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5. 2005 GSF1200
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• Page 1
  GSF1200/GSF1200S 9 9 5 0 0 — 3 9 2 8 0 — 0 1 E…
• Page 2
  * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
• 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 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 • Inspect each terminal for corrosion and to the specified torque. Wipe off grease contamination. The terminals must be clean and free and oil if a thread is smeared with them. of any foreign material which could impede proper terminal contact.
• Page 8
  00-3 Precautions: • Check the male connector for bend and female • Be careful not to touch the electrical terminals of the connector for excessive opening. Also check the Ignitor unit and ABS control unit/HU. The static coupler for locking (looseness), corrosion, dust, etc. electricity from your body may damage this part.
• Page 9
  Precautions: 00-4 • The ABS control unit/HU cannot be disassembled. • Before measuring voltage at each terminal, check to Replace the whole unit with a new one. make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous diagnosis.
• Page 10
  00-5 Precautions: 1) Disconnect the negative (–) cable from the battery. Continuity check 1) Measure resistance across coupler “B” (between “A” 2) Check each connector/coupler at both ends of the circuit being checked for loose connection. Also and “C” in figure). check for condition of the coupler lock if equipped.
• Page 11
  Precautions: 00-6 3) Also, if measured values are as listed below, a 3) Measure resistance between terminal at one end of resistance (abnormality) exists which causes the circuit (“A” terminal in figure) and body ground. If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”.
• Page 12
  00-7 Precautions: Using The Multi-Circuit Testers • After using the tester, turn the power off. • Use the Suzuki multi-circuit tester set. Special tool • Use well-charged batteries in the tester. : 09900–25008 (Multi-circuit tester set) • Be sure to set the tester to the correct testing range.

• Page 13: General Information

  Table of Contents 0- i Section 0 General Information CONTENTS General Information …….. 0A-1 Engine Oil and Filter Replacement …..0B-9 Throttle Cable Play Inspection General Description ……….0A-1 and Adjustment ……….0B-10 Symbols ………….. 0A-1 Engine Idle Speed Inspection Abbreviations …………0A-2 and Adjustment ……….0B-11 Vehicle Side View ……….

• Page 14
  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 15
  General Information: 0A-2 Abbreviations B649G10101002 HC: Hydrocarbons ABDC: After Bottom Dead Center IG: Ignition ABS: Anti-lock Brake System AC: Alternating Current JASO: Japanese Automobile Standards Organization ACL: Air Cleaner, Air Cleaner Box API: American Petroleum Institute LCD: Liquid Crystal Display ATDC: After Top Dead Center LED: Light Emitting Diode (Malfunction Indicator Lamp) A/F: Air Fuel Mixture…
• Page 16
  0A-3 General Information: Vehicle Side View SUZUKI GSF1200S (2006-model) B649G10101003 NOTE Right Side Difference between photographs and actual motorcycles may exist depending on the markets. SUZUKI GSF1200 (2006-model) Right Side I649G1010005-06 Left Side I649G1010008-01 Left Side I649G1010006-05 I649G1010009-01…
• Page 17
  Use of SF/SG or SH/SJ in API with MA in JASO. head pipe. The engine serial number “B” is located on Suzuki recommends the use of SAE 10W-40 engine oil. the right side of the crankcase. These numbers are…

• Page 18: Cylinder Identification

  0A-5 General Information: Cylinder Identification Country and Area Codes B649G10101008 B649G10101009 The four cylinders of this engine are identified as No.1, The following codes stand for the applicable country(- 2, 3 and No.4 cylinder, as counted from left to right (as ies) and area(-s).

• Page 19
  General Information: 0A-6 Warning, Caution and Information Labels Location B649G10101011 I649G1010011-04 GSF1200 GSF1200S 1. Noise label — For E-24 2. Information label — For E-28 3. Fuel caution label For E-02 For E-02, 24 4. Screen label — For E-02, 19, 24, 28 5.
• Page 20
  0A-7 General Information: Component Location Electrical Components Location B649G10103001 I649G1010003-05 1. Ignition coil 3. Handlebar switch (RH) 5. Rear brake light switch 7. CKP sensor 2. Ignition switch 4. Front brake light switch 6. Throttle position sensor 8. Oil pressure switch…
• Page 21
  General Information: 0A-8 I649G1010004-04 9. Clutch lever position switch 14. Main fuse 19. Generator 10. Handlebar switch (LH) 15. Battery 20. Carburetor heater (For E-02, 19) 11. Fuse box 16. Ignitor 21. Speed sensor 12. Turn signal/Side-stand relay 17. Horn 22.
• Page 22
  0A-9 General Information: Specifications Specifications B649G10107001 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) GSF1200 Overall height 1 235 mm (48.6 in)
• Page 23
  General Information: 0A-10 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) Caster 35° (right & left) Trail 25°…

• Page 24: Special Tools

  0A-11 General Information: Special Tools and Equipment Special Tools B649G10108001 TT09900-06106-01 TT09900-06107-02 TT09900-06108-02 TT09900-20102-01 09900-06106 09900-06107 09900-06108 09900-20102 Snap ring pliers Snap ring pliers Snap ring pliers Vernier calipers (1/20 mm, 200 mm) TT09900-20202-01 TT09900-20204-01 TT09900-20205-01 TT09900-20508-01 09900-20202 09900-20204 09900-20205 09900-20508 Micrometer Micrometer…

• Page 25
  General Information: 0A-12 TT09913-50121-01 TT09913-60910-01 TT09913-61510-01 TT09913-70210-01 09913-50121 09913-60910 09913-61510 09913-70210 Oil seal remover Bearing remover Bearing remover Bearing installer set TT09915-40610-01 TT09915-63210-01 TT09915-64510-01 TT09915-74521-01 09915-40610 09915-63210 09915-64510 09915-74521 Oil filter wrench Compression gauge adaptor Compression gauge set Oil pressure gauge hose TT09915-74540-01 TT09915-77331-01 TT09916-10911-01…
• Page 26
  0A-13 General Information: TT09917-14920-01 TT09917-47010-01 TT09920-34820-01 TT09920-34840-01 09917-14920 09917-47010 09920-34820 09920-34840 Valve adjuster driver Vacuum pump gauge Clutch pressure plate holder Starter clutch holder TT09920-53740-02 TT09921-20240-01 TT09922-22711-01 TT09923-73210-01 09920-53740 09921-20240 09922-22711 09923-73210 Clutch sleeve hub holder Bearing remover set Drive chain cutting and Bearing remover joining tool TT09924-84510-01…

• Page 27: Maintenance And Lubrication

  Maintenance and Lubrication: 0B-1 Maintenance and Lubrication Precautions Precautions for Maintenance B649G10200001 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 28: Scheduled Maintenance

  0B-2 Maintenance and Lubrication: Scheduled Maintenance Periodic Maintenance Schedule Chart B649G10205001 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace T = Tighten Interval 1 000 6 000 12 000 18 000 24 000 Item mile 4 000…

• Page 29: Lubrication Points

  Maintenance and Lubrication: 0B-3 Lubrication Points B649G10205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. NOTE • Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. •…

• Page 30
  0B-4 Maintenance and Lubrication: Repair Instructions Air Cleaner Element Removal and Installation • After cleaning or installing the air cleaner element, B649G10206001 drain water from the air cleaner by removing the drain plug. Inspect air cleaner element Every 6 000 km (4 000 miles, 12 months) Replace air cleaner element Every 18 000 km (11 000 miles, 36 months) Removal…
• Page 31
  Maintenance and Lubrication: 0B-5 Cleaning 1) Remove the spark plug caps. Carefully use compressed air to clean the air cleaner element. CAUTION Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the outside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.
• Page 32
  0B-6 Maintenance and Lubrication: Spark Plug Inspection and Cleaning Electrodes Condition B649G10206004 Check to see the worn or burnt condition of the Refer to “Spark Plug Removal and Installation: ”. electrodes. If it is extremely worn or burnt, replace the plug. And also Inspect spark plug replace the plug if it has a broken insulator, damaged Every 6 000 km (4 000 miles, 12 months)
• Page 33
  Maintenance and Lubrication: 0B-7 Valve Clearance Inspection and Adjustment B649G10206005 “A” “A” Inspect valve clearance Initially at 1 000 km (600 miles, 2 month) and every “B” “B” 12 000 km (7 500 miles, 24 months) thereafter. Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.
• Page 34
  0B-8 Maintenance and Lubrication: 9) Insert the thickness gauge between the valve stem end and adjusting screw on the rocker arm. If the Notch “C” position Camshaft position clearance is out of specification, hold the lock-nut faces inside with a wrench and use the special tools to adjust the Measuring position “E”…
• Page 35
  Maintenance and Lubrication: 0B-9 Engine Oil and Filter Replacement 3) Tighten the oil drain plug (1) to the specified torque, B649G10206007 and pour new oil through the oil filler. When performing an oil change (without oil filter Replace engine oil replacement), the engine will hold about 3.3 L of oil.
• Page 36
  Also, do not use a genuine Suzuki automobile oil filter on this motorcycle. 4) Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting “a”…
• Page 37
  Maintenance and Lubrication: 0B-11 Engine Idle Speed Inspection and Adjustment WARNING B649G10206011 The clutch system of this motorcycle is filled Inspect engine idle speed with a glycol-based brake fluid. Do not use or Initially at 1 000 km (600 miles, 2 month) and every 6 mix different types of fluid such as silicone- 000 km (4 000 miles, 12 months) thereafter.
• Page 38
  0B-12 Maintenance and Lubrication: Clutch Hose Replacement Drive Chain Length Inspection B649G10206031 1) Remove the cotter pin. (For E-28) Refer to “Clutch Hose Removal and Installation: in 2) Loosen the axle nut (1). Section 5C”. 3) Loosen the chain adjuster lock-nuts (2). Air Bleeding from Clutch Fluid Circuit 4) Give tension to the drive chain fully by turning both B649G10206032…
• Page 39
  • Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is a RK GB50GSVZ3. SUZUKI recommends to use this standard drive chain as a replacement. I649G1020035-02 “a”…
• Page 40
  0B-14 Maintenance and Lubrication: Brake Pads Check WARNING The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pad. When the • The brake system of this motorcycle is wear exceeds the grooved limit line, replace the pads filled with a glycol-based brake fluid.
• Page 41
  Maintenance and Lubrication: 0B-15 Brake Fluid Replacement Rear Brake Hose Inspection B649G10206035 Inspect the brake hose for crack, damage or brake oil Refer to “Brake Fluid Replacement: in Section 4A”. leakage. If any defects are found, replace the brake hose with a new one. Tire Inspection B649G10206017 Inspect tire…
• Page 42
  It is highly recommended to use a Replace any defective parts, if necessary. Refer to SUZUKI Genuine Tire. “Front Fork Parts Inspection: in Section 2B”. Tire type DUNLOP •…
• Page 43
  Maintenance and Lubrication: 0B-17 Chassis Bolt and Nut Inspection B649G10206022 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 month) 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 44: Compression Pressure Check

  0B-18 Maintenance and Lubrication: I649G1020061-04 I649G1020064-04 15. Front axle bolt 21. Air bleeder valve (Brake) 30. Rear sprocket nut : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 16. Front axle pinch bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 31. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 17.

• Page 45
  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G10208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — Special Tool B649G10208002 09900–20803…
• Page 46
  0C-1 Service Data: Service Data Specifications Service Data B649G10307003 Valve + Guide Unit: mm (in) Item Standard Limit 28.5 (1.12) — Valve diameter 25 (1.0) — 0.10 – 0.15 (0.004 – 0.006) — Valve clearance (when cold) 0.18 – 0.23 (0.007 – 0.009) —…
• Page 47
  Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 875 kPa Compression pressure 1 250 kPa (12.5 kgf/cm , 178 psi) (8.75 kgf/cm , 124 psi) 200 kPa Compression pressure difference — (2 kgf/cm , 28 psi) Piston-to-cylinder clearance 0.050 –…
• Page 48
  0C-3 Service Data: Oil Pump Item Standard Limit Oil pump reduction ratio 1.703 (72/46 x 37/34) — Above 300 kPa (3.0 kgf/cm , 43 psi) Oil pressure (at 60 °C, 140 °F) Below 600 kPa (6.0 kgf/cm , 85 psi) —…
• Page 49
  Service Data: 0C-4 Electrical Unit: mm (in) Item Specification Note 7° B.T.D.C. at 1 300 r/min. E-28 Ignition timing 7° B.T.D.C. at 1 200 r/min. Others 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order Type NGK: JR9B Spark plug 0.6 –…
• Page 50
  0C-5 Service Data: Brake + Wheel Unit: mm (in) Item Standard Limit Rear brake pedal height 60 (2.4) — Front 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc thickness Rear 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc runout —…
• Page 51
  Service Data: 0C-6 Tire Item Standard Limit Cold inflation tire pressure Front 250 kPa (2.50 kgf/cm , 36 psi) — (Solo/Dual riding) Rear 250 kPa (2.50 kgf/cm , 36 psi) — Front 120/70 ZR17M/C (58 W) — Tire size Rear 180/55 ZR17M/C (73 W) —…
• Page 52
  0C-7 Service Data: Tightening Torque Specifications B649G10307002 Engine Item N⋅m kgf–m lb–ft Cylinder head cover bolt (10 pcs) 10.0 Cylinder head cover plug 11.0 Cylinder head cover union bolt 14.5 Cylinder head nut [M10] 27.5 Cylinder head bolt [M6] Cylinder head plug 20.0 Cylinder base nut Cylinder stud bolt…
• Page 53
  Service Data: 0C-8 Item N⋅m kgf–m lb–ft Fuel level gauge mounting bolt Oil filter 14.5 Chassis Item N⋅m kgf–m lb–ft Steering stem head nut 47.0 Tighten 45 N⋅m (4.5 kgf-m, 32.5 lb-ft) then turn back 1/2 – Steering stem nut 1/4.
• Page 54
  0C-9 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 16.5 21.0 36.0…

• Page 55: Table Of Contents

  Table of Contents 1- i Section 1 Engine CONTENTS Precautions ……….1-1 Camshaft Sprocket Inspection ……1D-27 Camshaft Sprocket Removal and Installation …1D-27 Precautions…………. 1-1 Cam Chain Tension Adjuster Inspection…1D-28 Precautions for Engine………. 1-1 Cam Chain Guide Removal and Installation ..1D-28 Engine General Information and Cam Chain Guide Inspection ……1D-29 Cam Chain Tensioner Inspection……1D-29 Diagnosis ……….

• Page 56
  1-ii Table of Contents Oil Pressure Regulator Inspection …… 1E-5 Fuel Tank Drain Hose and Breather Hose Oil Pan / Oil Sump Filter Cleaning …… 1E-6 Routing Diagram ……….1G-10 Oil Pressure Switch Removal and Installation ..1E-6 Throttle Cable / Starter Cable Oil Pressure Switch Inspection ……
• Page 57
  Table of Contents 1-iii CKP Sensor Removal and Installation ….1H-8 Special Tools and Equipment ……1I-17 Engine Stop Switch Inspection ……1H-10 Recommended Service Material ……1I-17 Ignition Switch Inspection ………1H-10 Special Tool …………1I-17 Ignition Switch Removal and Installation…1H-10 Charging System ……..1J-1 Specifications………….1H-11 General Description ……….
• Page 58
  1-1 Precautions: Precautions Precautions Precautions for Engine B649G11000001 Refer to “General Precautions: in Section 00” and “Precautions for Electrical Circuit Service: in Section 00”.

• Page 59: Engine General Information And Diagnosis

  Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Diagnostic Information and Procedures Engine Symptom Diagnosis B649G11104011 Condition Possible cause Correction / Reference Item Engine will not start or is Worn cylinder. Rebore or replace. hard to start Worn piston ring.

• Page 60
  1A-2 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine noisy (Noise Worn or rubbing gear. Replace. seems to come from Worn countershaft spline. Replace countershaft. transmission.) Worn driveshaft spline. Replace driveshaft. Worn or rubbing primary gear. Replace.
• Page 61
  A jet needle with only one clip position, is also used. If jet needle replacement is necessary, only replace it with a jet needle of the same type. Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and durability.

• Page 62: Crankcase Emission Control System Description

  1B-2 Emission Control Devices: Crankcase Emission Control System Description B649G11201006 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 hose, air cleaner box and carburetors.

• Page 63: Exhaust Emission Control System Description

  Emission Control Devices: 1B-3 Exhaust Emission Control System Description B649G11201008 The exhaust emission control system is composed of the PAIR system and three-way catalyst system. The fresh air is drawn into the exhaust port through the PAIR control valve and PAIR reed valve. The PAIR control valve is operated by the engine vacuum which is connected to the No.4 carburetor, and the fresh air flow is controlled according to the exhaust gas pulsation.

• Page 64: Schematic And Routing Diagram

  1B-4 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B649G11202001 “I” “A” “D” “B” “G” “C” “F” “H” “E” I649G1120008-04 1. PAIR hose No.1 7. PAIR control valve “F”: Marking (White) must face front side. 2. PAIR hose No.2 “A”: Be careful not to contact the PAIR hoses with the throttle cables.

• Page 65: Repair Instructions

  Emission Control Devices: 1B-5 Repair Instructions PAIR System Removal and Installation Installation B649G11206001 Install the PAIR valve in the reverse order of removal. Removal Pay attention to the following points: 1) Remove the fuel tank. Refer to “Fuel Tank Removal CAUTION and Installation: in Section 1G”.

