Element Removal and Installation in Section Every 18 000 km (11 000 miles, 36 months) 1D (Page 1D-6)”.
• Page 35
  Maintenance and Lubrication: 0B-4 Exhaust Pipe Bolt and Muffler Bolt Inspection Spark Plug Inspection and Cleaning B718H10206005 B718H10206004 Tighten exhaust pipe bolts, muffler bolt and nut Inspect spark plug Initially at 1 000 km (600 miles, 2 months) and every Every 6 000 km (4 000 miles, 12 months) 12 000 km (7 500 miles, 24 months) thereafter.
• Page 36
  IN.: 0.10 – 0.20 mm (0.004 – 0.008 in) and Installation in Section 1G (Page 1G-9)”. EX.: 0.20 – 0.30 mm (0.008 – 0.012 in) 2) Remove the frame head covers. (GSF1250/A) Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
• Page 37
  Maintenance and Lubrication: 0B-6 NOTE • The cam must be at positions, “A” or “B”, when checking or adjusting the valve “D” clearance. Clearance readings should not “C” be taken with the cam in any other position than these two positions. •…
• Page 38
  0B-7 Maintenance and Lubrication: 11) Turn the crankshaft clockwise 360° (one full rotation) 2) Remove the tappet (1) and shim (2) by fingers or and align the match mark on the crankshaft with the magnetic hand. mating surfaces of crankcases. Also, position the notches “E”…
• Page 39
  Maintenance and Lubrication: 0B-8 (INTAKE SIDE) I718H1020003-02…
• Page 40
  0B-9 Maintenance and Lubrication: (EXHAUST SIDE) I718H1020004-02…
• Page 41
  Maintenance and Lubrication: 0B-10 Engine Oil and Filter Replacement 6) Install the camshafts and cam chain tension adjuster. Refer to “Engine Top Side Assembly in Section 1D B718H10206008 (Page 1D-28)”. Replace engine oil Initially at 1 000 km (600 miles, 2 months) and every 7) Rotate the engine so that the tappet is depressed 6 000 km (4 000 miles, 12 months) thereafter.
• Page 42
  MOTORCYCLE OIL FILTER. Other manufacturer’s oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle.
• Page 43
  Maintenance and Lubrication: 0B-12 4) Install a new oil filter. Turn it by hand until you feel 1) Loosen the lock-nut (1) of the throttle pulling cable that the oil filter O-ring contacts the oil filter mounting (2). surface. Then, tighten the oil filter two full turns (or to 2) Turn the adjuster (3) in or out until the throttle cable specified torque) using the special tool.
• Page 44
  0B-13 Maintenance and Lubrication: 3) Check the engine coolant level by observing the full 3) Drain engine coolant by disconnecting the water and lower lines on the engine coolant reservoir tank. pump outlet hose (2). If the level is below the lower line, add engine coolant to the full line from the engine coolant reservoir tank filler.
• Page 45
  Maintenance and Lubrication: 0B-14 Clutch System Inspection 5) Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. B718H10206013 Inspect clutch hose and clutch fluid 6) Add engine coolant up to the thermostat connector Every 6 000 km (4 000 miles, 12 months) inlet.
• Page 46
  0B-15 Maintenance and Lubrication: 3) Inspect the clutch hose for crack, damage or clutch 2) Visually check the drive chain for the possible fluid leakage. If it is damaged, replace the clutch defects listed as follows. If any defects are found, the hose with a new one.
• Page 47
  “drive chain oil”. Such oil can damage the O-rings. Drive chain slack “a” • The standard drive chain is a RK Standard 20 – 30 mm (0.8 – 1.2 in) GB50GSVZ3. SUZUKI recommends to use this standard drive chain as a replacement. “A” “A” I718H1020037-02 I718H1020038-01 “a”…
• Page 48
  0B-17 Maintenance and Lubrication: Brake System Inspection B718H10206019 Inspect brake system Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Inspect brake hose and brake fluid Every 6 000 km (4 000 miles, 12 months) WARNING •…
• Page 49
  Maintenance and Lubrication: 0B-18 GSF1250A/SA only Front and Rear Brake Hose Inspection 1) Remove the seat, right frame cover and fuel tank. (GSF1250A/SA) Refer to “Exterior Parts Construction in Section 9D (Page 9D-2)” and “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”.
• Page 50
  0B-19 Maintenance and Lubrication: Air Bleeding from Brake Fluid Circuit Tire Pressure Refer to “Air Bleeding from Brake Fluid Circuit in Section If the tire pressure is too high or too low, steering will be 4A (Page 4A-8)”. adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or Rear Brake Light Switch Adjustment shorter tire life will result.
• Page 51
  Maintenance and Lubrication: 0B-20 Steering System Inspection Rear Suspension Inspection B718H10206025 B718H10206027 Inspect steering system Inspect rear suspension Initially at 1 000 km (600 miles, 2 months) and every Every 12 000 km (7 500 miles, 24 months) 12 000 km (7 500 miles, 24 months) thereafter. Inspect the rear shock absorbers for oil leakage and Steering should be adjusted properly for smooth turning check that there is no play in the swingarm.
• Page 52
  0B-21 Maintenance and Lubrication: Chassis Bolt and Nut Inspection B718H10206028 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque.
• Page 53
  Maintenance and Lubrication: 0B-22 I718H1020058-01 I718H1020061-02 13. Front fork lower clamp bolt 7. Brake hose union bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 21. Front footrest bolt 22. Rear brake master cylinder mounting bolt 23. Rear brake master cylinder rod lock-nut 24.
• Page 54
  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-14) /…
• Page 55
  Service Data: 0C-1 Service Data General Information Specifications Service Data B718H10307001 Valve + Guide Unit: mm (in) Item Standard Limit 31 (1.22) — Valve diam. 27 (1.06) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —…
• Page 56
  0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 000 kPa Compression pressure 1 300 – 1 700 kPa (13 – 17 kgf/cm , 185 – 242 psi) (10 kgf/cm , 142 psi) 200 kPa Compression pressure difference —…
• Page 57
  Service Data: 0C-3 Oil Pump Item Standard Limit 100 – 400 kPa (1.0 – 4.0 kgf/cm , 14 – 57 psi) Oil pressure (at 60 °C, 140 °F) — at 3 000 r/min Clutch Unit: mm (in) Item Standard Limit Clutch drive plate thickness No.1, 2, 3 3.72 –…
• Page 58
  0C-4 Service Data: Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 166 ml (5.6/5.8 US/lmp oz) and more/10 sec. Fuel pressure regulator operating set Approx.
• Page 59
  30 A ABS motor (GSF1250A/ 20 A SA only) ABS valve (GSF1250A/ 15 A SA only) Wattage Unit: W Specification Item GSF1250/A GSF1250S/SA Headlight ← Position/Parking light 5 x 2 ← Brake light/Taillight 21/5 ← Turn signal light 21 x 4 ←…
• Page 60
  Front fork oil level (Without spring, GSF1250S/ outer tube fully compressed) 144 (5.7) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — GSF1250/A 472 ml (16.0/16.6 US/lmp oz) — Front fork oil capacity (Each leg) GSF1250S/ 471 ml (15.9/16.6 US/lmp oz)
• Page 61
  Service Data: 0C-7 Fuel + Oil Item Specification Note 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 E-03, 28, 33 Fuel type than 10% ethanol, or less than 5% methanol with…
• Page 62
  0C-8 Service Data: Item N⋅m kgf-m lb-ft Oil pressure switch lead wire bolt 0.15 (initial) [M6] (Final) Crankcase bolt (initial) 11.0 [M8] (Final) 19.0 (initial) 13.0 Crankshaft journal bolt [M9] (Final) 23.0 [M6] [M8] Oil gallery plug [M12] 11.0 [M16] 25.5 Oil gallery bolt Oil gallery jet…
• Page 63
  Service Data: 0C-9 Chassis Item N⋅m kgf-m lb-ft Steering stem head nut 47.0 Tighten 45 N⋅m (4.5 kgf-m, 32.5 Ib-ft) then turn back 1/2 – Steering stem nut 1/4. Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5…
• Page 64
  0C-10 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lb-ft N⋅m kgf-m lb-ft 0.15 0.23 0.45 0.55…

• Page 65: Table Of Contents

  Table of Contents 1- i Section 1 Engine CONTENTS Precautions ……….1-1 DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction….1A-73 Precautions…………. 1-1 DTC “C29” (P1654-H/L): Secondary Throttle Precautions for Engine………. 1-1 Position Sensor (STPS) Circuit Malfunction..1A-77 Engine General Information and DTC “C31”…

• Page 66
  1-ii Table of Contents PAIR Control Solenoid Valve Removal and Compression Pressure Check ……1D-3 Installation …………1B-6 Repair Instructions ……….1D-4 PAIR System Inspection ……..1B-6 Engine Components Removable with the Crankcase Breather (PCV) Hose Inspection..1B-8 Engine in Place ……….1D-4 Crankcase Breather (PCV) Hose / Cover / Air Cleaner Element Removal and Installation ..1D-6 Separator Removal and Installation ….
• Page 67
  Table of Contents 1-iii Schematic and Routing Diagram……1E-2 Water Pump Disassembly and Assembly ..1F-14 Engine Lubrication System Chart Diagram ..1E-2 Water Pump Related Parts Inspection ….1F-17 Diagnostic Information and Procedures…. 1E-3 Specifications …………. 1F-18 Engine Lubrication Symptom Diagnosis ….. 1E-3 Service Data…………
• Page 68
  1-iv Table of Contents CKP Sensor Removal and Installation ….1H-8 Charging System ……..1J-1 Engine Stop Switch Inspection……1H-8 Schematic and Routing Diagram ……1J-1 Ignition Switch Inspection……..1H-9 Charging System Diagram ……..1J-1 Ignition Switch Removal and Installation…..1H-9 Component Location ……….. 1J-1 Specifications………….1H-11 Charging System Components Location…..

• Page 69: Precautions

  Precautions: Precautions Engine Precautions Precautions for Engine B718H11000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

• Page 70: Engine General Information And Diagnosis

  1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B718H11101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

• Page 71: Self-Diagnosis Function

  Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.

• Page 72
  1A-3 Engine General Information and Diagnosis: For Example: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code.

• Page 73: Schematic And Routing Diagram

  Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram FI System Wiring Diagram B718H11102001 I718H1110249-04…

• Page 74: Terminal Alignment Of Ecm Coupler

  1A-5 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B718H11102002 I718H1110004-02 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT STVA signal (STVA, 2A) CKP sensor signal (CKP-) STVA signal (STVA, 1A) Serial data for self-diagnosis EVAP page control valve [E-33 only] Power source for fuel injector (VM) —…

• Page 75: Component Location

  Engine General Information and Diagnosis: 1A-6 Component Location FI System Parts Location B718H11103001 “B” “J” “I” “C” “H” “D” “E” “F” I718H1110146-04 “A”: ECM “C”: Cooling fan relay “E”: ISC valve “G”: Cooling fan “I”: PAIR control solenoid valve “B”: TO sensor “D”: STV actuator “F”: HO2 sensor “H”: Ignition coil…

• Page 76: Diagnostic Information And Procedures

  1A-7 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B718H11104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guides or poor seating of Repair or replace.

• Page 77
  Engine General Information and Diagnosis: 1A-8 Condition Possible cause Correction / Reference Item Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. Defective fuel pump. Replace. Defective fuel pressure regulator. Replace.
• Page 78
  1A-9 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noisy (Noise Worn or damaged impeller shaft. Replace. seems to come from Worn or damaged mechanical seal. Replace. water pump) Contact between pump case and Replace. impeller.
• Page 79
  Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP sensor. Replace.

• Page 80: Self-Diagnostic Procedures

  1A-11 Engine General Information and Diagnosis: Self-Diagnostic Procedures 5) Check the DTC to determine the malfunction part. B718H11104005 Refer to “DTC Table (Page 1A-18)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble…

• Page 81
  Engine General Information and Diagnosis: 1A-12 Use of SDS NOTE • Do not disconnect the coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory.

• Page 82: Use Of Sds Diagnosis Reset Procedures

  1A-13 Engine General Information and Diagnosis: 3) Check the DTC. 4) Start the engine or crank the engine for more than 4 seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.

• Page 83: Show Data When Trouble (Displaying Data At The Time Of Dtc)

  Engine General Information and Diagnosis: 1A-14 Show Data When Trouble (Displaying Data at the Time of DTC) B718H11104008 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory.

• Page 84: Sds Check

  1A-15 Engine General Information and Diagnosis: 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110270-01 SDS Check B718H11104009 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user.

• Page 85
  Engine General Information and Diagnosis: 1A-16 Sample Data sampled from cold starting through warm-up Check the engine r/min. 1 200 r/min. Check the water temperature. 50 ˚C and more Check the manifold absolute pressure. XXX kPa I718H1110149-01 Data at 3 000 r/min under no load Approx.
• Page 86
  1A-17 Engine General Information and Diagnosis: Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve OFF in according with the throttle valve opens closes I718H1110151-01 Data of intake negative pressure during idling (100 °C)

• Page 87: Dtc Table

  Engine General Information and Diagnosis: 1A-18 Example of Trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.

• Page 88
  1A-19 Engine General Information and Diagnosis: Code Malfunction Part Remarks C26 (P0353) Ignition signal #3 (IG coil #3) For #3 cylinder (Page 1A-73) C27 (P0354) Ignition signal #4 (IG coil #4) For #4 cylinder (Page 1A-73) C28 (P1655) Secondary throttle valve actuator (STVA) (Page 1A-73) C29 (P1654-H/L) Secondary throttle position sensor (STPS)

• Page 89: Fail-Safe Function Table

  Engine General Information and Diagnosis: 1A-20 Fail-Safe Function Table B718H11104003 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability Intake air pressure is fixed to 101 kPa (760…

• Page 90: Fi System Troubleshooting

  1A-21 Engine General Information and Diagnosis: FI System Troubleshooting B718H11104004 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.

• Page 91: Malfunction Code And Defective Condition Table

  Engine General Information and Diagnosis: 1A-22 Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.

• Page 92
  1A-23 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor should produce following voltage. 0.5 V ≤ sensor voltage < 4.85 V IAP sensor (No.2), lead wire/ In other than the above range, C17 (P1750) is coupler connection indicated.
• Page 93
  Engine General Information and Diagnosis: 1A-24 Malfunction Detected Item Detected Failure Condition Check For Code C32/C33 CKP sensor (pickup coil) signal is produced, C34/C35 but fuel injector signal is interrupted 4 times or Primary fuel injector, wiring/ Fuel injector more continuously. In this case, the code C32 coupler connection, power P0201/P0202 (P0201), C33 (P0202), C34 (P0203) or C35…

• Page 94: Dtc «C12» (P0335): Ckp Sensor Circuit Malfunction

  1A-25 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B718H11104011 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.

• Page 95
  Engine General Information and Diagnosis: 1A-26 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. I718H1110154-02 3) Disconnect the CKP sensor coupler and measure the resistance.
• Page 96
  1A-27 Engine General Information and Diagnosis: Step Action 1) Crank the engine several seconds with the starter motor, • G/Y or Br wire open • Inspect that metal and measure the CKP sensor peak voltage at the or shorted to the particles or foreign coupler.

• Page 97: Dtc «C13» (P0105-H/L): Iap Sensor (No.1) Circuit Malfunction

  Engine General Information and Diagnosis: 1A-28 DTC “C13” (P0105-H/L): IAP Sensor (No.1) Circuit Malfunction B718H11104012 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor (No.1) voltage is not within the • Clogged vacuum passage between throttle body and following range.

• Page 98
  1A-29 Engine General Information and Diagnosis: C13 for IAP sensor No.1 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
• Page 99
  Engine General Information and Diagnosis: 1A-30 P0105-H for IAP sensor (No.1) (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 1 data. I718H1110161-02 Approx.
• Page 100
  1A-31 Engine General Information and Diagnosis: Step Action 4) Disconnect the IAP sensor (No.1) coupler. Go to Step 4. W/Bl wire shorted to Vcc, or B/Br wire open. 5) Check the continuity between the B wire and W/Bl wire. If the sound is not heard from the tester, the circuit condition is OK.
• Page 101
  Engine General Information and Diagnosis: 1A-32 P0105-L for IAP sensor (No.1) (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 1 data. I718H1110163-02 Approx.
• Page 102
  1A-33 Engine General Information and Diagnosis: Step Action 4) Disconnect the IAP sensor (No.1) coupler. Go to Step 3. B and W/Bl wire open, W/Bl wire shorted to the 5) Check the continuity between the W/Bl wire and ground. ground. Also, check the continuity between the W/Bl wire and B/ Br wire.
• Page 103
  Engine General Information and Diagnosis: 1A-34 Step Action 1) Connect the ECM coupler. Go to Step 4. Open or short circuit in the B wire or B/Br wire. 2) Turn the ignition switch ON. 3) Measure the input voltage at the B wire and ground with the needle pointed probes.
• Page 104
  1A-35 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 5. • Check the vacuum hose for crack or 2) Connect the ECM coupler and IAP sensor (No.1) damage. coupler. • Open or short circuit 3) Insert the needle pointed probes to the lead wire coupler.
• Page 105
  Engine General Information and Diagnosis: 1A-36 Step Action 1) Turn the ignition switch OFF. • B, W/Bl or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor (No.1). Refer to “IAP Sensor the ground, or poor IAP sensor (No.1) with a (No.1) Removal and Installation in Section 1C (Page 1C-…

• Page 106: Dtc «C14» (P0120-H/L): Tp Sensor Circuit Malfunction

  1A-37 Engine General Information and Diagnosis: DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B718H11104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •…

• Page 107
  Engine General Information and Diagnosis: 1A-38 C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Check the TP sensor coupler for loose or poor contacts. coupler.
• Page 108
  1A-39 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the throttle position data. I718H1110169-01 ° Throttle position approx. 125 and more OK? 1) Turn the ignition switch OFF.
• Page 109
  Engine General Information and Diagnosis: 1A-40 Step Action 4) Insert the needle pointed probes to the lead wire coupler. Go to Step 4. P/B wire shorted to Vcc, or B/Br wire open. 5) Check the continuity between the P/B wire and R wire. If the sound is not heard from the tester, the circuit condition is OK.
• Page 110
  1A-41 Engine General Information and Diagnosis: P0120-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the throttle position data. I718H1110172-01 ° Throttle position approx. 0 1) Turn the ignition switch OFF.
• Page 111
  Engine General Information and Diagnosis: 1A-42 Step Action 5) Check the continuity between the P/B wire and ground. Go to Step 3. R and P/B wire open, or Also, check the continuity between the P/B wire and B/Br P/B wire shorted to the wire.
• Page 112
  1A-43 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Turn the ignition switch Open or short circuit in OFF and go to Step 4. the R or B/Br wire. 2) Turn the ignition switch ON. 3) Measure the input voltage at the R wire and ground. If OK, the measure the input voltage at the R and B/Br wire.
• Page 113
  Engine General Information and Diagnosis: 1A-44 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the ECM coupler and TP sensor coupler. the ground, or poor sensor with a new one.

• Page 114: Dtc «C15» (P0115-H/L): Ect Sensor Circuit Malfunction

  1A-45 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B718H11104014 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤…

• Page 115
  Engine General Information and Diagnosis: 1A-46 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the ECT sensor coupler for loose or poor coupler.
• Page 116
  1A-47 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the engine coolant/oil temperature data. I718H1110175-01 ° ° Approx. –30 C (–22 F) and less OK?
• Page 117
  Engine General Information and Diagnosis: 1A-48 Step Action 1) Turn the ignition switch OFF. Go to Step 3. B/Bl or B/Br wire open. 2) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. I718H1110174-02 3) Disconnect the ECT coupler.
• Page 118
  1A-49 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the engine coolant/oil temperature data. I718H1110176-01 ° ° Approx. 120 C (248 F) and more OK? 1) Turn the ignition switch OFF.
• Page 119
  Engine General Information and Diagnosis: 1A-50 Step Action 4) Check the continuity between the B/Bl wire and ground. Go to Step 3. • B/Bl wire shorted to If the sound is not heard from the tester, the circuit the ground. condition is OK.
• Page 120
  1A-51 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Bl or B/Br wire Replace the ECT open or shorted to sensor with a new one. 2) Connect the ECM coupler. the ground, or poor Refer to “ECT Sensor 3) Remove the regulator/rectifier.

• Page 121: Dtc «C17» (P1750-H/L): Iap Sensor (No.2) Circuit Malfunction

  Engine General Information and Diagnosis: 1A-52 DTC “C17” (P1750-H/L): IAP Sensor (No.2) Circuit Malfunction B718H11104030 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor (No.2) voltage is not within the • Clogged vacuum passage. following range. • IAP sensor (No.2) circuit open or shorted to the ground. 0.5 V ≤…

• Page 122
  1A-53 Engine General Information and Diagnosis: NOTE • After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-13)”. • IAP sensor (No.2) is incorporated in the TP sensor/IAT sensor. C17 for IAP sensor No.2 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF.
• Page 123
  Engine General Information and Diagnosis: 1A-54 P1750-H for IAP sensor No.2 (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 2 data. I718H1110181-03 Approx.
• Page 124
  1A-55 Engine General Information and Diagnosis: Step Action 6) Check the continuity between the R and G/B wire. Go to Step 4. W/Bl wire shorted to If the sound is not heard from the tester, the circuit Vcc, or B/Br wire open. condition is OK.
• Page 125
  Engine General Information and Diagnosis: 1A-56 P1750-L for IAP sensor No.2 (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 2 data. I718H1110183-02 Approx.
• Page 126
  1A-57 Engine General Information and Diagnosis: Step Action 3) Disconnect the IAP sensor (No.2) coupler. Go to Step 3. R and G/B wire open, W/Bl wire shorted to the 4) Insert the needle pointed probes to the lead wire coupler. ground.
• Page 127
  Engine General Information and Diagnosis: 1A-58 Step Action 1) Connect the ECM coupler. Go to Step 4. Open or short circuit in the R wire or B/Br wire. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the lead wire coupler. 4) Measure the input voltage at the R wire and ground with the needle pointed probes.
• Page 128
  1A-59 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire • Open or short circuit open or shorted to in the G/B wire. 2) Connect the ECM coupler and IAP sensor (No.2) the ground, or poor coupler.

