Suzuki GSF650SA Manuals

Manuals and User Guides for Suzuki GSF650SA. We have 2 Suzuki GSF650SA manuals available for free PDF download: Service Manual

Suzuki GSF650SA Service Manual (697 pages)

Brand: Suzuki | Category: Motorcycle | Size: 60.73 MB

Section 1 Engine

71
- General Information
  13
- Vehicle Identification Number
  16
- Fuel and Oil Recommendation
  16
- Cylinder Identification
  17
- Maintenance and Lubrication
  34
- Scheduled Maintenance
  34
- Fuel Line Inspection
  45
- Table of Contents
  71
- Table of Contents
  72
- Precautions
  
  75
  - Precautions for Engine
    75
  - Section
    75
- Engine General Information and Diagnosis
  
  76
- General Description
  
  76
- Schematic and Routing Diagram
  
  81
- Diagnostic Information and Procedures
  
  84
- Specifications
  
  193
  - Service Data
    193
- Special Tools and Equipment
  
  194
  - Special Tool
    194
- Emission Control Devices
  
  195
- Precautions
  
  195
  - Precautions for Emission Control Devices
    195
- General Description
  
  195
- Schematic and Routing Diagram
  
  198
  - PAIR System Hose Routing Diagram
    198
- Repair Instructions
  
  199
- Special Tools and Equipment
  
  204
  - Recommended Service Material
    204
  - Special Tool
    204
- Engine Electrical Devices
  
  205
- Precautions
  
  205
  - Precautions for Engine Electrical Device
    205
  - Engine Electrical Components Location
    205
- Diagnostic Information and Procedures
  
  205
  - Engine Symptom Diagnosis
    205
- Repair Instructions
  
  205
  - ECM Removal and Installation
    205
  - CKP Sensor Inspection
    205
  - CKP Sensor Removal and Installation
    205
  - IAP Sensor (#1) Removal and Installation
    206
  - IAP / TP / IAT Sensor Inspection
    206
  - IAP / TP / IAT Sensor Removal and Installation
    206
  - ECT Sensor Removal and Installation
    206
  - ECT Sensor Inspection
    207
  - TO Sensor Removal and Installation
    207
  - TO Sensor Inspection
    207
  - STP Sensor Inspection
    207
  - STP Sensor Adjustment
    208
  - STP Sensor Removal and Installation
    208
  - STV Actuator Inspection
    209
  - STV Actuator Removal and Installation
    209
  - ISC Valve Inspection
    209
  - ISC Valve Removal and Installation
    209
  - ISC Valve Preset and Opening Initialization
    209
  - HO2 Sensor Inspection
    210
  - HO2 Sensor Removal and Installation
    210
  - GP Switch Inspection
    210
  - GP Switch Removal and Installation
    210
  - Service Data
    211
  - Tightening Torque Specifications
    211
- Special Tools and Equipment
  
  212
  - Recommended Service Material
    212
  - Special Tool
    212
- Engine Mechanical
  
  213
- Schematic and Routing Diagram
  
  213
- Diagnostic Information and Procedures
  
  216
  - Engine Mechanical Symptom Diagnosis
    216
  - Compression Pressure Check
    216
- Repair Instructions
  
  217
  - Engine Components Removable with the Engine in Place
    217
  - Air Cleaner Element Removal and Installation
    219
  - Air Cleaner Element Inspection and Cleaning
    219
  - Air Cleaner Box Removal and Installation
    219
  - Throttle Cable Removal and Installation
    219
  - Throttle Cable Inspection
    220
  - Adjustment
    220
  - Throttle Body Components
    220
  - Throttle Body Construction
    221
  - Throttle Body Removal and Installation
    222
  - Throttle Body Disassembly and Assembly
    223
  - Throttle Body Inspection and Cleaning
    227
  - Throttle Valve Synchronization
    228
  - Engine Assembly Removal
    230
  - Engine Assembly Installation
    233
  - Engine Top Side Disassembly
    236
  - Engine Top Side Assembly
    238
  - Valve Clearance Inspection and Adjustment
    245
  - Cylinder Head Cover Inspection
    246
  - Camshaft Inspection
    246
  - Camshaft Sprocket Inspection
    248
  - Camshaft Sprocket Removal and Installation
    248
  - Cam Chain Tension Adjuster Inspection
    248
  - Cam Chain Guide Removal and Installation
    249
  - Cam Chain Guide Inspection
    249
  - Cam Chain Tensioner Inspection
    249
  - Cylinder Head Disassembly and Assembly
    250
  - Cylinder Head Related Parts Inspection
    253
  - Valve Guide Replacement
    256
  - Valve Seat Repair
    257
  - Cylinder Disassembly and Assembly
    258
  - Cylinder Inspection
    259
  - Piston Ring Removal and Installation
    260
  - Piston and Piston Ring Inspection
    261
  - Engine Bottom Side Disassembly
    263
  - Engine Bottom Side Assembly
    270
  - Conrod Removal and Installation
    279
  - Conrod and Crankshaft Inspection
    281
  - Conrod Crank Pin Bearing Inspection and Selection
    282
  - Crankshaft Journal Bearing Inspection and Selection
    283
  - Crankshaft Thrust Clearance Inspection and Selection
    285
  - Service Data
    288
  - Tightening Torque Specifications
    290
- Special Tools and Equipment
  