• Page 66
  1B-6 Emission Control Devices: PAIR System Inspection 3) Remove the reed valves. B649G11206004 4) Inspect the reed valves for the carbon deposit. PAIR Hose and Pipe If the carbon deposit is found in the reed valve, 1) Remove the fuel tank. Refer to “Fuel Tank Removal replace the PAIR valve with a new one.

• Page 67: Pcv Hose Removal And Installation

  Emission Control Devices: 1B-7 b) Connect the vacuum pump gauge to the vacuum PCV Hose Removal and Installation B649G11206007 port of the PAIR valve as shown. Apply negative Removal pressure slowly to the PAIR valve and blow into it 1) Remove the fuel tank. Refer to “Fuel Tank Removal as shown above.

• Page 68: Tightening Torque Specifications

  1B-8 Emission Control Devices: Specifications Tightening Torque Specifications B649G11207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft PAIR pipe mounting nut PAIR valve mounting bolt Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”.

• Page 69: Engine Mechanical

  Engine Mechanical: 1D-1 Engine Mechanical Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B649G11402001 24th pin 1st pin I649G1140075-03…

• Page 70
  1D-2 Engine Mechanical: Diagnostic Information and Procedures Compression Pressure Check 6) Keep the throttle grip in the fully-opened position. B649G11404001 The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test.

• Page 71: Repair Instructions

  Engine Mechanical: 1D-3 Repair Instructions Engine Components Removable with the Engine in Place B649G11406001 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 72
  1D-4 Engine Mechanical: Engine Left Side Item Removal Inspection Installation Refer to “Engine Sprocket Refer to “Engine Sprocket Engine sprocket cover Removal and Installation: in — Removal and Installation: in Section 3A”. Section 3A”. Refer to “Engine Sprocket Refer to “Drive Chain Refer to “Engine Sprocket Engine sprocket Removal and Installation: in…
• Page 73
  Engine Mechanical: 1D-5 Engine Assembly Removal 9) Disconnect all of the spark plug caps (3). B649G11406002 10) Disconnect the breather (PCV) hose (4). Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps: 1) Drain engine oil.
• Page 74
  1D-6 Engine Mechanical: 13) Remove the wire harness clamp (7). 19) Disengage the gearshift lever link by removing the bolt. 14) Disconnect the gear position switch lead wire couplers (8). 20) Remove the engine sprocket cover by removing the bolts. I649G1140007-03 15) Disconnect the CKP sensor lead wire coupler (9).
• Page 75
  Engine Mechanical: 1D-7 25) Loosen the rear axle nut (16) and chain adjusters 28) Remove the oil cooler and oil cooler hoses. Refer to (17) to provide additional chain slack. “Oil Cooler / Oil Cooler Hose Removal and Installation: in Section 1F”. I649G1140011-03 26) Remove the engine sprocket (18).
• Page 76
  1D-8 Engine Mechanical: 33) Gradually lower the front side of the engine and remove the engine. WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts and nuts are removed. I649G1140018-04 19. Frame down tube mounting bolt 22.
• Page 77
  Engine Mechanical: 1D-9 Engine Assembly Installation B649G11406003 Reinstall the engine in the reverse order of engine removal. Pay attention to the following points: • Insert the two long bolts (1), (2) from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration.
• Page 78
  Speed sensor rotor bolt (h): 20 N·m (2.0 kgf-m, 14.5 lb-ft) • Before installing the engine sprocket cover, apply a small quantity of SUZUKI SUPER GREASE “A” to the push rod. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1140025-03 •…
• Page 79
  Engine Mechanical: 1D-11 • Position the carburetor clamps as shown. I649G1170033-01 • After remounting the engine, route the wire harness, cables and hoses properly. Refer to “Wiring Harness Routing Diagram: in Section 9A” and “Throttle Cable / Starter Cable Routing Diagram: in Section 1G”. •…
• Page 80
  1D-12 Engine Mechanical: • Pour 4.6 L (4.9/4.0 US/lmp qt) of SF/SG or SH/SJ with JASO MA engine oil, with a viscosity rating of 10W-40, into the engine after overhauling it. • Start up the engine and allow it run for several minutes at idle speed and then stop the engine. Wait three minutes and then check that the oil level remains between the marks on the oil level inspection window.
• Page 81
  Engine Mechanical: 1D-13 Cylinder Head Cover 4) After removing the spring holder bolt (2) and spring (3), remove the cam chain tension adjuster (4). 1) Remove the breather cover (1). 2) Remove the cylinder head cover (2) from the cylinder head. I649G1140039-02 5) Remove the camshaft journal holders.
• Page 82
  1D-14 Engine Mechanical: 2) Remove the cylinder head bolt (2). Cylinder 1) Remove the cylinder head gasket (1), O-rings (2) and dowel pins (3). I649G1140042-02 I649G1140355-02 3) The cylinder head can be removed after its twelve 2) Remove the left and right oil return pipes (4). nuts (M10) are removed.
• Page 83
  • Install each cylinder stud bolt as shown. NOTE Before installing the cylinder stud bolt (4), apply a light coat of the recommended bond to its threads. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) Tightening torque Cylinder stud bolt: 15 N·m (1.5 kgf-m, 11.0 lb-ft) I649G1140050-02 4) Draw out each piston pin and remove the pistons.
• Page 84
  1D-16 Engine Mechanical: Oil Jet (For the Cylinder Head) • Install the dowel pins and the new cylinder gasket. • Make sure that the oil jets (1) in the upper crankcase • Before installing the cylinder, oil the big and small are not clogged.
• Page 85
  • With pistons #2 and #3 in place, install pistons #1 and • Install the new O-rings (2) onto the oil return pipes #4, and then insert them into the respective cylinders. and apply SUZUKI SUPER GREASE “A” to the O- rings. NOTE…
• Page 86
  1D-18 Engine Mechanical: • Tighten the twelve nuts (M10) in ascending order and • Install the cam chain guide (2) as shown. to the specified torque. Tightening torque Cylinder head nut: 38 N·m (3.8 kgf-m, 27.5 lb-ft) “10” “2” “4” “8”…
• Page 87
  Camshaft NOTE Before installing the camshafts onto the cylinder head, apply SUZUKI MOLY PASTE onto the camshaft journals and do not leave any dry spots. Also, apply engine oil onto the camshaft journal holders. M/O: Molybdenum oil (Molybdenum oil solution) I649G1140069-02 •…
• Page 88
  1D-20 Engine Mechanical: • When the “T” mark on the CKP rotor is aligned with the center of the CKP sensor, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the crankshaft sprocket and the exhaust camshaft sprocket.
• Page 89
  Engine Mechanical: 1D-21 “B” I649G1140073-02 “C” I649G1140074-02 24th pin 1st pin I649G1140075-03…
• Page 90
  1D-22 Engine Mechanical: • Each camshaft journal holder is identified with an embossed letter and install the dowel pins into each camshaft journal holder. I649G1140076-01 • Have the camshaft journal holders seated (IN and EX) evenly by tightening the camshaft journal holder bolts sequentially and in a crisscross pattern.
• Page 91
  I649G1140082-01 CKP Sensor Cover • Apply a bond lightly to the CKP sensor cover gasket mating surface as shown. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) I649G1140079-02 • Insert the spring into the cam chain tension adjuster and tighten the spring holder bolt (4) to the specified torque.
• Page 92
  Replace the cylinder head cover gasket (1) and oil nozzle gaskets (2) with new ones. • Apply a bond to the four camshaft end caps of the gasket as shown. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) I649G1140087-04 I649G1140351-01 •…

• Page 93: Valve Clearance Inspection And Adjustment

  Engine Mechanical: 1D-25 Cooling Hose • Install the left and right cooling hoses and tighten their mounting bolts to the specified torque. CAUTION Replace the O-rings (1) with new ones to prevent oil leakage. Tightening torque Cooling hose mounting bolt (a): 10 N·m (1.0 kgf- m, 7.0 lb-ft) I649G1140093-02 Valve Clearance Inspection and Adjustment…

• Page 94
  1D-26 Engine Mechanical: Camshaft Runout 3) Install each camshaft journal holder to its original Measure the runout using the dial gauge. Replace the position. Refer to “Engine Top Side Assembly: ”. camshaft if the runout exceeds the limit. 4) Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque.

• Page 95: Camshaft Sprocket Inspection

  Engine Mechanical: 1D-27 Camshaft journal holder I.D. (IN & EX) Camshaft Sprocket Removal and Installation B649G11406050 Standard: 22.012 – 22.025 mm (0.8666 – 0.8671 Removal 1) Remove the camshafts. Refer to “Engine Top Side Special tool Disassembly: ”. (E): 09900–20205 (Micrometer (0-25mm)) 2) Remove the camshaft sprockets (1).

• Page 96: Cam Chain Guide Removal And Installation

  1D-28 Engine Mechanical: 1) Apply THREAD LOCK SUPER “1303” to the threads Cam Chain Guide Removal and Installation B649G11406068 of the camshaft sprocket bolts and then tighten them Removal to the specified torque. 1) Remove the cylinder head cover. Refer to “Engine : Thread lock cement 99000–32030 (Thread Top Side Disassembly: ”.

• Page 97: Cam Chain Guide Inspection

  Installation Install The cam chain guides in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI THREAD LOCK SUPER “1303” to thread part and tighten the mounting bolt to the specified torque. : Thread lock cement 99000–32030 (Thread…

• Page 98: Cylinder Head Disassembly And Assembly

  1D-30 Engine Mechanical: Cylinder Head Disassembly and Assembly B649G11406054 Refer to “Engine Top Side Disassembly: ”. Refer to “Engine Top Side Assembly: ”. Disassembly 1) Remove the intake pipes. 2) Remove the rocker arm shaft set bolt (1) and cylinder head plug (2). I649G1140214-02 I649G1140212-02 3) Remove the rocker arm shaft (3), rocker arm (4) and…

• Page 99
  Engine Mechanical: 1D-31 Assembly 4) Insert the valves with their stems coated with molybdenum oil solution. 1) Locate the plate (1) on the cylinder head of exhaust Coat the entire stem making sure that there are no side. gaps. CAUTION When inserting each valve, take care not to damage the lip of the oil seal.
• Page 100
  Be sure to install all of the parts in their original positions. “E” “F” I649G1140227-02 10) Apply SUZUKI SUPER GREASE “A” to the O-ring of the intake pipe. CAUTION Use new O-rings to prevent the joints from I649G1140224-01 sucking air.

• Page 101: Cylinder Head Related Parts Inspection

  Engine Mechanical: 1D-33 11) Apply a small quantity of THREAD LOCK “1342” to Valve Stem Runout the thread of the intake pipe bolt. Support the valve using V-blocks, as shown, and check its runout using the dial gauge. If the runout exceeds the : Thread lock cement 99000–32050 (Thread service limit, replace the valve.

• Page 102
  1D-34 Engine Mechanical: Valve Face Wear NOTE Visually inspect each valve face for wear. Replace any If valve guides have to be removed for valve with an abnormally worn face. The thickness of the replacement after inspecting related parts, valve face decreases as the face wears. Measure the carry out the steps shown in valve guide valve face “a”.
• Page 103
  Engine Mechanical: 1D-35 Valve spring free length (IN & EX) Rocker Arm Inside Diameter Service limit: INNER: 35.0 mm (1.38 in) Measure the rocker arm inside diameter in two directions Service limit: OUTER: 37.8 mm (1.49 in) at right angle to each other. If the inside diameter measured exceeds the standard value, replace the Valve spring tension (IN &…

• Page 104: Valve Guide Replacement

  1D-36 Engine Mechanical: 4) Check that the transferred red lead (blue) on the WARNING valve face is uniform all around and in center of the Always use extreme caution when handling valve face. gasoline. If the seat width “a” measured exceeds the standard value, or seat width is not uniform reface the seat using the seat cutter.

• Page 105
  Engine Mechanical: 1D-37 4) Refinish the valve guide holes in the cylinder head Drive the guide into the guide hole using the valve using the reamer and handle. guide installer. CAUTION CAUTION When refinishing or removing the reamer Failure to oil the valve guide hole before from the valve guide hole, always turn it driving the new guide into place may result in clockwise.

• Page 106: Valve Seat Repair

  1D-38 Engine Mechanical: Valve Seat Repair Special tool B649G11406069 : 09900–20803 (Thickness gauge) The valve seats (1) for both the intake and exhaust Cylinder distortion valves are machined to two different angles. The seat Service limit: 0.2 mm (0.008 in) contact surface is cut at 45°.

• Page 107: Piston Ring Components

  Engine Mechanical: 1D-39 Piston Ring Components B649G11406071 1 [A] 2 [A] 1 [B] 2 [B] I649G1140362-02 1. 1st ring [A]: Standard piston ring 2. 2nd ring [B]: Oversize piston ring 3. Oil ring spacer [C]: Color (Red is standard) (Blue is 0.5 mm oversize) 4.

• Page 108
  1D-40 Engine Mechanical: Installation NOTE Face the side with the stamped mark “A” NOTE upward when assembling. • When installing the piston ring, be careful not to damage the piston. • Do not expand the piston ring excessively since it is apt to be broken down. “A”…
• Page 109
  Engine Mechanical: 1D-41 Piston-to-cylinder Clearance Piston Ring Free End Gap and Piston Ring End Gap Subtract the piston diameter from the cylinder bore Measure the piston ring free end gap using vernier diameter. If the piston-to-cylinder clearance exceeds the calipers. Next, fit the piston ring squarely into the service limit, replace both the cylinder and the piston.

• Page 110: Engine Bottom Side Disassembly

  1D-42 Engine Mechanical: Piston Pin and Pin Bore Engine Bottom Side Disassembly B649G11406005 Measure the piston pin bore inside diameter using the NOTE small bore gauge. If either is out of specification or the The crankcase must be separated to service difference between these measurement is more than the the crankshaft and conrod.

• Page 111
  Engine Mechanical: 1D-43 CKP Sensor / Oil Pressure Switch Gearshift 1) Remove the CKP sensor component parts (1). Refer 1) Remove the snap ring and washer from the gearshift to “CKP Sensor Removal and Installation: in Section shaft. 1H”. Special tool 2) Disconnect the oil pressure switch lead wire and : 09900–06107 (Snap ring pliers) remove the oil pressure switch (2).
• Page 112
  1D-44 Engine Mechanical: 2) Remove the washers (2), oil pump driven gear (3) 3) Remove the gear position switch (2). and pin (4). NOTE Be careful not to drop the circlip, pin and washers into the oil pan. I649G1140117-01 4) Remove the O-ring (3), switch contact (4) and spring (5).
• Page 113
  Engine Mechanical: 1D-45 2) Remove the plug (2). Remove the lower crankcase bolts and nut. 3) Remove the upper crankcase bolts and nut. I649G1140123-01 I649G1140120-02 4) Remove the oil pan (3). I649G1140124-01 9) Remove the main oil gallery plug (7) and O-ring. I649G1140121-03 5) Remove the shim (4) and O-ring (5).
• Page 114
  1D-46 Engine Mechanical: 12) Make sure that all of the bolts are removed. Then, Crankshaft tap the sides of the lower crankcase using a plastic 1) Remove the crankshaft assembly (1) from the upper mallet to separate the upper and lower crankcase crankcase.
• Page 115
  Engine Mechanical: 1D-47 Crankshaft Journal Bearing / Oil Jet (For the Piston Transmission Cooling) 1) Remove the countershaft assembly (1) and 1) Remove the crankshaft journal bearings. driveshaft assembly (2). CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.

• Page 116: Engine Bottom Side Assembly

  1D-48 Engine Mechanical: 4) Unhook the gearshift cam stopper spring (7) from the 7) Remove the gearshift cam stopper bolt (13). lower crankcase. I649G1140138-01 I649G1140135-01 Oil Pump / Oil Jet (For The Transmission) 5) Remove the snap ring (8) from the gearshift cam, 1) Remove the oil pump (1).