• Page 129: Dtc «C21» (P0110-H/L): Iat Sensor Circuit Malfunction

  Engine General Information and Diagnosis: 1A-60 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B718H11104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤…

• Page 130
  1A-61 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the IAT sensor coupler for loose or poor contacts. coupler.
• Page 131
  Engine General Information and Diagnosis: 1A-62 P0110-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the intake air temperature data. I718H1110184-02 ° ° Approx. –30 C (–22 F) and less OK?
• Page 132
  1A-63 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. I718H1110168-03 3) Disconnect the IAT sensor coupler.
• Page 133
  Engine General Information and Diagnosis: 1A-64 P0110-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the intake air temperature data. I718H1110185-02 ° ° Approx. 125 C (257 F) and more OK? 1) Turn the ignition switch OFF.
• Page 134
  1A-65 Engine General Information and Diagnosis: Step Action 4) Insert the needle pointed probes to the lead wire coupler. Go to Step 3. • Dg wire shorted to the ground. 5) Check the continuity between the Dg wire and ground. If the sound is not heard from the tester, the circuit •…
• Page 135
  Engine General Information and Diagnosis: 1A-66 Step Action 1) Turn the ignition switch OFF. • Dg or B/Br wire open Replace the IAT sensor or shorted to the with a new one. Refer to 2) Disconnect the IAT sensor coupler. ground, or poor “27”…

• Page 136: Dtc «C23» (P1651-H/L): To Sensor Circuit Malfunction

  1A-67 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B718H11104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •…

• Page 137
  Engine General Information and Diagnosis: 1A-68 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the seat. Refer to “Exterior Parts Removal and “TO Sensor Removal Installation in Section 9D (Page 9D-6)”.
• Page 138
  1A-69 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to Vcc, or B/Br wire open. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.
• Page 139
  Engine General Information and Diagnosis: 1A-70 Step Action Check the continuity between the B wire “B” and terminal Go to Step 2. B wire shorted to Vcc, or “22”. Also, check the continuity between B/Br wire “C” B/Br wire open. and terminal “29”.
• Page 140
  1A-71 Engine General Information and Diagnosis: Step Action 4) Disconnect the TO sensor coupler. Go to Step 2. R or B wire open, or B wire shorted to the 5) Check the continuity between the B wire “B” and ground. ground.
• Page 141
  Engine General Information and Diagnosis: 1A-72 Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Dismount the TO sensor from its bracket. Refer to “TO the ground, or poor coupler.

• Page 142: Dtc «C24» (P0351), «C25» (P0352), «C26» (P0353) Or «C27» (P0354): Ignition System Malfunction

  1A-73 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B718H11104017 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-3)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B718H11104018 Detected Condition and Possible Cause Detected Condition…

• Page 143
  Engine General Information and Diagnosis: 1A-74 Step Action 1) Remove the regulator/rectifier. Refer to “Regulator / Go to Step 2. • Loose or poor Rectifier Construction in Section 1J (Page 1J-8)”. contacts on the coupler. 2) Check the STVA lead wire coupler for loose or poor contacts.
• Page 144
  1A-75 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • W/B, P/W, G and B/ • Loose or poor Lg wire open or contacts on the ECM 2) Move the throttle body right side. Refer to “Throttle Body shorted to the coupler.
• Page 145
  Engine General Information and Diagnosis: 1A-76 Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I718H1110247-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

• Page 146: Dtc «C29» (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction

  1A-77 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B718H11104019 Detected Condition and Possible Cause Detected Condition Possible Cause Signal voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •…

• Page 147
  Engine General Information and Diagnosis: 1A-78 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Check the STP sensor coupler for loose or poor coupler.
• Page 148
  1A-79 Engine General Information and Diagnosis: P1654-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the secondary throttle actuator position sensor data. I718H1110198-01 Secondary throttle position approx. 100% and more OK? 1) Turn the ignition switch OFF.
• Page 149
  Engine General Information and Diagnosis: 1A-80 Step Action 3) Disconnect the STP sensor coupler. Go to Step 4. Y/W wire shorted to Vcc, or B/Br wire open. 4) Check the continuity between the Y/W wire and R wire. If the sound is not heard from the tester, the circuit condition is OK.
• Page 150
  1A-81 Engine General Information and Diagnosis: P1654-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the secondary throttle actuator position sensor data. I718H1110199-01 Secondary throttle position approx. 0% OK? 1) Turn the ignition switch OFF.
• Page 151
  Engine General Information and Diagnosis: 1A-82 Step Action 4) Check the continuity between the Y/W wire and ground. Go to Step 3. R or Y/W wire open, or Also, check the continuity between the Y/W wire and B/ Y/W wire shorted to the Br wire.
• Page 152
  1A-83 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Go to Step 4. Open or short circuit in the R or B/Br wire. 2) Disconnect the STP sensor coupler. 3) Turn the ignition switch ON. 4) Measure the input voltage at the R wire and ground. Also, measure the input voltage at the R wire and B/Br wire.
• Page 153
  Engine General Information and Diagnosis: 1A-84 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler and STP sensor coupler. the ground, or poor STP sensor with a new 3) Move the air cleaner box backward.

• Page 154: Dtc «C31» (P0705): Gp Switch Circuit Malfunction

  1A-85 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B718H11104020 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • Gear position switch circuit open or short. Switch voltage is not within the following range. •…

• Page 155
  Engine General Information and Diagnosis: 1A-86 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to the or P wire shorted to 2) Remove the left frame cover. Refer to “Exterior Parts ground.

• Page 156: Dtc «C32» (P0201), «C33» (P0202), «C34» (P0203) Or «C35» (P0204): Fuel Injector Circuit Malfunction

  1A-87 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Fuel Injector Circuit Malfunction B718H11104021 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 4 times or more continuity.

• Page 157
  Engine General Information and Diagnosis: 1A-88 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.
• Page 158
  1A-89 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-10)”.
• Page 159
  Engine General Information and Diagnosis: 1A-90 Step Action 1) Turn the ignition switch ON. • Gr/W wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor “44” ground.

• Page 160: Dtc «C40» (P0505 / P0506 / P0507): Isc Valve Circuit Malfunction

  1A-91 Engine General Information and Diagnosis: DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction B718H11104022 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to the ground. C40/P0505 unusual.

• Page 161
  Engine General Information and Diagnosis: 1A-92 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Lbl, W/Y, Dgr or Lg wire open. 2) Check the ISC valve coupler for loose or poor contacts. If OK, then check the ISC valve lead wire continuity. I718H1110208-02 3) Disconnect the ISC valve coupler and ECM coupler.
• Page 162
  1A-93 Engine General Information and Diagnosis: Step Action 1) Move the throttle body right side. Refer to “Throttle Body If wire is OK, Replace the ISC valve Removal and Installation in Section 1D (Page 1D-9)”. intermittent trouble or with a new one. Refer to faulty ECM.
• Page 163
  Engine General Information and Diagnosis: 1A-94 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control”…
• Page 164
  1A-95 Engine General Information and Diagnosis: Check 2 1) Click the button (4) and decrease the “Spec” (2) to 1 100 rpm slowly. 2) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). At the same time, check that the number of steps (5) in the ISC valve position decreases.
• Page 165
  Engine General Information and Diagnosis: 1A-96 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 400 rpm. 2) Check that the “Desired idle speed” (3) is approx. 1 400 rpm. 3) Check that the “Engine speed” (7) is close to 1 400 rpm. NOTE Be careful not to increase the “Spec”…

• Page 166: Dtc «C41» (P0230-H/L): Fp Relay Circuit Malfunction

  1A-97 Engine General Information and Diagnosis: DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B718H11104023 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump • Fuel pump relay circuit open or short. although fuel pump relay is turned ON, or •…

• Page 167
  Engine General Information and Diagnosis: 1A-98 C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. • ECM power input Replace the FP relay signal malfunction. with a new one. 2) Remove the seat. Refer to “Exterior Parts Removal and Refer to “DTC “C41”…
• Page 168
  1A-99 Engine General Information and Diagnosis: P0230-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire open or poor Replace the FP relay “38” connection. with a new one. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.

• Page 169: Dtc «C41» (P2505): Ecm Power Input Signal Malfunction

  Engine General Information and Diagnosis: 1A-100 DTC “C41” (P2505): ECM Power Input Signal Malfunction B718H11104031 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM, • Lead wire/coupler connection of ECM terminal to fuel although FP relay is turned ON.

• Page 170
  1A-101 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • Fuel pump relay Open or short circuit in circuit malfunction. the R/Bl wire. 2) Remove the seat. Refer to “Exterior Parts Removal and Refer to “DTC “C41” Installation in Section 9D (Page 9D-6)”.

• Page 171: Dtc «C42» (P1650): Ig Switch Circuit Malfunction

  Engine General Information and Diagnosis: 1A-102 DTC “C42” (P1650): IG Switch Circuit Malfunction B718H11104024 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input in the ECM. • Ignition system circuit open or short. • ECM malfunction. Troubleshooting NOTE •…

• Page 172
  1A-103 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool.
• Page 173
  Engine General Information and Diagnosis: 1A-104 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. W/G wire shorted to the and Installation in Section 1C (Page 1C-1)”. power source, or W/G or B/Br wire open. 7) Check the continuity between the W/G wire “A”…
• Page 174
  1A-105 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. 2) Warm up the engine enough. the power source, or Refer to “Heated 3) Insert the needle pointed probes to the lead wire coupler.
• Page 175
  Engine General Information and Diagnosis: 1A-106 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-13)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
• Page 176
  1A-107 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler. • O/W or W/B wire • Open or short circuit open or shorted to in the W/B wire or O/ 2) Insert the needle pointed probes to the lead wire coupler. the ground, or poor W wire.

• Page 177: Dtc «C49» (P1656): Pair Control Solenoid Valve Circuit Malfunction

  Engine General Information and Diagnosis: 1A-108 DTC “C49” (P1656): PAIR Control Solenoid Valve Circuit Malfunction B718H11104028 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve ampere is not input to ECM. • PAIR control solenoid valve circuit open or short. •…

• Page 178
  1A-109 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid with a 2) Remove the fuel tank. Refer to “Fuel Tank Removal and new one. Refer to “PAIR Installation in Section 1G (Page 1G-9)”.
• Page 179
  Engine General Information and Diagnosis: 1A-110 Step Action 1) Turn the ignition switch ON. • B/G wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor “39”…

• Page 180: Dtc «C60» (P0480): Cooling Fan Relay Circuit Malfunction

  1A-111 Engine General Information and Diagnosis: 4) Click each button (2). At this time, if an operating sound is heard from the PAIR control solenoid valve, the function is normal. I718H1110236-01 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B718H11104029 Detected Condition and Possible Cause Detected Condition Possible Cause…

• Page 181
  Engine General Information and Diagnosis: 1A-112 Troubleshooting CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-13)”.
• Page 182
  1A-113 Engine General Information and Diagnosis: Active Control Inspection NOTE Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °C (212 °F) after starting the engine. 1) Set up the SDS tool. (Refer to SDS operation manual for further details.) 2) Start the engine and run it in idling condition.

• Page 183: Specifications

  Engine General Information and Diagnosis: 1A-114 Specifications Service Data B718H11107001 Injector Item Specification Note 11 – 13 Ω at 20 °C (68 F°) Injector resistance — FI Sensors Item Specification Note 90 – 150 Ω CKP sensor resistance CKP sensor peak voltage 2.0 V and more When cranking IAP sensor input voltage (No.1)

• Page 184: Special Tools And Equipment

  1A-115 Engine General Information and Diagnosis: Special Tools and Equipment Special Tool B718H11108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-26) / (Page 1A-107) / (Page 1A-27) / (Page 1A-31) / (Page 1A-29) / (Page 1A-33) / (Page 1A-109) / (Page 1A-35) / (Page 1A-110) /…

• Page 185: Emission Control Devices

  Fuel Injection System Description B718H11201001 GSF1250 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to reduce CO, NOX and HC.

• Page 186: Crankcase Emission Control System Description

  1B-2 Emission Control Devices: Crankcase Emission Control System Description B718H11201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.

• Page 187: Exhaust Emission Control System Description

  Emission Control Devices: 1B-3 Exhaust Emission Control System Description B718H11201003 The exhaust emission control system is composed of the PAIR system, HO2 sensor, catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ECTS, IATS, IAPS and CKPS.

• Page 188: Schematic And Routing Diagram

  1B-4 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B718H11202001 “B” “ a” “C” “B” “a” “B” “A” “a” “A” “A” “ a” “a” “C” I718H1120043-01 1. PAIR control solenoid valve “A”: Marking (Yellow) “C”: To air cleaner box 2.

• Page 189: Repair Instructions

  Emission Control Devices: 1B-5 Repair Instructions Heated Oxygen Sensor (HO2S) Removal and 6) Remove the HO2 sensor (3). Installation B718H11206005 Removal WARNING Do not remove the HO2 sensor while it is hot. CAUTION • Be careful not to expose the HO2 sensor to excessive shock.

• Page 190: Pair Reed Valve Removal And Installation

  1B-6 Emission Control Devices: PAIR Reed Valve Removal and Installation B718H11206008 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 2) Drain engine coolant and remove the thermostat connector. Refer to “Thermostat Connector / Thermostat Removal and Installation in Section 1F (Page 1F-9)”.

• Page 191
  Emission Control Devices: 1B-7 PAIR Control Solenoid Valve 2) Inspect the hoses for wear or damage. If it is worn or damaged, replace the PAIR hose with a new one. NOTE Refer to “PAIR System Hose Routing Diagram (Page 1B-4)”. PAIR control solenoid valve can be checked without removing it from the motorcycle.

• Page 192: Crankcase Breather (Pcv) Hose Inspection

  1B-8 Emission Control Devices: 4) Check the resistance between the terminals of the PAIR control solenoid valve. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication Resistance (Ω) PAIR control solenoid valve resistance 18 – 22 Ω at 20 – 30 °C (68 – 86 °F) I718H1120036-01 4) Remove the PCV hose (1).

• Page 193: Crankcase Breather (Pcv) Cover Inspection

  • Connect the PCV hose (2) securely. Pay attention to the following points: • Apply bond to the mating surface of the breather cover. : Sealant 99000–31110 (SUZUKI BOND No.1215 or equivalent) NOTE • Make surfaces free from moisture, oil, dust and other foreign materials.

• Page 194: Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H11208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110 (Page 1B-9)

• Page 195: Engine Electrical Devices

  Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B718H11300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical Components Location B718H11303001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 196: Iap Sensor (No.1) Removal And Installation

  1C-2 Engine Electrical Devices: IAP Sensor (No.1) Removal and Installation ECT Sensor Removal and Installation B718H11306035 B718H11306011 Removal Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal 1) Drain engine coolant. Refer to “Cooling System and Installation in Section 1G (Page 1G-9)”. Inspection in Section 0B (Page 0B-12)”.

• Page 197: Ect Sensor Inspection

  Engine Electrical Devices: 1C-3 ECT Sensor Inspection TO Sensor Removal and Installation B718H11306010 B718H11306019 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Removal Malfunction in Section 1A (Page 1A-45)”. 1) Remove the seat. Refer to “Exterior Parts Removal Inspect the ECT sensor in the following procedures: and Installation in Section 9D (Page 9D-6)”.

• Page 198: Stp Sensor Adjustment

  1C-4 Engine Electrical Devices: STP Sensor Adjustment 6) Loosen the STP sensor mounting screw adjust the B718H11306025 STP sensor (2) until the output voltage comes within Adjust the STP sensor in the following procedures: the specified value and tighten the STP sensor 1) Remove the air cleaner cover and air cleaner mounting screw.

• Page 199: Stv Actuator Inspection

  “A” if necessary. coupler at least 5 seconds after ignition switch is turned to OFF. If the ECM coupler or : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) ISC valve coupler is disconnected within 5 seconds after ignition switch is turned to…

• Page 200: Isc Valve Preset And Opening Initialization

  1C-6 Engine Electrical Devices: ISC Valve Preset and Opening Initialization NOTE B718H11306036 The leaned value of the ISC valve is set at When removing or replacing the ISC valve, set the ISC Preset position. valve to the following procedures: 1) Turn the ignition switch ON. 2) Set up the SDS tool.

• Page 201: Specifications

  Engine Electrical Devices: 1C-7 Specifications Service Data B718H11307001 FI Sensors Item Specification Note 90 – 150 Ω CKP sensor resistance CKP sensor peak voltage 2.0 V and more When cranking IAP sensor input voltage (No.1) 4.5 – 5.5 V IAP sensor output voltage (No.1) Approx.

• Page 202: Tightening Torque Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H11308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-5)

• Page 203: Engine Mechanical

  Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B718H11402001 I718H1140393-01…

• Page 204: Throttle Cable Routing Diagram

  1D-2 Engine Mechanical: Throttle Cable Routing Diagram B718H11402002 “A” “ a” “ a ” I718H1140308-03 1. Wiring harness 4. Throttle cable No.2 7. Ignition switch lead wire 2. Cable guide (GSF1250S/SA only) 5. Handlebar switch lead wire (L) “a”: 0 mm (0 in) 3.

• Page 205: Diagnostic Information And Procedures

  Low compression pressure can indicate any of 3) Remove the frame head covers, left and right. the following conditions: (GSF1250/A) Refer to “Exterior Parts Removal and • Excessively worn cylinder walls Installation in Section 9D (Page 9D-6)”. • Worn piston or piston rings 4) Remove all the spark plugs.

• Page 206: Repair Instructions

  1D-4 Engine Mechanical: Repair Instructions Engine Components Removable with the Engine in Place B718H11406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal…

• Page 207
  Engine Mechanical: 1D-5 Engine Right Side Item Removal Inspection Installation Refer to “Clutch Removal in Refer to “Clutch Installation Clutch cover — Section 5C (Page 5C-13)”. in Section 5C (Page 5C-14)”. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C…

• Page 208: Air Cleaner Element Removal And Installation

  1D-6 Engine Mechanical: Air Cleaner Element Removal and Installation 3) Release the drain hose from the clamp (1). B718H11406034 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 2) Remove the air cleaner cover screws. 3) Remove the air cleaner cover (1).

• Page 209: Throttle Cable Inspection

  Engine Mechanical: 1D-7 Throttle Cable Inspection Installation Install the throttle cables in the reverse order of removal. B718H11406038 Check that the throttle grip moves smoothly from full Pay attention to the following points: open to full close. If it does not move smoothly, lubricate •…

• Page 210: Throttle Body Construction

  1D-8 Engine Mechanical: Throttle Body Construction B718H11406041 Upper Upper Air cleaner side Engine side “A” “B” I718H1140314-01 1. Clamp (Air cleaner side) “B”: Clamp the drain hose at mark position. : After tighten the clamp band #2, 3 and tighten the clamp band #1, 4. 2.

• Page 211: Throttle Body Removal And Installation

  Engine Mechanical: 1D-9 Throttle Body Removal and Installation 7) Loosen the throttle body clamp screws and B718H11406042 disconnect the ISC valve hose (6). Removal Move the air cleaner box backward. 1) Disconnect the battery (–) lead wire. Refer to “Battery Removal and Installation in Section 1J (Page 1J-12)”.

• Page 212: Throttle Body Disassembly And Assembly

  1D-10 Engine Mechanical: Throttle Body Disassembly and Assembly Installation Install the throttle body in the reverse order of removal. B718H11406043 Refer to “Throttle Body Removal and Installation Pay attention to the following points: (Page 1D-9)”. • Connect the throttle pulling cable (1) and throttle returning cable (2) to the throttle cable drum.

• Page 213
  Engine Mechanical: 1D-11 3) Remove the fuel delivery pipe assembly (6). 6) Remove the plates and joint pipes (10). CAUTION Be careful not to twist the fuel delivery pipe’s T-joint (7), when disconnecting the fuel feed hose or removing the fuel delivery pipes, or joint part “A”…
• Page 214
  1D-12 Engine Mechanical: 9) Remove the STP sensor (13). CAUTION NOTE Never remove the throttle valve (15) and secondary throttle valve (16). Prior to disassembly, mark sensor’s original position with a paint or scribe for accurate reinstallation. Special tool : 09930–11950 (Torx wrench) I718H1140333-03 CAUTION These adjusting screws (17), (18) are factory-…
• Page 215
  ISC valve mounting screw (a): 3.5 N·m (0.35 kgf- with the groove “B” of STP sensor. m, 2.5 lb-ft) • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Special tool : 09930–11950 (Torx wrench) Tightening torque STP sensor mounting screw: 3.5 N·m (0.35 kgf-…
• Page 216
  1D-14 Engine Mechanical: • Apply a thin coat of engine oil to the new cushion seal • Install the fuel injector (5) by pushing it straight to the (2) and the O-ring (3). delivery pipe (6). CAUTION CAUTION Replace the cushion seal and O-ring with the Never turn the injector while pushing it.

• Page 217: Throttle Body Inspection And Cleaning

  Engine Mechanical: 1D-15 • Tighten the fuel delivery pipe mounting screws to the Inspection specified torque. Check following items for any defects or clogging. Replace the throttle body if necessary. Tightening torque • O-ring Fuel delivery pipe mounting screw (a): 3.5 N·m ( •…

• Page 218
  1D-16 Engine Mechanical: 3) Connect the respective vacuum tester hoses to each vacuum nipple on the throttle body. I718H1140382-01 Click “Active control”. 9) Click “ISC air volume control” (2). I718H1140389-01 4) Start the engine. 5) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 6) Click “Data monitor”.

• Page 219: Engine Assembly Removal

  9D (Page 9D-6)”. 17) After compleating the throttle valve synchronization, 3) Remove the frame head covers (GSF1250/A) or clear the DTC and reset the ISC learned valve using cowling (GSF1250S/SA). Refer to “Exterior Parts SDS tool. Refer to “ISC Valve Preset and Opening Removal and Installation in Section 9D (Page 9D- Initialization in Section 1C (Page 1C-6)”.

• Page 220
  1D-18 Engine Mechanical: 4) Remove the fuel tank. Refer to “Fuel Tank Removal 11) Remove the throttle body assembly (5). Refer to and Installation in Section 1G (Page 1G-9)”. “Throttle Body Removal and Installation (Page 1D- 9)”. 5) Drain engine coolant. Refer to “Cooling System Inspection in Section 0B (Page 0B-12)”.
• Page 221
  Engine Mechanical: 1D-19 15) Disengage the gearshift link arm by removing the 20) Loosen the rear axle nut (12) and chain adjusters bolt. (13) to provide additional chain slack. NOTE Mark the gearshift shaft head at which the gearshift link arm slit is set for correct reinstallation.
• Page 222
  1D-20 Engine Mechanical: 23) Disconnect the engine ground wire coupler (18) and 27) Remove the frame down tube (23) by removing their oil pressure switch coupler (19). bolts and nuts. I718H1140366-01 I718H1140369-01 24) Disconnect the GP switch coupler (20) and starter 28) Remove the engine mounting brackets, No.1 (24) motor lead wire (21).

• Page 223: Engine Assembly Installation

  Engine Mechanical: 1D-21 Engine Assembly Installation B718H11406003 Reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • Insert the two mounting bolts from left side, and tighten their nuts. NOTE The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.

• Page 224: Tightening Torque

  1D-22 Engine Mechanical: • Tighten all engine mounting bolts and nuts to the specified torque, as shown in the following illustration. Left Right Left Right “a” “ c ” “b” “c” 2 “b” I718H1140375-02 1. Engine mounting bolt (Front upper) “a”: 215 mm (8.5 in) : 47 N⋅m (4.7 kgf-m, 34.0 lb-ft) 2.

• Page 225
  Tightening torque Speed sensor rotor bolt (h): 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Before installing the engine sprocket inner cover, apply a small quantity of SUZUKI SUPER GREASE to the clutch push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1140377-01 •…

• Page 226: Engine Top Side Disassembly

  Removal and Installation in Section 1G (Page 1G- I718H1140007-01 9)”. PAIR System 3) Remove the frame head covers (3) (GSF1250/A) or 1) Disconnect the PAIR hoses and lead wire coupler. cowling (GSF1250S/SA). Refer to “Exterior Parts Removal and Installation in 2) Remove the PAIR control solenoid valve (1).