  291
  - Recommended Service Material
    291
  - Special Tool
    291
- Engine Lubrication System
  
  294
- Precautions
  
  294
  - Precautions for Engine Oil
    294
- Schematic and Routing Diagram
  
  295
  - Engine Lubrication System Chart Diagram
    295
  - Oil Pan
    295
- Diagnostic Information and Procedures
  
  296
  - Engine Lubrication Symptom Diagnosis
    296
  - Oil Pressure Check
    296
- Repair Instructions
  
  297
- Specifications
  
  305
  - Service Data
    305
  - Tightening Torque Specifications
    305
- Special Tools and Equipment
  
  306
  - Recommended Service Material
    306
  - Special Tool
    306
- Engine Cooling System
  
  307
- Precautions
  
  307
  - Engine Cooling System Warning
    307
  - Precautions for Engine Coolant
    307
- General Description
  
  307
  - Engine Coolant Description
    307
- Schematic and Routing Diagram
  
  308
  - Cooling Circuit Diagram
    308
  - Water Hose Routing Diagram
    309
- Diagnostic Information and Procedures
  
  310
  - Engine Cooling Symptom Diagnosis
    310
- Repair Instructions
  
  310
  - Cooling Circuit Inspection
    310
  - Radiator Cap Inspection
    311
  - Radiator / Cooling Fan Motor Removal and Installation
    311
  - Radiator Inspection and Cleaning
    312
  - Radiator Hose Removal and Installation
    312
  - Radiator Reservoir Tank Inspection
    313
  - Water Hose Inspection
    313
  - Radiator Reservoir Tank Removal and Installation
    313
  - Cooling Fan Inspection
    314
  - Cooling Fan Relay Inspection
    314
  - ECT Sensor Removal and Installation
    315
  - ECT Sensor Inspection
    315
  - Thermostat Connector / Thermostat Removal and Installation
    315
  - Thermostat Inspection
    316
  - Water Pump Components
    317
  - Water Pump Construction
    318
  - Water Pump Removal and Installation
    318
  - Water Pump Disassembly and Assembly
    319
  - Water Pump Related Parts Inspection
    322
- Specifications
  
  323
  - Service Data
    323
  - Tightening Torque Specifications
    324
- Special Tools and Equipment
  
  324
  - Recommended Service Material
    324
  - Special Tool
    324
- Fuel System
  
  325
- Precautions
  
  325
  - Precautions for Fuel System
    325
- General Description
  
  326
  - Fuel System Description
    326
- Schematic and Routing Diagram
  
  327
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram
    327
- Diagnostic Information and Procedures
  
  328
  - Fuel System Diagnosis
    328
- Repair Instructions
  
  329
- Specifications
  
  339
  - Service Data
    339
  - Tightening Torque Specifications
    339
- Special Tools and Equipment
  
  340
  - Recommended Service Material
    340
  - Special Tool
    340
- Ignition System
  
  341
- Schematic and Routing Diagram
  
  341
  - Ignition System Diagram
    341
  - Ignition System Components Location
    341
- Diagnostic Information and Procedures
  
  341
  - Ignition System Symptom Diagnosis
    341
  - No Spark or Poor Spark
    342
- Repair Instructions
  
  343
- Specifications
  
  349
  - Service Data
    349
  - Tightening Torque Specifications
    349
- Special Tools and Equipment
  
  349
  - Special Tool
    349
- Starting System
  
  350
- Schematic and Routing Diagram
  
  350
  - Starting System Diagram
    350
- Component Location
  
  350
  - Starting System Components Location
    350
- Diagnostic Information and Procedures
  
  350
- Repair Instructions
  
  352
- Specifications
  
  361
  - Service Data
    361
  - Tightening Torque Specifications
    361
- Special Tools and Equipment
  
  362
  - Recommended Service Material
    362
  - Special Tool
    362
- Charging System
  
  363
- Schematic and Routing Diagram
  
  363
  - Charging System Diagram
    363
- Component Location
  
  363
  - Charging System Components Location
    363
- Diagnostic Information and Procedures
  
  363
  - Charging System Symptom Diagnosis
    363
  - Battery Runs down Quickly
    364
- Repair Instructions
  