• Page 117
  Engine Mechanical: 1D-49 Oil Pump Transmission • Install the O-rings ((1) and (2)) and dowel pins (3) in • Install the gearshift cam stopper bolt (1). the correct position as shown. NOTE CAUTION Before installing the gearshift cam stopper bolt (1), apply a small quantity of THREAD Replace the O-rings with new ones to prevent LOCK “1342”…
• Page 118
  1D-50 Engine Mechanical: • Install the gearshift cam (3) and its related parts. • Install the gearshift forks into the crankcase in the correct position and direction. – Gearshift cam stopper (4) – For the 6th (Top) driven gear (8) –…
• Page 119
  Engine Mechanical: 1D-51 • Install the countershaft assembly (15) and driveshaft Crankshaft Journal Bearing assembly (16) into the upper crankcase. • When installing the crankshaft journal bearings into the upper and lower crankcases, be sure to install the NOTE tab “A” first, and then press in the opposite side of the bearing.
• Page 120
  1D-52 Engine Mechanical: Crankshaft • Install the crankshaft assembly along with the cam chain into the upper crankcase. • Install the O-rings ((1) and (2)). • Insert the right-and left-thrust bearings with the oil CAUTION grooves facing towards the crankshaft web. Replace the O-rings with new ones to prevent NOTE oil leakage.
• Page 121
  • Install the dowel pins in the upper crankcase. • Apply a bond to the mating surface of the lower crankcase as follows. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) NOTE • Make sure that the mating surfaces are free from moisture, oil, dust and other foreign materials.
• Page 122
  1D-54 Engine Mechanical: • Match the upper and lower crankcases. • Install the right oil return pipe (1) with the bolt “1”. • Install the copper washers onto bolts “9” and “11”. • Install the two allen bolts at position “A”. •…
• Page 123
  Engine Mechanical: 1D-55 CAUTION Use a new gasket washer to prevent oil leakage. I649G1140349-01 “B” I649G1140363-01 “C” I649G1140364-01 I649G1140358-01…
• Page 124
  1D-56 Engine Mechanical: • Install the left oil return pipe (6). • Install a new O-ring (7) and shim (8). • Install a new gasket and the oil sump filter (9). CAUTION Replace the gasket and O-ring with new ones to prevent oil leakage. I649G1140165-02 •…
• Page 125
  Engine Mechanical: 1D-57 • Apply a small quantity of THREAD LOCK “1342” to the two screws. : Thread lock cement 99000–32050 (Thread Lock Cement 1342 or equivalent) • Install the countershaft bearing retainer (12). I649G1140168-02 Gear Position Switch • Install the oil seal retainer (4) with the four bolts and then bend up the tabs on the retainer.
• Page 126
  1D-58 Engine Mechanical: Oil Pump Driven Gear • Install the washer and fix the gearshift shaft with the snap ring. • Install the washer (1), pin (2), oil pump driven gear (3) and washer (4). CAUTION Replace the snap ring with a new one. Special tool : 09900–06107 (Snap ring pliers) I649G1140178-01…
• Page 127
  Then, tighten the oil filter two full turns (or to specified torque) using the special tool. Replace the O-ring with a new one. NOTE : Grease 99000–25010 (SUZUKI SUPER • Before installing the oil filter, apply a light GREASE A or equivalent) coat of engine oil onto its O-ring.

• Page 128: Conrod Removal And Installation

  1D-60 Engine Mechanical: Conrod Removal and Installation NOTE B649G11406060 Inspect and select the conrod crank pin Removal bearing if necessary. Refer to “Conrod Crank 1) Remove the crankshaft assembly from the Pin Bearing Inspection and Selection: ”. crankcase. Refer to “Engine Bottom Side Disassembly: ”.

• Page 129: Conrod And Crankshaft Inspection

  Engine Mechanical: 1D-61 Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B649G11406064 and measure the conrod big end width and crank pin Refer to “Conrod Removal and Installation: ”. width. Refer to “Conrod Removal and Installation: ”. If any of the measurements are out of specification, Conrod Small End I.D.

• Page 130: Conrod Crank Pin Bearing Inspection And Selection

  1D-62 Engine Mechanical: Conrod Crank Pin Bearing Inspection and Selection B649G11406061 Refer to “Conrod Removal and Installation: ”. Inspection 1) Inspect the bearing surfaces for any signs of fusion, pitting, burn or flaws. If any, replace them with a specified set of bearings. “A”…

• Page 131
  Engine Mechanical: 1D-63 2) Check the corresponding crank pin O.D. code 4) Select the specified bearings from the bearing numbers ([1], [2] or [3]) “B”. selection table. CAUTION The bearings should be replaced as a set. Bearing selection table Crank pin O.D. “B” Code “B”…

• Page 132: Crankshaft Journal Bearing Inspection And Selection

  1D-64 Engine Mechanical: Crankshaft Journal Bearing Inspection and Selection B649G11406062 Refer to “Engine Bottom Side Disassembly: ”. “12” “2” “4” Refer to “Engine Bottom Side Assembly: ”. “8” “10” “6” Inspection 1) Inspect each upper and lower crankcase bearing for “9”…

• Page 133
  Engine Mechanical: 1D-65 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 Crankcase Green Black Brown…

• Page 134: Crankshaft Thrust Clearance Inspection And Selection

  1D-66 Engine Mechanical: Crankshaft Thrust Clearance Inspection and Selection Selection 1) Remove the right-side thrust bearing and measure B649G11406063 its thickness using the micrometer. If the thickness of Refer to “Engine Bottom Side Disassembly: ”. the right-side thrust bearing is below standard, Refer to “Engine Bottom Side Assembly: ”.

• Page 135
  Engine Mechanical: 1D-67 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-48B00-0E0) 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 136: Specifications

  1D-68 Engine Mechanical: Specifications Service Data B649G11407002 Valve + Guide Unit: mm (in) Item Standard Limit 28.5 (1.12) — Valve diameter 25 (1.0) — 0.10 – 0.15 (0.004 – 0.006) — Valve clearance (when cold) 0.18 – 0.23 (0.007 – 0.009) —…

• Page 137
  Engine Mechanical: 1D-69 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 875 kPa Compression pressure 1 250 kPa (12.5 kgf/cm , 178 psi) (8.75 kgf/cm , 124 psi) 200 kPa Compression pressure difference — (2 kgf/cm , 28 psi) Piston-to-cylinder clearance 0.050 –…

• Page 138: Tightening Torque Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G11408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent…

• Page 139
  Engine Mechanical: 1D-71 NOTE Required service material is also described in the following. “Engine Assembly Installation: ” Special Tool B649G11408002 09900–06106 09900–06107 Snap ring pliers Snap ring pliers 09900–20102 09900–20202 Vernier calipers (1/20 mm, Micrometer (1/100 mm, 25 — 200 mm) 50mm) 09900–20204 09900–20205…
• Page 140
  1D-72 Engine Mechanical: 09900–22302 09900–22403 Plastigauge (0.051 — 0.152 Small bore gauge (18- 35mm) 09915–40610 09915–63210 Oil filter wrench Compression gauge adaptor 09915–64510 09916–10911 Compression gauge set Valve lapper set 09916–14510 09916–14910 Valve spring compressor Valve lifter attachment 09916–34542 09916–34570 Reamer handle Valve guide reamer (4.95 09916–34580…

• Page 141: Engine Lubrication System

  Engine Lubrication System: 1E-1 Engine Lubrication System Precautions Precautions for Engine Oil B649G11500001 Refer to “Fuel and Oil Recommendation: in Section 0A”. Schematic and Routing Diagram Engine Lubrication Circuit Diagram B649G11502002 I649G1150002-01…

• Page 142: Engine Lubrication System Chart Diagram

  1E-2 Engine Lubrication System: Engine Lubrication System Chart Diagram B649G11502001 EXHAUST EXHAUST CAMSHAFT INTAKE CAMSHAFT INTAKE CAM FACES JOURNALS JOURNALS CAM FACES EXHAUST EXHAUST ROCKER INTAKE ROCKER INTAKE ROCKER ARMS ARM SHAFTS ARM SHAFTS ROCKER ARMS CAM CHAIN CONROD SMALL END NO.1 PISTON NO.2 PISTON NO.3 PISTON…

• Page 143: Engine Lubrication Symptom Diagnosis

  Engine Lubrication System: 1E-3 Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B649G11504004 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 144: Repair Instructions

  1E-4 Engine Lubrication System: 6) Stop the engine and remove the oil pressure gauge Tightening torque and attachment. Main oil gallery plug: 40 N·m (4.0 kgf-m, 29.0 lb- 7) Reinstall the main oil gallery plug and tighten it to the specified torque.

• Page 145: Oil Pressure Regulator Inspection

  Engine Lubrication System: 1E-5 Installation 4) Install a new gasket and the oil pan. Tighten the oil pan bolts to the specified torque. 1) Tighten the oil pressure regulator to the specified torque. CAUTION Tightening torque Replace the oil pan gasket and gasket Oil pressure regulator (a): 28 N·m (2.8 kgf-m, washer with new ones to prevent oil leakage.

• Page 146: Oil Pan / Oil Sump Filter Cleaning

  I649G1150010-01 Oil Pan Wash the oil pan with kerosine. I649G1150013-01 Installation 1) Install the oil pressure switch, apply the SUZUKI BOND to its thread and tighten it to the specified torque. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0…

• Page 147: Oil Pressure Switch Inspection

  Installation is in the reverse order of removal. Refer to NOTE “Engine Top Side Assembly: in Section 1D”. The SUZUKI BOND should be applied to the Pay attention to the following points: groove of the CKP sensor lead wire grommet NOTE (1).

• Page 148: Oil Pump Removal And Installation

  1E-8 Engine Lubrication System: Installation Oil Pump Removal and Installation B649G11506030 Installation is in the reverse order of removal. Refer to “Oil Pump / Oil Pressure Regulator Removal Pay attention to the following point: and Installation: in Section 1F”. NOTE Oil Pump Inspection Before installing the oil jets, apply a light coat B649G11506031…

• Page 149: Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G11508001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140 Special Tool B649G11508002 09915–74521…

• Page 150: Precautions

  1F-1 Engine Cooling System: Engine Cooling System Precautions Engine Cooling System Warning B649G11600001 WARNING To avoid the danger of being burned, do not touch the oil cooling system when the system is hot. Any service on the oil cooling system should be performed when the system is cool. Precautions for Engine Oil B649G11600002 Refer to “Fuel and Oil Recommendation: in Section 0A”.

• Page 151: General Description

  Engine Cooling System: 1F-2 General Description Engine Cooling System Description B649G11601005 • To cool the engine, engine oil is jet-sprayed to the combustion chamber area of the cylinder head where temperature is the highest. • Oil discharged from the oil pump is sent to the cylinder head cover through the cooling hoses located in the center area of upper crankcase and enters the drilled passage in the cylinder head cover.

• Page 152: Cylinder Head Cooling System Chart Diagram

  1F-3 Engine Cooling System: Schematic and Routing Diagram Cylinder Head Cooling System Chart Diagram B649G11602003 I649G1160002-02…

• Page 153: Engine Cooling Symptom Diagnosis

  Engine Cooling System: 1F-4 Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B649G11604003 Condition Possible cause Correction / Reference Item Engine overheats. Carbon build-up on piston crown. Clean. Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace.

• Page 154: Repair Instructions

  1F-5 Engine Cooling System: Repair Instructions Engine Cooling System Components B649G11606037 “A” I649G1160027-02 1. Cooling oil hose mounting bolt 9. O-ring 17. Upper oil return pipe (LH) 2. O-ring 10. Gasket 18. Upper oil return pipe (RH) 3. Cooling oil hoses 11.

• Page 155: Oil Cooler And Oil Cooler Hose Components

  Engine Cooling System: 1F-6 Oil Cooler and Oil Cooler Hose Components B649G11606038 I649G1160028-01 1. Oil cooler mounting bolt 5. Oil cooler hose (RH) : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Oil cooler 6. Gasket washer : 28 N⋅m (2.8 kgf-m, 20.0 lb-ft) 3.

• Page 156: Oil Cooler And Oil Cooler Hose Construction

  1F-7 Engine Cooling System: Oil Cooler and Oil Cooler Hose Construction B649G11606028 I649G1160003-04 : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) : Apply THREAD LOCK “1322” to thread part : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Do not reuse.

• Page 157: Oil Cooler / Oil Cooler Hose Removal And Installation

  Engine Cooling System: 1F-8 Oil Cooler / Oil Cooler Hose Removal and 5) Remove the oil cooler hoses (2) and O-rings from the oil cooler. Installation B649G11606030 Removal 1) Drain engine oil. Refer to “Engine Oil and Filter Replacement: in Section 0B”. 2) Remove the oil cooler hose union bolts (1) and gasket washers.

• Page 158: Engine Cooling Hose Removal And Installation

  1F-9 Engine Cooling System: • Apply THREAD LOCK SUPER “1322” to the oil cooler Engine Cooling Hose Removal and Installation B649G11606029 hose bracket bolts. : Thread lock cement 99000–32110 (Thread Removal Lock Cement Super 1322 or equivalent) 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation: in Section 1G”.

• Page 159: Oil Pump / Oil Pressure Regulator Removal And Installation

  Engine Cooling System: 1F-10 Oil Pump / Oil Pressure Regulator Removal and • Install the O-rings ((1) and (2)) and dowel pins (3) in Installation the correct position as shown. B649G11606031 Removal 1) Separate the crankcases, upper and lower. Refer to “Engine Bottom Side Disassembly: in Section 1D”.

• Page 160: Oil Return Pipe (Cylinder Side) Removal And Installation

  1F-11 Engine Cooling System: Installation Oil Cooler Hose Install the oil nozzle in the reverse order of removal. Inspect the oil cooler hoses for damage and oil leaks. If Pay attention to the following point: any defects are found, replace the oil cooler hose(-s) with a new one.

• Page 161: Oil Cooler Cleaning

  Engine Cooling System: 1F-12 3) Remove the oil pressure regulator from the oil pump. Oil Cooler Cleaning B649G11606036 4) Check the operation of the oil pressure regulator by Blow out any foreign matter that is stuck in the oil cooler pushing on the piston with an appropriately sharped fins using compressed air.

• Page 162: Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G11608001 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement 1342 or P/No.: 99000–32050 equivalent Thread Lock Cement Super 1322 or P/No.: 99000–32110…

• Page 163: Fuel System

  Fuel System: 1G-1 Fuel System Precautions Precautions for Fuel System B649G11700001 WARNING Gasoline is highly flammable and explosive. Extreme care must be taken. Keep heat, sparks and flames away from gasoline.

• Page 164: General Description

  1G-2 Fuel System: General Description I.D. No. Location B649G11701001 Each carburetor has an I.D. number “A” printed on its body. “A” I649G1170001-01 Fuel System Description B649G11701002 Fuel System The fuel system consists of a fuel tank, fuel filter, fuel valve, vacuum hose, fuel hose and carburetor assembly. When there is negative pressure (vacuum) in the combustion chamber, the fuel is able to flow from the fuel tank, through the fuel valve and then to the carburetor assembly.

• Page 165
  Fuel System: 1G-3 Fuel Valve When the engine is not operating, the fuel valve (1) is kept closed by the tension of the spring (2), which closes the fuel passageway and stops the flow of fuel to the carburetors. When the engine has started, negative pressure (vacuum) “A” is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor’s main bore and the vacuum hose.
• Page 166
  1G-4 Fuel System: Diaphragm and Piston Operation The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve (1). The piston valve moves according to the negative pressure present on the downstream side of the venturi “A”.
• Page 167
  Fuel System: 1G-5 Slow System This system supplies fuel during engine operation when the throttle valve (1) is closed or slightly opened. The fuel from the float chamber (2) is metered by the pilot jet (3) where it mixes with air coming in through the pilot air jet (4). This mixture, rich with fuel, then goes up through the pilot passage to the pilot screw (5).
• Page 168
  1G-6 Fuel System: Main System As the throttle valve (1) is opened, engine speed rises and negative pressure in the venturi “A” increases. This causes the piston valve (2) to move upward. The fuel in the float chamber (3) is metered by the main jet (4). The metered fuel enters the needle jet (5), mixes with the air admitted through the main air jet (6) and forms an emulsion.
• Page 169
  Fuel System: 1G-7 Starter (Enricher) System Pulling the starter (enricher) plunger causes fuel to be drawn into the starter circuit from the float chamber (1). The starter jet (2) meters this fuel. The fuel then flows into the fuel pipe (3) and mixes with the air coming from the float chamber (1).
• Page 170
  1G-8 Fuel System: Float System The float (1) and needle valve (2) work in conjunction with one another. As the float (1) moves up and down, so does the needle valve (2). When there is a high fuel level in the float chamber (3), the float (1) rises and the needle valve (2) pushes up against the valve seat.

• Page 171: Schematic And Routing Diagram

  Fuel System: 1G-9 Schematic and Routing Diagram Carburetor Hose Routing Diagram B649G11702002 Engine side Air cleaner side 5 — 15 5 — 15 RH LH I649G1170009-02 1. Fuel hose (Connected to the carburetor and fuel valve) 5. Air vent hose (RH) 9.

• Page 172: Fuel Tank Drain Hose And Breather Hose Routing Diagram

  1G-10 Fuel System: Fuel Tank Drain Hose and Breather Hose Routing Diagram B649G11702005 I649G1170010-02 1. Fuel tank drain hose 5. Air cleaner drain hose 2. Fuel tank breather hose No.1 6. Hoses : Be careful not to bind the fuel tank drain hose and fuel tank breather hose with the other hoses and wire harness.

• Page 173: Throttle Cable / Starter Cable Routing Diagram

  Fuel System: 1G-11 Throttle Cable / Starter Cable Routing Diagram B649G11702004 3 — 5 mm (0.12 — 0.20 in) “A” 3, [C] “B” 0 mm (0 in) 0 mm (0 in) 3, [C] 3, [C] “a” I649G1170011-06 1. No.1 throttle cable 6.

• Page 174: Diagnostic Information And Procedures

  1G-12 Fuel System: Diagnostic Information and Procedures Carburetor Symptom Diagnosis B649G11704001 Condition Possible cause Correction / Reference Item Starting difficulty. Clogged starter jet. Clean. Clogged starter jet passage. Clean. Air leaking from joint between starter Tighten, adjust or replace gasket. body and carburetor.

• Page 175: Repair Instructions

  Fuel System: 1G-13 Repair Instructions Fuel Tank Construction B649G11706018 “A” I649G1170013-03 1. Fuel valve 5. Rear bracket cushion : Be careful not to mistake the assembling position and direction. 2. Gasket washer “A”: Apply adhesive agent to the cushion rubber. 3.