• Page 227
  Engine Mechanical: 1D-25 Camshaft 4) Remove the throttle body (2). Refer to “Throttle Body Removal and Installation (Page 1D-9)”. 1) Remove the right crankshaft cover (1). I718H1140022-01 I718H1140011-01 5) Remove the cam chain tension adjuster cap bolt (3) 2) Remove all of the spark plugs. Refer to “Ignition Coil and spring.
• Page 228
  1D-26 Engine Mechanical: 3) Remove the water hoses (3). I718H1140035-01 Remove the intake (7) and exhaust camshafts (8). I718H1140037-01 9) Remove the dowel pins. 4) Remove the cylinder head bolts (L65) (4). 5) Remove the cylinder head bolts (L175) and washers. NOTE When loosening the cylinder head bolts, loosen each bolt little by little diagonally.
• Page 229
  Engine Mechanical: 1D-27 Cam Chain No.1 Guide 3) Remove the cylinder (3). Remove the cam chain No.1 guide (1). NOTE If the cylinder does not come off easily, lightly tap it using a plastic hammer. I718H1140041-01 Cylinder 1) Disconnect the water hoses (1). I718H1140044-02 4) Remove the cylinder gasket (4) and dowel pins.

• Page 230: Engine Top Side Assembly

  1D-28 Engine Mechanical: 3) Draw out each piston pin (2) and remove the pistons • Place a clean rag over the cylinder base so as not to (3). drop the piston pin circlips (1) into the crankcase. • Install the piston pin circlips (1). NOTE Scribe the cylinder number on the piston CAUTION…

• Page 231
  Engine Mechanical: 1D-29 • Position the piston ring gaps as shown. Before • Install each special tool to the #2 and #3 pistons. inserting each piston into its cylinder, check that the NOTE gaps are properly positioned. Do not overtighten the bands, or piston installation into the cylinders will be difficult.
• Page 232
  1D-30 Engine Mechanical: Cam Chain No.1 Guide • Place the cylinder head (3) on the cylinder. • Pull the cam chain out of the cylinder and install the NOTE cam chain guide (1). When installing the cylinder head (3), keep CAUTION the cam chain taut.
• Page 233
  Engine Mechanical: 1D-31 Water Hose • Install the water hoses (1). Refer to “Water Hose Routing Diagram in Section 1F (Page 1F-3)”. “B” “A” I718H1140062-02 • Before replacing the camshafts on cylinder head, apply engine oil to their journals and cam faces. •…
• Page 234
  1D-32 Engine Mechanical: • The other arrow marked “2” “D” should now be • Install the camshaft journal holders. pointing straight up. Starting from the roller pin that is CAUTION directly above the arrow marked “2” “D”, count out 16 roller pins (from the exhaust camshaft side going Damage to head or camshaft journal holder towards the intake camshaft side).
• Page 235
  Engine Mechanical: 1D-33 • Install the oil pipe and tighten the mounting bolts to • Install the cam chain tension adjuster (3) and tighten specified torque. its mounting bolts. Tightening torque NOTE Cam chain tension adjuster mounting bolt (a): 10 Fit the washer (1) to each oil pipe mounting N·m (1.0 kgf-m, 7.0 lb-ft) bolt.
• Page 236
  • After installing the cam chain tension adjuster, rotate Right Crankshaft Cover the crankshaft (some turns), and recheck the • Apply SUZUKI BOND lightly to the mating surfaces at positions of the camshafts. the parting line between the upper and lower crankcases as shown.
• Page 237
  Engine Mechanical: 1D-35 • Apply SUZUKI BOND to the cam end caps of the PAIR System gasket as shown. • Install the PAIR component parts. Refer to “PAIR Reed Valve Removal and Installation in Section 1B : Sealant 99000–31140 (SUZUKI Bond (Page 1B-6)”.

• Page 238: Valve Clearance Inspection And Adjustment

  1D-36 Engine Mechanical: Valve Clearance Inspection and Adjustment Camshaft Runout B718H11406008 Measure the runout using the dial gauge. Replace the Refer to “Valve Clearance Inspection and Adjustment in camshaft if the runout exceeds the limit. Section 0B (Page 0B-5)”. Special tool (A): 09900–20607 (Dial gauge (1/100 mm, 10 Camshaft Inspection mm))

• Page 239
  Engine Mechanical: 1D-37 3) Install each camshaft journal holder to its original 7) If the camshaft journal oil clearance exceeds the position. Refer to “Engine Top Side Assembly limit, measure the inside diameter of the camshaft (Page 1D-28)”. journal holder and the outside diameter of the camshaft journal.

• Page 240: Camshaft Sprocket Inspection

  1D-38 Engine Mechanical: Camshaft Sprocket Inspection Installation B718H11406010 1) Set the camshaft sprocket to the camshafts. Inspect the camshaft sprocket in the following procedures: NOTE 1) Remove the intake and exhaust camshafts. Refer to Align the arrow mark “3” on camshaft “Engine Top Side Disassembly (Page 1D-24)”.

• Page 241: Cam Chain Tension Adjuster Inspection

  Engine Mechanical: 1D-39 Cam Chain Tension Adjuster Inspection 3) Remove the cylinder head. Refer to “Engine Top B718H11406012 Side Disassembly (Page 1D-24)”. The cam chain tension adjuster is maintained at the 4) Remove the cam chain No.1 guide (2). proper tension by an automatically adjusted. 1) Remove the cam chain tension adjuster.

• Page 242: Cam Chain Tensioner Inspection

  1D-40 Engine Mechanical: Cam Chain Tensioner Inspection Cylinder Head Disassembly and Assembly B718H11406015 B718H11406016 Inspect the cam chain tensioner in the following Refer to “Engine Top Side Disassembly (Page 1D-24)”. procedures: Refer to “Engine Top Side Assembly (Page 1D-28)”. 1) Separate the crankcases, upper and lower. Refer to CAUTION “Engine Bottom Side Disassembly (Page 1D-53)”.

• Page 243
  Oil gallery plug (cylinder head) (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft) • Apply grease to O-ring of the intake pipe. CAUTION Replace the O-rings with new ones. I718H1140103-01 : Grease 99000–25010 (SUZUKI SUPER Remove the intake pipes. GREASE A or equivalent) I718H1140105-01 I718H1140109-01…
• Page 244
  1D-42 Engine Mechanical: NOTE • Install the valve spring seat. • Apply engine oil to the oil seal (1), and press-fit it into • When replacing the intake pipes, identify position. the different intake pipes according to each I.D. code “A”. CAUTION (1-18H0 for cylinder #1 and #4) Do not reuse the removed oil seal.
• Page 245
  Engine Mechanical: 1D-43 • Install the valve spring with the small-pitch portion “B” • Be sure that the rounded lip “F” of the cotter fits snugly facing cylinder head. into the groove “G” in the stem end. “F” “E” “D” “C”…

• Page 246: Cylinder Head Related Parts Inspection

  1D-44 Engine Mechanical: Cylinder Head Related Parts Inspection Valve Head Radial Runout B718H11406017 Place the dial gauge at a right angle to the valve head Refer to “Cylinder Head Disassembly and Assembly face and measure the valve head radial runout. If it (Page 1D-40)”.

• Page 247
  Engine Mechanical: 1D-45 NOTE Valve Stem Deflection Lift the valve about 10 mm (0.39 in) “a” from the valve If valve guides have to be removed for seat. Measure the valve stem deflection in two replacement after inspecting related parts, directions, “X”…
• Page 248
  1D-46 Engine Mechanical: 4) Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the “ a” valve face. If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat “b”…

• Page 249: Valve Guide Replacement

  Engine Mechanical: 1D-47 Valve Guide Replacement 5) Cool down the new valve guides in a freezer for B718H11406018 about one hour and heat the cylinder head to 100 – 1) Remove the cylinder head. Refer to “Engine Top 150 °C (212 – 302 °F) with a hot plate. Side Disassembly (Page 1D-24)”.

• Page 250: Valve Seat Repair

  1D-48 Engine Mechanical: After installing the valve guides, refinish their guiding CAUTION bores using the reamer. Be sure to clean and oil the • The valve seat contact area must be guides after reaming. inspected after each cut. NOTE •…

• Page 251
  Engine Mechanical: 1D-49 3) Remove the water jacket plugs (4). I718H1140136-01 • Apply engine coolant to O-ring of water inlet I718H1140133-01 connector. CAUTION Replace the O-ring with a new one. I718H1140134-01 Assembly Assembly is in the reverse order of disassembly. Pay attention to the following points: •…

• Page 252: Cylinder Inspection

  1D-50 Engine Mechanical: • Apply engine oil to O-ring and install the oil jet. Cylinder Bore Measure the cylinder bore diameter at six places. If any • Tighten the ECT sensor to the specified torque. one of the measurements exceed the limit, overhaul the CAUTION cylinder and replace the piston with an oversize piston.

• Page 253: Piston Ring Removal And Installation

  Engine Mechanical: 1D-51 Piston Ring Removal and Installation B718H11406022 Removal “A” 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-24)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring (2) to remove it.

• Page 254: Piston And Piston Ring Inspection

  1D-52 Engine Mechanical: 2) Position the gaps of the three rings and side rails as Piston-to-cylinder Clearance shown. Before inserting piston into the cylinder, Subtract the piston diameter from the cylinder bore check that the gaps are so located. diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.

• Page 255: Engine Bottom Side Disassembly

  Engine Mechanical: 1D-53 Piston Ring Free End Gap and Piston Ring End Gap Measure the piston ring free end gap using vernier calipers. Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge.

• Page 256
  1D-54 Engine Mechanical: 3) Remove the water hoses (2) and regulator/rectifier Clutch bracket (3). Remove the clutch component parts (1). Refer to “Clutch Removal in Section 5C (Page 5C-13)”. I718H1140005-01 I718H1140160-01 Engine Top Side Disassemble the engine top side (1). Refer to “Engine Oil Pump Top Side Disassembly (Page 1D-24)”.
• Page 257
  Engine Mechanical: 1D-55 Generator 6) Remove the pin (8) and washer (9). Remove the generator component parts (1). Refer to NOTE “Generator Removal and Installation in Section 1J Do not drop the pin (8) and washer (9) into (Page 1J-4)”. the crankcase.
• Page 258
  1D-56 Engine Mechanical: Gear Position Switch Oil Filter Remove the gear position switch (1). Remove the oil filter (1) with the special tool. Special tool (A): 09915–40610 (Oil filter wrench) I718H1140169-01 Crankcase Breather Cover I718H1140172-01 Remove the crankcase breather cover (1) and oil breather separator (2).
• Page 259
  Engine Mechanical: 1D-57 Oil Pressure Regulator / Oil Strainer 3) Draw out the balancer shaft (3) and remove the crank balancer assembly (4). 1) Remove the oil pressure regulator (1). 2) Remove the oil strainer (2). NOTE 3) Remove the O-rings (3). Disassemble the crank balancer assembly if necessary.
• Page 260
  1D-58 Engine Mechanical: 3) Loosen the crankcase bolts evenly by shifting the Crankshaft / Conrod / Cum Chain wrench in the descending order of numbers. 1) Remove the crankshaft assembly (1) from the upper crankcase. 2) Remove the thrust bearings (2). NOTE The crankshaft thrust bearings (2) are located between the crankshaft assembly and upper…
• Page 261
  Engine Mechanical: 1D-59 Transmission 3) Remove the oil gallery jet (2) from the upper Remove the transmission component. Refer to crankcase. “Transmission Removal in Section 5B (Page 5B-3)”. I718H1140190-01 4) Remove the oil jet (for transmission) from the lower I718H1140187-01 crankcase.
• Page 262
  1D-60 Engine Mechanical: NOTE 2) Remove the oil gallery plugs (2) from the lower crankcase. • Do not remove the crankshaft journal bearings unless absolutely necessary. • Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions.

• Page 263: Engine Bottom Side Assembly

  Engine Mechanical: 1D-61 Engine Mount Bushing Remove the engine mount bushings (1) if necessary. I718H1140201-01 I718H1140199-02 Engine Bottom Side Assembly B718H11406025 Assemble the engine bottom side in the reverse order of disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling.

• Page 264
  1D-62 Engine Mechanical: Oil Jet • Fit the new O-ring (1) to each piston cooling oil jet as shown and apply engine oil to them. CAUTION Use the new O-rings to prevent oil pressure leak. I718H1140206-02 • Install the oil jets, (2) and (3). I718H1140204-01 •…
• Page 265
  Engine Mechanical: 1D-63 • Apply SUZUKI BOND to the mating surface of the • Before installing the crankshaft assembly, apply engine oil to each crankshaft journal bearing. lower crankcase as follows. • Install the crankshaft assembly along with the cam NOTE chain into the upper crankcase.
• Page 266
  1D-64 Engine Mechanical: • Tighten the other crankcase bolts a little at a time to • After the crankshaft journal bolts and crankcase bolts equalize the pressure. have been tightened, check that the crankshaft rotates smoothly. CAUTION • Also check that the driveshaft and countershaft rotate Fit new gasket washer to the bolt “A”.
• Page 267
  Engine Mechanical: 1D-65 • Hold the crankshaft and install the crank balancer • Install the balancer shaft arm. assembly. • Apply a small quantity of THREAD LOCK to the balancer shaft arm bolt and tighten it to the specified NOTE torque.
• Page 268
  1D-66 Engine Mechanical: “C” “a” “D” I718H1140227-02 • Apply SUZUKI BOND to the mating surface of the oil pan. I718H1140401-03 “a”: 1.5 – 2 graduations NOTE Oil Pressure Regulator / Oil Strainer / Oil Pan • Make surfaces free from moisture, oil, dust and other foreign materials.
• Page 269
  Replace the O-ring with a new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1140232-01 Oil Pressure Switch • Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. NOTE I718H1140230-02 Be careful not to apply SUZUKI BOND to the •…
• Page 270
  “a”: 20° ± 10° Replace the O-ring with a new one. Crankcase Breather Cover NOTE • Apply SUZUKI BOND to the mating surface of the Align the gear position switch pin “A” with breather cover. the gearshift cam hole “B”.
• Page 271
  Engine Mechanical: 1D-69 Water Pump Generator • Apply SUZUKI SUPER GREASE to the O-ring. • Install the generator component parts (1). Refer to “Generator Removal and Installation in Section 1J CAUTION (Page 1J-4)”. Replace the O-ring with a new one.
• Page 272
  1D-70 Engine Mechanical: • Install the gearshift cam stopper plate (5). NOTE Align the gearshift cam pin “B” with the gearshift cam stopper plate hole “C”. I718H1140247-02 • Install the gearshift shaft assembly (7) and washer (8) as shown. “B” “C”…
• Page 273
  Engine Mechanical: 1D-71 Oil Pump • Install the oil pimp driven gear (3). • Install the O-ring to the oil pump and apply SUZUKI • Install the snap ring (4). SUPER GREASE to it. CAUTION CAUTION Never reuse a snap ring.

• Page 274: Crank Balancer Disassembly And Assembly

  1D-72 Engine Mechanical: • Install the spacer (7). Engine Top Side • Assemble the engine top side. Refer to “Engine Top Side Assembly (Page 1D-28)”. “C” I718H1140255-01 Clutch I718H1140258-01 • Install the clutch component parts (1). Refer to “Clutch Installation in Section 5C (Page 5C-14)”. Water Hose •…

• Page 275: Crank Balancer Inspection

  Engine Mechanical: 1D-73 Disassembly • Apply engine oil to the bearings, spacer and washers. 1) Remove the washers (1), bearings (2) and spacer (3) from the crank balancer. I718H1140262-01 Crank Balancer Inspection I718H1140260-01 B718H11406033 2) Remove the balancer gear (4) along with the Refer to “Crank Balancer Disassembly and Assembly dampers (5) from the crank balancer.

• Page 276: Conrod Removal And Installation

  1D-74 Engine Mechanical: Balancer Shaft Inspect the balancer shaft for wear or damage. Replace the balancer shaft if there is anything unusual. I718H1140269-01 Installation 1) When installing the bearings into the conrod cap and conrod, be sure to install the tab “A” first, and then press in the opposite side of the bearing.

• Page 277: Conrod And Crankshaft Inspection

  Engine Mechanical: 1D-75 4) Apply engine oil to the conrod cap bolts. 5) Tighten the conrod cap bolt by using a 10 mm, 12 point socket wrench in the following two steps. Tightening torque Conrod cap bolt: 21 N⋅m (2.1 kgf-m, 15.0 Ib-ft) then turn in 1/4 (90°) turn.

• Page 278: Conrod Crank Pin Bearing Inspection And Selection

  1D-76 Engine Mechanical: Crankshaft Runout 2) Place the plastigauge axially along the crank pin, Support the crankshaft using V-blocks as shown, with avoiding the oil hole, as shown. the two end journals resting on the blocks. Set up the Special tool dial gauge as shown, and rotate the crankshaft slowly to (A): 09900–22301 (Plastigauge (0.025 — read the runout.

• Page 279
  Engine Mechanical: 1D-77 4) Remove the conrod caps and measure the width of 2) Check the corresponding crank pin O.D. code the compressed plastigauge using the envelope numbers ([1], [2] or [3]) “B”. scale. This measurement should be taken at the widest part of the compressed plastigauge.

• Page 280: Crankshaft Journal Bearing Inspection And Selection

  1D-78 Engine Mechanical: Crankshaft Journal Bearing Inspection and 4) Select the specified bearings from the bearing selection table. Selection B718H11406029 Refer to “Engine Bottom Side Disassembly (Page 1D- CAUTION 53)”. The bearings should be replaced as a set. Refer to “Engine Bottom Side Assembly (Page 1D-61)”. Inspection Bearing selection table 1) Inspect each upper and lower crankcase bearing for…

• Page 281
  Engine Mechanical: 1D-79 2) Install the plastigauge onto each crankshaft journal 5) Remove the lower crankcase and measure the width as shown. of compressed plastigauge using the envelope scale. This measurement should be taken at the Special tool widest part of the compressed plastigauge. If the oil (A): 09900–22301 (Plastigauge (0.025 –…

• Page 282: Crankshaft Thrust Clearance Inspection And Selection

  1D-80 Engine Mechanical: 2) Check the corresponding crankshaft journal O.D. 4) Select the specified bearings from the bearing codes ([A], [B] or [C]) “B”, which are stamped on the selection table. crankshaft. Bearing selection table Crankshaft O.D. “B” Code Green Black Brown Crankcase…

• Page 283
  Engine Mechanical: 1D-81 2) Measure the thrust clearance “a” between the left- Selection side thrust bearing and crankshaft using the 1) Remove the right-side thrust bearing and measure thickness gauge. If the thrust clearance exceeds the its thickness using the micrometer. If the thickness of standard range, adjust the thrust clearance.
• Page 284
  1D-82 Engine Mechanical: 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-17E00-0D0) of left-side thrust bearing. Left-side thrust bearing selection table Clearance before inserting Color “A” (Part No.) Thrust bearing thickness Thrust clearance the left-side thrust bearing…

• Page 285: Specifications

  Engine Mechanical: 1D-83 Specifications Service Data B718H11407001 Valve + Guide Unit: mm (in) Item Standard Limit 31 (1.22) — Valve diam. 27 (1.06) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —…

• Page 286: Tightening Torque Specifications

  1D-84 Engine Mechanical: Item Standard Limit Piston pin bore 18.002 – 18.008 (0.7087 – 0.7090) 18.030 (0.7098) Piston pin O.D. 17.996 – 18.000 (0.7085 – 0.7087) 17.980 (0.7079) Conrod + Crankshaft Unit: mm (in) Item Standard Limit Conrod small end I.D. 18.010 –…

• Page 287: Special Tools And Equipment

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) /…

• Page 288: Special Tool

  1D-86 Engine Mechanical: Material SUZUKI recommended product or Specification Note Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32030 (Page 1D-22) / 1303 or equivalent (Page 1D-38) / (Page 1D-70) THREAD LOCK CEMENT SUPER P/No.: 99000–32110 (Page 1D-62) / 1322 or equivalent…

• Page 289
  Engine Mechanical: 1D-87 09900–20803 09900–21304 Thickness gauge V-block (100 mm) (Page 1D-44) / (Page 1D-36) / (Page 1D-50) / (Page 1D-44) / (Page 1D-52) / (Page 1D-44) / (Page 1D-53) / (Page 1D-76) (Page 1D-75) / (Page 1D-81) / (Page 1D-81) 09900–22301 09900–22302 Plastigauge (0.025 –…
• Page 290
  1D-88 Engine Mechanical: 09916–43211 09916–43230 Valve guide remover/ Attachment installer (Page 1D-47) / (Page 1D-47) (Page 1D-47) 09916–74521 09916–74550 Holder body Band (Piston diam.: 73 – 85 (Page 1D-29) (Page 1D-29) 09916–84511 09930–10121 Valve adjuster driver Spark plug wrench set (Page 1D-40) / (Page 1D-25) (Page 1D-43)

• Page 291: Engine Lubrication System

  Engine Lubrication System: 1E-1 Engine Lubrication System Engine Precautions Precautions for Engine Oil B718H11500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-4)”.

• Page 292: Schematic And Routing Diagram

  1E-2 Engine Lubrication System: Schematic and Routing Diagram Engine Lubrication System Chart Diagram B718H11502002 EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER (B) CAMSHAFT JOURNALS, CAMFACES, TAPPETS INTAKE CAMSHAFT EXHAUST CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER (D) JOURNAL HOLDER (A) OIL JET (#8) CAMSHAFT JOURNALS, CAMFACES, TAPPETS CAM CHAIN…

• Page 293: Diagnostic Information And Procedures

  Engine Lubrication System: 1E-3 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B718H11504001 Condition Possible cause Correction / Reference Item Engine overheats. Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler Clean or replace.

• Page 294: Repair Instructions

  1E-4 Engine Lubrication System: 6) Stop the engine and remove the oil pressure gauge and attachment. 7) Reinstall the main oil gallery plug and tighten it to the specified torque. CAUTION Use a new gasket to oil leakage. Tightening torque Main Oil gallery plug (M16) (a): 35 N·m (3.5 kgf- m, 25.5 lb-ft) I718H1150020-01…

• Page 295
  Oil gallery plug (M12) (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft) I718H1150064-01 7) Remove the oil gallery plug (6) from the oil pan. I718H1150026-01 • Apply SUZUKI SUPER GREASE to the O-rings and install them. I718H1150024-02 CAUTION Remove the O-rings (7), oil pressure regulator (8) and oil strainer (9).

• Page 296: Oil Pressure Regulator / Oil Strainer Inspection

  Use a new gasket washer to prevent oil leakage. “B” “A” I718H1150029-01 • Apply SUZUKI BOND to the mating surface of the oil pan. I718H1150032-01 NOTE • After installing the removed parts, pour engine oil and engine coolant. Refer to “Engine Oil and Filter Use of SUZUKI BOND is as follows: Replacement in Section 0B (Page 0B-10)”…

• Page 297: Oil Cooler Removal And Installation

  Install the oil cooler in the revers order of removal. Pay Inspect the oil strainer body for damage. If necessary, attention to the following points: replace it with a new one. • Apply SUZUKI SUPER GREASE to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. NOTE When installing the oil cooler, fit the concave part “A”…

• Page 298: Oil Pressure Switch Inspection

  Oil Jet Removal and Installation Installation B718H11506018 Oil Jet (For Cam Chain Tension Adjuster) 1) Install the oil pressure switch, apply the SUZUKI Removal BOND to its thread and tighten it to the specified 1) Remove the cam chain tension adjuster. Refer to torque.

