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* 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.
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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 ........
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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...
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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...
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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.
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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.
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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.
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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.
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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”.
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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.
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 ..........
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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.
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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...
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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...
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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...
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).
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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.
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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)
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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°...
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.
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. •...
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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...
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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.
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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)
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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.
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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”...
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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.
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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”...
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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.
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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...
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• 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”...
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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.
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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...
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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 •...
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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.
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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...
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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) —...
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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...
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 ..........
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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 ......
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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 ..........
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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”.
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.
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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.
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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.
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.
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.
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.
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”.
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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.
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.
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”.
Engine Mechanical: 1D-1 Engine Mechanical Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B649G11402001 24th pin 1st pin I649G1140075-03...
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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.
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...
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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...
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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.
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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).
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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).
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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.
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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.
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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 •...
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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”. •...
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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.
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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.
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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.
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• 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.
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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.
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• 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...
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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”...
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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 •...
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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.
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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.
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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.
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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 •...
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...
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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.
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: ”.
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...
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...
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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.
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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.
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.
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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”.
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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 &...
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.
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Engine Mechanical: 1D-37 4) Refinish the valve guide holes in the cylinder head 8) 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.
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°.
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.
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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”...
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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.
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.
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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).
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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).
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Engine Mechanical: 1D-45 2) Remove the plug (2). 8) 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).
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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.
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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.
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).
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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”...
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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) –...
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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.
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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.
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• 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.
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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”. •...
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Engine Mechanical: 1D-55 CAUTION Use a new gasket washer to prevent oil leakage. I649G1140349-01 “B” I649G1140363-01 “C” I649G1140364-01 I649G1140358-01...
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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 •...
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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.
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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...
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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.
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: ”.
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.
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”...
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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”...
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”...
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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...
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: ”.
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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...
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...
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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...
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.
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.
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...
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).
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...
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...
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”.
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.
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.
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”.
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”.
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.
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.
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...
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.
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.
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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.
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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”.
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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).
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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.
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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).
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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.
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.
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.
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.
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.
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.
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...
Fuel System: 1G-19 Carburetor Assembly Removal and Installation 7) Disconnect the carburetor heater lead wire coupler B649G11706002 (2). (For E-02, 19) 8) 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”.
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 –...
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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 8) Remove the spring (6) and the piston valve along with its diaphragm (7).
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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) •...
• 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...
• 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.
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”...
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: ”.
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.
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.
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.
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.
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).
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.
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”.
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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.
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”.
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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.
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”.
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: 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”...
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.
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...
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.
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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.
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”...
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.
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...
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.
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”...
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.
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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: ”.
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.
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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.
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...
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.
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...
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.
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.
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. •...
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.
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...
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.
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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)
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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”...
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.
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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...
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...
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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.
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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.
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.
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.
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...
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.
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.
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)
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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...
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.
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.
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.
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”.
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 8) 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”.
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Front Suspension: 2B-4 2) Remove the spring seat (2). 8) 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).
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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.
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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)
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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.
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.
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) —...
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.
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.
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.
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 •...
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.
(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).
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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). •...
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.
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”.
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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.
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...
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: ”...
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. •...
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.
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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...
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”.
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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...
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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)
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.
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...
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.
(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...
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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.
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 8) As necessary, adjust the tire balance. Refer to “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.
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 —...
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: ”...
• 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.
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.
(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...
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.
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”.
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.
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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”...
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3A-8 Drive Chain / Drive Train / Drive Shaft: 8) 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.
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...
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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 ...
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.
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.
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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.
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.
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).
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.
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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.
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”.
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.
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: ”. •...
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.
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: ”.
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.
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.
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.
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”.
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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.
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: ”.
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.
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.
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...
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.
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.
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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).
• 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.
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: •...
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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...
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...
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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 ..
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).
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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).
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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).
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.
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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.
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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”.
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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.
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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). •...
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5B-10 Manual Transmission: CAUTION Use a new gasket washer to prevent oil leakage. I649G1520033-02 “B” I649G1520032-02 “C” I649G1520034-01 I649G1520031-01...
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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.
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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.
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...
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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...
• 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”...
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...
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 •...
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.
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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.
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.
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.
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...
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.
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.
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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.
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.
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.
5C-6 Clutch: 7) Close the air bleeder valve and disconnect a clear Clutch Hose Removal and Installation B649G15306012 hose. Removal 8) Fill the reservoir with new fluid to the upper mark of 1) Drain clutch fluid. Refer to “Clutch Fluid the reservoir.
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.
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) •...
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.
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).
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 •...
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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.
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.
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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.
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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 8) Put the clutch pressure plate onto the clutch sleeve (A): 09920–34820 (Clutch pressure plate hub securely.
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.
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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...
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...
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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...
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.
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.
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.
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.
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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...
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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...
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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.
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 •...
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...
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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...
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.
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...
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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 ......
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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...
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”.
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...
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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...
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.
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.
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...
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...
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.
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”.
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...
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Combination Meter / Fuel Meter / Horn: 9C-2 GSF1200S I649G1930002-02 1. Upper case assembly 2. Combination meter 3. Lower case...
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).
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.
9C-5 Combination Meter / Fuel Meter / Horn: 7) Replace the 180 Ω resister “B” with a 5 Ω one “C”. Speedometer Inspection B649G19306018 8) 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.
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: ”.
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...
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”.
← 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...
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.
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.
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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”...
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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 8) Disconnect the headlight and position light couplers.
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”.
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...
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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”.
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Prepared by December, 2005 Part No. 99500-39280-01E Printed in Japan...