• Page 176: Fuel Tank Removal And Installation

  1G-14 Fuel System: Fuel Tank Removal and Installation Installation B649G11706019 Install the fuel tank in the reverse order of removal. Pay attention to the following point: Removal CAUTION WARNING Be careful not to bend the hoses. Gasoline is highly flammable and explosive. Keep heat, sparks and flames away from Fuel Valve Removal and Installation gasoline.

• Page 177: Fuel Filter Inspection And Cleaning

  Fuel System: 1G-15 Fuel Level Gauge Removal and Installation • Tighten the fuel valve mounting bolts to the specified B649G11706022 torque. Removal Tightening torque WARNING Fuel valve mounting bolt (a): 4.4 N·m (0.44 kgf-m, 3.2 lb-ft) Gasoline is very explosive. Extreme care must be taken.

• Page 178: Fuel Level Gauge Inspection

  Routing Diagram: ”. 3) Remove the throttle cables as shown in the cable routing diagram. Refer to “Throttle Cable / Starter • Apply SUZUKI SUPER GREASE “A” to the starter Cable Routing Diagram: ”. cable and cable pulley. : Grease 99000–25010 (SUZUKI SUPER…

• Page 179: Carburetor Components

  Fuel System: 1G-17 Carburetor Components B649G11706001 Carburetor Related Parts I649G1170027-02 1. Air vent hose 8. Throttle position sensor : 5.0 N⋅m (0.5 kgf-m, 3.5 lb-ft) 2. Fuel joint pipe (No.1) 9. Carburetor set shaft : 2.0 N⋅m (0.2 kgf-m, 1.5 lb-ft) 3.

• Page 180
  1G-18 Fuel System: Carburetor Parts I649G1170077-01 1. Top cap 8. Spacer 15. Needle valve assembly 22. Starter jet 2. Spring 9. Jet needle 16. Float 23. Gasket (O-ring) 3. Jet needle stopper 10. Diaphragm 17. Needle jet 24. Float chamber 4.

• Page 181: Carburetor Assembly Removal And Installation

  Fuel System: 1G-19 Carburetor Assembly Removal and Installation 7) Disconnect the carburetor heater lead wire coupler B649G11706002 (2). (For E-02, 19) Remove the thermo-switch (3). (For E-02, 19) Removal 1) Remove the seat and frame covers. Refer to “Exterior Parts Removal and Installation: in Section 9D”.

• Page 182: Carburetor Disassembly

  1G-20 Fuel System: • After all of the work has been completed, install the 1) Disconnect the fuel hose (1). carburetor assembly onto the engine and perform the 2) Disconnect the air vent hoses (2). following adjustments. 3) Disconnect the carburetor heater terminal lead wires –…

• Page 183
  Fuel System: 1G-21 7) Remove the top cap (5). 11) Remove the starter (enricher) plunger assembly (14). CAUTION Do not use compressed air on the carburetor body, before removing the diaphragm; this may damage the diaphragm. I649G1170041-01 CAUTION Never remove the throttle valve (15). I649G1170038-01 Remove the spring (6) and the piston valve along with its diaphragm (7).
• Page 184
  1G-22 Fuel System: 13) Remove the float chamber (18). 17) Remove the following parts. 14) Remove the carburetor heater (19). (For E-02, 19) • Main jet (24) • Needle jet (25) • Pilot jet (26) • Pilot screw (27) (with tampering plug type) •…

• Page 185: Carburetor Assembly

  • Apply thin coat of the grease to each new O-ring. carburetor heater. (For E-02, 19) : Grease 99000–59029 (THERMO-GREASE or CAUTION equivalent) Replace the O-rings with new ones. Tightening torque Carburetor heater: 3.0 N·m (0.3 kgf-m, 2.0 lb-ft) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1170052-01 I649G1170049-01…

• Page 186: Float Height Inspection And Adjustment

  • Before installing the top cap, install the new O-ring. • Apply thin coat of the grease to the fuel joint pipe O- rings and seals. CAUTION : Grease 99000–25010 (SUZUKI SUPER Replace the O-ring with a new one. GREASE A or equivalent) CAUTION Replace the O-rings and seals with new ones.

• Page 187: Carburetor Inspection And Cleaning

  Fuel System: 1G-25 5) Measure the float height “a” while the float arm is just • Piston valve contacting the needle valve using vernier calipers. • Starter (enricher) jet Bend the tongue “A” as necessary to bring the float • Gasket and O-ring height “a”…

• Page 188: Carburetor Heater Inspection (For

  1G-26 Fuel System: 2) Clean all circuits of the carburetor thoroughly – not Thermo-switch (For E-02, 19) just the perceived problem area. 1) Remove the fuel tank. Refer to “Fuel Tank Removal 3) Clean the circuits in the carburetor body with a and Installation: ”.

• Page 189: Tp Sensor Replacement

  Fuel System: 1G-27 2) Measure the resistance between the terminals “A” to 2) Temporary install the TP sensor. “C” as shown. 3) Measure the resistance between the TP sensor If the resistance is not within the specified value, terminals “A” to “C” as shown. replace the TP sensor.

• Page 190: Carburetor Synchronization

  1G-28 Fuel System: 6) Under above condition, position the TP sensor until 4) Start up the engine and run it in idling condition for resistance is 2.66 – 4.94 kΩ. warming up. 7) When the resistance is within specification, tighten 5) Stop the warmed-up engine.

• Page 191: Engine Idle Speed Inspection

  Fuel System: 1G-29 11) Check the vacuum of the four cylinders. 13) After balancing the carburetor, set the engine speed by turning the throttle stop screw. Engine idle speed 1 300 ± 100 r/min (E-28) 1 200 ± 100 r/min (Others) 14) Remove the digital vacuum tester, tachometer and fuel bottle.

• Page 192: Specifications

  1G-30 Fuel System: Specifications Service Data B649G11707004 Carburetor Specification Item E-02, 19, 24 E-28 ← Carburetor type MIKUNI BSR36 ← Bore size 36 mm (1.42 in) I.D. No. 49G0 49G1 1 200 ± 100 r/min 1 300 ± 100 r/min Idle r/min.

• Page 193: Special Tools And Equipment

  Fuel System: 1G-31 Special Tools and Equipment Recommended Service Material B649G11708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent THERMO-GREASE or equivalent P/No.: 99000–59029 NOTE Required service material is also described in the following.

• Page 194: Ignition System

  1H-1 Ignition System: Ignition System Schematic and Routing Diagram Ignition System Diagram B649G11802001 The fully transistorized ignition system consists of the following components: a CKP sensor (which is made up of the CKP sensor rotor and CKP sensor), ignitor, throttle position sensor, two ignition coils and four spark plugs. The ignition timing is programmed and stored in the ignitor’s ROM (Read Only Memory).

• Page 195: Diagnostic Information And Procedures

  Ignition System: 1H-2 Diagnostic Information and Procedures Ignition System Symptom Diagnosis B649G11804005 Condition Possible cause Correction / Reference Item Spark plug not sparking Damaged spark plug. Replace. Damaged spark plug cap. Replace. Fouled spark plug. Clean or replace. Wet spark plug. Clean and dry or replace.

• Page 196: No Spark Or Poor Spark

  1H-3 Ignition System: No Spark or Poor Spark B649G11804001 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 197: Repair Instructions

  Ignition System: 1H-4 Repair Instructions Ignition Coil and Spark Plug Cap Components B649G11806007 I649G1180002-04 1. Frame 2. Plug cap cover 3. Plug cap Spark Plug Removal and Installation NOTE B649G11806017 Be sure that all the spark plugs are Refer to “Spark Plug Removal and Installation: in connected properly and the battery used is in Section 0B”.

• Page 198
  1H-5 Ignition System: 4) Connect the multi-circuit tester with the peak voltage 5) Measure the ignition coil primary peak voltage in the adaptor as follows. following procedure. a) Shift the transmission into neutral, turn the CAUTION ignition switch to the “ON” position and grasp the Before using the multi-circuit tester and peak clutch lever.

• Page 199: Ignition Coil Assembly Removal And Installation

  Ignition System: 1H-6 4) Measure the ignition coil resistance in both the Spark Plug Removal and Installation B649G11806016 primary and secondary windings. If the windings are Refer to “Spark Plug Inspection and Cleaning: in in sound condition, their resistance should be close Section 0B”.

• Page 200
  1H-7 Ignition System: 3) Connect the multi-circuit tester with the peak volt 6) If the peak voltage measured on the ignitor coupler is adaptor as follows. lower than the standard value, measure the peak voltage on the CKP sensor coupler as follows. CAUTION a) Remove the left frame cover.

• Page 201: Ckp Sensor Removal And Installation

  Ignition System: 1H-8 d) Measure the CKP sensor peak voltage in the CKP Sensor Removal and Installation B649G11806012 same manner as on the ignitor coupler. Removal If the peak voltage on the CKP sensor lead wire 1) Remove the left frame cover. Refer to “Exterior Parts couplers is within specification, but on the ignitor Removal and Installation: in Section 9D”.

• Page 202
  : Sealant 99000–31140 (SUZUKI Bond NOTE 1207B or equivalent) The SUZUKI BOND should be applied to the groove of the CKP sensor lead wire grommet (2). : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) “B”…

• Page 203: Engine Stop Switch Inspection

  Ignition System: 1H-10 • Apply a small quantity of THREAD LOCK “1342” to 3) Inspect the engine stop switch for continuity with a the CKP sensor cover bolts. tester. If any abnormality is found, replace the right : Thread lock cement 99000–32050 (Thread handlebar switch assembly with a new one.

• Page 204: Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G11808001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140 Thread lock cement Thread Lock Cement 1342 or P/No.: 99000–32050…

• Page 205: Starting System

  Starting System: 1I-1 Starting System General Description Starting System Diagram B649G11901001 Refer to “Wire Color Symbols: in Section 0A”. The starter system consists of the following components: the starter motor, starter relay, clutch lever position switch, turn signal/side-stand relay, side-stand switch, gear position switch, starter button, engine stop switch, ignition switch and battery.

• Page 206
  1I-2 Starting System: The circuit consists of the turn signal/side-stand relay, neutral indicator light and switches. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down.

• Page 207: Schematic And Routing Diagram

  Starting System: 1I-3 Schematic and Routing Diagram Starting System Diagram B649G11902001 Refer to “Wire Color Symbols: in Section 0A”. Ignition Engine stop switch switch Fuse (30 A) Bl/B Gear B/Bl Fuse position Starter Starter (15 A) switch button motor Starter relay Turn signal/ side-stand relay Clutch lever…

• Page 208: Starter Motor Will Not Run

  1I-4 Starting System: Starter motor will not run B649G11904001 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 209: Repair Instructions

  Starting System: 1I-5 Repair Instructions Starter Motor Components B649G11906013 I649G1190005-03 1. O-ring 6. Armature 11. Starter motor lead wire nut : 6.5 N⋅m (0.65 kgf-m, 4.7 lb-ft) 2. Housing end (Inside) 7. Washer set 12. Starter motor mounting bolt : Apply grease to sliding surface. 3.

• Page 210: Starter Motor Removal And Installation

  Install the starter motor in the reverse order of removal. Refer to “Electrical Components Location: in Section Pay attention to the following points: 0A”. • Apply SUZUKI SUPER GREASE “A” to the starter motor O-ring. Removal : Grease 99000–25010 (SUZUKI SUPER 1) Disconnect the battery (–) lead wire.

• Page 211: Starter Motor Disassembly And Assembly

  Replace the O-rings with new ones to prevent oil leakage and moisture. : Thread lock cement 99000–32050 (Thread Lock Cement 1342 or equivalent) • Apply SUZUKI SUPER GREASE “A” to the lip of the Tightening torque oil seal. Starter motor housing bolt (a): 6.5 N·m (0.65 kgf- : Grease 99000–25010 (SUZUKI SUPER…

• Page 212: Starter Motor Inspection

  1I-8 Starting System: Starter Motor Inspection Armature Coil B649G11906003 Measure for continuity between each segment. Measure Refer to “Starter Motor Disassembly and Assembly: ”. for continuity between each segment and the armature shaft. Carbon Brush If there is no continuity between the segments or there is Inspect the carbon brushes for abnormal wear, cracks or continuity between the segments and shaft, replace the smoothness in the brush holder.

• Page 213: Starter Relay Removal And Installation

  Starting System: 1I-9 Starter Relay Removal and Installation Starter Relay Inspection B649G11906014 B649G11906015 Refer to “Electrical Components Location: in Section Inspect the starter relay in the following procedures: 0A”. 1) Remove the starter relay. Refer to “Starter Relay Removal and Installation: ”. Removal 2) Apply 12 V to “A”…

• Page 214: Turn Signal / Side-Stand Relay Removal And Installation

  1I-10 Starting System: 3) Measure the relay coil resistance between the Side-stand / Ignition Interlock System Parts terminals using the multi-circuit tester. If the Inspection resistance is not within the specified value, replace B649G11906017 Refer to “Electrical Components Location: in Section the starter relay with a new one.

• Page 215
  Starting System: 1I-11 4) Connect the side-stand switch coupler. Diode inspection 1) Remove the turn signal/side-stand relay. Refer to 5) Install the left frame cover. Refer to “Exterior Parts Removal and Installation: in Section 9D”. “Turn Signal / Side-stand Relay Removal and Installation: ”.

• Page 216: Starter Clutch Components

  1I-12 Starting System: 3) Check the continuity between Blue and Black/White Starter Clutch Components B649G11906018 lead wires with the transmission in “NEUTRAL”. CAUTION When disconnecting and connecting the gear position switch coupler, make sure to turn off the ignition switch, or electronic parts may get damaged.

• Page 217
  Starting System: 1I-13 4) Remove the idle gear shaft (1) and starter idle gear Installation (2). Install the starter clutch assembly in the reverse order of removal. Pay attention to the following points: • Remove the grease from the tapered portion of the starter clutch and crankshaft.

• Page 218: Starter Clutch Inspection

  If any wear or damage is found, replace the defective part(-s). I649G1190039-01 • Apply a light coat of SUZUKI BOND to the starter clutch cover gasket mating surface as shown. : Sealant 99000–31140 (SUZUKI Bond…

• Page 219: Starter Button Inspection

  Starting System: 1I-15 Starter Button Inspection 3) Inspect the starter button for continuity with a tester. B649G11906021 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.

• Page 220: Specifications

  1I-16 Starting System: Specifications Service Data B649G11907002 Unit: mm (in) Item Specification Note Standard 12.5 (0.49) Starter motor brush length Limit 6.0 (0.24) 3 – 6 Ω Starter relay resistance Tightening Torque Specifications B649G11907003 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Starter motor mounting bolt…

• Page 221: Special Tools And Equipment

  Starting System: 1I-17 Special Tools and Equipment Recommended Service Material B649G11908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140 Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140…

• Page 222: Charging System

  1J-1 Charging System: Charging System General Description Charging System Description (Generator with IC Regulator) B649G11A01001 The generator features a solid-state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator voltage setting cannot be adjusted.

• Page 223: Component Location

  Charging System: 1J-2 Component Location Charging System Components Location B649G11A03001 Refer to “Electrical Components Location: in Section 0A”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B649G11A04009 Condition Possible cause Correction / Reference Item Generator does not Open- or short-circuited lead wires, or Repair, replace or connect properly.

• Page 224: Battery Runs Down Quickly

  1J-3 Charging System: Battery Runs Down Quickly B649G11A04001 Troubleshooting Step Action Check accessories which use excessive amounts of Remove accessories. Go to Step 2. electricity. Are accessories being installed? Check the battery for current leakage. Refer to “Battery Go to Step 3. •…

• Page 225: Repair Instructions

  Charging System: 1J-4 Repair Instructions Battery Current Leakage Inspection Regulated Voltage Inspection B649G11A06001 B649G11A06002 Inspect the battery current leakage in the following NOTE procedures: When making this test, be sure that the 1) Turn the ignition switch to the OFF position. battery is in fully charged condition.

• Page 226: Generator Components

  1J-5 Charging System: Generator Components B649G11A06010 I649G11A0004-07 1. Generator driven gear 9. Stud bolt 17. IC regulator : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Damper (4 pcs.) 10. Retainer 18. Brush holder : 4.5 N⋅m (0.45 kgf-m, 3.25 lb-ft) 3.

• Page 227: Generator Removal And Installation

  4) Disconnect the generator lead wire (2) and coupler • Before installing the engine sprocket cover, apply a (3). small quantity of SUZUKI SUPER GREASE “A” to the 5) Remove the generator (4). clutch push rod. : Grease 99000–25010 (SUZUKI SUPER…

• Page 228: Generator Disassembly And Assembly

  1J-7 Charging System: Generator Disassembly and Assembly 4) Remove the brush holder (3) and IC regulator (4). B649G11A06011 Refer to “Generator Removal and Installation: ”. Disassembly 1) Hold the generator driven gear using a vise “A” and two pieces of wood “B” as shown. Then, remove the generator driven gear nut.

• Page 229
  I649G11A0018-03 • Replace the O-ring with a new one. 12) Remove the bearing retainer (12). • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)
• Page 230
  1J-9 Charging System: • Apply a small quantity of THREAD LOCK “1342” to NOTE the bearing retainer screws and tighten them to the Before reinstalling the slip ring side bearing specified torque. onto the generator end housing, turn the expander ring and align the expander ring lug : Thread lock cement 99000–32050 (Thread “C”…

• Page 231: Generator Parts Inspection

  Generator driven gear nut (c): 55 N·m (5.5 kgf-m, 4.0 lb-ft) NOTE When installing the generator driven gear NOTE dampers, apply SUZUKI MOLY PASTE to the After tightening the generator driven gear nut damper surface. to the specified torque, stake the nut using a punch.