• Page 299
  Engine Lubrication System: 1E-9 Installation 3) Remove the crankshaft assembly. Refer to “Engine Installation is in the reverse order of removal. Pay Bottom Side Disassembly in Section 1D (Page 1D- attention to the following points: 53)”. • Apply engine oil to the O-ring. 4) Remove the piston cooling oil jets (1) from the upper crankcase.

• Page 300: Oil Gallery Jet Removal And Installation

  1E-10 Engine Lubrication System: • Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque. : Thread lock cement 99000–32110 (THREAD LOCK CEMENT SUPER 1322 or equivalent) Tightening torque Piston cooling oil jet bolt (a): 10 N·m (1.0 kgf-m, 7.0 lb-ft) I718H1150051-02 Oil Jet / Oil Gallery Jet Inspection…

• Page 301: Oil Pump Removal And Installation

  5) Remove the thrust washer (4) and washer (5). I718H1150057-01 Installation Installation is in reverse order of removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE to the O-ring. CAUTION Use a new O-ring to prevent oil leakage. I718H1150056-01 : Grease 99000–25010 (SUZUKI SUPER…

• Page 302
  1E-12 Engine Lubrication System: • Install the oil pump. NOTE Set the oil pump shaft end “A” to the water pump shaft. “A” I718H1150060-01 • Install the washer (5) and thrust washer (6) onto the countershaft. NOTE The chamfer side “B” of thrust washer faces inside.

• Page 303: Oil Pump Inspection

  Engine Lubrication System: 1E-13 Oil Pump Inspection B718H11506014 Inspect the oil pump in the following procedures: 1) Remove the oil pump. Refer to “Oil Pump Removal and Installation (Page 1E-11)”. 2) Rotate the oil pump by hand and check that it moves smoothly.

• Page 304: Special Tools And Equipment

  1E-14 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B718H11508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-5) / (Page 1E- equivalent 7) / (Page 1E-11) Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110…

• Page 305: Engine Cooling System

  Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Precautions for Engine Cooling System B718H11600001 WARNING • You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

• Page 306: Schematic And Routing Diagram

  1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B718H11602004 RESERVOIR TANK THERMOSTAT CONNEECTOR CYLINDER HEAD THERMOSTAT ECT SENSOR CYLINDER COOLER RADIATOR WATER PUMP I718H1160029-03…

• Page 307: Water Hose Routing Diagram

  “L”: The clamp screw head should face upward. 4. Radiator heat shield “M”: The clamp screw head should face left upward. 5. Radiator cover molding (GSF1250/A only) “N”: The clamp screw head should face right side. 6. Tape (GSF1250/A only) “O”: The clamp screw head should face left side.

• Page 308: Diagnostic Information And Procedures

  1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B718H11604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

• Page 309: Radiator Cap Inspection

  Engine Cooling System: 1F-5 Radiator Cap Inspection Radiator Cleaning B718H11606013 Blow out any foreign matter that is stuck in the radiator Inspect the radiator cap in the following procedures: fins using compressed air. 1) Remove the radiator cap. Refer to “Cooling Circuit CAUTION Inspection (Page 1F-4)”.

• Page 310: Water Hose Inspection

  1F-6 Engine Cooling System: 4) Disconnect the cooling fan motor coupler (2), water 7) Remove the spacers (7) and mounting bolt. bypass hose (3) and radiator outlet hose (4). Remove the cooling fan motor from the radiator (8). I718H1160034-01 I718H1160037-02 5) Remove the radiator assembly (5) by removing the 9) Remove the radiator covers (9), left and right.

• Page 311: Water Hose Removal And Installation

  Engine Cooling System: 1F-7 Water Hose Removal and Installation 3) Any leakage from the connecting section should be corrected by proper tightening. Refer to “Water Hose B718H11606016 Removal Routing Diagram (Page 1F-3)”. 1) Drain engine coolant. Refer to “Cooling System Inspection in Section 0B (Page 0B-12)”.

• Page 312: Radiator Reservoir Tank Removal And Installation

  1F-8 Engine Cooling System: 2) Inspect the radiator reservoir tank cooling leaks. If Installation any defects are found, replace the radiator reservoir Install radiator reservoir tank in the reverse order of tank with a new one. removal. Pay attention to the following points: •…

• Page 313: Cooling Fan Relay Inspection

  Engine Cooling System: 1F-9 2) Test the cooling fan motor for load current with an 3) First check the insulation between “A” and “B” ammeter connected as shown in the figure. terminals with tester. Then apply 12 volts to “C” and If the fan motor does not turn, replace the cooling fan “D”…

• Page 314
  1F-10 Engine Cooling System: 5) Remove the thermostat connector (1) along with Remove the thermostat (9). bracket (7). I718H1160050-01 I718H1160004-02 Installation 6) Remove the bracket (7) from the thermostat Install the thermostat in the reverse order of removal. connector (1). Pay attention to the following points: •…

• Page 315: Thermostat Inspection

  Engine Cooling System: 1F-11 • Connect the water hoses securely. Refer to “Water 5) Heat the water by placing the beaker on a stove and Hose Routing Diagram (Page 1F-3)”. observe the rising temperature on a thermometer (2). • Pour engine coolant and bleed air from the cooling circuit.

• Page 316: Water Pump Components

  1F-12 Engine Cooling System: Water pump Components B718H11606026 I718H1160062-01 1. Water pump case 4. Mechanical seal : 6 N⋅m (0.6 kgf-n, 4.5 Ib-ft) : Apply engine coolant. 2. O-ring 5. Oil seal : 13 N⋅m (1.3 kgf-n, 9.5 Ib-ft) : Do not reuse. 3.

• Page 317: Water Pump Removal And Installation

  If engine oil is leaking, visually inspect the oil seal and O-ring. If engine : Grease 99000–25010 (SUZUKI SUPER coolant is leaking, visually inspect the GREASE A or equivalent) mechanical seal and seal washer. Refer to •…

• Page 318: Water Pump Disassembly And Assembly

  1F-14 Engine Cooling System: Water Pump Disassembly and Assembly 6) Remove the impeller shaft (6) and washer (7). B718H11606029 Refer to “Water Pump Removal and Installation (Page 1F-13)”. Disassembly 1) Remove the air vent bolt (1) if necessary. 2) Remove the water pump case (2). I718H1160014-01 7) Remove the mechanical seal with the special tool.

• Page 319
  : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1160059-01 4) Apply SUZUKI SUPER GREASE to the impeller shaft. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) 5) Install the impeller shaft and washer (1) to the water I718H1160057-01 pump body.
• Page 320
  1F-16 Engine Cooling System: 6) Install the rubber seal (2) into the impeller. 10) Install a new O-ring (7) and apply engine coolant to 7) After wiping off the oily or greasy matter from the mechanical seal ring (3), install it into the impeller. CAUTION NOTE Use a new O-ring to prevent engine coolant…

• Page 321: Water Pump Related Parts Inspection

  Engine Cooling System: 1F-17 Water Pump Related Parts Inspection Seal Washer B718H11606030 Visually inspect the seal washer for damage, with Refer to “Water Pump Disassembly and Assembly particular attention given to the sealing face. (Page 1F-14)”. Replace the seal washer that shows indications of leakage.

• Page 322: Specifications

  1F-18 Engine Cooling System: Specifications Service Data B718H11607001 Thermostat + Radiator + Fan + Coolant Item Specification Note Approx. 82 °C (180 °F) Thermostat valve opening temperature — 8 mm (0.31 in) and over at 95 °C (203 °F) Thermostat valve lift —…

• Page 323: Special Tools And Equipment

  Engine Cooling System: 1F-19 Special Tools and Equipment Recommended Service Material B718H11608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-13) / equivalent (Page 1F-15) / (Page 1F-15) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110…

• Page 324: Fuel System

  1G-1 Fuel System: Fuel System Engine Precautions Precautions for Fuel System B718H11700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •…

• Page 325: General Description

  Fuel System: 1G-2 General Description Fuel System Description B718H11701002 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injectors) and fuel pressure regulator (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (8) installed in the fuel delivery pipe (5).

• Page 326: Schematic And Routing Diagram

  1G-3 Fuel System: Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B718H11702002 “a” “C” “A” “ b ” “B” “D” I718H1170040-02 1. Fuel tank drain hose 8. Clamp : Clamp end should face inside. Tip of clamp should face downward. 2.

• Page 327: Diagnostic Information And Procedures

  Fuel System: 1G-4 Diagnostic Information and Procedures Fuel System Diagnosis B718H11704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

• Page 328: Repair Instructions

  1G-5 Fuel System: Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B718H11706042 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43.5 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •…

• Page 329: Fuel Discharge Amount Inspection

  Fuel System: 1G-6 Fuel Discharge Amount Inspection 5) Disconnect the fuel pump lead wire coupler (3). B718H11706028 WARNING • Keep away from fire or spark. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. Inspect the fuel discharge amount in the following procedures: I718H1170043-01 1) Lift and support the fuel tank.

• Page 330: Fuel Pump Relay Inspection

  1G-7 Fuel System: Fuel Pump Relay Inspection Fuel Hose Inspection B718H11706029 B718H11706030 Refer to “Electrical Components Location in Section 0A Refer to “Fuel Line Inspection in Section 0B (Page 0B- (Page 0A-8)”. 10)”. Inspect the fuel pump relay in the following procedures: Fuel Level Gauge Inspection 1) Remove the seat.

• Page 331: Fuel Tank Construction

  Fuel System: 1G-8 Fuel Tank Construction B718H11706001 “A” I718H1170020-03 1. Fuel tank rear cushion 3. Rear bracket cushion : Be careful not to mistake the assembling position and direction. : Be careful not to mistake the assembling position and direction. 2.

• Page 332: Fuel Tank Removal And Installation

  1G-9 Fuel System: Fuel Tank Removal and Installation 4) Disconnect the fuel tank breather hose (2) and drain B718H11706002 hose (3). 5) Disconnect the fuel pump lead wire coupler (4). Removal 6) Remove the fuel tank. WARNING • Keep away from fire or spark. •…

• Page 333: Fuel Pump Components

  Fuel System: 1G-10 Fuel Pump Components B718H11706033 I718H1170002-03 1. Vessel 5. Thermistor : Apply grease. 2. Fuel mesh filter 6. Fuel level gauge : Do not reuse. 3. Fuel pump 7. O-ring : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 4. Fuel pressure regulator assembly : Apply engine oil.

• Page 334: Fuel Pump Assembly / Fuel Level Gauge Removal And Installation

  1G-11 Fuel System: Fuel Pump Assembly / Fuel Level Gauge 4) Remove the fuel level gauge (3) while pushing the pawl end “A”. Removal and Installation B718H11706034 CAUTION Removal Do not pull the lead wire when removing the fuel gauge. WARNING •…

• Page 335: Fuel Pump Disassembly And Assembly

  Refer to “Fuel Pump Assembly / Fuel Level Gauge CAUTION Removal and Installation (Page 1G-11)”. Replace the O-ring with a new one. Disassembly : Grease 99000–25010 (SUZUKI SUPER 1) Remove the vessel (1). GREASE A or equivalent) I718H1170029-01 I718H1170027-02 2) Remove the fuel mesh filter (2).

• Page 336
  1G-13 Fuel System: 5) Remove the cup cover (6) and fuel pump (7) from Disconnect the lead wire (BI) (11) and remove the the reservoir cup. fuel level gauge coupler (12). I718H1170032-02 I718H1170036-03 6) Remove the fuel pressure regulator assembly (8). 9) Disconnect the lead wire (W) (13) and remove the thermistor (14).

• Page 337: Fuel Mesh Filter Inspection And Cleaning

  Fuel System: 1G-14 2) If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power. Such a filter should be cleaned by blowing with compressed air. NOTE When the fuel mesh filter is dirtied excessively, replace the fuel filter cartridge with a new one.

• Page 338: Specifications

  1G-15 Fuel System: Specifications Service Data B718H11707001 Injector + Fuel Pump + Fuel Pressure Regulator Item Specification Note 11 – 13 Ω at 20 °C (68 °F) Injector resistance — Fuel pump discharge amount 166 ml (5.6/5.8 US/lmp oz) and more/10 sec. —…

• Page 339: Special Tools And Equipment

  Fuel System: 1G-16 Special Tools and Equipment Recommended Service Material B718H11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-12) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-10)”…

• Page 340: Ignition System

  1H-1 Ignition System: Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B718H11802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I718H1180001-02 Ignition System Components Location B718H11802002 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 341: Diagnostic Information And Procedures

  Ignition System: 1H-2 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B718H11804001 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Fouled spark plugs. Clean or replace. Wet spark plugs. Clean and dry or replace. Defective ignition coil/plug caps.

• Page 342: No Spark Or Poor Spark

  1H-3 Ignition System: No Spark or Poor Spark B718H11804002 Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing. Step Action Check the ignition system couplers for poor connections.

• Page 343: Repair Instructions

  1) Turn the ignition switch OFF. 2) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 3) Remove the frame head cover. (GSF1250/A) Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.

• Page 344: Spark Plug Inspection And Cleaning

  1H-5 Ignition System: Ignition Coil / Plug Cap Inspection • Install the ignition coil/plug caps and connect their lead wire couplers. B718H11806004 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”. CAUTION Do not hit the ignition coil/plug cap with a Ignition Coil Primary Peak Voltage plastic hammer when installing it.

• Page 345
  Ignition System: 1H-6 5) Insert the needle pointed probe to the lead wire 7) Measure the ignition coil primary peak voltage in the coupler. following procedures. NOTE WARNING Use the special tool, to prevent the rubber of Do not touch the tester probes and spark the water proof coupler from damage.

• Page 346: Ckp Sensor Inspection

  1H-7 Ignition System: CKP Sensor Inspection Ignition Coil / Plug Cap Resistance B718H11806008 1) Remove the ignition coil/plug caps. Refer to “Ignition Refer to “Electrical Components Location in Section 0A Coil / Plug Cap and Spark Plug Removal and (Page 0A-8)”. Installation (Page 1H-4)”.

• Page 347: Ckp Sensor Removal And Installation

  Inspect the engine stop switch in the following procedures: 1) Turn the ignition switch OFF. 2) Remove the right frame head cover. (GSF1250/A) Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 3) Disconnect the right handlebar switch coupler (1).

• Page 348: Ignition Switch Inspection

  I718H1180021-03 10) Using a center punch, remove the ignition switch mounting bolts. 11) Remove the ignition switch (6) from the upper bracket. I718H1180018-01 4) Remove the brake hose clamp bolt (GSF1250/S) or brake hose joint bolt (2) (GSF1250A/SA). I718H1180022-01 I718H1180019-01…

• Page 349
  Ignition System: 1H-10 Installation • Tighten the handlebar holder set nuts (3) to the Install the ignition switch in the reverse order of removal. specified torque. Pay attention to the following points: Tightening torque • Install the ignition switch and new bolts. Handlebar holder set nut (c): 45 N·m (4.5 kgf-m, •…

• Page 350: Specifications

  1H-11 Ignition System: Specifications Service Data B718H11807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR7E Type DENSO: U22ESR-N Spark plug 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 90 –…

• Page 351: Starting System

  Starting System: 1I-1 Starting System Engine Schematic and Routing Diagram Starting System Diagram B718H11902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. Ignition Engine stop switch switch Fuse (30 A) Bl/B Gear B/Bl Fuse position Starter Starter (15 A) switch button motor…

• Page 352: Starter Motor Will Not Run

  1I-2 Starting System: Starter motor will not run B718H11904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to step 2. Go to step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”…

• Page 353: Repair Instructions

  Starting System: 1I-3 Repair Instructions Starter Motor Components B718H11906001 I718H1190038-03 1. O-ring 5. O-ring : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Housing end (Inside) 6. Starter motor case : Apply grease to sliding surface. 3. O-ring 7: Housing end assembly (Outside) : Apply moly past to sliding surface.

• Page 354: Starter Motor Removal And Installation

  Install the starter motor in the reverse order of removal. Pay attention to the following points: • Apply grease to the starter motor O-ring. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1190002-01 4) Remove the regulator/rectifier bracket mounting CAUTION bolts.

• Page 355: Starter Motor Disassembly And Assembly

  • Apply a small quantity of moly paste to the armature battery (–) lead wire. Refer to “Wiring Harness shaft. Routing Diagram in Section 9A (Page 9A-8)”. : Moly paste 99000–25140 (SUZUKI Moly paste or equivalent) I718H1190008-01 I718H1190011-01 Starter Motor Disassembly and Assembly •…

• Page 356: Starter Motor Inspection

  1I-6 Starting System: Starter Motor Inspection Armature Coil B718H11906004 Measure for continuity between each segment. Measure Refer to “Starter Motor Disassembly and Assembly for continuity between each segment and the armature (Page 1I-5)”. shaft. If there is no continuity between the segments or there is Carbon Brush continuity between the segments and shaft, replace the Inspect the carbon brushes for abnormal wear, cracks or…

• Page 357: Starter Relay Removal And Installation

  Starting System: 1I-7 Starter Relay Removal and Installation Starter Relay Inspection B718H11906005 B718H11906006 Removal Inspect the starter relay in the following procedures: 1) Turn the ignition switch OFF. 1) Remove the starter relay. Refer to “Starter Relay Removal and Installation (Page 1I-7)”. 2) Remove the seat.

• Page 358: Turn Signal / Side-Stand Relay Removal And Installation

  1I-8 Starting System: Side-stand / Ignition Interlock System Parts 3) Measure the relay coil resistance between the terminals using the multi-circuit tester. If the Inspection resistance is not within the specified value, replace B718H11906008 Check the interlock system for proper operation. If the the starter relay with a new one.

• Page 359
  Starting System: 1I-9 5) Connect the side-stand switch coupler. 4) Install the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and Installation 6) Install the left frame cover. Refer to “Exterior Parts (Page 1I-8)”. Removal and Installation in Section 9D (Page 9D- 6)”.

• Page 360: Starter Clutch Removal And Installation

  1I-10 Starting System: Gear Position Switch 7) Measure the voltage between Pink and Black/White lead wires using the multi-circuit tester when shifting 1) Remove the left frame cover. Refer to “Exterior Parts the gearshift lever from low to top. Removal and Installation in Section 9D (Page 9D- 6)”.

• Page 361
  Starting System: 1I-11 3) Remove the idle gear shaft (2) and starter idle gear 7) Remove the one way clutch (7) from the guide (8). (3). 4) Remove the generator rotor assembly (4). Refer to “Generator Removal and Installation in Section 1J (Page 1J-4)”.

• Page 362: Starter Clutch Inspection

  1I-12 Starting System: Starter Clutch Inspection • Install the guide (2) to the generator rotor. B718H11906011 Refer to “Starter Clutch Removal and Installation NOTE (Page 1I-10)”. The arrow mark “B” must face to the generator rotor side. Starter Clutch 1) Install the starter driven gear onto the starter clutch. 2) Turn the starter driven gear by hand to inspect the starter clutch for a smooth movement.

• Page 363: Starter Button Inspection

  If any abnormality is found, replace the right handle Inspect the starter button in the following procedures: switch assembly with a new one. Refer to 1) Remove the right frame head cover. (GSF1250/A) “Handlebar Removal and Installation in Section 6B Refer to “Exterior Parts Removal and Installation in (Page 6B-3)”.

• Page 364: Special Tools And Equipment

  1I-14 Starting System: Special Tools and Equipment Recommended Service Material B718H11908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-5) equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140…

• Page 365: Charging System

  Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B718H11A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B718H11A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B718H11A04001 Condition…

• Page 366: Battery Runs Down Quickly

  1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. Battery runs down quickly Trouble in charging system. Check the generator, regulator/rectifier and circuit connections and make necessary adjustments to obtain specified charging operation.

• Page 367: Repair Instructions

  Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B718H11A06001 B718H11A06002 Inspect the battery current leakage in the following Inspect the regulated voltage in the following procedures: procedures: 1) Turn the ignition switch OFF. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.

• Page 368: Generator Removal And Installation

  1J-4 Charging System: 2) Measure the resistance between the three lead 2) Start the engine and keep it running at 5 000 r/min. wires. 3) Using the multi-circuit tester, measure the voltage If the resistance is out of specified value, replace the between three lead wires.

• Page 369
  Charging System: 1J-5 5) Remove the generator cover (4). Hold the generator rotor with the special tool. Special tool (A): 09930–44530 (Rotor holder) 9) Loosen the generator rotor bolt. NOTE When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor.
• Page 370
  1J-6 Charging System: 12) Remove the generator stator (10) along with the • Degrease the tapered portion “A” of generator rotor CKP sensor (11). and also the crankshaft “B”. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry.
• Page 371
  • Install the generator cover and tighten the generator line between the upper and lower crankcases as cover bolts. shown. WARNING : Sealant 99000–31140 (SUZUKI BOND Be careful not to pinch the finger between the No.1207B or equivalent) generator cover and the crankcase. CAUTION Fit new gasket washer to the bolt (4).

• Page 372: Regulator / Rectifier Construction

  1J-8 Charging System: Regulator / Rectifier Construction B718H11A06013 I718H11A0002-01 1. Regulator/rectifier 3. Regulator/rectifier bracket No.2 5. Engine sprocket inner cover 2. Regulator/rectifier bracket No.1 4. Breather cover : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) Regulator / Rectifier Inspection 3) Disconnect the regulator/rectifier couplers (1). B718H11A06012 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF.

• Page 373: Battery Components

  Charging System: 1J-9 4) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. Refer to “Regulator / Rectifier Construction (Page 1J-8)”.

• Page 374
  1J-10 Charging System: 1) Remove the aluminum tape (1) which seals the 5) Make sure that air bubbles (4) rise to the top of each battery filler holes “A”. electrolyte container, and leave in this position for about more than 20 minutes. “A”…
• Page 375
  Charging System: 1J-11 6) After confirming that the electrolyte has entered the Charging battery completely, remove the electrolyte containers For initial charging, use the charger specially designed from the battery. for MF battery. 7) Wait for about 20 minutes. CAUTION Insert the caps (2) into the filler holes, pressing in firmly so that the top of the caps do not protrude •…

• Page 376: Battery Removal And Installation

  1J-12 Charging System: 3) After recharging, wait at least 30 minutes and then 5) Remove the battery (4) from the motorcycle. measure the battery voltage using the multi-circuit tester. If the battery voltage is less than 12.5 V, recharge the battery again. If the battery voltage is still less than 12.5 V after recharging, replace the battery with a new one.

