Suzuki GSX650F Supplementary Service Manual
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Suzuki GSX650F Supplementary Service Manual

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GSX650F
USE THIS MANUAL WITH:
GSF650/S SERVICE MANUAL (99500-36170-01E)
9 9 5 0 1 - 3 6 1 8 0 - 0 1 E

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  • Page 1 GSX650F USE THIS MANUAL WITH: GSF650/S SERVICE MANUAL (99500-36170-01E) 9 9 5 0 1 - 3 6 1 8 0 - 0 1 E...
  • Page 2 * 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 NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-* Precautions ............. 00-* General Information ........... 0-i General Information ..........

  • Page 5: General Information

    Symbols ...............0A-* Air Cleaner Element Inspection and Cleaning ..0B-* Abbreviations ............0A-* Exhaust Pipe Bolt and Muffler Bolt Inspection ..0B-* SAE-to-Former SUZUKI Term ......0A-* Spark Plug Replacement ........0B-* Vehicle Side View ..........0A-* Spark Plug Inspection and Cleaning ....0B-* Vehicle Identification Number ......0A-*...
  • Page 6 Country and Area Codes (GSX650FK8) B817H20101017 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX650F K8 (E-02) U.K. JS1CJ135200100001 – GSX650F K8 (E-03) U.S.A (Except for California) JS1GP74A 82100001 – GSX650F K8 (E-19) E.U.

  • Page 7: Warning/Caution/Information Labels Location

    General Information: 0A-2 Warning, Caution and Information Labels Location (GSX650FK8) B817H20101018 1, 11 12, 13 I817H2010003-03 GSX650F GSX650FU 1. Noise label For E-03, 24, 33 — 2. Information label For E-03, 28, 33 — 3. Vacuum hose routing label For E-33 —...
  • Page 8 0A-3 General Information: Specifications Specifications (GSX650FK8) B817H20107005 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650/SK7 (’07-model) and GSX650FK8 (’08-model) in specifications are indicated an asterisk mark (*). Dimensions and dry mass Item Specification Remark Overall length...
  • Page 9 General Information: 0A-4 Special Tools and Equipment Special Tool B817H20108001 09930–82720 Mode select switch...

  • Page 10: Scheduled Maintenance

    0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Scheduled Maintenance Periodic Maintenance Schedule Chart (GSX650FK8) B817H20205003 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...
  • Page 11 Maintenance and Lubrication: 0B-2 Lubrication Points (GSX650FK8) B817H20205004 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows. NOTE • Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. •...
  • Page 12 0C-1 Service Data: Service Data General Information Specifications Service Data (GSX650FK8) B817H20307007 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650/SK7 (’07-model) and GS650FK8 (’08-model) in service data are indicated an asterisk mark (*). Throttle Body Item Specification...
  • Page 13 Front fork oil level (Without spring, * 132 (5.2) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil — Front fork oil capacity (Each leg) * 459 ml (15.5/16.2 US/lmp oz) —...
  • Page 14 0C-3 Service Data:...
  • Page 15 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction....
  • Page 16 1-ii Table of Contents PAIR Reed Valve Removal and Installation..1B-* Throttle Cable Routing Diagram PAIR Control Solenoid Valve Removal and (GSX650FK8)............1D-1 Installation ............1B-* Diagnostic Information and Procedures .... 1D-* PAIR System Inspection ........1B-* Engine Mechanical Symptom Diagnosis ..... 1D-* Crankcase Breather (PCV) Hose Inspection..
  • Page 17 Table of Contents 1-iii Engine Lubrication System ..... 1E-* Water pump Components ........1F-* Water Pump Construction ........1F-* Precautions............1E-* Water Pump Removal and Installation....1F-* Precautions for Engine Oil ........1E-* Water Pump Disassembly and Assembly ....1F-* Schematic and Routing Diagram......1E-* Water Pump Related Parts Inspection ....1F-* Engine Lubrication System Chart Diagram ..1E-* Specifications ............1F-* Diagnostic Information and Procedures.....1E-*...
  • Page 18 1-iv Table of Contents Repair Instructions ..........1H-* Special Tools and Equipment .......1I-* Ignition Coil / Plug Cap and Spark Plug Recommended Service Material ......1I-* Removal and Installation........1H-* Special Tool ............1I-* Spark Plug Inspection and Cleaning ....1H-* Charging System ........1J-* Ignition Coil / Plug Cap Inspection ......

  • Page 19: Engine General Information And Diagnosis

    Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Engine General Description Self-Diagnosis Function (GSX650FK8) B817H21101003 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.