• Page 232
  1J-11 Charging System: Rotor Coil Continuity Check Measure the continuity between the two slip rings (1) on the rotor coil using a tester. If there is no continuity, replace the rotor. “a ” Also check that the rotor is properly insulated. I649G11A0035-02 Rectifier Measure the voltage among the terminal (1) and the…

• Page 233: Battery Components

  Charging System: 1J-12 Battery Charging IC Regulator B649G11A06013 Measure the voltage between terminal “F” and terminal Initial Charging “B”. If the voltage measured is excessively out of Filling electrolyte specification, replace the IC regulator. NOTE Special tool (A): 09900–25008 (Multi-circuit tester set) When filling electrolyte, the battery must be removed from the vehicle and must be put on Tester knob indication…

• Page 234
  1J-13 Charging System: 3) Insert the nozzles of the electrolyte container (3) into 6) After confirming that the electrolyte has entered the the electrolyte filler holes of the battery. battery completely, remove the electrolyte containers from the battery. 4) Hold the electrolyte container firmly so that it does not fall.
• Page 235
  Charging System: 1J-14 Charging 3) After recharging, wait at least 30 minutes and then For initial charging, use the charger specially designed measure the battery voltage using the multi-circuit for MF battery. tester. If the battery voltage is less than 12.5 V, recharge CAUTION the battery again.

• Page 236: Battery Removal And Installation

  1J-15 Charging System: Battery Removal and Installation Battery Visual Inspection B649G11A06014 B649G11A06017 Refer to “Electrical Components Location: in Section Inspect the battery in the following procedures: 0A”. 1) Remove the seat. Refer to “Exterior Parts Removal and Installation: in Section 9D”. Removal 2) Visually inspect the surface of the battery container.

• Page 237: Specifications

  Charging System: 1J-16 Specifications Service Data B649G11A07001 Battery CAUTION Never use anything except the specified battery. Item Specification Note Type designation FT12A-BS Capacity 12V, 36.0 kC (10 Ah)/10HR 1.320 at 20 °C (68 °F) Standard electrolyte S.G. Generator Item Specification Note Generator maximum output More than 550 W at 5 000 r/min.

• Page 238: Special Tools And Equipment

  1J-17 Charging System: Special Tools and Equipment Recommended Service Material B649G11A08001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140 Thread lock cement Thread Lock Cement 1342 or P/No.: 99000–32050…

• Page 239: Exhaust System

  Exhaust System: 1K-1 Exhaust System Precautions Precautions for Exhaust System B649G11B00001 WARNING To avoid the danger 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 pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

• Page 240: Exhaust Pipe / Muffler Removal And Installation

  1K-2 Exhaust System: Exhaust Pipe / Muffler Removal and Installation Installation B649G11B06005 Installation is in the reverse order of removal. Pay attention to the following points: Removal CAUTION 1) Loosen the muffler connecting bolt (1). 2) Remove the muffler by removing the mounting bolts Replace the gaskets with new ones.

• Page 241: Exhaust System Inspection

  Exhaust System: 1K-3 • Tighten the exhaust pipe bolts, muffler connecting bolt Exhaust System Inspection B649G11B06006 and muffler mounting bolts to the specified torque. Inspect the exhaust pipe connection and muffler Tightening torque connection for exhaust gas leakage and mounting Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb- condition.

• Page 242: Specifications

  For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”. Special Tools and Equipment Recommended Service Material B649G11B08001 Material SUZUKI recommended product or Specification Note Exhaust gas sealer PERMATEX 1372 (commercial — available)

• Page 243
  Table of Contents 2- i Section 2 Suspension CONTENTS Precautions ……….2-1 Swingarm Bearing Removal and Installation ..2C-10 Specifications ………….2C-12 Precautions…………. 2-1 Service Data…………2C-12 Precautions for Suspension ……..2-1 Tightening Torque Specifications……2C-12 Suspension General Diagnosis….2A-1 Special Tools and Equipment ……2C-13 Recommended Service Material …….2C-13 Diagnostic Information and Procedures….2A-1 Special Tool …………2C-13…

• Page 244: Precautions

  2-1 Precautions: Precautions Precautions Precautions for Suspension B649G12000001 Refer to “General Precautions: in Section 00”. 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 245: Suspension General Diagnosis

  Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B649G12104009 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

• Page 246: Front Suspension

  2B-1 Front Suspension: Front Suspension Repair Instructions Front Fork Components B649G12206001 I649G1220038-04 1. Front fork protector 8. Gasket 15. Spring adjuster 22. Spring 2. Dust seal 9. Damper rod bolt 16. Front fork cap bolt : 20 N⋅m (2.0 kgf-m, 14.5 lb-ft) 3.

• Page 247: Front Fork Removal And Installation

  Front Suspension: 2B-2 Front Fork Removal and Installation 6) Loosen the front fork lower clamp bolts (6) and B649G12206002 remove the front fork. Removal NOTE 1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation: in Hold the front fork by the hand to prevent Section 2D”.

• Page 248: Front Fork Disassembly And Assembly

  2B-3 Front Suspension: 4) Tighten the front fork lower clamp bolts. 7) Remount the front fender along with the fender plate nut. Tightening torque Install the front wheel assembly. Refer to “Front Front fork lower clamp bolt (b): 23 N·m (2.3 kgf- Wheel Assembly Removal and Installation: in m, 16.5 lb-ft) Section 2D”.

• Page 249
  Front Suspension: 2B-4 2) Remove the spring seat (2). Remove the oil seal stopper ring (9). 3) Remove the front fork cap bolt with spring adjuster (3) by loosening the inner rod lock-nut (4). I649G1220014-02 9) Remove the damper rod bolt (10). I649G1220040-01 4) Remove the spacer (5), washer (6) and spring (7).
• Page 250
  12) Remove the oil seal by slowly pulling out the inner • Apply fork oil to the outer slide metal and oil seal lip. tube. : Oil 99000–99001–SS8 (SUZUKI FORK OIL SS-08 or equivalent) NOTE Be careful not to damage the inner tube.
• Page 251
  Make sure that the oil seal stopper ring is • Pour specified front fork oil up to the top level of the fitted securely. inner tube. : Oil 99000–99001–SS8 (SUZUKI FORK OIL • Install the dust seal (5). SS-08 or equivalent) Capacity (each leg) 516 ml (17.4/18.2 US/lmp oz)
• Page 252
  2B-7 Front Suspension: • Refill specified front fork oil up to the top level of the Fork spring inner tube again. Move the inner tube up and down • Install the fork spring as shown. several strokes until bubbles do not come out from the NOTE oil.

• Page 253: Front Fork Inspection

  Use a new O-ring (3) to prevent oil leakage. • Apply fork oil lightly to the O-ring (3). I649G1220035-02 : Oil 99000–99001–SS8 (SUZUKI FORK OIL SS-08 or equivalent) Fork Spring Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one.

• Page 254: Specifications

  2B-9 Front Suspension: Specifications Service Data B649G12207004 Front Fork Unit: mm (in) Item Standard Limit Front fork stroke 130 (5.1) — Front fork inner tube O.D. 43 (1.69) — Front fork spring free length 392.8 (15.46) 384 (15.1) Front fork oil level 107 (4.2) —…

• Page 255: Special Tools And Equipment

  Front Suspension: 2B-10 Special Tools and Equipment Recommended Service Material B649G12208001 Material SUZUKI recommended product or Specification Note SUZUKI FORK OIL SS-08 or P/No.: 99000–99001– equivalent Thread lock cement Thread Lock Cement 1342 or P/No.: 99000–32050 equivalent NOTE Required service material is also described in the following.

• Page 256: Rear Suspension

  2C-1 Rear Suspension: Rear Suspension Repair Instructions Rear Suspension Components B649G12306001 I649G1230043-01 1. Rear shock absorber 6. Cushion rod mounting nut 11. Chain buffer : Apply grease to bearing. 2. Rear shock absorber mounting nut 7. Chain case 12. Swingarm pivot nut : Do not reuse.

• Page 257: Rear Suspension Assembly Construction

  Rear Suspension: 2C-2 Rear Suspension Assembly Construction B649G12306019 Left Right I649G1230040-04 1. Rear shock absorber mounting nut (Upper) 4. Cushion rod (Lower) : 50 N⋅m (5.0 kgf-m 36.0 lb-ft) : Apply grease to bearing. 2. Rear shock absorber mounting nut (Lower) 5.

• Page 258: Rear Shock Absorber Removal And Installation

  2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation • Tighten the rear shock absorber upper/lower B649G12306002 mounting bolts and nuts. Tightening torque Removal Rear shock absorber mounting nut (a): 50 N·m ( 1) Place the motorcycle on the center stand and 5.0 kgf-m, 36.0 lb-ft) support the motorcycle with a jack to be no load for the rear shock absorber.

• Page 259: Rear Suspension Adjustment

  Rear Suspension: 2C-4 Rear Suspension Adjustment Rear Shock Absorber Disposal B649G12306005 B649G12306013 After installing the rear suspension, adjust the spring Refer to “Rear Shock Absorber Removal and pre-load and damping force as follows. Installation: ”. The rear shock absorber unit contains high-pressure Spring Pre-load Adjustment nitrogen gas.

• Page 260: Cushion Lever Removal And Installation

  2C-5 Rear Suspension: 2) Wrap rear shock absorber (1) with a vinyl bag (2) Installation and fix it on a vise as shown. Install the cushion lever in the reverse order of removal. Pay attention to the following point: 3) Drill a 2 – 3 mm (0.08 – 0.12 in) hole at the marked drill center using a drilling machine and let out gas •…

• Page 261: Cushion Lever Bearing Removal And Installation

  Rear Suspension: 2C-6 Cushion Lever Bearing Cushion Lever Bearing Removal and Installation 1) Insert the spacers into bearings. B649G12306015 2) Check the play by moving the spacers up and down. If excessive play is noted, replace the bearing with a Removal new one.

• Page 262: Swingarm / Cushion Rod Removal And Installation

  (A): 09924–84521 (Bearing installer set) I649G1230018-01 3) Remove the brake hose clamps. I649G1230016-02 2) Apply SUZUKI SUPER GREASE “A” to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1230019-01 4) Remove the cushion lever (2) and rear shock absorber (3).

• Page 263
  Rear Suspension: 2C-8 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: and nut (5). •…

• Page 264: Swingarm Related Parts Inspection

  2C-9 Rear Suspension: • Tighten the cushion lever, cushion rod lower and rear Swingarm Related Parts Inspection B649G12306017 shock absorber lower mounting nut to the specified Refer to “Swingarm / Cushion Rod Removal and torque. Installation: ”. Tightening torque Cushion rod mounting nut (a): 78 N·m (7.8 kgf-m, Spacers 56.5 lb-ft) 1) Remove the spacers from the swingarm.

• Page 265: Swingarm Bearing Removal And Installation

  Rear Suspension: 2C-10 Swingarm Bearing Removal and Installation Swingarm B649G12306018 Inspect the swingarm for damage. If any defect is found, 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 266
  2C-11 Rear Suspension: Installation 4) Apply SUZUKI SUPER GREASE “A” to the bearings. : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) The removed bearings must be replaced with new ones. 1) Press the swingarm cushion rod bearings with the special tool.

• Page 267: Specifications

  Rear Suspension: 2C-12 Specifications Service Data B649G12307002 Unit: mm (in) Item Standard Limit Rear shock absorber spring adjuster 4th position — 1-1/8 turns out from GSF1200 Rear shock absorber damping force stiffest position Rebound — adjuster 1-1/4 turns out from GSF1200S stiffest position Rear wheel travel…

• Page 268: Special Tools And Equipment

  2C-13 Rear Suspension: Special Tools and Equipment Recommended Service Material B649G12308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent NOTE Required service material is also described in the following. “Rear Suspension Components: ”…

• Page 269: Wheels And Tires

  Wheels and Tires: 2D-1 Wheels and Tires Precautions Precautions for Wheel and Tire B649G12400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. • Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear. •…

• Page 270: Repair Instructions

  2D-2 Wheels and Tires: Repair Instructions Front Wheel Components B649G12406003 I649G1240052-02 1. Front axle 6. Spacer 11. Wheel balancer : Apply thread lock to thread part. 2. Brake disc bolt 7. Front wheel 12. Air valve : Do not reuse. 3.

• Page 271: Front Wheel Assembly Construction

  Wheels and Tires: 2D-3 Front Wheel Assembly Construction B649G12406027 Left Right “a ” I649G1240050-04 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. 3.

• Page 272: Front Wheel Assembly Removal And Installation

  2D-4 Wheels and Tires: Front Wheel Assembly Removal and Installation 6) Loosen two axle pinch bolts (3) on the left front fork B649G12406005 leg. 7) Draw out the front axle and remove the front wheel. Removal 1) Support the motorcycle with a jack or a wooden NOTE block.

• Page 273
  Wheels and Tires: 2D-5 2) Install the front wheel with the front axle and tighten 5) Tighten two axle pinch bolts (2) on the right fork leg the front axle bolt temporarily. to the specified torque. Tightening torque WARNING Front axle pinch bolt (b): 23 N·m (2.3 kgf-m, 16.5 The directional arrow on the tire should point lb-ft) to the wheel rotation, when remounting the…

• Page 274: Front Wheel Related Parts Inspection

  2D-6 Wheels and Tires: Front Wheel Related Parts Inspection Wheel runout B649G12406019 Service limit (Axial and Radial): 2.0 mm (0.08 in) Refer to “Front Wheel Assembly Removal and Installation: ” Tire Refer to “Tire Inspection: in Section 0B”. Front Brake Disc Refer to “Front Brake Disc Inspection: in Section 4B”.

• Page 275
  Installation CAUTION The removed dust seals and bearings must be replaced with new ones. Right Left 1) Apply SUZUKI SUPER GREASE “A” to the wheel bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “a ” I649G1240021-05 1. Spacer “a”: Clearance…
• Page 276
  2D-8 Wheels and Tires: 3) Install the dust seals with the special tool. 4) Apply SUZUKI SUPER GREASE “A” to the lip of dust seals. Special tool (B): 09913–70210 (Bearing installer set) : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent)

• Page 277: Rear Wheel Components

  Wheels and Tires: 2D-9 Rear Wheel Components B649G12406004 I649G1240053-03 1. Spacer 8. Bearing 15. Rear wheel : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Rear sprocket 9. Spacer 16. Air valve : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Dust seal 10.

• Page 278: Rear Wheel Assembly Construction

  2D-10 Wheels and Tires: Rear Wheel Assembly Construction B649G12406028 Left Right “ a ” I649G1240051-04 1. Rear sprocket nut 4. Brake disc bolt : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut “a”: Clearance : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) : Apply grease.

• Page 279: Rear Wheel Assembly Removal And Installation

  Wheels and Tires: 2D-11 Rear Wheel Assembly Removal and Installation Installation B649G12406010 1) Install the spacer (1) and collar (2). Removal 1) Support the motorcycle with the center stand. 2) Remove the cotter pin. (For E-28) 3) Remove the rear axle nut (1) and draw out the rear axle.

• Page 280: Rear Wheel Related Parts Inspection

  2D-12 Wheels and Tires: Rear Wheel Related Parts Inspection Axle Shaft B649G12406021 Using a dial gauge, check the rear axle for runout, If the Refer to “Rear Wheel Assembly Removal and runout exceeds the limit, replace the axle shaft. Installation: ”. Axle shaft runout Service limit: 0.25 mm (0.010 in) Tire…

• Page 281: Rear Wheel Dust Seal / Bearing / Removal And Installation

  The removed dust seal and bearings must be replaced with new ones. Removal 1) Remove the rear wheel assembly. Refer to “Rear 1) Apply SUZUKI SUPER GREASE “A” to the wheel Wheel Assembly Removal and Installation: ”. bearings. 2) Remove the rear sprocket mounting drum assembly from the rear wheel.

• Page 282: Tire Removal And Installation

  (A): 09941–34513 (Steering race installer) (B): 09924–84510 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I649G1240035-01 4) Apply SUZUKI SUPER GREASE “A” to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1240030-01 Right…

• Page 283
  Wheels and Tires: 2D-15 3) Remove the valve core. 2) Install the tire onto the wheel. 4) Remove the tire using the tire charger. CAUTION CAUTION For installation procedure of tire onto the wheel, follow the instructions given by the For operating procedures, refer to the tire changer manufacturer.

• Page 284: Wheel / Tire / Air Valve Inspection And Cleaning

  2D-16 Wheels and Tires: 7) When the bead has been fitted properly, install the • Localized tread wear due to skidding (Flat spot) valve core and adjust the pressure to specification. • Abnormal condition of inner liner As necessary, adjust the tire balance. Refer to “Wheel Balance Check and Adjustment: ”.

• Page 285: Wheel Balance Check And Adjustment

  Wheels and Tires: 2D-17 2) Remove the tire. Refer to “Tire Removal and Wheel Balance Check and Adjustment B649G12406026 Installation: ”. Check and adjust the wheel balance in the following 3) Remove the air valve (1) from the wheel. procedures: 1) Removal the wheel assembly.