• Page 377: Specifications

  Charging System: 1J-13 Specifications Service Data B718H11A07001 Battery CAUTION Never use anything except the specified battery. Item Specification Note Type designation FT12A-BS Capacity 12 V, 36.0 kC (10 Ah)/10HR 1.330 at 20 °C (68 °F) Standard electrolyte S.G. Generator Item Specification Note 0.2 –…

• Page 378: Special Tools And Equipment

  1J-14 Charging System: Special Tools and Equipment Recommended Service Material B718H11A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-7) equivalent Special Tool B718H11A08002 09900–25008 09930–34970 Multi-circuit tester set Rotor remover set (Page 1J-3) /…

• Page 379: Exhaust System

  Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B718H11B00001 WARNING To avoid the risk of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipes and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

• Page 380: Repair Instructions

  1K-2 Exhaust System: Repair Instructions Exhaust System Construction B718H11B06001 “A” “B” I718H11B0001-03 1. Exhaust pipes 5. Exhaust pipe mounting bolt “A”: Chamfer : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Muffler 6. Muffler connecting bolt “B”: Apply exhaust gas sealer. : Do not reuse.

• Page 381: Exhaust Pipe / Muffler Removal And Installation

  Exhaust System: 1K-3 Exhaust Pipe / Muffler Removal and Installation 5) Disconnect the HO2 sensor coupler (4) and clamps. B718H11B06002 Removal 1) Loosen the muffler connecting bolts (1). 2) Remove the muffler (3) by removing the mounting bolt (2) and nut. NOTE Support the muffler to prevent it from falling.

• Page 382
  1K-4 Exhaust System: 7) Remove the HO2 sensor (6) from the exhaust pipe. • Install the exhaust pipe gaskets (1) and connector (2). CAUTION CAUTION Replace the gaskets and connector with new • Be careful not to expose it to an excessive ones.
• Page 383
  Exhaust System: 1K-5 • Tighten the exhaust pipe bolts and exhaust pipe • Route the HO2 sensor lead wire. Refer to “Throttle mounting bolt to the specified torque. Body Construction in Section 1D (Page 1D-8)” and “Wiring Harness Routing Diagram in Section 9A Tightening torque (Page 9A-8)”.

• Page 384: Exhaust System Inspection

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H11B08001 Material SUZUKI recommended product or Specification Note Exhaust gas sealer PERMATEX 1372 (commercially — (Page 1K-4)

• Page 385
  Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ……….2-1 Swingarm Related Parts Inspection ….2C-9 Swingarm Bearing Removal and Installation ..2C-10 Precautions…………. 2-1 Specifications ………….2C-12 Precautions for Suspension ……..2-1 Service Data…………2C-12 Suspension General Diagnosis….2A-1 Tightening Torque Specifications……2C-12 Special Tools and Equipment ……2C-13 Diagnostic Information and Procedures….2A-1 Recommended Service Material …….2C-13…

• Page 386: Precautions

  2-1 Precautions: Precautions Suspension Precautions Precautions for Suspension B718H12000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

• Page 387: Suspension General Diagnosis

  Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B718H12104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

• Page 388: Front Suspension

  2B-1 Front Suspension: Front Suspension Suspension Repair Instructions Front Fork Components B718H12206001 I718H1220001-04 1. Front fork protector 10. Front axle pinch bolt 19. Spring seat 2. Dust seal 11. Inner tube 20. Spacer 3. Oil seal stopper ring 12. Inner tube slide metal 21.

• Page 389: Front Fork Removal And Installation

  3) Remove the brake hose clamp bolt (2). Hold the front fork by the hand to prevent 4) Remove the front fender by removing the bolts (3), sliding out of the steering stem. left and right. GSF1250/S I718H1220005-03 I718H1220003-03 Installation GSF1250A/SA 1) Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts (1).

• Page 390: Front Fork Inspection

  2B-3 Front Suspension: 2) Tighten the front fork cap bolt (2) to the specified 7) Set the front fender plate nut to the front fender. torque with the special tool. NOTE Tightening torque Face the triangle mark on the front fender Front fork cap bolt (a): 23 N·m (2.3 kgf-m, 16.5 brace to the front side “A”.

• Page 391: Front Fork Adjustment

  Front Suspension: 2B-4 Front Fork Adjustment 2) Remove the front fork cap bolt (3) from the outer B718H12206006 tube. Turn the adjustment (1) to the desired position. 3) Remove the spring seat (2). CAUTION 4) Remove the front fork cap bolt (3) with spring adjuster by loosening the inner rod lock-nut (4).

• Page 392
  2B-5 Front Suspension: Remove the dust seal (8). 12) Remove the oil lock piece (12). I649G1220013-03 I649G1220017-03 9) Remove the oil seal stopper ring (9). 13) Remove the oil seal by slowly pulling out the inner tube. NOTE Be careful not to damage the inner tube. I649G1220014-03 10) Remove the damper rod bolt (10).
• Page 393
  2B-6 Assembly • Apply fork oil to the inner tube slide metal. Assemble the front fork in the reverse order of : Oil 99000–99001–SS8 (SUZUKI FORK OIL disassembly. Pay attention to the following points: SS-08 or equivalent) CAUTION The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork.
• Page 394
  : Oil 99000–99001–SS8 (SUZUKI FORK OIL SS-08 or equivalent) Capacity (each leg) GSF1250/A: 472 ml (16.0/16.6 US/lmp oz) GSF1250S/SA: 471 ml (15.9/16.0 US/lmp oz) I649G1220024-02 • Apply thread lock to the damper rod bolt and tighten it to the specified torque with a 6-mm hexagon wrench and special tools.
• Page 395
  When adjusting the fork oil level, remove the fork spring and compress the inner tube fully. Special tool (A): 09943–74111 (Fork oil level gauge) Fork oil level “a” GSF1250/A: 143 mm (5.6 in.) I649G1220031-04 GSF1250S/SA: 144 mm (5.7 in) “ a ” I649G1220029-03…

• Page 396: Front Fork Parts Inspection

  • Apply fork oil lightly to the O-ring (3). Inner and Outer Tubes Inspect the inner tube sliding surface and outer tube CAUTION sliding surface for scuffing. Use a new O-ring (3) to prevent oil leakage. : Oil 99000–99001–SS8 (SUZUKI FORK OIL SS-08 or equivalent) I649G1220035-03 I718H1220016-01…

• Page 397: Specifications

  Front fork inner tube O.D. 43 (1.7) — Front fork spring free length 390.4 (15.37) 382 (15.0) Front fork oil level (without spring, GSF1250/A 143 (5.6) — outer tube fully compressed ) GSF1250S/SA 144 (5.7) Front fork spring adjuster 3rd groove from top —…

• Page 398: Special Tools And Equipment

  2B-11 Front Suspension: Special Tools and Equipment Recommended Service Material B718H12208001 Material SUZUKI recommended product or Specification Note SUZUKI FORK OIL SS-08 or P/No.: 99000–99001– (Page 2B-6) / (Page 2B- equivalent 6) / (Page 2B-7) / (Page 2B-9) Thread lock cement THREAD LOCK CEMENT SUPER P/No.: 99000–32110…

• Page 399: Rear Suspension

  Rear Suspension: 2C-1 Rear Suspension Suspension Repair Instructions Rear Suspension Components B718H12306001 I718H1230001-01 1. Rear shock absorber 7. Chain case : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber mounting nut 8. Swingarm : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 3.

• Page 400: Rear Suspension Assembly Construction

  2C-2 Rear Suspension: Rear Suspension Assembly Construction B718H12306002 Left Right I718H1230042-01 1. Rear shock absorber mounting nut (Upper) 5. Cushion lever mounting nut : 100 N⋅m (10.0 kgf-m 72.5 lb-ft) 2. Rear shock absorber mounting nut (Lower) 6. Swingarm pivot nut : Apply grease to the bearing.

• Page 401: Rear Shock Absorber Removal And Installation

  Rear Suspension: 2C-3 Rear Shock Absorber Removal and Installation Installation B718H12306003 Install the rear shock absorber in the reverse order of removal. Pay attention to the following points: Removal • Temporary install the rear shock absorber and 1) Place the motorcycle on the center stand and cushion lever.

• Page 402: Rear Shock Absorber Inspection

  7 provides the stiffest. damper unit since it can explode or oil can splash hazardously. STD position • When discarding the rear cushion unit, be GSF1250/A: 3rd position sure to release gas pressure from the unit GSF1250S/SA: 4th position following the procedures. I649G1230006-03…

• Page 403: Cushion Lever Removal And Installation

  Rear Suspension: 2C-5 Cushion Lever Removal and Installation 1) Mark the drill center at the location “A” using a center punch. B718H12306008 Removal 1) Place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the cushion lever.

• Page 404: Cushion Lever Inspection

  2C-6 Rear Suspension: Cushion Lever Inspection Cushion Rod B718H12306009 Refer to “Swingarm Related Parts Inspection (Page 2C- Refer to “Cushion Lever Removal and Installation 9)”. (Page 2C-5)”. Cushion Lever Bearing Removal and Spacer Installation 1) Remove the spacers from the cushion lever. B718H12306010 2) Inspect the spacers for any flaws or other damage.

• Page 405: Swingarm / Cushion Rod Removal And Installation

  I718H1230017-01 3) Remove the brake hose clamps. I718H1230014-02 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1230018-01 4) Remove the cushion lever (2) and rear shock absorber (3). Refer to “Cushion Lever Removal and Installation (Page 2C-5)”…

• Page 406
  2C-8 Rear Suspension: 5) Remove the pivot shaft end caps (4), left and right. Installation Install the swingarm in the reverse order of removal. Pay 6) Remove the swingarm by removing the pivot shaft attention to the following points: nut (5) and washer. •…

• Page 407: Swingarm Related Parts Inspection

  Rear Suspension: 2C-9 Swingarm Related Parts Inspection • Tighten the cushion lever, cushion rod and rear shock absorber mounting nut to the specified torque. B718H12306012 Refer to “Swingarm / Cushion Rod Removal and Tightening torque Installation (Page 2C-7)”. Cushion rod mounting nut (b): 78 N·m (7.8 kgf-m, 56.5 lb-ft) Spacers Cushion lever mounting nut (c): 78 N·m (7.8 kgf-…

• Page 408: Swingarm Bearing Removal And Installation

  2C-10 Rear Suspension: Swingarm Bearing Removal and Installation Swingarm Inspect the swingarm for damage. If any defect is found, B718H12306013 replace the swingarm with a new one. Removal 1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation in Section 2D (Page 2D-16)”.

• Page 409
  Special tool (A): 09924–84521 (Bearing installer set) I649G1230039-04 4) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1230036-01 I718H1230038-03 5) Install the swingarm. Refer to “Swingarm / Cushion Rod Removal and Installation (Page 2C-7)”.

• Page 410: Specifications

  2C-12 Rear Suspension: Specifications Service Data B718H12307001 Unit: mm (in) Item Standard Limit Rear shock absorber spring GSF1250/A 3rd position adjuster GSF1250S/SA 4th position — Rear shock absorber damping Rebound 1-1/4 turns out from stiffest position — force adjuster Rear wheel travel 136 (5.4)

• Page 411: Special Tools And Equipment

  Rear Suspension: 2C-13 Special Tools and Equipment Recommended Service Material B718H12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-7) / (Page 2C- equivalent NOTE Required service material is also described in the following.

• Page 412: Wheels And Tires

  2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B718H12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •…

• Page 413: Repair Instructions

  Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components B718H12406015 GSF1250/S I718H1240050-02 1. Front axle 7. Front wheel : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 8. Collar : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Brake disc 9.

• Page 414
  2D-3 Wheels and Tires: GSF1250A/SA I718H1240001-04 1. Front axle 8. Wheel speed sensor rotor : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 9. Sensor rotor bolt : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Brake disc 10. Wheel speed sensor bracket : Apply grease.

• Page 415: Front Wheel Assembly Construction

  Wheels and Tires: 2D-4 Front Wheel Assembly Construction B718H12406002 GSF1250/S Left Right “a” I718H1240044-02 1. Brake disc bolt “a”: Clearance : Apply grease. 2. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply thread lock to thread part.

• Page 416
  2D-5 Wheels and Tires: GSF1250A/SA Right Left “a” “b ” I718H1240002-02 1. Brake disc bolt 5. Front wheel speed sensor : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft) 2. Brake caliper mounting bolt “a”: Clearance : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3.

• Page 417: Front Wheel Assembly Removal And Installation

  3) Remove the brake calipers. Refer to “Front Brake Caliper Removal and Installation in Section 4B I718H1240006-02 (Page 4B-3)”. Remove the collar (4) (GSF1250/S) or front wheel speed sensor bracket (5) (GSF1250A/SA). CAUTION GSF1250/S Do not operate the brake lever while removing the caliper.

• Page 418
  2D-7 Wheels and Tires: Installation 3) Install the front wheel with the front axle and tighten the front axle bolt temporarily. 1) Install the collar (1) (GSF1250/S) or front wheel speed sensor bracket (2) (GSF1250A/SA) into the WARNING right side of the wheel.

• Page 419: Front Wheel Related Parts Inspection

  Wheels and Tires: 2D-8 Front Wheel Related Parts Inspection 6) Tighten two axle pinch bolts on the right fork leg to the specified torque. B718H12406004 Refer to “Front Wheel Assembly Removal and Tightening torque Installation (Page 2D-6)” Front axle pinch bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Tire Refer to “Tire Inspection in Section 0B (Page 0B-19)”.

• Page 420: Front Wheel Dust Seal / Bearing Removal And Installation

  2D-9 Wheels and Tires: Front Wheel Dust Seal / Bearing Removal and Wheel Installation 1) Remove the brake pads. Refer to “Front Brake Pad B718H12406005 Replacement in Section 4B (Page 4B-2)”. 2) Make sure that the wheel runout checked as shown Removal does not exceed the service limit.

• Page 421
  Special tool be replaced with new ones. (A): 09924–84510 (Bearing installer set) 1) Apply grease to the wheel bearings. CAUTION : Grease 99000–25010 (SUZUKI SUPER The sealed cover of the bearing must face GREASE A or equivalent) outside. I649G1240019-02 I649G1240020-03…
• Page 422
  2D-11 Wheels and Tires: 3) Install the dust seals with the special tool. 4) Apply grease to the lip of dust seals. Special tool : Grease 99000–25010 (SUZUKI SUPER (B): 09913–70210 (Bearing installer set) GREASE A or equivalent) I718H1240021-01 I718H1240022-01 5) Install the front wheel speed sensor rotor as the letters “50T”…

• Page 423: Rear Wheel Components

  Wheels and Tires: 2D-12 Rear Wheel Components B718H12406006 GSF1250/S I718H1240024-03 1. Spacer 10. Bearing : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Rear sprocket 11. Dust seal : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 3. Dust seal 12. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 4.

• Page 424
  2D-13 Wheels and Tires: GSF1250A/SA I718H1240025-03 1. Spacer 10. Bearing 19. Tire 2. Rear sprocket 11. Dust seal 20. Wheel balancer 3. Dust seal 12. Collar : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 4. Bearing 13. Wheel speed sensor rotor : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 5.

• Page 425: Rear Wheel Assembly Construction

  Wheels and Tires: 2D-14 Rear Wheel Assembly Construction B718H12406018 GSF1250/S Left Right “a” I718H1240027-03 1. Rear sprocket nut “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : Apply grease.

• Page 426
  2D-15 Wheels and Tires: GSF1250A/SA Right Left “b” “ a” I718H1240026-07 1. Rear sprocket nut “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut “b”: 0.3 – 1.5 mm (0.012 – 0.059 in) : Apply grease. 3.

• Page 427: Rear Wheel Assembly Removal And Installation

  Wheels and Tires: 2D-16 Rear Wheel Assembly Removal and Installation 6) Remove the spacer (2) and collar (3). B718H12406008 Removal 1) Support the motorcycle with the center stand. CAUTION Make sure that the motorcycle is supported securely. 2) Remove the rear wheel speed sensor by removing the mounting bolts.

• Page 428: Rear Wheel Related Parts Inspection

  2D-17 Wheels and Tires: 5) Install the rear wheel speed sensor mounting bolts. Wheel Axle (GSF1250A/SA) Refer to “Rear Wheel Speed Using a dial gauge, check the wheel axle for runout, If Sensor Removal and Installation in Section 4E the runout exceeds the limit, replace the axle shaft. (Page 4E-71)”.

• Page 429: Rear Wheel Dust Seal / Bearing Removal And Installation

  (1) from the rear wheel. I718H1240040-03 6) Remove the spacer. Installation CAUTION I718H1240052-02 The removed dust seals and bearings must be replaced with new ones. 1) Apply grease to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240019-02…

• Page 430
  (B): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I718H1240042-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-02 Left Right I718H1240043-01 5) Install the rear wheel speed sensor rotor.

• Page 431: Tire Removal And Installation

  Wheels and Tires: 2D-20 Tire Removal and Installation Installation B718H12406011 Removal CAUTION The most critical factor of a tubeless tire is the seal Do not reuse the valve which has been once between the wheel rim and the tire bead. For this removed.

• Page 432: Wheel / Tire / Air Valve Inspection And Cleaning

  2D-21 Wheels and Tires: Wheel / Tire / Air Valve Inspection and Cleaning 3) Bounce the tire several times while rotating. This makes the tire bead expand outward to contact the B718H12406012 Refer to “Tire Removal and Installation (Page 2D-20)”. wheel, thereby facilitating air inflation.

• Page 433: Air Valve Removal And Installation

  Wheels and Tires: 2D-22 Air Valve Installation Inspect the air valve for peeling and damage. If any Install the air valve in the reverse order of removal. Pay defect is found, replace the air valve with a new one. attention to the following points: Refer to “Air Valve Removal and Installation (Page 2D- •…

• Page 434: Wheel Balance Check And Adjustment

  2D-23 Wheels and Tires: Wheel Balance Check and Adjustment 4) When installing the balancer weight to the wheel, set B718H12406014 the balancer weight on center rib of the wheel. Check and adjust the wheel balance in the following procedures: 1) Removal the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (Page 2D-6)”…

• Page 435: Tightening Torque Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B718H12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2D-10) /…

• Page 436
  2D-25 Wheels and Tires: 09913–50121 09913–70210 Oil seal remover Bearing installer set (Page 2D-9) / (Page 2D- (Page 2D-11) / (Page 2D-19) 09921–20240 09924–84510 Bearing remover set Bearing installer set (Page 2D-9) / (Page 2D- (Page 2D-10) / (Page 2D-19) 09941–34513 Steering race installer (Page 2D-19)
• Page 437
  Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ……….3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ……3A-4 Precautions…………. 3-1 Drive Chain Related Parts Inspection ….3A-5 Precautions for Driveline / Axle ……3-1 Sprocket Mounting Drum Dust Seal / Bearing Drive Chain / Drive Train / Drive Shaft…

• Page 438: Precautions

  • Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK GB50GSVZ3. Suzuki recommends to use this standard drive chain as a replacement.

• Page 439: Drive Chain / Drive Train / Drive Shaft

  Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B718H13104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

• Page 440: Engine Sprocket Removal And Installation

  3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 5) Remove the speed sensor (3). B718H13106002 6) Remove the engine sprocket inner cover (4) along with the clutch release cylinder. Removal 1) Support the motorcycle with the center stand. 2) Remove the engine sprocket outer cover (1).

• Page 441
  Speed sensor rotor bolt (b): 25 N·m (2.5 kgf-m, 18.0 lb-ft) • Before installing the engine sprocket inner cover, apply a small quantity of SUZUKI SUPER GREASE to the clutch push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1310023-05 12) Remove the engine sprocket (10).

• Page 442: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

  • Apply grease to the contacting surface between the rear sprocket (1) from its mounting drum (2). rear wheel hub and the mounting drum. 3) Draw out the mounting drum (2) from the wheel hub. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1310014-03 I718H1310036-01…

• Page 443: Drive Chain Related Parts Inspection

  Drive Chain / Drive Train / Drive Shaft: 3A-5 • Tighten the rear sprocket nuts to the specified torque. Bearing Inspect the play of the sprocket mounting drum bearings Tightening torque by hand while they are in the wheel and drum. Rotate Rear sprocket nut (a): 60 N·m (6.0 kgf-m, 43.5 lb- the inner race by hand to inspect for abnormal noise and smooth rotation.

• Page 444: Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation

  Refer to “Rear Sprocket / 1) Apply grease to the bearing before installing. Rear Sprocket Mounting Drum Removal and : Grease 99000–25010 (SUZUKI SUPER Installation (Page 3A-4)”. GREASE A or equivalent) 2) Remove the retainer (1).

• Page 445: Drive Chain Replacement

  Drive Chain / Drive Train / Drive Shaft: 3A-7 4) Install the rear sprocket mounting drum. NOTE 5) Install the rear sprocket mounting drum assembly to The tip of pin remover (1) should be rear wheel hub. Refer to “Rear Sprocket / Rear positioned inside “a”…

• Page 446
  3A-8 Drive Chain / Drive Train / Drive Shaft: 6) Remove the joint pin (9) of the other side of joint Joint plate installation plate. 1) Set up the special tool as shown in the illustration. CAUTION Never reuse joint pins, O-rings and plates. (C50) I718H1310027-03 1.
• Page 447
  Drive Chain / Drive Train / Drive Shaft: 3A-9 5) Set the drive chain on the tool as illustrated and turn Joint pin staking in the adjuster bolt (5) to secure the wedge holder 1) Set up the special tool as shown in the illustration. and wedge pin (4).

• Page 448: Specifications

  3A-10 Drive Chain / Drive Train / Drive Shaft: 3) Adjust the drive chain slack, after connecting it. Refer to “Drive Chain Inspection and Adjustment in Section 0B (Page 0B-15)”. “a” I649G1310036-03 Specifications Service Data B718H13107001 Drive Chain Unit: mm (in) Item Standard Limit…

• Page 449: Special Tools And Equipment

  Drive Chain / Drive Train / Drive Shaft: 3A-11 Special Tools and Equipment Recommended Service Material B718H13108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) / (Page 3A- equivalent 4) /…

• Page 450
  3A-12 Drive Chain / Drive Train / Drive Shaft:…
• Page 451
  Table of Contents 4- i Section 4 Brake CONTENTS Precautions ……….4-1 Front Brakes ……….4B-1 Precautions…………. 4-1 Repair Instructions ……….4B-1 Precautions for Brake System ……4-1 Front Brake Components ……..4B-1 Brake Fluid Information ……… 4-1 Front Brake Pad Inspection………4B-2 Front Brake Pad Replacement……4B-2 Brake Control System and Diagnosis …
• Page 452
  4-ii Table of Contents ABS Control Unit Description ……4E-2 DTC “43” (C1643): Wheel Speed Sensor Hydraulic Unit (HU) Description ……4E-4 Circuit Short (F)……….4E-53 Self-diagnosis Function and ABS Indicator DTC “44” (C1644): Wheel Speed Sensor Light Description ……….4E-5 Signal Malfunction (R)……..4E-55 Fail-safe Function Description……

• Page 453: Precautions

  Precautions: Precautions Brake Precautions Precautions for Brake System B718H14000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B718H14000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.

• Page 454: Brake Control System And Diagnosis

  4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram B718H14102001 GSF1250 (c ) I718H1410001-04 1. Front brake hose No.1 6: Clamp : Insert the clamp to the hole of the front fender fully.