  • Page 20: Diagnostic Information And Procedures

    1A-2 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.
  • Page 21 Engine General Information and Diagnosis: 1A-3 3) Start the engine or crank the engine for more than 4 6) After repairing the trouble, turn OFF the ignition seconds. switch and turn ON again. If DTC is indicated (C00), the malfunction is cleared. 4) Turn the special tool’s switch ON.

  • Page 22: Engine Mechanical

    1D-1 Engine Mechanical: Engine Mechanical Engine Schematic and Routing Diagram Throttle Cable Routing Diagram (GSX650FK8) B817H21402003 “A” “a” “ a ” I817H2140001-01 1. Wiring harness 4. Throttle cable No. 2 7. Ignition switch lead wire 2. Cable guide 5. Handlebar switch lead wire (L) “a”: 0 mm (0 in) 3.
  • Page 23 Table of Contents 6- i Section 6 Steering CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........6-* Handlebar Height Adjustment ......6B-* Steering Components .........
  • Page 24 6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebar Construction (GSX650FK8) B817H26206012 “A” I817H2620001-01 1. Handlebar switch (LH) : Apply bond. “A”: Apply a small amount of the bond 1207B to inside of the handlebar switchbox. Special Tools and Equipment Recommended Service Material B817H26208003 NOTE...

  • Page 25: Table Of Contents

    Table of Contents 9- i Section 9 Body and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* Turn Signal / Side-stand Relay Removal and Installation ............
  • Page 26 9-ii Table of Contents Horn Inspection ........... 9C-* Exterior Parts Removal and Installation ....9D-* Horn Removal and Installation ......9C-* Seat Height Adjustment ........9D-* Combination Meter Components Cowling Construction (GSX650FK8)....9D-1 (GSX650FK8) ...........9C-2 Under Cowl Construction (GSX650FK8).....9D-2 Combination Meter Removal and Installation Under Cowl Bracket Cushion Attachment (GSX650FK8) ...........9C-2 (GSX650FK8)............9D-2...

  • Page 27: Wiring Systems

    Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (GSX650FK8) B817H29102007 Refer to “Wire Color Symbols in Section 0A in related manual”.
  • Page 28 9A-2 Wiring Systems: For E-02, 19 I817H2910901-01...
  • Page 29 Wiring Systems: 9A-3 For E-03, 24, 28 I817H2910902-01...

  • Page 30: Wiring Harness Routing Diagram (Gsx650Fk8)

    9A-4 Wiring Systems: Wiring Harness Routing Diagram (GSX650FK8) B817H29102008 “A” “B” “C” I817H2910903-02 1. EVAP purge control valve (E-33 only) “A”: Pass the EVAP purge control valve lead wire lower the clutch hose (E-33 only). 2. Wiring harness No. 1 “B”: Do not make slacked lead wire.

  • Page 31: Lighting Systems

    Lighting Systems: 9B-1 Lighting Systems Body and Accessories Repair Instructions Headlight Components (GSX650FK8) B817H29206024 I817H2920001-01 1. Headlight low beam bulb (12 V 55 W, H7) 3. Position light bulb (12 V 5 W x 2) 2. Headlight high beam bulb (12 V 60 W, HB3) 4.

  • Page 32: Headlight Removal And Installation

    9B-2 Lighting Systems: Headlight Removal and Installation 3) Disconnect the low beam lead wire coupler (2). (GSX650FK8) 4) Replace the low beam bulb (3) by unhooking the B817H29206025 bulb holder spring (4). Removal 1) Remove the body cowling assembly. Refer to “Exterior Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-5)”.

  • Page 33: Headlight Beam Adjustment (Gsx650Fk8)

    Lighting Systems: 9B-3 Headlight Beam Adjustment (GSX650FK8) 3) Replace the high beam bulb (3). B817H29206027 1) Remove the combination meter assembly. Refer to “Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”. 2) Insert 8 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally.

  • Page 34: Reflex Refractor Construction (Gsx650Fk8)

    9B-4 Lighting Systems: Reflex Refractor Construction (GSX650FK8) B817H29206028 I817H2920014-01 1. Front reflex refractor (For E-03, 24, 28, 33) 2. Front fork : 2 N⋅m (0.2 kgf-m, 1.5 lb-ft) Specifications Service Data (GSX650FK8) B817H29207003 Wattage Unit: W Item Specification Headlight Parking or position light 5 x 2 Brake light/Taillight 21/5...