• Page 286: Specifications

  2D-18 Wheels and Tires: Specifications Service Data B649G12407002 Wheel Unit: mm (in) Item Standard Limit Axial — 2.0 (0.08) Wheel rim runout Radial — 2.0 (0.08) Front — 0.25 (0.010) Wheel axle runout Rear — 0.25 (0.010) Front 17 M/C x MT3.50 —…

• Page 287: Special Tools And Equipment

  Wheels and Tires: 2D-19 Special Tools and Equipment Recommended Service Material B649G12408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent NOTE Required service material is also described in the following. “Front Wheel Components: ”…

• Page 288
  2D-20 Wheels and Tires:…
• Page 289
  Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ……….3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation……..3A-3 Precautions…………. 3-1 Drive Chain Related Parts Inspection ….3A-4 Precautions for Driveline / Axle ……3-1 Sprocket Mounting Drum Dust Seal / Bearing Drive Chain / Drive Train / Drive Removal and Installation……..3A-5 Drive Chain Replacement ……..3A-6…

• Page 290: 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 291: Drive Chain / Drive Train / Drive Shaft

  Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B649G13104003 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket. Replace.

• Page 292: Engine Sprocket Removal And Installation

  3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 7) Loosen the rear axle nut (4) and chain adjusters (5) B649G13106008 to provide additional chain slack. Removal 1) Disengage the gearshift lever link by removing the bolt.

• Page 293: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

  (2) from its mounting drum (3). • Before installing the engine sprocket cover, apply a 4) Draw out the mounting drum (3) from the wheel hub. small quantity of SUZUKI SUPER GREASE “A” to the clutch push rod. : Grease 99000–25010 (SUZUKI SUPER…

• Page 294: Drive Chain Related Parts Inspection

  Replace the bearing if there is anything • Apply grease to the contacting surface between the unusual. rear wheel hub and the mounting drum. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1310015-01 Engine Sprocket and Rear Sprocket Inspect the sprocket teeth for wear.

• Page 295: Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation

  Drive Chain / Drive Train / Drive Shaft: 3A-5 Sprocket Mounting Drum Dust Seal / Bearing 1) Apply grease to the bearing before installing. Removal and Installation : Grease 99000–25010 (SUZUKI SUPER B649G13106011 GREASE A or equivalent) Removal 1) Remove the rear wheel assembly. Refer to “Rear Wheel Assembly Removal and Installation: in Section 2D”.

• Page 296: Drive Chain Replacement

  3A-6 Drive Chain / Drive Train / Drive Shaft: Drive Chain Replacement NOTE B649G13106012 The tip of pin remover (1) should be Use the special tool in the following procedures, to cut positioned inside “a” approximately 5 mm and rejoin the drive chain. (0.2 in) from the end face of pressure bolt [A] NOTE (2) as shown in the illustration.

• Page 297
  Drive Chain / Drive Train / Drive Shaft: 3A-7 6) Remove the joint pin (9) of the other side of joint 2) Apply grease to the joint pins (8), O-rings (9) and plate. plates (10). 3) Connect both ends of the drive chain with the joint CAUTION pin (8) inserted from the wheel side “A”…
• Page 298
  3A-8 Drive Chain / Drive Train / Drive Shaft: Continue pressing the joint plate until the distance 2) Stake the joint pin by turning (approximately 7/8 turn) between the two joint plates come to the the pressure bolt [A] (3) with the bar until the pin end specification.

• Page 299: Specifications

  Drive Chain / Drive Train / Drive Shaft: 3A-9 Specifications Service Data B649G13107002 Drive Chain Unit: mm (in) Item Standard Limit Final reduction ratio 3.000 (45/15) — Type RK GB50GSVZ3 — Drive chain Links 116 links — 20-pitch length — 319.4 (12.57) Drive chain slack 20 –…

• Page 300: Special Tools And Equipment

  3A-10 Drive Chain / Drive Train / Drive Shaft: Special Tools and Equipment Recommended Service Material B649G13108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent Thread lock cement Thread Lock Cement Super 1303 or P/No.: 99000–32030…

• Page 301
  Table of Contents 4- i Section 4 Brake CONTENTS Precautions ……….4-1 Special Tools and Equipment ……4A-16 Recommended Service Material …….4A-16 Precautions…………. 4-1 Special Tool …………4A-16 Precautions for Brake System ……4-1 Brake Fluid Information ……… 4-1 Front Brakes ……….4B-1 Brake Control System and Diagnosis …

• Page 302: Precautions

  4-1 Precautions: Precautions Precautions Precautions for Brake System B649G14000001 Refer to “General Precautions: in Section 00”. Brake Fluid Information B649G14000002 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 303: Brake Control System And Diagnosis

  Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Schematic and Routing Diagram Front Brake Hose Routing Diagram B649G14102001 GSF1200 I649G1410001-04 1. Front brake hose No.1 6: Clamp : Insert the clamp to the hole of the front fender fully. 2.

• Page 304
  4A-2 Brake Control System and Diagnosis: GSF1200S I649G1410002-04 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 305: Rear Brake Hose Routing Diagram

  Brake Control System and Diagnosis: 4A-3 Rear Brake Hose Routing Diagram B649G14102002 I649G1410003-05 1. Brake hose clamp : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Brake hose clamp ends should face forward. 2. Brake hose clamp : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft) : Brake hose clamp ends should face backward.

• Page 306: Diagnostic Information And Procedures

  4A-4 Brake Control System and Diagnosis: Diagnostic Information and Procedures Brake Symptom Diagnosis B649G14104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Worn disc.

• Page 307: Rear Brake Light Switch Inspection

  Brake Control System and Diagnosis: 4A-5 Rear Brake Light Switch Inspection Brake Fluid Level Check B649G14106019 B649G14106021 Inspect the rear brake light switch in the following Refer to “Brake System Inspection: in Section 0B”. procedures: Brake Hose Inspection 1) Disconnect the rear brake light switch lead coupler B649G14106022 (1).

• Page 308: Brake Fluid Replacement

  4A-6 Brake Control System and Diagnosis: 4) Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. 5) Close the air bleeder valve, pump and squeeze the lever, and open the valve.

• Page 309
  Brake Control System and Diagnosis: 4A-7 6) Loosen the air bleeder valve and pump the brake 5) Fill the reservoir with new brake fluid. lever until the old brake fluid flows out of the brake BF: Brake fluid (DOT 4) system.

• Page 310: Front Brake Hose Removal And Installation

  4A-8 Brake Control System and Diagnosis: Front Brake Hose Removal and Installation Rear Brake Hose Removal and Installation B649G14106025 B649G14106026 Removal Removal 1) Drain brake fluid. Refer to “Brake Fluid 1) Remove right frame cover. Refer to “Exterior Parts Replacement: ”. Removal and Installation: in Section 9D”.

• Page 311: Front Brake Master Cylinder Assembly Removal And Installation

  Brake Control System and Diagnosis: 4A-9 Front Brake Master Cylinder Assembly Removal • When installing the master cylinder (1) onto the and Installation handlebars (2), align the master cylinder holder’s B649G14106028 mating surface “A” with the punch mark “B” on the handlebars (2) and tighten the upper holder bolt first.

• Page 312: Front Master Cylinder / Brake Lever Disassembly And Assembly

  4A-10 Brake Control System and Diagnosis: Front Master Cylinder / Brake Lever 4) Remove the following parts from the master cylinder. Disassembly and Assembly • Piston (8) B649G14106029 • Secondary cup (9) Refer to “Front Brake Master Cylinder Assembly Removal and Installation: ”. •…

• Page 313: Front Master Cylinder Parts Inspection

  Master Cylinder Inspect the master cylinder bore for any scratches or other damage. I649G1410025-01 • Apply SUZUKI SILICONE GREASE to the brake lever pivot bolt. • Apply SUZUKI SILICONE GREASE to the contact I649G1410027-01 point between piston and brake lever.

• Page 314: Rear Brake Master Cylinder Components

  4A-12 Brake Control System and Diagnosis: Rear Brake Master Cylinder Components B649G14106031 I649G1410029-05 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 315: Rear Brake Master Cylinder Disassembly And Assembly

  Brake Control System and Diagnosis: 4A-13 Installation Rear Brake Master Cylinder Disassembly and Install the rear brake master cylinder in the reverse order Assembly of removal. Pay attention to the following points: B649G14106033 Refer to “Rear Brake Master Cylinder Assembly Removal and Installation: ”.

• Page 316: Rear Brake Master Cylinder Parts Inspection

  Refer to “Rear Brake Master Cylinder Disassembly and Assembly: ”. Master Cylinder Inspect the master cylinder bore for any scratches or other damage. I649G1410036-01 • Apply SUZUKI SILICONE GREASE to the push rod end. : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) I649G1410038-01 Piston Inspect the piston surface for any scratches or other damage.

• Page 317: Specifications

  Brake Control System and Diagnosis: 4A-15 Specifications Service Data B649G14107004 Brake Unit: mm (in) Item Standard Limit Rear brake pedal height 60 (2.4) — Front 15.870 – 15.913 (0.6248 – 0.6264) — Master cylinder bore Rear 14.000 – 14.043 (0.5512 – 0.5529) —…

• Page 318: Special Tools And Equipment

  4A-16 Brake Control System and Diagnosis: Special Tools and Equipment Recommended Service Material B649G14108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — Grease SUZUKI Silicone Grease or P/No.: 99000–25100 equivalent NOTE Required service material is also described in the following.

• Page 319: Front Brakes

  Front Brakes: 4B-1 Front Brakes Repair Instructions Front Brake Components B649G14206011 I649G1420001-04 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 320: Front Brake Pad Inspection

  4B-2 Front Brakes: Front Brake Pad Inspection CAUTION B649G14206012 The extent of brake pad wear can be checked by Do not operate the brake lever while observing the grooved limit line “A” on the pad. When the dismounting the pads. wear exceeds the grooved limit line, replace the pads with new ones.

• Page 321: Front Brake Caliper Removal And Installation

  Front Brakes: 4B-3 Front Brake Caliper Removal and Installation • After setting the brake hose union to the stopper, B649G14206014 tighten the union bolt to the specified torque. Removal CAUTION 1) Drain brake fluid. Refer to “Brake Fluid The seal washers should be replaced with the Replacement: in Section 4A”.

• Page 322
  4B-4 Front Brakes: 2) Separate the caliper halves to remove the caliper 5) Remove the dust seals and piston seals. housing bolts. Special tool (A): 09930–11920 (Torx bit (JT 40H)) (B): 09930–11940 (Bit holder) I649G1420011-01 Assembly Assemble the caliper in the reverse order of disassembly.

• Page 323: Front Brake Caliper Parts Inspection

  Front Brakes: 4B-5 • Apply the brake fluid to piston seals (1) and dust seals (2). CAUTION • Replace the piston seals (1) and dust seals (2) with new ones BF: Brake fluid (DOT 4) I649G1420008-03 • Install the brake pads. Refer to “Front Brake Pad Replacement: ”.

• Page 324: Front Brake Disc Removal And Installation

  4B-6 Front Brakes: Front Brake Disc Removal and Installation Front Brake Disc Inspection B649G14206017 B649G14206018 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 service limit or if defect is found.

• Page 325: Specifications

  Front Brakes: 4B-7 Specifications Service Data B649G14207004 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 30.230 – 30.306 (1.1902 – 1.1931) — Brake caliper cylinder bore Front Trailing…

• Page 326: Special Tools And Equipment

  4B-8 Front Brakes: Special Tools and Equipment Recommended Service Material B649G14208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130 equivalent NOTE Required service material is also described in the following.

• Page 327: Rear Brakes

  Rear Brakes: 4C-1 Rear Brakes Repair Instructions Rear Brake Components B649G14306011 I649G1430001-04 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. 3.

• Page 328: Rear Brake Pad Inspection

  4C-2 Rear Brakes: Rear Brake Pad Inspection 2) Loosen the pad mounting pin (2). B649G14306012 3) Remove the caliper mounting bolt (3). The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pad. When the CAUTION wear exceeds the grooved limit line, replace the pads Do not operate the brake pedal while…

• Page 329: Rear Brake Caliper Removal And Installation

  Rear Brakes: 4C-3 7) Install the new brake pads. 9) Install the plug (9) to the specified torque. Tightening torque NOTE Pad pin plug (c): 2.5 N·m (0.25 kgf-m, 1.8 lb-ft) Make sure that the detent of the pad is seated onto the retainer on the caliper bracket.

• Page 330: Rear Brake Caliper Disassembly And Assembly

  4C-4 Rear Brakes: 4) Pivot the caliper up and remove the caliper from the • After setting the brake hose union to the stopper, caliper bracket. tighten the union bolt (2) to the specified torque. CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage.

• Page 331
  Rear Brakes: 4C-5 2) Remove the pad spring (3). 6) Remove the dust seal (7) and piston seal (8). I649G1430014-01 I649G1430017-01 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 332: Rear Brake Caliper Parts Inspection

  • Install the piston seals as shown. I649G1430020-01 I649G1420013-01 Brake Caliper Piston • Apply SUZUKI SILICONE GREASE to the inside of Inspect the brake caliper piston surface for any the boot. scratches or other damage. If any damage is found, replace the piston with a new one.

• Page 333: 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 334
  4C-8 Rear Brakes: Brake Disc Runout 1) Remove the rear brake caliper. Refer to “Rear Brake Caliper Removal and Installation: ”. 2) Measure the runout using the dial gauge. Replace the disc if the runout exceeds the service limit. Special tool (A): 09900–20606 (Dial gauge (1/100 mm)) (B): 09900–20701 (Magnetic stand) Brake disc runout…

• Page 335: Specifications

  Rear Brakes: 4C-9 Specifications Service Data B649G14307004 Brake Unit: mm (in) Item Standard Limit Brake disc thickness Rear 4.8 – 5.2 (0.189 – 0.205) 4.5 (0.18) Brake disc runout — 0.30 (0.012) Brake caliper cylinder bore Rear 38.180 – 38.256 (1.5031 – 1.5061) —…

• Page 336: Special Tools And Equipment

  4C-10 Rear Brakes: Special Tools and Equipment Recommended Service Material B649G14308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — Grease SUZUKI Silicone Grease or P/No.: 99000–25100 equivalent Thread lock cement Thread Lock Cement Super 1360 or P/No.: 99000–32130…

• Page 337
  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 338: Precautions

  5-1 Precautions: Precautions Precautions Precautions for Transmission / Transaxle B649G15000001 Refer to “General Precautions: in Section 00”.

• Page 339: Manual Transmission

  Manual Transmission: 5B-1 Manual Transmission Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B649G15204022 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. transmission).

• Page 340: Repair Instructions

  5B-2 Manual Transmission: Repair Instructions Transmission Components B649G15206029 I649G1520041-03 1. 1st (Low) driven gear 9. 3rd drive gear 17. Gearshift cam stopper 2. 4th driven gear 10. 5th (Top) drive gear : Apply oil. 3. 3rd driven gear 11. 2nd drive gear : Apply molybdenum oil solution.

• Page 341
  Manual Transmission: 5B-3 10) Remove the oil seal retainer (1) and gear position 15) Remove the shim (6) and O-ring (7). switch assembly (2). Refer to “Gear Position Switch 16) Remove the oil sump filter (8). Removal and Installation: ”. 17) Remove the oil return pipe (9).
• Page 342
  5B-4 Manual Transmission: 20) Loosen the crankcase bolts (crankshaft tightening 23) Remove the countershaft assembly (12) and bolts) in descending numerical order and then driveshaft assembly (13). remove them. NOTE Two allen bolts are located at position “A” to tighten the crankshaft. 21) Remove the oil return pipe (11).

• Page 343: Transmission Installation

  Manual Transmission: 5B-5 26) Unhook the gearshift cam stopper spring (18) from 29) Remove the gearshift cam stopper bolt (23). the lower crankcase. I649G1520018-01 Transmission Installation I649G1520015-01 B649G15206028 27) Remove the snap ring (19) from the gearshift cam, Install the transmission in the reverse order of removal. then draw out the gearshift cam (20) from the Pay attention to the following points: opposite side.

• Page 344
  5B-6 Manual Transmission: • Install the gearshift cam (2) and its related parts. Gearshift Fork • Install the gearshift forks into the crankcase in the CAUTION correct position and direction. Always use new snap rings ((4) and (6)). Special tool (A): 09900–06107 (Snap ring pliers) I649G1520024-01 1.
• Page 345
  Manual Transmission: 5B-7 Countershaft and Driveshaft • Install the bearing pins (1) and C-rings (2) into the upper crankcase. I649G1520026-01 • Install the countershaft assembly (3) and driveshaft assembly (4) into the upper crankcase. • Install the countershaft end cap in the proper position “A”.
• Page 346
  5B-8 Manual Transmission: Crankcase • Apply the SUZUKI BOND to the mating surface of the lower crankcase. : Sealant 99000–31140 (SUZUKI Bond 1207B or equivalent) NOTE • Make sure that the mating surfaces are free from moisture, oil, dust and other foreign materials.
• Page 347
  Manual Transmission: 5B-9 • Install the right oil return pipe along with the bolt “1”. • Install the copper washers to the bolts “9” and “11”. • Install the two allen bolts at position “A”. • Install the ten crankcase bolts (M8). •…
• Page 348
  5B-10 Manual Transmission: CAUTION Use a new gasket washer to prevent oil leakage. I649G1520033-02 “B” I649G1520032-02 “C” I649G1520034-01 I649G1520031-01…
• Page 349
  Manual Transmission: 5B-11 Left Oil Return Pipe and Oil Sump Filter • Install the left oil return pipe (1). • Install a new O-ring (2) and shim (3). • Install a new gasket and the oil sump filter (4). CAUTION Replace the gasket and O-ring with new ones to prevent oil leakage.
• Page 350
  5B-12 Manual Transmission: Oil Seal Retainer • Install the gearshift shaft and gearshift driven gear. Refer to “Gearshift Shaft / Gearshift Cam Driven Gear • Install the oil seal retainer (1) with the four bolts and Removal and Installation: ”. then bend up the tabs on the retainer.