• Page 455
  Brake Control System and Diagnosis: 4A-2 GSF1250S I718H1410002-05 1. Front brake hose No.1 6: Clamp : Insert the clamp to the hole of the front fender fully. 2. Front brake hose No.2 7: Front brake hose No.1 : Pass the front brake hose No.1 to the brake hose guide. 3: Stopper : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : After the brake hose union has contacted the stopper, tighten the union bolt.
• Page 456
  4A-3 Brake Control System and Diagnosis: GSF1250A “A” “B” “C” 42 49 I718H1410003-07 1. Brake hose No.1 (ABS) “A”: Clamp white paint part of brake hose. 2. Brake hose No.2 (ABS) “B”: White paint 3. Rubber cushion “C”: Yellow paint 4.
• Page 457
  Brake Control System and Diagnosis: 4A-4 GSF1250SA “A” “B” “C” I718H1410004-05 1. Brake hose No.1 (ABS) 9. Clamp :After positioning the clamp with the stopper, tighten the clamp bolt. 2. Brake hose No.2 (ABS) 10. Clamp :Insert the clamp to the hole of the fender fully. 3.

• Page 458: Rear Brake Hose Routing Diagram

  4A-5 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B718H14102002 GSF1250/S “B” “A” I718H1410062-03 1. Brake hose clamp “B”: White paint : Brake hose clamp ends should face forward. 2. Brake hose clamp : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Brake hose clamp ends should face backward.

• Page 459
  Brake Control System and Diagnosis: 4A-6 GSF1250A/SA “B” “A” I718H1410005-03 1. Brake hose clamp “B” : White paint : Brake hose clamp ends should face forward. 2. Brake hose clamp : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Brake hose clamp ends should face backward. 3: Stopper : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : After the brake hose union has contacted the stopper, tighten the union bolt.

• Page 460: Diagnostic Information And Procedures

  4A-7 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B718H14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads and disc. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Air in hydraulic system.

• Page 461: Rear Brake Light Switch Inspection

  Brake Control System and Diagnosis: 4A-8 Rear Brake Light Switch Inspection and 2) Inspect the switch for continuity with a tester. If any abnormality is found, replace the front brake Adjustment light switch with a new one. Refer to “Front Brake B718H14106004 Check the rear brake light switch so that the brake light Master Cylinder / Brake Lever Disassembly and…

• Page 462
  4A-9 Brake Control System and Diagnosis: Front Brake 5) Close the air bleeder valve, pump and squeeze the lever, and open the valve. 1) Fill the master cylinder reservoir to the top of the inspection window. Place the reservoir cap to 6) Repeat this process until the fluid flowing into the prevent dirt from entering.

• Page 463: Brake Fluid Replacement

  Brake Control System and Diagnosis: 4A-10 Brake Fluid Replacement Rear Brake Bleed air from the rear brake system as the same B718H14106008 CAUTION manner of front brake. Handle brake fluid with care: the fluid reacts NOTE chemically with paint, plastic, rubber The only difference of bleeding operation materials, etc.

• Page 464
  4A-11 Brake Control System and Diagnosis: 7) Close the air bleeder valve and disconnect the clear Rear Brake hose. 1) Place the motorcycle on a level surface. Tightening torque 2) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D Air bleeder valve (Front brake) (a): 7.5 N·m (0.75 (Page 9D-6)”.

• Page 465: Front Brake Hose Removal And Installation

  Front Brake Hose Removal and Installation The seal washers should be replaced with the B718H14106009 new ones to prevent fluid leakage. GSF1250/S Removal 1) Install the front brake hose as shown in the front 1) Drain brake fluid. Refer to “Brake Fluid Replacement brake hose routing diagram.

• Page 466: Rear Brake Hose Removal And Installation

  4A-13 Brake Control System and Diagnosis: Rear Brake Hose Removal and Installation GSF1250A/SA B718H14106019 Removal GSF1250/S 1) Remove the right frame cover. Refer to “Exterior Removal Parts Removal and Installation in Section 9D 1) Remove the right frame cover. Refer to “Exterior (Page 9D-6)”.

• Page 467: Front Brake Master Cylinder Components

  3) Place a rag underneath the brake hose union bolt (2) on the master cylinder to catch any spilt brake fluid. 4) Remove the brake hose union bolt (2) and disconnect the brake hose. I718H1410048-04 5) Remove the right rear view mirror. (GSF1250/A)

• Page 468: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly

  4A-15 Brake Control System and Diagnosis: Installation • After setting the brake hose union to the stopper, Install the front brake master cylinder in the reverse tighten the union bolt to the specified torque. order of removal. Pay attention to the following points: CAUTION •…

• Page 469
  Brake Control System and Diagnosis: 4A-16 2) Remove the reservoir cap (3), plate (4) and Assembly diaphragm (5). Assemble the master cylinder in the reverse order of disassembly. Pay attention to the following points: CAUTION • Wash the master cylinder components with new brake fluid before reassembly.

• Page 470: Front Brake Master Cylinder Parts Inspection

  • Apply grease to the contact point between piston and Refer to “Front Brake Master Cylinder / Brake Lever brake lever. Disassembly and Assembly (Page 4A-15)”. : Grease 99000–25100 (SUZUKI Silicone Master Cylinder Grease or equivalent) Inspect the master cylinder bore for any scratches or other damage.

• Page 471: Rear Brake Master Cylinder Components

  Brake Control System and Diagnosis: 4A-18 Rear Brake Master Cylinder Components B718H14106015 I649G1410029-06 1. Reservoir tank 4. Master cylinder : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply brake fluid. 2. Brake hose union bolt 5. Piston/Cup set : 18 N⋅m (1.8 kgf-m, 13.0 lb-ft) : Do not reuse.

• Page 472: Rear Brake Master Cylinder Disassembly And Assembly

  4A-19 Brake Control System and Diagnosis: 4) Place a rag underneath the brake hose union bolt (2) • Adjust the brake pedal height. Refer to “Brake System on the master cylinder to catch any spilt brake fluid. Inspection in Section 0B (Page 0B-17)”. 5) Remove the brake hose union bolt (2) and Rear Brake Master Cylinder Disassembly and disconnect the brake hose.

• Page 473: Rear Brake Master Cylinder Parts Inspection

  Master Cylinder Inspect the master cylinder bore for any scratches or other damage. I649G1410036-02 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) I649G1410038-02 Piston Inspect the piston surface for any scratches or other damage.

• Page 474: Specifications

  4A-21 Brake Control System and Diagnosis: Specifications Service Data B718H14107001 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 50 – 60 (2.0 – 2.4) — Front 14.000 – 14.043 (0.5512 – 0.5529) — Master cylinder bore Rear 14.000 –…

• Page 475: Special Tools And Equipment

  Brake Control System and Diagnosis: 4A-22 Special Tools and Equipment Recommended Service Material B718H14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-10) / (Page 4A-11) / (Page 4A-16) / (Page 4A-20) Grease SUZUKI Silicone Grease or P/No.: 99000–25100…

• Page 476: Front Brakes

  4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B718H14206001 I649G1420001-05 1. O-ring 6. Front brake disc : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal : 7.5 N⋅m (0.75 kgf-m, 5.5 lb-ft) : Apply thread lock to thread part. 3.

• Page 477: Front Brake Pad Inspection

  Front Brakes: 4B-2 Front Brake Pad Inspection 2) Remove the brake pads (2) by removing the pad B718H14206002 mounting pin (3). The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When NOTE the wear exceeds the grooved limit line, replace the When removing the pads, push the piston all…

• Page 478: Front Brake Caliper Removal And Installation

  4B-3 Front Brakes: 5) Tighten the pad mounting pin to the specified torque. 3) Remove the brake caliper by removing the caliper mounting bolts (2). Tightening torque Front brake pad mounting pin (a): 16 N·m (1.6 kgf-m, 11.5 lb-ft) I718H1420014-01 Installation I718H1420013-01 Install the brake caliper in the reverse order of removal.

• Page 479: Front Brake Caliper Disassembly And Assembly

  Front Brakes: 4B-4 • Check the brake fluid leakage and brake operation. 3) Remove the O-ring. WARNING Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose and hose joints for cracks and fluid leakage. Front Brake Caliper Disassembly and Assembly B718H14206005 Refer to “Front Brake Caliper Removal and Installation…

• Page 480
  4B-5 Front Brakes: Assembly • Apply the brake fluid to piston seals (1) and dust seals Assemble the caliper in the reverse order of (2). disassembly. Pay attention to the following points: CAUTION • Wash the caliper bores and pistons with specified Replace the piston seals (1) and dust seals brake fluid.

• Page 481: Front Brake Caliper Parts Inspection

  Front Brakes: 4B-6 • Temporarily tighten the brake caliper housing bolts. Brake Caliper Piston Inspect the brake caliper piston surface for any CAUTION scratches or other damage. If any damage is found, replace the piston with a new one. After installing the brake caliper to the front fork, tighten the brake caliper housing bolts to the specified torque.

• Page 482: Front Brake Disc Removal And Installation

  4B-7 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B718H14206007 B718H14206008 Brake Disc Thickness Removal Check the brake disc for damage or cracks and measure the thickness using the micrometer. 1) Remove the front wheel assembly. Refer to “Front Replace the brake disc if the thickness is less than the Wheel Assembly Removal and Installation in Section service limit or if defect is found.

• Page 483: Specifications

  Front Brakes: 4B-8 Specifications Service Data B718H14207001 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc runout — 0.30 (0.012) Leading 27.050 – 27.126 (1.0650 – 1.0680) — Brake caliper cylinder bore Front Trailing…

• Page 484: Special Tools And Equipment

  4B-9 Front Brakes: Special Tools and Equipment Recommended Service Material B718H14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-5) / (Page 4B- Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 (Page 4B-7)

• Page 485: Rear Brakes

  Rear Brakes: 4C-1 Rear Brakes Brake Repair Instructions Rear Brake Components B718H14306001 I649G1430001-05 1. Rear caliper bracket : 6.0 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Apply silicone grease to sliding surface. 2. Piston : 27 N⋅m (2.7 kgf-m, 19.5 lb-ft) : Apply thread lock to thread part.

• Page 486: Rear Brake Pad Inspection

  4C-2 Rear Brakes: Rear Brake Pad Inspection 2) Loosen the pad mounting pin (2). B718H14306002 3) Remove the caliper mounting bolt (3). The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When CAUTION the wear exceeds the grooved limit line, replace the Do not operate the brake pedal while…

• Page 487
  Rear Brakes: 4C-3 5) Clean up the caliper, especially around the caliper Tighten the caliper mounting bolt (7) and pad piston. mounting pin (8) to the specified torque. 6) Assemble the new brake pad (4), insulator (5) and Tightening torque shim (6).

• Page 488: Rear Brake Caliper Removal And Installation

  4C-4 Rear Brakes: Rear Brake Caliper Removal and Installation • After setting the brake hose union to the stopper, B718H14306004 tighten the union bolt (2) to the specified torque. Removal CAUTION 1) Drain brake fluid. Refer to “Brake Fluid Replacement The seal washers should be replaced with the in Section 4A (Page 4A-10)”.

• Page 489
  Rear Brakes: 4C-5 2) Remove the pad spring (3). 6) Remove the dust seal (7) and piston seal (8). I649G1430014-02 I649G1430017-02 3) Remove the spacer (4) and rubber boot (5) from the Assembly caliper. Assemble the caliper in the reverse order of 4) Remove the slide pin (6).

• Page 490: Rear Brake Caliper Parts Inspection

  Brake Caliper Piston • Apply grease to the inside of the boot. Inspect the brake caliper piston surface for any : Grease 99000–25100 (SUZUKI Silicone scratches or other damage. If any damage is found, replace the piston with a new one.

• Page 491: Rear Brake Disc Removal And Installation

  Rear Brakes: 4C-7 Boot and Spacer Installation Inspect the boots and spacer for damage and wear. If Install the rear brake disc in the reverse order of any defects are found, replace them with new ones. removal. Pay attention to the following points: •…

• Page 492: Specifications

  4C-8 Rear Brakes: Brake Disc Runout 1) Dismount the rear brake caliper. Refer to “Rear Brake Caliper Removal and Installation (Page 4C- 4)”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit.

• Page 493: Special Tools And Equipment

  Rear Brakes: 4C-9 Special Tools and Equipment Recommended Service Material B718H14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) / (Page 4C- Grease SUZUKI Silicone Grease or P/No.: 99000–25100 (Page 4C-6) / (Page 4C-…

• Page 494: Abs

  4E-1 ABS: Brake Precautions Precautions for ABS • Be sure to route the brake hoses correctly. B718H14500001 • The ABS does not shorten the motorcycle’s braking Refer to “Precautions for Electrical Circuit Service in distance. When riding down slopes or on wet or Section 00 (Page 00-2)”.

• Page 495: Abs Control Unit Description

  ABS: 4E-2 ABS Control Unit Description B718H14501002 ABS control unit (1) calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to Hydraulic Unit (HU) (2). This ABS control unit/HU can not be disassembled.

• Page 496
  4E-3 ABS: ABS Control Unit Calculating Process The ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the ABS control unit calculating process. ABS control is performed in one cycle every 10/1 000 seconds. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlled by the ABS and a diagnostic trouble code is stored.

• Page 497: Hydraulic Unit (Hu) Description

  ABS: 4E-4 Hydraulic Unit (HU) Description B718H14501003 The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by operating separate components for the front and the rear, except for the pump drive motor, which is shared by both systems.

• Page 498: Self-Diagnosis Function And Abs Indicator Light Description

  4E-5 ABS: Self-diagnosis Function and ABS Indicator • If an ABS malfunction has occurred, the ABS indicator light keeps lighting up. Light Description B718H14501006 The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of the malfunction.

• Page 499: Fail-Safe Function Description

  ABS: 4E-6 Stored DTCs (Diagnostic Trouble Codes) As for the diagnostic trouble code, the code of the first malfunction occurred during one ignition ON period will be stored. Pay attention to the fact that even though there may occur several malfunctions in one ON-period, only one code will be stored.

• Page 500: Schematic And Routing Diagram

  4E-7 ABS: Schematic and Routing Diagram ABS Wiring Diagram B718H14502001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. I718H1450020-06…

• Page 501: Abs Unit Diagram

  ABS: 4E-8 ABS Unit Diagram B718H14502002 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. I718H1450021-04 “A”: Rear brake solenoid OUT “C”: Front brake solenoid OUT “E”: Fail safe (+) B “G”: Motor (+) B “B”: Rear brake solenoid IN “D”: Front brake solenoid IN “F”: Motor relay (+) B…

• Page 502: Front Wheel Speed Sensor Routing Diagram

  4E-9 ABS: Front Wheel Speed Sensor Routing Diagram B718H14502003 GSF1250A “B” “C” “D” “E” “I” “F” “H” “A” “G” I718H1450022-03 1. Clamp 7: Clamp “E”: Clamp the sensor lead wire sleeve with the brake : Clamp the sensor lead wire at the white marking. hose.

• Page 503
  ABS: 4E-10 GSF1250SA “B” “C” “D” “E” “I” “F” “H” “A” “G” I718H1450023-03 1. Clamp 7: Clamp “E”: Clamp the sensor lead wire sleeve with the brake : Clamp the sensor lead wire at the white marking. hose. 2. Guide 8.

• Page 504: Rear Wheel Speed Sensor Routing Diagram

  4E-11 ABS: Rear Wheel Speed Sensor Routing Diagram B718H14502004 “G” “ a ” “C” “B” “F” “E” “A” “D” I718H1450118-03 1. Rear wheel speed sensor “A”: Outside mark “E”: Pass through the sensor lead wire on the brake hose. 2. Brake hose No.2 “B”: After the clamp has contacted to the “F”: Clamp the sensor lead wire upper side of brake hose.

• Page 505: Component Location

  ABS: 4E-12 Component Location ABS Components Location B718H14503001 I718H1450119-02 1. ABS control unit/HU 4. Front wheel speed sensor 7. Rear wheel speed sensor rotor 2. Mode select coupler 5. Front wheel speed sensor rotor 3. SDS coupler 6. Rear wheel speed sensor…

• Page 506: Diagnostic Information And Procedures

  4E-13 ABS: Diagnostic Information and Procedures ABS Troubleshooting 4) and inspect the wiring. Refer to “ABS Wiring B718H14504001 Diagram (Page 4E-7)” and “ABS Unit Diagram Many of the ABS malfunction diagnosing operations are (Page 4E-8)”. performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex CAUTION circuitry assures the proper operation of the ABS.

• Page 507
  ABS: 4E-14 EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS ABS operation Past malfunctions and repairs ABS does not work ABS works so often with Too long stopping distance Other CONDITION WHEN MALFUNCTION OCCURED ABS indicator light…

• Page 508: Pre-Diagnosis Inspection

  55ZR17M/C (73W) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. • Replace the tire as a set, otherwise the DTC “25” (C1625) may be stored.

• Page 509
  ABS: 4E-16 ABS Component ABS control unit/HU ground wire inspection Wheel speed sensor – sensor rotor clearance 1) Turn the ignition switch OFF. inspection 2) Remove the seat. Refer to “Exterior Parts Removal Inspect the clearance between the wheel speed sensor and Installation in Section 9D (Page 9D-6)”.

• Page 510: Abs Indicator Light Inspection

  4E-17 ABS: 7) Check for continuity between “24” (B/W) at the coupler and the battery (–) terminal, also “25” (B/W) at the coupler and the battery (–) terminal. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Continuity ( ABS control unit coupler (Harness end) I718H1450125-01 I718H1450030-03…

• Page 511
  ABS: 4E-18 Step Action (The ABS indicator light does not light up) Go to Step 4. Replace the ignition fuse. 1) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 2) Remove the fuse box (1) by removing the mounting bolt. I718H1450034-01 3) Open the fuse box and inspect the ignition fuse (2).
• Page 512
  4E-19 ABS: Step Action 1) Turn the ignition switch OFF. Go to Step 5. Inspect the wire harness. (Faulty ignition 2) Disconnect the ABS control unit coupler. Refer to “ABS or ground wire) Control Unit Coupler Disconnect and Connect (Page 4E- 70)”.
• Page 513
  ABS: 4E-20 Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ground 2) Check for continuity between “24” (B/W) at the coupler wire) and body ground, also “25” (B/W) at the coupler and body ground.
• Page 514
  4E-21 ABS: Step Action 1) Turn the ignition switch OFF. Go to Step 9. Inspect the wire harness. (Faulty ignition 2) Disconnect the ABS control unit coupler. Refer to “ABS or ground wire) Control Unit Coupler Disconnect and Connect (Page 4E- 70)”…
• Page 515
  ABS: 4E-22 Step Action 10 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty mode 2) Remove the left frame cover. Refer to “Exterior Parts select switch wire) Removal and Installation in Section 9D (Page 9D-6)”. 3) Short the mode select coupler terminals (O –…

• Page 516: Dtc (Diagnostic Trouble Code) Output

  4E-23 ABS: DTC (Diagnostic Trouble Code) Output 4) Switch the special tool to ON. B718H14504021 NOTE • Even through the ABS is operating correctly, a DTC is memorized in any of the following conditions. – If the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated.

• Page 517
  ABS: 4E-24 Understanding the DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation between the tens and ones are indicated by the light staying off for 1.6 seconds.

• Page 518: Dtc (Diagnostic Trouble Code) Deleting

  4E-25 ABS: 1) Remove the right frame cover. Refer to “Exterior 3) Read the DTC (Diagnostic Trouble Code) and show Parts Removal and Installation in Section 9D data when trouble (displaying data at the time of (Page 9D-6)”. DTC) according to instructions displayed on SDS. 2) Set up the SDS tool.

• Page 519
  ABS: 4E-26 4) In the DTC deletion mode, switch the ABS test 3) While the DTCs are being output, set the special tool to OFF. switch from OFF to ON three times, each time leaving it at ON for more than 1 second. CAUTION The DTC deletion mode starts 12.5 seconds after the switch is set to OFF.
• Page 520
  4E-27 ABS: Use of SDS 5) Click the “DTC inspection” button (2). 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 2) After repairing the trouble, turn OFF the ignition switch and turn ON again. 3) Set up the SDS tool.
• Page 521
  ABS: 4E-28 Follow the displayed instructions. 9) Check that both “Current DTC” (4) and “Past DTC” (5) are deleted (NIL). I705H1110006-01 I718H1450057-01 10) Close the SDS tool and turn the ignition switch OFF. 11) Disconnect the SDS tool and install the left frame cover.

• Page 522: Sds Check

  4E-29 ABS: SDS Check B718H14504023 Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealer. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

• Page 523: Active Control Inspection

  ABS: 4E-30 Active Control Inspection 4) Click “Active control” (2). B718H14504024 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Click “ABS”…

• Page 524
  4E-31 ABS: 6) Click “Next” according to the screen indication. Return Next Cancel Help Return Next Cancel Help I718H1450060-02 NOTE Skip this screen as this vehicle is not equipped with parking brake. Return Next Cancel Help I718H1450121-01…
• Page 525
  ABS: 4E-32 NOTE • If the front wheel is selected, place the motorcycle on the center stand and lift the front wheel off the ground using a jack. • Two operators are needed in this work; One should apply a rotational force to the front wheel. Return Next Cancel…
• Page 526
  4E-33 ABS: Return Finish Cancel Help I718H1450062-01 NOTE • Inspect the rear brake in the same manner of front brake. • If the ABS does not function, the cause may lie in the ABS control unit/HU. • In checking the rear brake at the time of pressure reduction drive (4/7), “brake lever” appears on the screen.

• Page 527: Dtc Table

  ABS: 4E-34 DTC Table B718H14504002 Indicator Malfunction cause Reference status None Normal ON * — Refer to “DTC “13” (C1613): Wheel 13 (C1613) Wheel speed sensor rotor malfunction (F) Speed Sensor Rotor Malfunction (F) (Page 4E-35)”. Refer to “DTC “14” (C1614): Wheel 14 (C1614) Wheel speed sensor rotor malfunction (R) Speed Sensor Rotor Malfunction…

• Page 528: Dtc «13» (C1613): Wheel Speed Sensor Rotor Malfunction

  4E-35 ABS: CAUTION When disconnecting couplers and turning the ignition switch ON, disconnect the ABS control unit coupler in order to prevent a DTC from being stored. Each time a resistance is measured, the ignition switch should be set to OFF. DTC “13”…

• Page 529
  ABS: 4E-36 Step Action 1) Check that the front wheel speed sensor is mounted Go to Step 4. Tighten the mounting securely. bolts or replace the bracket if necessary. I718H1450066-01 Is the sensor mounted securely? 1) Inspect the front tire and wheel. Replace the ABS Adjust or replace the control unit/HU.

• Page 530: Dtc «14» (C1614): Wheel Speed Sensor Rotor Malfunction

  4E-37 ABS: DTC “14” (C1614): Wheel Speed Sensor Rotor Malfunction (R) B718H14504004 Possible Cause • Rear wheel speed sensor rotor distortion • Faulty rear wheel speed sensor or wiring discontinuity, etc. Troubleshooting Step Action 1) Inspect the clearance between the rear wheel speed Go to Step 2.

• Page 531
  ABS: 4E-38 Step Action 1) Check that the rear wheel speed sensor is mounted Go to Step 4. Tighten the mounting securely. bolts or replace the bracket if necessary. I718H1450068-01 Is the sensor mounted securely? 1) Inspect the rear tire and wheel. Replace the ABS Adjust or replace the control unit/HU.