  365
  - Battery Current Leakage Inspection
    365
  - Regulated Voltage Inspection
    365
  - Generator Inspection
    365
  - Generator Removal and Installation
    366
  - Regulator / Rectifier Construction
    370
  - Regulator / Rectifier Inspection
    370
  - Battery Components
    371
  - Battery Charging
    371
  - Battery Removal and Installation
    374
  - Battery Visual Inspection
    374
- Specifications
  
  375
  - Service Data
    375
  - Tightening Torque Specifications
    375
- Special Tools and Equipment
  
  375
  - Recommended Service Material
    375
  - Special Tool
    376
- Exhaust System
  
  377
- Precautions
  
  377
  - Precautions for Exhaust System
    377
- Repair Instructions
  
  378
- Specifications
  
  382
  - Tightening Torque Specifications
    382
- Special Tools and Equipment
  
  382
  - Recommended Service Material
    382
Section 2 Suspension

383
- Precautions
  
  385
  - Precautions for Suspension
    385
- 2A-1 Suspension General Diagnosis
  
  386
- Diagnostic Information and Procedures
  
  386
  - Suspension and Wheel Symptom Diagnosis
    386
- Repair Instructions
  
  387
  - Front Fork Components
    387
  - Front Fork Removal and Installation
    388
  - Front Fork Disassembly and Assembly
    389
  - Front Fork Inspection
    395
  - Front Fork Parts Inspection
    395
- Front Suspension
  
  387
- Special Tools and Equipment
  
  396
  - Recommended Service Material
    396
  - Special Tool
    397
- Specifications
  
  396
  - Service Data
    396
  - Tightening Torque Specifications
    396
- Rear Suspension
  
  398
- Repair Instructions
  
  398
- Specifications
  
  410
  - Service Data
    410
  - Tightening Torque Specifications
    410
- Special Tools and Equipment
  
  410
  - Recommended Service Material
    410
  - Special Tool
    411
- Wheels and Tires
  
  412
- Precautions
  
  412
  - Precautions for Wheel and Tire
    412
- Repair Instructions
  
  413
- Specifications
  
  437
  - Service Data
    437
  - Tightening Torque Specifications
    437
Section 3 Driveline / Axle

439
- Precautions
  
  440
  - Precautions for Driveline / Axle
    440
- Diagnostic Information and Procedures
  
  441
  - Drive Chain and Sprocket Symptom Diagnosis
    441
- Repair Instructions
  
  441
- Drive Chain / Drive Train / Drive Shaft
  
  441
- Specifications
  
  450
  - Service Data
    450
  - Tightening Torque Specifications
    451
- Special Tools and Equipment
  
  451
  - Recommended Service Material
    451
  - Special Tool
    451
Section 4 Brake

453
- Precautions
  
  455
  - Precautions for Brake System
    455
  - Brake Fluid Information
    455
- Schematic and Routing Diagram
  
  456
- Brake Control System and Diagnosis
  
  456
- Repair Instructions
  
  459
- Diagnostic Information and Procedures
  
  459
  - Brake Symptom Diagnosis
    459
- Specifications
  
  470
  - Service Data
    470
  - Tightening Torque Specifications
    471
- Special Tools and Equipment
  
  471
  - Recommended Service Material
    471
  - Special Tool
    471
- Front Brakes
  
  472
- Repair Instructions
  
  472
- Specifications
  
  478
  - Service Data
    478
  - Tightening Torque Specifications
    478
- Special Tools and Equipment
  
  478
  - Recommended Service Material
    478
  - Special Tool
    479
- Rear Brakes
  
  480
- Repair Instructions
  
  480
  - Rear Brake Components
    480
  - Rear Brake Pad Inspection
    481
  - Rear Brake Pad Replacement
    481
  - Rear Brake Caliper Removal and Installation
    482
  - Rear Brake Caliper Disassembly and Assembly
    483
  - Rear Brake Caliper Parts Inspection
    485
  - Rear Brake Disc Removal and Installation
    485
  - Rear Brake Disc Inspection
    486
- Specifications
  
  486
  - Service Data
    486
  - Tightening Torque Specifications
    487
- Special Tools and Equipment
  
  487
  - Recommended Service Material
    487
  - Special Tool
    487
- Precautions
  
  488
  - Precautions for ABS
    488
  - ABS Information
    488
- General Description
  
  488
- Abs
  
  488
- Schematic and Routing Diagram
  
  494
  - ABS Wiring Diagram
    494
  - ABS Unit Diagram
    495
  - Front Wheel Speed Sensor Routing Diagram
    496
  - Rear Wheel Speed Sensor Routing Diagram
    498
- Component Location
  