• Page 351: Transmission Construction

  Manual Transmission: 5B-13 Transmission Construction B649G15206030 I649G1520042-02 Countershaft Gear and Driveshaft Gear 1) Remove the left end bearing (1) and oil seal (2). Disassembly B649G15206031 Refer to “Transmission Removal: ” and “Transmission Installation: ”. Countershaft Gear Disassembly CAUTION Identify the position of each removed part. Organize the parts in their respective groups (i.e., drive or driven) so that they can be I649G1520043-01…

• Page 352
  5B-14 Manual Transmission: 2) Remove the 5th (Top) drive gear snap ring (3) from 6) Remove the snap ring (11) and 4th drive gear (10). its groove and slide it towards the 3rd drive gear (4). Special tool Special tool : 09900–06107 (Snap ring pliers) : 09900–06107 (Snap ring pliers) I649G1520047-01…

• Page 353: Countershaft Gear And Driveshaft Gear Assembly

  • Before installing the gears, lightly coat the driveshaft, countershaft and bushings with “D” molybdenum oil solution. • Before installing the oil seal, apply SUZUKI SUPER GREASE “A” to the oil seal lip. : Moly paste 99000–25140 (SUZUKI Moly paste “E”…

• Page 354: Transmission Related Parts Inspection

  5B-16 Manual Transmission: Countershaft Gear Assembly Transmission Related Parts Inspection B649G15206032 • Align the bushing oil hole “A” with the shaft oil hole Refer to “Transmission Removal: ”, “Transmission “B”. Installation: ” and “Countershaft Gear and Driveshaft Gear Disassembly: ”. Gearshift Fork to Groove Clearance “A”…

• Page 355: Gear Position Switch Inspection

  Manual Transmission: 5B-17 Gearshift Fork Thickness 3) Check the continuity between Blue and Black/White Measure the gearshift fork thickness using the vernier lead wires with the transmission in “NEUTRAL”. calipers. CAUTION Special tool When disconnecting and connecting the gear (A): 09900–20102 (Vernire calipers) position switch coupler, make sure to turn off Gearshift fork thickness the ignition switch, or electronic parts may…

• Page 356: Gearshift Shaft / Gearshift Cam Driven Gear Components

  5B-18 Manual Transmission: 4) Disconnect the gear position switch coupler (1). • Install the gear position switch. NOTE When installing the gear position switch, be sure to install the spring (2), switch contact (3) and O-ring (1) properly. I649G1520080-01 5) Remove the gear position switch. I649G1520084-01 •…

• Page 357: Gearshift Shaft / Gearshift Cam Driven Gear Removal And Installation

  Manual Transmission: 5B-19 Gearshift Shaft / Gearshift Cam Driven Gear 5) Remove the gearshifting pawls (3), pins (4) and springs (5) from the gearshift cam driven gear (2). Removal and Installation B649G15206035 It is unnecessary to remove the engine assembly from the frame when servicing the gearshift linkage.

• Page 358
  5B-20 Manual Transmission: • Fit the springs (1), pins (2) and pawls (3) to the • Install the gearshift shaft (7). gearshift cam driven gear (4). NOTE Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear.

• Page 359: Gearshift Linkage Inspection

  The removed oil seal must be replaced with a new one. • Install the oil seal using the special tool. Special tool (A): 09913–70210 (Bearing installer set) • Apply SUZUKI SUPER GREASE “A” onto the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1520075-01 Gearshift Shaft Hole Check the gearshift shaft hole for damage or wear.

• Page 360: Gearshift Lever Height Inspection And Adjustment

  5B-22 Manual Transmission: Gearshift Lever Height Inspection and 2) Loosen the lock-nuts (1). Adjustment 3) Turn the gearshift link rod (2) until the gearshift lever B649G15206039 is 55 mm (2.2 in) below the top of the footrest. Inspect and adjust the gearshift lever height in the 4) Tighten the lock-nuts securely.

• Page 361: Specifications

  Manual Transmission: 5B-23 Specifications Service Data B649G15207002 Transmission + Drive Chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.565 (72/46) — Final reduction ratio 3.000 (45/15) — 1st (Low) 2.384 (31/13) — 1.631 (31/19) — Gear ratios 1.250 (25/20) —…

• Page 362: Special Tools And Equipment

  5B-24 Manual Transmission: Special Tools and Equipment Recommended Service Material B649G15208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140 Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140…

• Page 363: Clutch

  Clutch: 5C-1 Clutch Precautions Precautions for Clutch System B649G15300001 Refer to “General Precautions: in Section 00”. Clutch Fluid (Brake Fluid) Information B649G15300002 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 364: Schematic And Routing Diagram

  5C-2 Clutch: Schematic and Routing Diagram Clutch Hose Routing Diagram B649G15302001 GSF1200 I649G1530001-04 1. Clutch hose guide 6. Fixed clamp : Align the white paint mark on the clutch hose to the fixed clamp. 2. Stopper 7. Clutch hose : After the clutch hose union has contacted the stopper, tighten the union bolt. : Pass the clutch hose through outside of the wire harness.

• Page 365
  Clutch: 5C-3 GSF1200S I649G1530002-04 1. Clutch hose 7. Clutch hose clamp : Insert the clutch hose clamp end to the hole of the frame fully. 2. Wire harness 8. Clutch hose : Pass through the clutch hose between the frame and fuel tank rail. Be careful not to contact the clutch hose and frame cover bracket.

• Page 366: Diagnostic Information And Procedures

  5C-4 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis B649G15304003 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 367: Clutch Fluid Replacement

  Clutch: 5C-5 3) Attach a pipe to the bleeder valve and insert the free Clutch Fluid Replacement B649G15306011 end of the pipe into a receptacle. CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. 1) Place the motorcycle on a level surface and keep the handlebars straight.

• Page 368: Clutch Hose Removal And Installation

  5C-6 Clutch: 7) Close the air bleeder valve and disconnect a clear Clutch Hose Removal and Installation B649G15306012 hose. Removal Fill the reservoir with new fluid to the upper mark of 1) Drain clutch fluid. Refer to “Clutch Fluid the reservoir.

• Page 369: Clutch Control System Components

  Clutch: 5C-7 Clutch Control System Components B649G15306013 I649G1530005-03 1. Push rod 7. Push rod : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft) 2. Piston/Cup set 8. Clutch release cylinder set : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 3. Clutch hose 9. Air bleeder : Apply brake fluid.

• Page 370: Clutch Master Cylinder Assembly Removal And Installation

  5C-8 Clutch: Clutch Master Cylinder Assembly Removal and • When installing the master cylinder (1) onto the handlebars (2), align the master cylinder holder’s Installation mating surface “A” with the punch mark “B” on the B649G15306016 handlebars (2) and tighten the upper holder bolt first. Removal Tightening torque 1) Drain clutch fluid.

• Page 371: Clutch Master Cylinder / Clutch Lever Disassembly And Assembly

  Clutch: 5C-9 Clutch Master Cylinder / Clutch Lever 5) Remove the following parts from the master cylinder. Disassembly and Assembly • Washer (9) B649G15306015 • Secondary cup (10) Refer to “Clutch Master Cylinder Assembly Removal and Installation: ”. • Piston (11) •…

• Page 372: Clutch Master Cylinder Parts Inspection

  5C-10 Clutch: Clutch Master Cylinder Parts Inspection • Apply SUZUKI SILICONE GREASE to the push rod B649G15306017 end. Refer to “Clutch Master Cylinder / Clutch Lever Disassembly and Assembly: ”. : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) Master Cylinder Inspect the master cylinder bore for any scratches or other damage.

• Page 373: Clutch Release Cylinder Disassembly And Assembly

  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) I649G1530022-04 6) Remove the push rod (4).

• Page 374: Clutch Release Cylinder Inspection

  5C-12 Clutch: Assembly Clutch Release Cylinder Inspection B649G15306020 Assemble the clutch cylinder in the reverse order of Refer to “Clutch Release Cylinder Disassembly and disassembly. Pay attention to the following points: Assembly: ”. • Wash the cylinder bore and piston with specified •…

• Page 375: Clutch Components

  Clutch: 5C-13 Clutch Components B649G15306021 I649G1530062-01 1. Clutch pressure plate lifter 8. No.2 drive plate 15. Clutch sleeve hub 2. Clutch pressure plate 9. No.2 driven plate (1 – 4 pcs) 16. Primary driven gear assembly : The No.1 and No.2 driven plats are 9 in total. 3.

• Page 376: Clutch Assembly Diagram

  5C-14 Clutch: Clutch Assembly Diagram B649G15306022 I649G1530029-01 1. Diaphragm springs 3. Clutch sleeve hub nut 2. Diaphragm spring holder : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) Clutch Removal 3) Remove the clutch pressure plate lifter (2) by B649G15306023 removing the snap ring. 1) Drain engine oil.

• Page 377
  Clutch: 5C-15 4) Remove the thrust washer (3), bearing (4) and clutch 6) After removing the clutch sleeve hub nut, remove the push piece (5), and pull out the clutch push rod (6). lock washer (7). 7) Remove the clutch diaphragm spring holder (8) by NOTE removing the screws.

• Page 378: Clutch Installation

  5C-16 Clutch: 11) Remove the spacer and bearing. 2) Install the generator/oil pump drive gears (2) onto the primary driven gear assembly as shown. 12) Remove the primary driven gear assembly with the generator/oil pump drive gears. NOTE If it is difficult to remove the primary driven gear, rotate the crankshaft.

• Page 379
  Clutch: 5C-17 7) Insert the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order, No.3 drive plate (6) first. “B” “A” I649G1530044-02 6. No.3 drive plate 10. No.2 driven plate (1 – 4 pcs) : The No.1 and No.2 driven plats are 9 in total.
• Page 380
  5C-18 Clutch: 12) Tighten the clutch sleeve hub nut to the specified Driven plate Thickness torque by using the torque wrench and clutch No.1 1.6 mm (0.06 in) pressure plate holder. No.2 2 mm (0.08 in) Special tool Put the clutch pressure plate onto the clutch sleeve (A): 09920–34820 (Clutch pressure plate hub securely.

• Page 381: Clutch Parts Inspection

  B649G15306025 Refer to “Clutch Removal: ” and “Clutch Installation: ”. I649G1530052-01 17) Apply a light coat of the SUZUKI BOND “1207B” to Clutch Diaphragm Spring the clutch cover gasket mating surface as shown. Measure the free height “a” of each diaphragm spring with a vernier calipers.

• Page 382
  5C-20 Clutch: Clutch Drive and Driven Plate Measure each driven plate for distortion with a thickness gauge and surface plate. NOTE Replace driven plates which exceed the limit. Wipe off the engine oil from the drive and Special tool driven plates with a clean rag. (B): 09900–20803 (Thickness gauge) Measure the thickness of drive plates with a vernier Clutch driven plate distortion…

• Page 383: Specifications

  Clutch: 5C-21 Specifications Service Data B649G15307004 Clutch Unit: mm (in) Item Standard Limit Clutch drive plate thickness 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) Clutch drive plate claw width — 13.0 (0.51) Clutch driven plate distortion — 0.10 (0.004) Clutch spring free height —…

• Page 384: Special Tools And Equipment

  5C-22 Clutch: Special Tools and Equipment Recommended Service Material B649G15308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent SUZUKI Silicone Grease or P/No.: 99000–25100 equivalent Sealant SUZUKI Bond 1207B or equivalent P/No.: 99000–31140…

• Page 385
  Table of Contents 6- i Section 6 Steering CONTENTS Precautions ……….6-1 Steering Components ………6B-4 Steering Removal and Installation ……6B-5 Precautions…………. 6-1 Steering Related Parts Inspection…….6B-9 Precautions for Steering ……..6-1 Steering System Inspection ……..6B-9 Steering General Diagnosis….6A-1 Steering Stem Bearing Removal and Installation ……….6B-9 Diagnostic Information and Procedures….6A-1 Steering Tension Adjustment ……6B-10…

• Page 386: Precautions

  6-1 Precautions: Precautions Precautions Precautions for Steering B649G16000001 Refer to “General Precautions: in Section 00”.

• Page 387: Steering General Diagnosis

  Steering General Diagnosis: 6A-1 Steering General Diagnosis Diagnostic Information and Procedures Steering Symptom Diagnosis B649G16104003 Condition Possible cause Correction / Reference Item Heavy Steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace. Not enough pressure in tires.

• Page 388: Steering / Handlebar

  6B-1 Steering / Handlebar: Steering / Handlebar Repair Instructions Handlebars Components B649G16206001 “A” I649G1620001-04 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 389: Handlebars Removal And Installation

  Steering / Handlebar: 6B-2 Handlebars Removal and Installation 3) Remove the caps and handlebar holder bolts. B649G16206008 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror (GSF1200) b) Clutch master cylinder/clutch lever (1) CAUTION Do not turn the clutch master cylinder upside down.

• Page 390: Handlebars Inspection

  6B-3 Steering / Handlebar: • Apply SUZUKI SUPER GREASE to the throttle cables • Install the clutch master cylinder. Refer to “Clutch and cable pulley. Master Cylinder Assembly Removal and Installation: in Section 5C”. : Grease 99000–25010 (SUZUKI SUPER • After installing the steering, the following adjustments GREASE A or equivalent) are required before driving.

• Page 391: Steering Components

  Steering / Handlebar: 6B-4 Steering Components B649G16206010 I649G1620041-01 1. Handlebar holder bolt 8. Rubber seat 15. Headlight housing bracket 2. Handlebar holder (Upper) 9. Handlebar holder set nut [A]: For GSF1200 3. Handlebars 10. Steering stem nut : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 4.

• Page 392: Steering Removal And Installation

  6B-5 Steering / Handlebar: Steering Removal and Installation 10) Remove the ignition switch (5) using the special B649G16206012 tools. Special tool Removal (A): 09930–11920 (Torx bit (JT 40H)) (B): 09930–11940 (Bit holder) GSF1200 1) Support the motorcycle with a jack or a wooden 11) Dismount the handlebars by removing the handlebar block.

• Page 393
  Steering / Handlebar: 6B-6 14) Remove the steering stem nut using the special tool. 4) Remove the brake hose clamp (1). NOTE When loosening the stem nuts, hold the steering stem lower bracket to prevent it from falling. Special tool (C): 09940–14911 (Steering stem nut wrench) I649G1620018-01…
• Page 394
  Install the steering in the reverse order of removal. 9) Remove the steering stem upper bracket (3). Pay attention to the following points: Bearing • Apply SUZUKI SUPER GREASE to the bearings, races and dust seals before remounting the steering stem. : Grease 99000–25010 (SUZUKI SUPER…
• Page 395
  Steering / Handlebar: 6B-8 • Turn the steering stem lower bracket about five or six Ignition switch times to the left and right so that the angular ball • Apply THREAD LOCK SUPER “1322” to the ignition bearings seat properly. switch mounting bolts.

• Page 396: Steering Related Parts Inspection

  6B-9 Steering / Handlebar: Steering Related Parts Inspection Steering Stem Bearing Removal and Installation B649G16206013 B649G16206014 Refer to “Steering Removal and Installation: ”. Inspect the removed parts for the following Removal abnormalities. 1) Remove the steering stem lower bracket. Refer to •…

• Page 397: Steering Tension Adjustment

  Installation Bearing Install the steering stem bearings in the reverse order of • Apply SUZUKI SUPER GRASE to the bearings, races removal. Pay attention to the following points: and dust seals before remounting the steering stem. : Grease 99000–25010 (SUZUKI SUPER…

• Page 398
  6B-11 Steering / Handlebar: 4) Do the same on the other grip end. b) Tighten the steering stem nut, stem head nut and 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 to heavy or too the spring scale according to the previously…

• Page 399: Specifications

  Steering / Handlebar: 6B-12 Specifications Tightening Torque Specifications B649G16207001 Tightening torque Fastening part Note N⋅m kgf-m lb-ft Handlebar holder bolt 16.5 Steering stem nut then turn back 1/2 – 1/ 32.5 Steering stem head nut 47.0 Handlebar holder set nut 32.5 NOTE The specified tightening torque is also described in the following.