• Page 532: Dtc «22» (C1622): Abs Actuator Circuit Malfunction

  4E-39 ABS: DTC “22” (C1622): ABS Actuator Circuit Malfunction (F) B718H14504005 Possible Cause • Wire harness discontinuity • Front wheel locking, etc. Troubleshooting Step Action 1) Raise the front wheel off the ground and support the Inspect the front brake Go to step 2.

• Page 533
  ABS: 4E-40 Step Action 1) Check that the front wheel speed sensor is mounted Replace the ABS Tighten the mounting securely. control unit/HU. bolts or replace the bracket if necessary. I718H1450066-01 Is the sensor mounted securely?

• Page 534: Dtc «23» (C1623): Abs Actuator Circuit Malfunction

  4E-41 ABS: DTC “23” (C1623): ABS Actuator Circuit Malfunction (R) B718H14504006 Possible Cause • Wire harness discontinuity • Rear wheel locking, etc. Troubleshooting Step Action 1) Support the motorcycle with its center stand. Inspect the rear brake Go to step 2. master cylinder and the 2) Inspect the dragging of the rear brake.

• Page 535
  ABS: 4E-42 Step Action 1) Check that the rear wheel speed sensor is mounted Replace the ABS Tighten the mounting securely. control unit/HU. bolts or replace the bracket if necessary. I718H1450068-01 Is the sensor mounted securely?

• Page 536: Dtc «25» (C1625): Wheel Speed Sensor Related Malfunction

  4E-43 ABS: DTC “25” (C1625): Wheel Speed Sensor Related Malfunction B718H14504007 Possible Cause • Incorrect tire size, poor tire pressure • Deformed wheel, etc. Troubleshooting Step Action 1) Check that the specified tires are installed. Go to Step 2. Use the specified tires. Tire type and size Front: DUNLOP D218FT 120/70ZR17M/C (58W) Rear: DUNLOP D218N 180/55ZR17M/C (73W)

• Page 537
  ABS: 4E-44 Step Action 1) Inspect both wheel speed sensor rotors for damage and Go to Step 4. Clean or replace the check that no foreign objects are caught in the rotor rotor. openings. I718H1450064-01 Are the rotors OK? 1) Inspect the clearances of the front and rear wheel speed Replace the ABS Adjust the clearance.

• Page 538: Dtc «35» (C1635): Abs Motor Malfunction

  4E-45 ABS: DTC “35” (C1635): ABS Motor Malfunction B718H14504008 Possible Cause • Faulty HU motor • Faulty wiring, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Inspect if the pump motor makes turning noise by setting •…

• Page 539
  ABS: 4E-46 Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty motor 2) Remove the left frame cover. Refer to “Exterior Parts power supply or ground Removal and Installation in Section 9D (Page 9D-6)”. wire) 3) Remove the fuse box mounting bolt.

• Page 540: Dtc «41» (C1641): Wheel Speed Sensor Signal Malfunction

  4E-47 ABS: DTC “41” (C1641): Wheel Speed Sensor Signal Malfunction (F) B718H14504009 Possible Cause • Poor contact in the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Troubleshooting Step Action 1) Inspect the clearance between the front wheel speed Go to Step 2.

• Page 541
  ABS: 4E-48 Step Action 1) Check that the front wheel speed sensor is mounted Go to DTC “42” Tighten the mounting securely. (C1642). (Refer to “DTC bolts or replace the “42” (C1642): Wheel bracket if necessary. Speed Sensor Circuit Open (F) (Page 4E- 49)”.) I718H1450066-01 Is the sensor mounted securely?

• Page 542: Dtc «42» (C1642): Wheel Speed Sensor Circuit Open

  4E-49 ABS: DTC “42” (C1642): Wheel Speed Sensor Circuit Open (F) B718H14504010 Possible Cause • Poor contact in the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action…

• Page 543
  ABS: 4E-50 Step Action 1) Disconnect the front wheel speed sensor coupler. Inspect the wire Faulty front wheel harness. (Faulty B/R speed sensor 2) Measure the resistance between “A” (Black) and ground wire) at the front wheel speed sensor coupler. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication…
• Page 544
  4E-51 ABS: Step Action 1) Measure the resistance between “B” (White) and ground Inspect the wire Faulty front wheel at the front wheel speed sensor coupler. harness. (Faulty W/R speed sensor wire) Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Resistance (Ω) Normal value (“B”…
• Page 545
  ABS: 4E-52 Step Action 1) Check for continuity between “3” (W/R) on the ABS Go to Step 7. Inspect the wire control unit coupler and “D” (W/R) on the front wheel harness. (Faulty W/R speed sensor coupler. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication…

• Page 546: Dtc «43» (C1643): Wheel Speed Sensor Circuit Short

  4E-53 ABS: DTC “43” (C1643): Wheel Speed Sensor Circuit Short (F) B718H14504011 Possible Cause • Poor contact in the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action…

• Page 547
  ABS: 4E-54 Step Action 1) Check for continuity between “2” (B/Y) and “3” (W/R) at • Inspect the wire Go to Step 3. the coupler. harness. (Faulty sensor wire) Special tool • Faulty front wheel (A): 09900–25008 (Multi-circuit tester set) speed sensor Tester knob indication Continuity (…

• Page 548: Dtc «44» (C1644): Wheel Speed Sensor Signal Malfunction

  4E-55 ABS: DTC “44” (C1644): Wheel Speed Sensor Signal Malfunction (R) B718H14504012 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Troubleshooting Step Action 1) Inspect the clearance between the rear wheel speed Go to Step 2.

• Page 549
  ABS: 4E-56 Step Action 1) Check that the rear wheel speed sensor is mounted Go to DTC “45” Tighten the mounting securely. (C1645). (Refer to “DTC bolts or replace the “45” (C1645): Wheel bracket if necessary. Speed Sensor Circuit Open (R) (Page 4E- 57)”.) I718H1450068-01 Is the sensor mounted securely?

• Page 550: Dtc «45» (C1645): Wheel Speed Sensor Circuit Open

  4E-57 ABS: DTC “45” (C1645): Wheel Speed Sensor Circuit Open (R) B718H14504013 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action…

• Page 551
  ABS: 4E-58 Step Action 1) Disconnect the rear wheel speed sensor coupler. Inspect the wire Replace the rear wheel harness. (Faulty B/Y speed sensor. 2) Measure the resistance between “A” (Black) and ground wire) at the rear wheel speed sensor coupler. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication…
• Page 552
  4E-59 ABS: Step Action 1) Measure the resistance between “B” (White) and ground Inspect the wire Replace the rear wheel at the rear wheel speed sensor coupler. harness. (Faulty W/Y speed sensor. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Resistance (Ω) Normal value (“B”…
• Page 553
  ABS: 4E-60 Step Action 1) Check the continuity between “18” (W/Y) on the ABS Go to Step 7. Inspect the wire control unit coupler and “D” (W/Y) on the rear wheel harness. (Faulty W/Y speed sensor coupler. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication…

• Page 554: Dtc «46» (C1646): Wheel Speed Sensor Circuit Short

  4E-61 ABS: DTC “46” (C1646): Wheel Speed Sensor Circuit Short (R) B718H14504014 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action…

• Page 555
  ABS: 4E-62 Step Action 1) Check for continuity between “12” (B/R) and “18” (W/Y) • Inspect the wire Go to Step 3. at the coupler. harness. (Faulty sensor wire) Special tool • Faulty wheel speed (A): 09900–25008 (Multi-circuit tester set) sensor Tester knob indication Continuity (…

• Page 556: Dtc «47» (C1647): Supply Voltage (Increased)

  4E-63 ABS: DTC “47” (C1647): Supply Voltage (Increased) B718H14504015 Possible Cause • Faulty regulator/rectifier • Faulty ABS control unit • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Remove the seat. Refer to “Exterior Parts Removal and Go to Step 2.

• Page 557
  ABS: 4E-64 Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ignition 2) Remove the left frame cover. Refer to “Exterior Parts or ground wire) Removal and Installation in Section 9D (Page 9D-6)”. 3) Remove the fuse box mounting bolt.

• Page 558: Dtc «48» (C1648): Supply Voltage (Decreased)

  4E-65 ABS: DTC “48” (C1648): Supply Voltage (Decreased) B718H14504016 Possible Cause • Faulty generator or regulator/rectifier • Faulty ABS control unit • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Remove the seat. Refer to “Exterior Parts Removal and Go to Step 2.

• Page 559
  ABS: 4E-66 Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ignition 2) Remove the left frame cover. Refer to “Exterior Parts or ground wire) Removal and Installation in Section 9D (Page 9D-6)”. 3) Remove the fuse box mounting bolt.

• Page 560: Dtc «55» (C1655): Abs Control Unit Malfunction

  4E-67 ABS: DTC “55” (C1655): ABS Control Unit Malfunction B718H14504017 Possible Cause Faulty ABS control unit Troubleshooting Step Action 1) Inspect the clearances of the front and rear wheel speed Go to Step 2. Adjust the clearance. sensor – sensor rotor using the thickness gauge. Special tool (A): 09900–20803 (Thickness gauge) (B): 09900–20806 (Thickness gauge)

• Page 561
  ABS: 4E-68 Step Action 1) Check that the front and rear wheel speed sensors are Go to Step 4. Tighten the mounting mounted securely. bolts or replace the bracket if necessary. I718H1450097-01 Are the sensors mounted securely? 1) Delete DTCs and repeat the code output procedure. Replace the ABS Intermittent trouble.

• Page 562: Dtc «61» (C1661): Abs Solenoid Malfunction

  4E-69 ABS: DTC “61” (C1661): ABS Solenoid Malfunction B718H14504018 Possible Cause Faulty solenoid valve or relay Troubleshooting Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the ABS solenoid valve fuse. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”.

• Page 563: Repair Instructions

  ABS: 4E-70 Step Action 1) Check the ABS control unit coupler for loose or poor Replace the ABS Inspect the wire contacts. control unit/HU. harness. (Faulty If OK, then disconnect the ABS control unit coupler. solenoid or ground wire) 2) Measure the voltage between “8” (R/Bl) and “24” (B/W) at the coupler.

• Page 564: Front Wheel Speed Sensor Removal And Installation

  4E-71 ABS: Front Wheel Speed Sensor Removal and Installation Refer to “Wheel Speed Sensor and Sensor Rotor Installation Inspection (Page 4E-74)”. B718H14506004 CAUTION Install the front wheel speed sensor in the reverse order of removal. Pay attention to the following points: •…

• Page 565: Front Wheel Speed Sensor Rotor Removal And Installation

  ABS: 4E-72 3) Disconnect the rear wheel speed sensor coupler (1). • Check the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge Special tool (A): 09900–20803 (Thickness gauge) (B): 09900–20806 (Thickness gauge) Wheel speed sensor – sensor rotor clearance 0.3 –…

• Page 566: Rear Wheel Speed Sensor Rotor Removal And Installation

  4E-73 ABS: Rear Wheel Speed Sensor Rotor Removal and Installation Refer to “Wheel Speed Sensor and Sensor Rotor Installation Inspection (Page 4E-74)”. B718H14506007 CAUTION Install the front wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: •…

• Page 567: Wheel Speed Sensor And Sensor Rotor Inspection

  ABS: 4E-74 • Install the rear wheel assembly. Refer to “Rear Wheel Wheel Speed Sensor Rotor Assembly Removal and Installation in Section 2D 1) Raise the wheel off the ground and support the (Page 2D-16)”. motorcycle with a jack or wooden block. •…

• Page 568
  4E-75 ABS: 1) Remove the seat and frame covers. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. 2) Remove the battery (1). Refer to “Battery Removal and Installation in Section 1J (Page 1J-12)”. 3) Remove the starter relay (2) from the battery case. 4) Remove the cooling fan relay (3) and fuel pump relay (4) from the battery case.

• Page 569: Specifications

  ABS: 4E-76 Specifications Tightening Torque Specifications B718H14507001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Brake pipe flare nut 11.5 (Page 4E-75) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”.

• Page 570
  4E-77 ABS: 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 4E-15) / (Page 4E-49) / (Page 4E-17) / (Page 4E-50) / (Page 4E-19) / (Page 4E-51) / (Page 4E-19) / (Page 4E-52) / (Page 4E-20) / (Page 4E-52) / (Page 4E-21) / (Page 4E-57) / (Page 4E-21) /…
• Page 571
  Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ……….5-1 Clutch …………5C-1 Precautions…………. 5-1 Precautions…………5C-1 Precautions for Transmission / Transaxle….. 5-1 Precautions for Clutch System……5C-1 Clutch Fluid (Brake Fluid) Information….5C-1 Manual Transmission……5B-1 Schematic and Routing Diagram ……5C-2 Diagnostic Information and Procedures….5B-1 Clutch Hose Routing Diagram……5C-2 Manual Transmission Symptom Diagnosis ..

• Page 572: Precautions

  5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B718H15000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

• Page 573: Manual Transmission

  Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B718H15204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.

• Page 574: Repair Instructions

  5B-2 Manual Transmission: Repair Instructions Transmission Components B718H15206001 I718H1520076-02 1. 1st driven gear 9. 5th drive gear 17. Gearshift cam plate 2. 5th driven gear 10. 3rd/4th drive gear 18. Gear position switch 3. 4th driven gear 11. 6th drive gear 19.

• Page 575: Transmission Removal

  Manual Transmission: 5B-3 Transmission Removal 2) Remove the bearing pin (2). B718H15206002 NOTE 1) Remove the engine assembly from the frame. Refer to “Engine Assembly Removal in Section 1D Do not lose the bearing pin (2). (Page 1D-17)”. 2) Disassemble the engine top side (1). Refer to “Engine Top Side Disassembly in Section 1D (Page 1D-24)”.

• Page 576
  5B-4 Manual Transmission: 4) Remove the No.3 gearshift fork (5). 2) Remove the countershaft bearing (3) with the special tool. Special tool (A): 09913–70210 (Bearing installer set) I718H1520009-01 Countershaft Assembly 1) Remove the bearing retainer (1). I718H1520013-01 3) Remove the snap ring (4). Special tool : 09900–06108 (Snap ring pliers) I718H1520010-01…

• Page 577: Transmission Installation

  (A): 09913–70210 (Bearing installer set) Pay attention to the following points: • Apply grease to the oil seal lip. Bearing / Oil Seal : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Replace the removed oil seal, bearings and snap ring with new ones.

• Page 578
  • Apply grease to the O-rings. • Install the No.3 gearshift fork (1) as shown. CAUTION Replace the O-rings (1) with new ones. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1520022-03 • Install the gearshift cam (2) with the bearing fitted.
• Page 579
  Manual Transmission: 5B-7 • Apply thread lock to the screws and tighten them to • Install the driveshaft assembly on the upper the specified torque. crankcase. : Thread lock cement 99000–32110 NOTE (THREAD LOCK CEMENT SUPER 1322 or • Align the gearshift forks (2) with their equivalent) grooves.

• Page 580: Transmission Construction

  5B-8 Manual Transmission: Transmission Construction B718H15206004 “ a” I718H1520071-04 1. Counter shaft 2. Drive shaft 3. Snap ring “a”: 0.2 mm (0.008 in) :Assemble snap ring with sharp edge side out.

• Page 581: Countershaft Gear / Driveshaft Gear Disassembly And Assembly

  Manual Transmission: 5B-9 Countershaft Gear / Driveshaft Gear • Remove the countershaft bearing (8) along with the housing (9), using the hydraulic press. Disassembly and Assembly B718H15206005 Refer to “Transmission Removal (Page 5B-3)” and “Transmission Installation (Page 5B-5)”. Disassembly CAUTION Identify the position of each removed part.

• Page 582
  • Before installing the oil seal, apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • When installing a new snap ring (1), pay attention to I718H1520035-01 its direction.
• Page 583
  Manual Transmission: 5B-11 • When installing the gear bushing onto the driveshaft, • Install the countershaft bearing (1) to the countershaft, align the shaft oil hole “A” with the bushing oil hole “B”. using the hydraulic press and special tool. Special tool (A): 09913–70210 (Bearing installer set) “A”…

• Page 584: Transmission Related Parts Inspection

  5B-12 Manual Transmission: Transmission Related Parts Inspection Gearshift Fork Thickness B718H15206007 Measure the gearshift fork thickness using the vernier Refer to “Transmission Removal (Page 5B-3)”, calipers. “Transmission Installation (Page 5B-5)” and Special tool “Countershaft Gear / Driveshaft Gear Disassembly and (A): 09900–20102 (Vernier calipers (1/20 mm, Assembly (Page 5B-9)”.

• Page 585: Gearshift Lever Construction

  Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with “A” the gearshift cam hole “B”. “a ” : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “B” “A” I718H1520074-02 1. Gearshift lever “a”: 45 – 55 mm (1.8 – 2.2 in) 2.

• Page 586: Gearshift Lever Removal And Installation

  5B-14 Manual Transmission: Gearshift Lever Removal and Installation 3) Loosen the lock-nuts (1). B718H15206017 4) Turn the gearshift link rod (2) until the gearshift lever Removal is 45 – 55 mm (1.8 – 2.2 in.) below the top of the 1) Place the motorcycle on the center stand.

• Page 587: Gearshift Construction

  Manual Transmission: 5B-15 Gearshift Construction 3) Remove the clutch components. Refer to “Clutch B718H15206015 Removal in Section 5C (Page 5C-13)”. 4) Remove the snap ring (1) from the gearshift shaft. Special tool : 09900–06107 (Snap ring pliers) I718H1520002-02 1. Gearshift shaft 2.

• Page 588
  5B-16 Manual Transmission: 7) Remove the gearshift cam plate bolt (11) and • Apply a small quantity of thread lock to the gearshift gearshift cam plate (12). arm stopper and tighten it to the specified torque. Remove the gearshift cam stopper (13). : Thread lock cement 99000–32030 (THREAD LOCK CEMENT SUPER 1303 or equivalent)
• Page 589
  Manual Transmission: 5B-17 • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of thread lock to the gearshift shaft end bolt and tighten it to the specified torque. • Locate the gearshift cam in the neutral position. •…

• Page 590: Gearshift Linkage Inspection

  5B-18 Manual Transmission: Gearshift Linkage Inspection • Install the gearshift shaft assembly (6) and washers (7) as shown. B718H15206012 Refer to “Gearshift Shaft / Gearshift Cam Plate Removal and Installation (Page 5B-15)”. NOTE Pinch the gearshift arm stopper (8) with Gearshift Shaft return spring ends “F”.

• Page 591: Gearshift Shaft Oil Seal / Bearing Removal And Installation

  (B): 09930–30104 (Rotor remover slide shaft) I718H1520066-01 • Install the oil seal with the special tool. Special tool (A): 09913–70210 (Bearing installer set) • Apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1520065-01 I718H1520067-01…

• Page 592: Specifications

  5B-20 Manual Transmission: Specifications Service Data B718H15207001 Transmission + Drive Chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.537 (83/54) — Final reduction ratio 2.388 (43/18) — 3.076 (40/13) — 2.058 (35/17) — 1.550 (31/20) — Gear ratios 1.304 (30/23) —…

• Page 593: Special Tools And Equipment

  Manual Transmission: 5B-21 Special Tools and Equipment Recommended Service Material B718H15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-5) / (Page 5B- equivalent 6) / (Page 5B-10) / (Page 5B-13) /…

• Page 594: Clutch

  5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B718H15300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Clutch Fluid (Brake Fluid) Information B718H15300002 WARNING • This clutch system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based.

• Page 595: Schematic And Routing Diagram

  Clutch: 5C-2 Schematic and Routing Diagram Clutch Hose Routing Diagram B718H15302001 “A” “B” “C” “D” I718H1530005-05 1. Wiring harness 9. Clutch hose No.3 clamp : After positioning the clamp with stopper, tighten the bolt. 2. Clutch hose 10. Grommet : Install the grommet of the clutch hose to the clutch hose guide properly.

• Page 596: Diagnostic Information And Procedures

  5C-3 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis B718H15304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline. Replace countershaft. seems to come from the Worn clutch hub spline. Replace clutch hub. clutch). Worn clutch plate teeth.

• Page 597: Air Bleeding From Clutch Fluid Circuit

  Clutch: 5C-4 Air Bleeding from Clutch Fluid Circuit 6) Loosen the bleeder valve by turning it a quarter of a B718H15306004 turn so that the fluid runs into the receptacle; this will CAUTION remove the tension of the clutch lever causing it to touch the handlebar grip.

• Page 598: Clutch Hose Removal And Installation

  5C-5 Clutch: 6) Connect a clear hose to the air bleeder valve and Clutch Hose Removal and Installation insert the other end of hose into a receptacle. B718H15306006 Removal 1) Drain clutch fluid. Refer to “Clutch Fluid Replacement (Page 5C-4)”. 2) Remove the fuel tank.

• Page 599: Clutch Control System Components

  8. Clutch release cylinder set : Apply brake fluid. 3. Clutch hose 9. Air bleeder : Apply grease. 4. Reservoir cap [A]: For GSF1250/A : Apply silicone grease. 5. Plate [B]: For GSF1250S/SA : Do not reuse. 6. Diaphragm : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)

• Page 600: Clutch Master Cylinder Assembly Removal And Installation

  “A” 4) Remove the clutch hose union bolt (2) and I718H1530020-01 disconnect the clutch hose. “C” “B” I718H1530018-01 5) Remove the left rear view mirror. (GSF1250/A) “A” “a” 6) Remove the master cylinder assembly. I718H1530073-01 “C”: “UP” mark “a”: Clearance…

• Page 601: Clutch Master Cylinder / Clutch Lever Disassembly And Assembly

  Clutch: 5C-8 • After setting the clutch hose union to the stopper, 2) Remove the reservoir cap (3), plate (4) and tighten the union bolt to the specified torque. diaphragm (5). CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage.

• Page 602
  • Apply brake fluid to the master cylinder I649G1530018-02 bore and to all of the master cylinder • Apply SUZUKI SILICONE GREASE to the clutch lever components to be inserted into the bore. pivot bolt when installing. : Grease 99000–25100 (SUZUKI Silicone…

• Page 603: Clutch Master Cylinder Parts Inspection

  Pay attention to the following points: CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage. • Apply a small quantity of SUZUKI SUPER GREASE “A” to the push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

• Page 604: Clutch Push Rod (Left) Inspection

  5C-11 Clutch: Clutch Push Rod (Left) Inspection Assembly B718H15306019 Assemble the clutch cylinder in the reverse order of Inspect the push rod in the following procedures: disassembly. Pay attention to the following points: 1) Remove the clutch push rod. Refer to “Clutch •…

• Page 605: Clutch Components

  Clutch: 5C-12 Clutch Components B718H15306014 6 / 7 6 / 7 I718H1530067-03 1. Clutch pressure plate 6. No.1 driven plate (0 – 2 pcs) 11. Primary driven gear assembly : The No.1 and No.2 driven plates are 8 in total. 2.

• Page 606: Clutch Removal

  5C-13 Clutch: Clutch Removal 5) Remove the clutch drive plates (4) and driven plates B718H15306016 (5). 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. 2) Remove the clutch cover (1). I718H1530033-01 6) Remove the spring washer (6) and its seat (7). I718H1530029-01 3) Remove the gasket (2) and dowel pins.