  • Page 35: Combination Meter / Fuel Meter / Horn

    Combination Meter / Fuel Meter / Horn: 9C-1 Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description (GSX650FK8) B817H29301002 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

  • Page 36: Repair Instructions

    9C-2 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components (GSX650FK8) B817H29306019 I817H2930002-01 1. Combination meter cover 2. Combination meter unit 3. Combination meter case Combination Meter Removal and Installation 2) Disconnect the combination meter coupler (3) and remove the combination meter assembly (4).

  • Page 37: Combination Meter Disassembly And Assembly

    Combination Meter / Fuel Meter / Horn: 9C-3 Installation If abnormal condition is found, replace the combination Install the combination meter in the reverse order of meter unit with a new one after checking its wire removal. harness/coupler. Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-2)”.

  • Page 38: Combination Meter Removal And Installation

    9C-4 Combination Meter / Fuel Meter / Horn: 2) With the adjuster switch (1) pressed, turn the ignition 2) Disconnect the ECT sensor coupler (1). switch on. 3) Release the adjuster switch (1), 3 to 5 seconds after turning the ignition switch on. 4) Press the adjuster switch (1) twice (within 1 second).

  • Page 39: Oil Pressure Indicator Inspection (Gsx650Fk8)

    Combination Meter / Fuel Meter / Horn: 9C-5 Oil Pressure Indicator Inspection (GSX650FK8) Horn Inspection (GSX650FK8) B817H29306024 B817H29306025 Inspect the oil pressure indicator in the following Inspect the horn in the following procedures: procedures: 1) Disconnect the couplers (1). NOTE Before inspecting the oil pressure switch, check if the engine oil level is correct.

  • Page 40: Specifications

    9C-6 Combination Meter / Fuel Meter / Horn: Specifications Service Data (GSX650FK8) B817H29307003 Wattage Unit: W Item Specification Speedometer light Tachometer light Turn signal indicator light LED x 2 High beam indicator light Neutral position indicator light Oil pressure/Engine coolant temperature indicator light FI indicator light Engine RPM indicator light...

  • Page 41: Exterior Parts

    Exterior Parts: 9D-1 Exterior Parts Body and Accessories Repair Instructions Cowling Construction (GSX650FK8) B817H29406011 I817H2940014-03 1. Under cowling (R) 3. Cushion 5. Upper panel 2. Body cowling 4. Windscreen 6. Under cowling (L)

  • Page 42: Under Cowl Construction (Gsx650Fk8)

    9D-2 Exterior Parts: Under Cowl Construction (GSX650FK8) B817H29406012 “ d ” “ a ” “ a ” “b” “ c” “c” I817H2940021-01 1. Heat shield “a”: Max. 5 mm (0.19 in) “c”: 55 mm (2.17 in) 2. Cushion “b”: 0 – 1 mm (0 – 0.039 in) “d”: 3 mm (0.12 in) Under Cowl Bracket Cushion Attachment (GSX650FK8) B817H29406013...

  • Page 43: Under Cowl Protector Cushion Attachment (Gsx650Fk8)

    Exterior Parts: 9D-3 Under Cowl Protector Cushion Attachment (GSX650FK8) B817H29406014 “ a ” I817H2940017-01 1. Cushion “a”: 85 mm (3.35 in) Upper Panel Cushion Attachment (GSX650FK8) B817H29406015 “ a ” I817H2940018-01 1. Panel cushion “a”: 5 mm (0.19 in)

  • Page 44: Windscreen Cushion Attachment (Gsx650Fk8)

    9D-4 Exterior Parts: Windscreen Cushion Attachment (GSX650FK8) B817H29406016 I817H2940019-01 1. Cushion 2. Tape Intake Net Cover Construction Attachment (GSX650FK8) B817H29406017 I817H2940020-01 1. Cover cushion...

  • Page 45: Exterior Parts Removal And Installation (Gsx650Fk8)

    Exterior Parts: 9D-5 Exterior Parts Removal and Installation 3) Remove the left under cowling (3) and right under cowling (4). (GSX650FK8) B817H29406010 Under Cowling Refer to “Exterior Parts Removal and Installation in related manual”. Removal 1) Remove the fasteners (1). I817H2940006-01 I817H2940001-01 2) Disconnect the turn signal light couplers (2), left and...

  • Page 46: Upper Panel

    9D-6 Exterior Parts: Upper Panel 3) Disconnect the high beam light coupler (2) and low beam light coupler (3). Removal 1) Remove the combination meter assembly. Refer to “Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”. 2) Remove the upper panel (1). I817H2940010-01 4) Remove the screws (4).
  • Page 47 Prepared by September, 2007 Part No. 99501-36180-01E Printed in Japan...
  • Page 48 Printed in Japan...

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