• Page 400: Special Tools And Equipment

  6B-13 Steering / Handlebar: Special Tools and Equipment Recommended Service Material B649G16208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 equivalent Handle grip bond Handle grip bond (commercial — available) Thread lock cement Thread Lock Cement Super 1322 or P/No.: 99000–32110…

• Page 401
  Table of Contents 9- i Section 9 Body and Accessories CONTENTS Precautions ……….9-1 Special Tools and Equipment ……9B-13 Special Tool …………9B-13 Precautions…………. 9-1 Precautions for Electrical System ……9-1 Combination Meter / Fuel Meter / Component Location ……….9-1 Horn …………9C-1 Electrical Components Location ……
• Page 402
  9-ii Table of Contents Center Stand Construction……..9E-4 Special Tools and Equipment ……9E-5 Center Stand Removal and Installation….9E-4 Recommended Service Material ……9E-5 Specifications…………9E-5 Tightening Torque Specifications……9E-5…

• Page 403: Precautions

  Precautions: Precautions Precautions Precautions for Electrical System B649G19000001 Refer to “General Precautions: in Section 00” and “Precautions for Electrical Circuit Service: in Section 00”. Component Location Electrical Components Location B649G19003001 Refer to “Electrical Components Location: in Section 0A”.

• Page 404: Wiring Systems

  9A-1 Wiring Systems: Wiring Systems Schematic and Routing Diagram Wiring Diagram B649G19102004 Refer to “Wire Color Symbols: in Section 0A”.

• Page 405: Gsf1200 (For E02, 19)

  Wiring Systems: 9A-2 GSF1200 (For E02, 19) I649G1910901-02…

• Page 406
  9A-3 Wiring Systems: GSF1200S (For E-02, 19) I649G1910902-02…
• Page 407
  Wiring Systems: 9A-4 GSF1200S (For E-24, 28) I649G1910903-02…

• Page 408: Wiring Harness Routing Diagram

  9A-5 Wiring Systems: Wiring Harness Routing Diagram B649G19102001 “A” I649G1910904-05 1. Battery 8. Throttle cables 15. Speed sensor switch coupler 2. Ignitor unit 9. Starter cable 16. Thermo-switch (For E02, 19) 3. Ignition coil 10. TPS 17. Carburetor heater lead wire (For E02, 19) 4.

• Page 409
  Wiring Systems: 9A-6 “ a ” “ b” I649G1910905-05 1. Starter relay 6. CKP sensor lead/Side-stand lead/Gear position lead/Starter motor lead/ [A]: For GSF1200/GSF1200A Speed sensor lead/Wiring harness 2. Side-stand switch 7. Starter motor lead/Clutch hose [B]: For GSF1200S/GSF1200SA 3. Starter motor 8.

• Page 410: Specifications

  9A-7 Wiring Systems: I649G1910906-03 1. Generator 4. Gear position switch 7. Cooling hose 2. Starter motor 5. Engine ground wire : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3. Starter motor lead wire 6. CKP sensor lead wire : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) Specifications Service Data B649G19107002…

• Page 411: Lighting Systems

  Lighting Systems: 9B-1 Lighting Systems Repair Instructions Headlight Components B649G19206001 GSF1200 I649G1920001-02 1. Headlight rim 4. Headlight housing 2. Headlight unit 5. Position light bulb (12 V 5 W) 3. Headlight bulb (12 V 60/55 W, H4) GSF1200S I649G1920002-03 1. Headlight high beam bulb (12 V 55 W, H7) 2.

• Page 412: Headlight Removal And Installation

  9B-2 Lighting Systems: Headlight Removal and Installation GSF1200S B649G19206014 1) Remove the cowling. Refer to “Exterior Parts Removal Removal and Installation: in Section 9D”. 2) Disconnect the headlight and position light couplers. GSF1200 3) Remove the headlight assembly. 1) Removal the headlight mounting screws. I649G1920006-01 I649G1920003-01 2) Disconnect the headlight coupler (1) and position…

• Page 413
  Lighting Systems: 9B-3 2) Disconnect the headlight coupler (1) and position 6) Reassemble the headlight. light coupler (2). 7) Install the headlight assembly so that the hook “A” on the headlight bezel engages with “B” of the housing. “B” “A” I649G1920004-01 3) Remove the position light socket (3) and replace the I649G1920009-01…

• Page 414: Headlight Beam Adjustment

  9B-4 Lighting Systems: 4) Replace the headlight bulb (Low beam) (4) by GSF1200S unhooking the bulb holder spring (5). 1) Insert 5 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally. NOTE To adjust the headlight beam, adjust the beam horizontally first, then vertically.

• Page 415: Rear Combination Light Components

  Lighting Systems: 9B-5 Rear Combination Light Components B649G19206004 I649G1920017-02 1. Brake light/Taillight bulb (12 V 21/5 W) 2. Lens Rear Combination Light Construction B649G19206015 I649G1920018-01 1. Seat tail cover 3. Rear combination light 2. Cushion : 2.0 N⋅m (0.2 kgf-m, 1.5 lb-ft)

• Page 416: Rear Combination Light Removal And Installation

  9B-6 Lighting Systems: Rear Combination Light Removal and 2) Remove the tool set (1). Installation B649G19206016 Removal 1) Remove the seat tail cover. Refer to “Exterior Parts Removal and Installation: in Section 9D”. 2) Remove the rear combination light (1) from the seat tail cover.

• Page 417: License Plate Light Components

  Lighting Systems: 9B-7 License Plate Light Components B649G19206018 I649G1920023-02 1. License plate light bulb (12 V 5 W) 2. Lens cover 3. Lens License Plate Light Removal and Installation License Plate Light Bulb Replacement B649G19206019 B649G19206020 Removal 1) Remove the license plate light. Refer to “License 1) Remove the seat.

• Page 418: Turn Signal Light Components

  9B-8 Lighting Systems: Turn Signal Light Components B649G19206021 I649G1920028-03 1. Turn signal light bulb (12 V 21 W x 4) 2. Lens Front Turn Signal Light Removal and GSF1200S Installation 1) Remove the wind screen and upper panel. Refer to B649G19206022 “Exterior Parts Removal and Installation: in Section Removal…

• Page 419: Rear Turn Signal Light Removal And Installation

  Lighting Systems: 9B-9 Rear Turn Signal Light Removal and Installation Turn Signal Light Bulb Replacement B649G19206023 B649G19206024 Removal CAUTION 1) Remove the seat. Refer to “Exterior Parts Removal and Installation: in Section 9D”. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with 2) Remove the tool set (1) and disconnect the turn alcohol or soapy water to prevent premature…

• Page 420: Reflex Refrector Construction

  9B-10 Lighting Systems: Reflex Refrector Construction (For E-24, 28) B649G19206025 Front side Rear side I649G1920035-04 1. Reflex refrector 3. Rear fender : 4.5 N⋅m (0.45 kgf-m, 3.25 lb-ft) 2. Front fork : 1.8 N⋅m (0.18 kgf-m, 1.3 lb-ft) Turn Signal / Side-stand Relay Inspection Turn Signal / Side-stand Relay Removal and B649G19206026 Installation…

• Page 421: Hazard Switch Inspection

  Lighting Systems: 9B-11 Hazard Switch Inspection 3) Inspect the turn signal switch for continuity with a B649G19206028 tester. If any abnormality is found, replace the left Inspect the hazard switch in the following procedures: handlebar switch assembly with a new one. 1) Remove the right frame head cover.

• Page 422: Dimmer Switch Inspection

  9B-12 Lighting Systems: 4) After finishing the passing light switch inspection, 3) Inspect the dimmer switch for continuity with a tester. reinstall the removed parts. If any abnormality is found, replace the left handlebar switch assembly with a new one. Refer to “Handlebars Removal and Installation: in Dimmer Switch Inspection Section 6B”.

• Page 423: Specifications

  Lighting Systems: 9B-13 Specifications Service Data B649G19207002 Wattage Unit: W Specification Item GSF1200 GSF1200S 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 B649G19207003 Tightening torque Fastening part…

• Page 424: Combination Meter / Fuel Meter / Horn

  9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Repair Instructions Combination Meter Components B649G19306014 GSF1200 I649G1930001-04 1. Upper case assembly 3. Lower case 5. Bracket 2. Combination meter 4. Cover…

• Page 425
  Combination Meter / Fuel Meter / Horn: 9C-2 GSF1200S I649G1930002-02 1. Upper case assembly 2. Combination meter 3. Lower case…

• Page 426: Combination Meter Removal And Installation

  9C-3 Combination Meter / Fuel Meter / Horn: Combination Meter Removal and Installation 2) Disconnect the combination meter coupler and B649G19306001 remove the combination meter assembly. Removal GSF1200 1) Remove the headlight. Refer to “Headlight Removal and Installation: in Section 9B”. 2) Disconnect the respective couplers and remove the headlight housing (1).

• Page 427: Combination Meter Led Check

  Combination Meter / Fuel Meter / Horn: 9C-4 Combination Meter LED Check 2) Connect a jumper wire “A” between the Y/B and B/W B649G19306015 lead wires from the wire harness. Check that the LEDs (Oil pressure indicator light and 3) Turn the ignition switch to ON. Meter panel illumination) immediately light up when the 4) Check if the fuel level indicator (LCD) indicates full ignition switch is turned to ON.

• Page 428: Fuel Level Gauge Inspection

  9C-5 Combination Meter / Fuel Meter / Horn: 7) Replace the 180 Ω resister “B” with a 5 Ω one “C”. Speedometer Inspection B649G19306018 The fuel level indicator is operating correctly if the If the speedometer, odometer or tripmeter does not LCD bars increase to five (full) when the ignition function properly, inspect the speed sensor and the switch is turned to ON.

• Page 429: Speed Sensor Inspection

  Combination Meter / Fuel Meter / Horn: 9C-6 Speed Sensor Inspection Oil Pressure Indicator Inspection B649G19306020 B649G19306021 Inspect the speed sensor in the following procedures: Inspect the oil pressure indicator in the following procedures: 1) Remove the speed sensor. Refer to “Speed Sensor Removal and Installation: ”.

• Page 430: Oil Pressure Switch Removal And Installation

  9C-7 Combination Meter / Fuel Meter / Horn: Oil Pressure Switch Removal and Installation 3) Remove the headlight housing (GSF1200). B649G19306022 4) Remove the ignition switch using the special tools. Refer to “Oil Pressure Switch Removal and Installation: in Section 1E”. Special tool : 09930–11920 (Torx bit (JT 40H)) Ignition Switch Inspection…

• Page 431: Horn Removal And Installation

  Combination Meter / Fuel Meter / Horn: 9C-8 3) Inspect the horn button for continuity with a tester. Horn Removal and Installation B649G19306028 If any abnormality is found, replace the left Removal handlebar switch assembly with a new one. 1) Disconnect the horn coupler (1). Refer to “Handlebars Removal and Installation: in Section 6B”.

• Page 432: Specifications

  ← Neutral position indicator light ← Oil pressure indicator light Special Tools and Equipment Recommended Service Material B649G19308001 Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 or P/No.: 99000–32110 equivalent Special Tool B649G19308002 09900–25008…

• Page 433: Exterior Parts

  Exterior Parts: 9D-1 Exterior Parts Schematic and Routing Diagram Seat Lock Cable Routing Diagram B649G19402002 I649G1940001-01 1. Screw 3. Seat lock 2. Seat lock cable 4. Plate…

• Page 434: Repair Instructions

  9D-2 Exterior Parts: Repair Instructions Exterior Parts Construction B649G19406001 GSF1200 I649G1940002-02 1. Frame head cover 2. Headlight housing cover 3. Headlight housing stay…

• Page 435
  Exterior Parts: 9D-3 GSF1200S I649G1940003-05 1. Cowling body 3. Cowling brace 5. Upper panel 7. Head pipe 2. Wind screen 4. Lower panel 6. Meter panel lid…

• Page 436: Frame Cover Cushion Construction

  9D-4 Exterior Parts: “A” I649G1940031-02 1. Front fender 3. Washer “A”: Before installing the front fender, apply an adhesive agent to the inside of the washer to prevent it from falling. 2. Fender plate nut 4. Front fork Frame Cover Cushion Construction B649G19406002 I649G1940004-02 1.

• Page 437: Fastener Removal And Installation

  Exterior Parts: 9D-5 Fastener Removal and Installation Exterior Parts Removal and Installation B649G19406003 B649G19406004 Removal Seat 1) Depress the head of fastener center piece (1). 2) Pull out the fastener (2). Removal 1) Unlock the seat with the ignition key. 2) Remove the front and rear seats as an assembly.

• Page 438
  9D-6 Exterior Parts: Installation Frame Head Cover (GSF1200) Install the frame covers in the reverse order of removal. Removal Pillion Rider Handle and Seat Tail Cover Removal the frame head covers (1), left and right. Removal 1) Remove the seat. “A”…
• Page 439
  Exterior Parts: 9D-7 3) Remove the combination meter assembly (1). Refer to “Combination Meter Removal and Installation: in Section 9C”. I649G1940019-01 7) Remove the lower panel (6) from the cowling (5). I649G1940017-01 4) Remove the wind screen (2) and upper panel (3). I649G1940021-01 Disconnect the headlight and position light couplers.

• Page 440: Seat Height Adjustment

  9D-8 Exterior Parts: Installation 5) Reinstall the front seat and adjust the seat height Install the cowling and cowling brace in the reverse order adjuster position “A” or “B”. of removal. Pay attention to the following point: • After installing, be sure to inspect the headlight beam. Refer to “Headlight Beam Adjustment: in Section 9B”.

• Page 441: Body Structure

  Body Structure: 9E-1 Body Structure Repair Instructions Body Frame Construction B649G19506007 I649G1950005-02 1. Frame 6. Engine mounting bolt (Front) [A]: Except for E-28 2. Crankcase 7. Engine mounting joint bolt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 3. Engine mount bushing 8.

• Page 442: Battery Protector Construction

  9E-2 Body Structure: Battery Protector Construction B649G19506001 “ a ” “ a ” I649G1950001-01 1. Protector 2. Battery “a”: 50 mm (1.97 in)

• Page 443: Front Footrest Bracket Construction

  Body Structure: 9E-3 Front Footrest Bracket Construction B649G19506002 I649G1950002-02 1. Frame 3. Washer : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Footrest bracket 4. Bolt Side-stand Construction B649G19506003 I649G1950003-02 1. Side-stand : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) 2. Spring : Apply grease to sliding surface.

• Page 444: Side-Stand Removal And Installation

  9E-4 Body Structure: Side-stand Removal and Installation B649G19506004 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: ”. Installation Install the side-stand as shown in the side-stand construction. Refer to “Side-stand Construction: ”. Center Stand Construction B649G19506005 I649G1950004-01…

• Page 445
  Body Structure: 9E-5 Specifications Tightening Torque Specifications B649G19507001 NOTE The specified tightening torque is also described in the following. “Body Frame Construction: ” “Front Footrest Bracket Construction: ” “Side-stand Construction: ” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”.
• Page 446
  Prepared by December, 2005 Part No. 99500-39280-01E Printed in Japan…
• Page 447
  Printed in Japan…

FOREWORD

This manual contains an introductory description on the SUZUKI GSF1200/GSF1200S and procedures for its inspection/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.

This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

*This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

*Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

*This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

!WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2005

TABLE OF CONTENTS

00-1 Precautions:

Precautions

Precautions

00-3 Precautions:

I649G1000004-01

I649G1000003-01

00-7 Precautions:

•Be sure to set the tester to the correct testingrange.

Special tool

(A): 09900–25008 (Multi-circuit tester set)

(A)

I649G1000025-02

Table of Contents 0- i

Section 0

General Information

0

CONTENTS

0A-1 General Information:

General Information

General Description

Symbols

B649G10101001

Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

Torque control required.

Data beside it indicates specified torque. 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. 99000-25100

Apply THERMO-GREASE or equivalent. 99000-59029

Apply SUZUKI BOND “1207B” or equivalent. 99000-31140

Apply SUZUKI BOND “1215” or equivalent. 99000-31110

Apply THREAD LOCK SUPER “1303” or equivalent. 99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent. 99000-32110

Apply THREAD LOCK “1342” or equivalent. 99000-32050

Apply THREAD LOCK SUPER “1360” or equivalent. 99000-32130

Use fork oil or equivalent. 99000-99001-SS8

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

Do not reuse.

Note on reassembly.

General Information: 0A-2

Wire Color Symbols

General Information: 0A-6

Warning, Caution and Information Labels Location

6

8

7

4

I649G1010011-04

0A-7 General Information:

Component Location

Electrical ComponentsLocation

B649G10103001

3

General Information: 0A-8

12

9

13 14

16

15

0A-9 General Information:

Specifications

Specifications

0A-11 General Information:

Special Tools and Equipment

Special Tools

General Information: 0A-12

0A-13 General Information:

Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

Precautions

Precautions for Maintenance

B649G10200001

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.

NOTE

More frequent servicing may be required on motorcycles that are used under severe conditions.

General Description

Recommended Fluids and Lubricants

B649G10201001

Refer to “Fuel and Oil Recommendation: in Section 0A”.

0B-2 Maintenance and Lubrication:

Scheduled Maintenance

Periodic Maintenance Schedule Chart

B649G10205001

NOTE

I = Inspect and clean, adjust, replace or lubricate as necessary.

R = Replace

T = Tighten

Maintenance and Lubrication: 0B-3

Lubrication Points

B649G10205002

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows.

NOTE

•Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt orgrime.

•Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions.

1

2

3

0B-4 Maintenance and Lubrication:

Repair Instructions

“A”

I649G1020006-01

I649G1020004-02

(A)

I649G1020053-02

I649G1020011-03

0B-8 Maintenance and Lubrication:

I649G1020065-01

“E” “E”

I649G1020018-02

0B-10 Maintenance and Lubrication:

4)Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting

0B-16 Maintenance and Lubrication:

I649G1020049-01

I649G1020051-01

I649G1020052-01