• Page 607: Clutch Installation

  Clutch: 5C-14 Remove the clutch push rod (11). 12) Remove the conical spring washer (12), washer (13) and clutch sleeve hub (14). NOTE If it is difficult to pull out the push rod (11), use a magnetic hand or a wire. I718H1530040-01 13) Remove the thrust washer (15), spacer (16) and bearing (17).

• Page 608
  5C-15 Clutch: 2) Install the spacers (2) and bearing (3), and apply 5) Hold the clutch sleeve hub with the special tools. engine oil to them. Special tool (A): 09920–53740 (Clutch sleeve hub holder) : 09920–31020 (Extension handle) 6) Tighten the clutch sleeve hub nut to the specified torque.
• Page 609
  Clutch: 5C-16 9) Install the clutch push piece (9), bearing (10) and 11) Insert the clutch drive plates and driven plates one thrust washer (11) to the countershaft. by one into the clutch sleeve hub in the prescribed order. NOTE NOTE Thrust washer (11) is located between the pressure plate and bearing (10).
• Page 610
  18) Pour engine oil. Refer to “Engine Oil and Filter Replacement in Section 0B (Page 0B-10)”. I718H1530072-01 14) Apply a light coat of the SUZUKI BOND “1207B” to the clutch cover gasket mating surface as shown. : Sealant 99000–31140 (SUZUKI Bond…

• Page 611: Clutch Parts Inspection

  Clutch: 5C-18 Clutch Parts Inspection Measure each driven plate for distortion with a thickness B718H15306018 gauge and surface plate. Refer to “Clutch Removal (Page 5C-13)” and “Clutch Replace driven plates which exceed the limit. Installation (Page 5C-14)”. Special tool (B): 09900–20803 (Thickness gauge) Clutch Drive and Driven Plate Clutch driven plate distortion NOTE…

• Page 612: Specifications

  5C-19 Clutch: Clutch Sleeve Hub and Primary Driven Gear Push Rod (Right) Inspect the push rod for wear and damage. Assembly If any defects are found, replace the push rod with a new Inspect the slot of the clutch sleeve hub and primary one.

• Page 613: Special Tools And Equipment

  Clutch: 5C-20 Special Tools and Equipment Recommended Service Material B718H15308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 5C-4) / (Page 5C- 9) / (Page 5C-11) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-10)

• Page 614
  5C-21 Clutch:…
• Page 615
  Table of Contents 6- i Section 6 Steering CONTENTS Precautions ……….6-1 Handlebars Inspection ……..6B-4 Steering Components ………6B-5 Precautions…………. 6-1 Steering Removal and Installation ……6B-6 Precautions for Steering ……..6-1 Steering Related Parts Inspection…….6B-9 Steering General Diagnosis….6A-1 Steering System Inspection ……..6B-9 Steering Stem Bearing Removal and Diagnostic Information and Procedures….6A-1 Installation …………6B-9…

• Page 616: Precautions

  6-1 Precautions: Precautions Steering Precautions Precautions for Steering B718H16000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

• Page 617: Steering General Diagnosis

  Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B718H16104001 Condition Possible cause Correction / Reference Item Heavy Steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.

• Page 618: Steering / Handlebar

  6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Components B718H16206001 “A” I718H1620037-01 1. Throttle grip 5. Handle expander “A”: Apply handle grip bond. 2. Handlebars 6. Handle balancer expander : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Handlebar holder (Upper) 7.

• Page 619: Handlebar Construction

  Steering / Handlebar: 6B-2 Handlebar Construction B718H16206013 “A” “A” “a” “B” “B” “A” “A” I718H1620040-01 1. Clutch master cylinder “A”: Punch mark : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Front brake master cylinder “B”: UP mark : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3.

• Page 620: Handlebar Removal And Installation

  3) Remove the caps and handlebar holder bolts. B718H16206002 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror (GSF1250/A) b) Clutch master cylinder/clutch lever (1) CAUTION Do not turn the clutch master cylinder upside down.

• Page 621: Handlebars Inspection

  Steering / Handlebar: 6B-4 • Apply SUZUKI SUPER GREASE to the end of the • Insert the projection “E” of the left handlebar switch throttle cables and cable pulley. box into the hole of the handlebars. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) •…

• Page 622: Steering Components

  2. Handlebar holder (Upper) 9. Handlebar holder set nut 16. Headlight housing bracket 3. Handlebars 10. Steering stem nut [A]: For GSF1250/A 4. Handlebar holder (Lower) 11. Dust seal : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 5. Steering stem head nut 12.

• Page 623: Steering Removal And Installation

  7) Dismount the handlebars and steering upper B718H16206005 bracket. Refer to “Ignition Switch Removal and Installation in Section 1H (Page 1H-9)”. Removal GSF1250/A NOTE 1) Support the motorcycle with a jack or a wooden If necessary, remove the ignition switch from block.

• Page 624
  6B-7 Steering / Handlebar: GSF1250S/SA 7) Remove the steering stem nut using the special tool. 1) Support the motorcycle with a jack or a wooden NOTE block. When loosening the stem nuts, hold the 2) Remove the front wheel assembly. Refer to “Front steering stem lower bracket to prevent it from Wheel Assembly Removal and Installation in Section falling.
• Page 625
  • Loosen the steering stem nut 1/4 – 1/2 turn “a”. Bearing NOTE • Apply SUZUKI SUPER GREASE to the bearings, races and dust seals before remounting the steering This adjustment will vary from motorcycle to stem.

• Page 626: Steering Related Parts Inspection

  6B-9 Steering / Handlebar: Handlebars If any abnormal points are found, replace defective parts with new ones. • Tighten the handlebar holder set nuts to the specified torque. Tightening torque Handlebar holder set nut (a): 45 N·m (4.5 kgf-m, 32.5 lb-ft) I718H1620026-02 I718H1620035-04 Inspection after installation…

• Page 627: Steering Tension Adjustment

  Steering / Handlebar: 6B-10 3) Remove the steering stem lower bearing and inner Inner race race using a chisel. • Press in the lower inner race and bearing using the special tool. Special tool (A): 09941–74911 (Steering bearing installer) I649G1620033-02 4) Remove the steering stem upper and lower bearing races using the special tools.

• Page 628: Specifications

  6B-11 Steering / Handlebar: b) Tighten the steering stem nut, stem head nut and 4) Do the same on the other grip end. front fork upper and lower clamp bolts to the 5) If the initial force read on the scale when the specified torque and recheck the initial force with handlebar starts turning is either too heavy or too the spring scale according to the previously…

• Page 629: Special Tools And Equipment

  Steering / Handlebar: 6B-12 Special Tools and Equipment Recommended Service Material B718H16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-4) / (Page 6B- equivalent Handle grip bond Handle Grip Bond (commercially —…

• Page 630
  6B-13 Steering / Handlebar:…
• Page 631
  Combination Meter / Fuel Meter / Horn.. 9C-1 Wiring Systems……..9A-1 General Description ……….9C-1 Schematic and Routing Diagram……9A-1 Combination Meter System Description….9C-1 Wiring Diagram (GSF1250)……… 9A-1 Repair Instructions ……….9C-2 Wiring Diagram (GSF1250S) ……9A-3 Combination Meter Components ……9C-2 Wiring Diagram (GSF1250A) ……9A-5 Combination Meter Removal and Installation ..9C-4…
• Page 632
  9-ii Table of Contents Engine Sprocket Outer Cover Cushion Engine Mount Bushing Replacement….9E-2 Construction …………9D-5 Front Footrest Bracket Construction ….9E-2 Fastener Removal and Installation……9D-5 Side-stand Construction……..9E-3 Exterior Parts Removal and Installation ….9D-6 Side-stand Removal and Installation….9E-4 Seat Height Adjustment ……..9D-9 Center Stand Construction……..9E-4 Center Stand Removal and Installation….9E-4 Body Structure ………9E-1…

• Page 633: Precautions

  Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B718H19000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B718H19003001 Refer to “Electrical Components Location in Section 0A (Page 0A-8)”.

• Page 634: Wiring Systems

  9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (GSF1250) B718H19102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”.

• Page 635
  Wiring Systems: 9A-2 For E-02, 19 I718H1910901-10…

• Page 636: Wiring Diagram (Gsf1250S)

  9A-3 Wiring Systems: Wiring Diagram (GSF1250S) B718H19102004 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. For E-02, 19 I718H1910902-09…

• Page 637
  Wiring Systems: 9A-4 For E-03, 24, 28 I718H1910903-12…

• Page 638: Wiring Diagram (Gsf1250A)

  9A-5 Wiring Systems: Wiring Diagram (GSF1250A) B718H19102005 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. For E-02, 19 I718H1910905-12…

• Page 639: Wiring Diagram (Gsf1250Sa)

  Wiring Systems: 9A-6 Wiring Diagram (GSF1250SA) B718H19102006 Refer to “Wire Color Symbols in Section 0A (Page 0A-6)”. For E-02, 19 I718H1910906-10…

• Page 640
  9A-7 Wiring Systems: For E-03, 24, 28 I718H1910915-02…

• Page 641: Wiring Harness Routing Diagram

  9. Brake hose (ABS) (GSF1250A/SA only) 2. EVAP purge control valve (E-33 only) 10. Rear wheel speed sensor coupler (GSF1250A/SA only) 3. Clamp (GSF1250/A only) 11. Clamp : Pass through the speed meter lead right side of ignition switch. : Clamp the lead wire and ABS brake hose (GSF1250A/SA).

• Page 642
  5. Frame 16. Clamp : Clamp the lead wire inside of clutch hose. 6. Wiring harness (GSF1250/A) “A”: Pass the regulator/rectifier lead wire behind hose. 7. Wiring harness (GSF1250S/SA) “B”: Set the generator lead wire between starter motor and sprocket inner cover.
• Page 643
  Wiring Systems: 9A-10 “a ” “b” “A” I718H1910913-02 1. Oil pressure lead wire : 6.5 N⋅m (0.65 kgf-m, 4.7 lb-ft) : Be careful not to slacken the oil pressure lead wire. 2. Generator cover : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft) 3.

• Page 644: Specifications

  9A-11 Wiring Systems: Specifications Service Data B718H19107001 Electrical Item Specification Note 10 A Headlight 10 A Fuel 10 A Ignition 15 A Signal 15 A Fuse size 15 A Main 30 A ABS motor 20 A (GSF1250A/SA only) ABS valve 15 A (GSF1250A/SA only) Tightening Torque Specifications…

• Page 645: Lighting Systems

  Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components B718H19206001 GSF1250/A I718H1920047-02 1. Headlight rim 3. Headlight bulb (12 V 60/55 W, H4) 5. Position light bulb (12 V 5 W) 2. Headlight unit 4. Headlight housing…

• Page 646: Headlight Removal And Installation

  Installation 3) Remove the front brake hose clamp bolt (3) Installation is in the reverse order of removal. Pay (GSF1250) or front brake hose joint mounting bolt attention to the following point: (4) (GSF1250A). • After installing, be sure to inspect the headlight beam.

• Page 647: Headlight Bulb Replacement

  5) Replace the headlight bulb (6) by unhooking the bulb When you touch the bulb with your bare holder spring (5). hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure. GSF1250/A 1) Remove the headlight mounting screws. I718H1920016-01 I718H1920006-01…

• Page 648
  9B-4 Lighting Systems: 6) Reassemble the headlight. 4) Remove the headlight bulb/socket (Low beam) (4) by unhooking the bulb holder spring (5). 7) Install the headlight assembly so that the hook “A” on the headlight bezel engages with “B” of the housing. “B”…

• Page 649: Headlight Beam Adjustment

  Lighting Systems: 9B-5 Headlight Beam Adjustment GSF1250S/SA B718H19206026 1) Insert 5 mm hexagon wrench as shown and adjust GSF1250/A the Low and High headlight beam horizontally. Adjust the headlight beam, both horizontally and vertically. NOTE NOTE To adjust the headlight beam, adjust the beam horizontally first, then vertically.

• Page 650: Rear Combination Light Construction

  9B-6 Lighting Systems: Rear Combination Light Construction B718H19206006 I649G1920018-02 1. Seat tail cover 2. Cushion 3. Rear combination light : 2.0 N⋅m (0.2 kgf-m, 1.5 lb-ft) Rear Combination Light Removal and Installation Install the rear combination light in the reverse order of Installation removal.

• Page 651: Brake Light Bulb / Taillight Bulb Replacement

  Lighting Systems: 9B-7 Brake Light Bulb / Taillight Bulb Replacement 3) Remove the bulb socket by turning it B718H19206008 counterclockwise. CAUTION When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soap water to prevent premature bulb failure.

• Page 652: License Plate Light Removal And Installation

  9B-8 Lighting Systems: License Plate Light Removal and Installation License Plate Light Bulb Replacement B718H19206010 B718H19206011 Removal 1) Remove the license plate light. Refer to “License 1) Remove the seat. Refer to “Exterior Parts Removal Plate Light Removal and Installation (Page 9B-8)”. and Installation in Section 9D (Page 9D-6)”.

• Page 653: Turn Signal Light Components

  GSF1250S/SA Installation Removal B718H19206013 1) Remove the wind screen and upper panel. Refer to GSF1250/A “Exterior Parts Removal and Installation in Section Removal 9D (Page 9D-6)”. 1) Remove the headlight housing. Refer to “Headlight 2) Disconnect the turn signal light coupler and clamp.

• Page 654: Rear Turn Signal Light Removal And Installation

  9B-10 Lighting Systems: Rear Turn Signal Light Removal and Installation Turn Signal Light Bulb Replacement B718H19206014 B718H19206015 Removal CAUTION 1) Remove the seat. Refer to “Exterior Parts Removal and Installation in Section 9D (Page 9D-6)”. When you touch the bulb with your bare hands, clean the bulb with a cloth moistened 2) Remove the tool set (1) and disconnect the turn with alcohol or soap water to prevent…

• Page 655: Turn Signal / Side-Stand Relay Inspection

  B718H19206019 Refer to “Electrical Components Location in Section 0A Inspect the hazard switch in the following procedures: (Page 0A-8)”. 1) Remove the right frame head cover. (GSF1250/A) Refer to “Exterior Parts Removal and Installation in NOTE Section 9D (Page 9D-6)”.

• Page 656: Passing Light Switch Inspection

  Section 6B (Page 6B-3)”. B718H19206022 Inspect the dimmer switch in the following procedures: Special tool 1) Remove the right frame head cover. (GSF1250/A) : 09900–25008 (Multi-circuit tester set) Refer to “Exterior Parts Removal and Installation in Tester knob indication Section 9D (Page 9D-6)”.

• Page 657: Specifications

  Lighting Systems: 9B-13 Specifications Service Data B718H19207001 Wattage Unit: W Specification Item GSF1250/A GSF1250S/SA Headlight ← Parking or position light 5 x 2 ← Brake light/Taillight 21/5 ← Turn signal light 21 x 4 ← License plate light Tightening Torque Specifications…

• Page 658: Combination Meter / Fuel Meter / Horn

  9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description B718H19301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

• Page 659: Repair Instructions

  Combination Meter / Fuel Meter / Horn: 9C-2 Repair Instructions Combination Meter Components B718H19306001 GSF1250/A I718H1930046-03 1. Upper case 2. Combination meter 3. Lower case 4. Cover 5. Bracket…

• Page 660
  9C-3 Combination Meter / Fuel Meter / Horn: GSF1250S/SA I718H1930047-02 1. Upper case 2. Combination meter 3. Lower case…

• Page 661: Combination Meter Removal And Installation

  Combination Meter / Fuel Meter / Horn: 9C-4 Combination Meter Removal and Installation 2) Disconnect the combination meter coupler and B718H19306002 remove the combination meter assembly. GSF1250/A Removal 1) Remove the combination meter mounting bolts. I718H1930018-01 3) Remove the combination meter (1). I718H1930057-01 2) Remove the headlight.

• Page 662: Combination Meter Inspection

  9C-5 Combination Meter / Fuel Meter / Horn: Combination Meter Inspection 2) With the adjuster switch (1) pressed, turn the ignition B718H19306004 switch on. LED Inspection 3) Release the adjuster switch (1), 3 to 5 seconds after Check that the LEDs (FI indicator light, ABS indicator turning the ignition switch on.

• Page 663: Engine Coolant Temperature Removal And Installation

  Combination Meter / Fuel Meter / Horn: 9C-6 Fuel Level Indicator Inspection 2) Connect the variable resistor (2) between the terminals. B718H19306030 Inspect the fuel level indicator in the following procedures: 1) Support the motorcycle with the center stand. 2) Lift and support the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”…

• Page 664: Fuel Level Indicator Switch (Thermistor) Inspection

  9C-7 Combination Meter / Fuel Meter / Horn: Fuel Level Indicator Switch (Thermistor) 5) Turn the ignition switch ON. Inspection 6) Check the display of fuel level indicator (LCD) as B718H19306031 shown. Inspect the fuel level indicator switch in the following If any abnormality is found, replace the combination procedures: meter with a new one.

• Page 665: Fuel Level Gauge Inspection

  Combination Meter / Fuel Meter / Horn: 9C-8 Fuel Level Gauge Inspection Speed Sensor Removal and Installation B718H19306006 B718H19306021 Inspect the fuel level gauge in the following procedures: Removal 1) Remove the fuel level gauge. Refer to “Fuel Pump 1) Remove the seat. Refer to “Exterior Parts Removal Assembly / Fuel Level Gauge Removal and and Installation in Section 9D (Page 9D-6)”.

• Page 666: Speed Sensor Inspection

  9C-9 Combination Meter / Fuel Meter / Horn: Installation 3) Move a screwdriver back and forth across the pick- Install the speed sensor in the reverse order of removal. up surface of the speed sensor. The voltage readings should cycle as follows (0 V → 12 V or 12 V Pay attention to the following points: →…

• Page 667: Oil Pressure Switch Removal And Installation

  B718H19306025 NOTE Inspect the ignition switch in the following procedures: 1) Remove the right frame head cover. (GSF1250/A) If the horn sound condition is normal, it is not Refer to “Exterior Parts Removal and Installation in necessary to inspect the horn button Section 9D (Page 9D-6)”.

• Page 668: Horn Removal And Installation

  9C-11 Combination Meter / Fuel Meter / Horn: 3) Inspect the horn button for continuity with a tester. 2) Connect a 12 V battery to terminal “A” and terminal If any abnormality is found, replace the left “B”. If the sound is not heard from the horn, replace handlebar switch assembly with a new one.

• Page 669: Specifications

  Combination Meter / Fuel Meter / Horn: 9C-12 Specifications Service Data B718H19307001 Wattage Unit: W Specification Item GSF1250/A GSF1250S/SA ← Speedometer light ← Tachometer light ← Turn signal indicator light LED x 2 ← High beam indicator light ← Neutral position indicator light ←…

• Page 670: Exterior Parts

  9D-1 Exterior Parts: Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B718H19402001 I718H1940028-01 1. Screw 2. Seat lock cable 3. Seat lock 4. Plate…

• Page 671: Repair Instructions

  Exterior Parts: 9D-2 Repair Instructions Exterior Parts Construction B718H19406006 GSF1250/A I718H1940033-01 1. Frame head cover 2. Headlight housing cover 3. Headlight housing stay…

• Page 672
  9D-3 Exterior Parts: GSF1250S/SA I718H1940026-02 1. Cowling body 3. Cowling brace 5. Upper panel 7. Head pipe 2. Wind screen 4. Lower panel 6. Meter panel lid 8. Bolt (Except E-33)

• Page 673: Front Fender Construction

  Exterior Parts: 9D-4 Front Fender Construction B718H19406007 I718H1940029-01 1. Front fender 2. Fender plate nut 3. Front fork Frame Cover Cushion Construction B718H19406002 I718H1940030-01 1. Frame cover 2. Cushion : Clean an adhesive surface before adhering the tape cushion.

• Page 674: Engine Sprocket Outer Cover Cushion Construction

  9D-5 Exterior Parts: Engine Sprocket Outer Cover Cushion Construction B718H19406008 I718H1940031-01 1. Engine sprocket outer cover cushion 2. Engine sprocket outer cover : Clear adhesive surface before adhering the tape cushion. Fastener Removal and Installation Installation B718H19406003 1) Let the center piece stick out toward the head so that Removal the pawls “A”…

• Page 675: Exterior Parts Removal And Installation

  Exterior Parts: 9D-6 2) Insert the fastener into the installation hole. Frame Cover Removal NOTE Remove the frame covers (1), left and right. To prevent the pawl “A” from damage, insert the fastener all the way into the installation hole. 3) Push in the head of center piece until it becomes flush with the fastener outside face.

• Page 676
  9D-7 Exterior Parts: 5) Disconnect the brake light/taillight lead wire coupler Headlight Housing Cover (GSF1250/A) (2). Removal Remove the headlight housing cover (1). 6) Unhook the seat lock cable (3). Refer to “Seat Lock Cable Routing Diagram (Page 9D-1)”. 7) Remove the seat tail cover (4).
• Page 677
  Exterior Parts: 9D-8 4) Remove the wind screen (2) and upper panel (3). 7) Remove the lower panel (6) from the cowling (5). I718H1940012-01 I718H1940017-01 5) Remove the turn signal lights (4), left and right. Refer Disconnect the headlight and position light couplers. to “Front Turn Signal Light Removal and Installation 9) Remove the headlight assembly (7).

• Page 678: Seat Height Adjustment

  9D-9 Exterior Parts: Seat Height Adjustment 5) Reinstall the front seat and adjust the seat height B718H19406005 adjuster position “A” or “B”. Adjust the seat height in the following procedures: 1) Remove the seat assembly. Refer to “Exterior Parts Removal and Installation (Page 9D-6)”. 2) Remove the seat height adjusting dampers.

• Page 679: Body Structure

  Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B718H19506001 I718H1950003-08 1. Frame 4. Bracket mounting bolt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Frame down tube bolt 5. Engine mounting bracket bushing : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3.

• Page 680: Engine Mount Bushing Replacement

  Engine Mount Bushing Replacement B718H19506003 Replace the engine mount bushing if necessary, as shown in the body frame construction. Refer to “Body Frame Construction (Page 9E-1)”. Front Footrest Bracket Construction B718H19506005 GSF1250/S I718H1950001-04 1. Frame 2. Footrest bracket 3. Washer 4. Bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft)

• Page 681: Side-Stand Construction

  Body Structure: 9E-3 Side-stand Construction B718H19506006 I718H1950005-05 1. Side-stand : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : Apply grease to sliding surface. 2. Spring : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft)

• Page 682: Side-Stand Removal And Installation

  9E-4 Body Structure: Side-stand Removal and Installation B718H19506007 Removal 1) Support the motorcycle with the center stand. 2) Remove the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Installation Install the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction (Page 9E-3)”. Center Stand Construction B718H19506008 I718H1950002-02…

• Page 683: Specifications

  Body Structure: 9E-5 Specifications Tightening Torque Specifications B718H19507001 NOTE The specified tightening torque is also described in the following. “Body Frame Construction (Page 9E-1)” “Front Footrest Bracket Construction (Page 9E-2)” “Side-stand Construction (Page 9E-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications in Section 0C (Page 0C-7)”.

• Page 684
  Prepared by December, 2006 Part No. 99500-39300-01E Printed in Japan…
• Page 685
  Printed in Japan…