  499
  - ABS Components Location
    499
- Diagnostic Information and Procedures
  
  500
- Repair Instructions
  
  556
- Specifications
  
  562
  - Tightening Torque Specifications
    562
- Special Tools and Equipment
  
  562
  - Special Tool
    562
Section 5 Transmission / Transaxle

565
- Precautions
  
  566
  - Precautions for Transmission / Transaxle
    566
- Diagnostic Information and Procedures
  
  567
  - Manual Transmission Symptom Diagnosis
    567
- Manual Transmission
  
  567
- Repair Instructions
  
  568
- Specifications
  
  585
  - Service Data
    585
  - Tightening Torque Specifications
    586
- Special Tools and Equipment
  
  586
  - Recommended Service Material
    586
  - Special Tool
    587
- Precautions
  
  588
  - Precautions for Clutch System
    588
  - Clutch Fluid (Brake Fluid) Information
    588
- Clutch
  
  588
- Schematic and Routing Diagram
  
  589
  - Clutch Hose Routing Diagram
    589
- Repair Instructions
  
  590
- Diagnostic Information and Procedures
  
  590
  - Clutch System Symptom Diagnosis
    590
- Specifications
  
  606
  - Service Data
    606
  - Tightening Torque Specifications
    606
- Special Tools and Equipment
  
  607
  - Recommended Service Material
    607
  - Special Tool
    607
Section 6 Steering

609
- Precautions
  
  610
  - Precautions for Steering
    610
- Steering General Diagnosis
  
  611
- Diagnostic Information and Procedures
  
  611
  - Steering Symptom Diagnosis
    611
- Repair Instructions
  
  612
  - Handlebars Components
    612
  - Handlebar Construction (GSF650/S/A/SAK7)
    613
  - Handlebars Removal and Installation
    614
  - Handlebars Inspection
    615
  - Handlebar Height Adjustment
    615
  - Steering Components
    616
  - Steering Removal and Installation
    617
  - Steering Related Parts Inspection
    619
  - Steering System Inspection
    620
  - Steering Stem Bearing Removal and Installation
    620
  - Steering Tension Adjustment
    621
  - Handlebar Construction (GSX650FK8)
    622
- Steering / Handlebar
  
  612
- Specifications
  
  622
  - Tightening Torque Specifications
    622
- Special Tools and Equipment
  
  623
  - Recommended Service Material
    623
  - Special Tool
    623
Section 9 Body and Accessories

625
- Precautions
  
  627
  - Precautions for Electrical System
    627
- Component Location
  
  627
  - Electrical Components Location
    627
- Schematic and Routing Diagram
  
  628
- Wiring Systems
  
  628
- Specifications
  
  641
- Repair Instructions
  
  642
- Lighting Systems
  
  642
- Specifications
  
  656
  - Service Data (GSF650/S/A/SAK7)
    656
  - Service Data (GSX650FK8)
    656
  - Tightening Torque Specifications
    657
- Special Tools and Equipment
  
  657
  - Special Tool
    657
- Combination Meter / Fuel Meter / Horn
  
  658
- General Description
  
  658
  - Combination Meter System Description (GSF650/S/A/SAK7)
    658
  - Combination Meter System Description (GSX650FK8)
    659
- Repair Instructions
  
  660
- Special Tools and Equipment
  
  674
  - Special Tool
    674
- Specifications
  
  674
  - Service Data (GSF650/S/A/SAK7)
    674
  - Service Data (GSX650FK8)
    674
  - Tightening Torque Specifications
    674
- Exterior Parts
  
  675
- Schematic and Routing Diagram
  
  675
  - Seat Lock Cable Routing Diagram
    675
- Repair Instructions
  
  676
- Body Structure
  
  691
- Repair Instructions
  
  691
  - Body Frame Construction
    691
  - Engine Mounting Bracket Bushing Replacement
    692
  - Engine Mount Bushing Replacement
    692
  - Front Footrest Bracket Construction
    692
  - Side-Stand Construction
    693
  - Side-Stand Removal and Installation
    693
  - Center Stand Construction
    694
  - Center Stand Removal and Installation
    694
- Specifications
  
  695
  - Tightening Torque Specifications
    695
- Special Tools and Equipment
  
  695
  - Recommended Service Material
    695

Suzuki GSF650SA Service Manual (66 pages)

Brand: Suzuki | Category: Motorcycle | Size: 2.93 MB

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Suzuki GSF650SA Manuals

Suzuki GSF650SA Service Manual (697 pages)

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Special Tools and Equipment

Engine Electrical Devices

Precautions

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Repair Instructions

Specifications

Special Tools and Equipment

Section 2 Suspension

Precautions

2A-1 Suspension General Diagnosis

Diagnostic Information and Procedures

Repair Instructions