FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GSF1200S and procedures for its inspection/service and overhaul of its main com- GENERAL INFORMATION ponents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Apply oil. Use engine oil unless Apply or use brake fluid. otherwise specified. Apply molybdenum oil solution (mix- ture of engine oil and SUZUKI MOLY Measure in voltage range. PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A”.
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............. 1- 2 GENERAL PRECAUTIONS .............. 1- 2 SUZUKI GSF1200SK1 (2001-MODEL) ..........1- 4 SERIAL NUMBER LOCATION ............1- 4 FUEL AND OIL RECOMMENDATION ..........1- 4 FUEL ....................1- 4 ENGINE OIL ................... 1- 5 BRAKE FLUID ................
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% etha- nol.
GENERAL INFORMATION ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer ser- vice life of your motorcycle. Use only oils which are rated SF or SG under the API service classification. MULTIGRADE The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.
GENERAL INFORMATION INFORMATION LABELS (Attached on the left frame pipe) (Attached on the right side of the rear fender) (Except E-03, 33) 5 mm (0.2 in) 10 mm 10 mm Document tray (0.4 in) (0.4 in) 10 mm 10 mm (0.4 in) (0.4 in) (E-28 Only)
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 070 mm (81.5 in) Overall width ..............765 mm (30.1 in) Overall height ..............1 220 mm (48.0 in) Wheelbase ..............1 430 mm (56.3 in) Ground clearance ............130 mm (5.1 in) Seat height ..............
GENERAL INFORMATION CHASSIS Front suspension ............Telescopic, coil spring, oil damped, spring pre-load fully adjustable Rear suspension ............Link type, oil damped, coil spring, spring pre-load 7-way adjustable, rebound damping force 4-way adjustable Steering angle .............. 35° (right & left) Caster ................
GENERAL INFORMATION COUNTRY OR AREA CODES The following codes stand for the applicable country(-ies) and area(-s). CODE COUNTRY or AREA E-02 England (UK) E-03 E-19 European markets E-24 Australia E-28 Canada E-33 California (USA) E-54 Israel...
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below 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, and are dependant on whichever comes first. NOTES: More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. !" Clutch lever holder #" Drive chain !" Gearshift lever pivot and footrest pivot Side-stand pivot !"...
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart. VALVE CLEARANCE Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 12 000 km (7 500 miles, 12 months). •...
($3-48) ( 99000-31140: SUZUKI BOND “1207B” • Tighten the cylinder head cover bolts to the specified torque. ) Cylinder head cover bolt: 14 N . m (1.4 kgf . m, 10.0 lb-ft) •...
PERIODIC MAINTENANCE NOTE: If it is difficult to remove any of the spark plug caps, pry them up using a screwdriver. & 09930-10121: Spark plug wrench set 09900-20803: Thickness gauge Standard Cold type Hot type JR9B JR10B JR8B CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug.
PERIODIC MAINTENANCE EXHAUST PIPE BOLTS AND MUFFLER BOLTS Tighten initially at 1 000 km (600 miles, 1 month) and ev- ery 12 000 km (7 500 miles, 12 months) thereafter. • Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.
PERIODIC MAINTENANCE • Reinstall the cleaned or new air cleaner element in the re- verse order of removal. • When installing the air cleaner element into the air cleaner case, make sure that the * mark A points up. If driving under dusty conditions, clean the air cleaner element more frequently.
PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER (ENGINE OIL) Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (600 miles, 1 month) and every 18 000 km (11 000 miles, 18 months) thereafter.
Other manufacturer’s oil filters may differ in thread speci- fications (thread diameter and pitch), filtering perfor- mance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automo- bile oil filter on this motorcycle. FUEL HOSE Inspect every 6 000 km (4 000 miles, 6 months).
PERIODIC MAINTENANCE 2-11 ENGINE IDLE SPEED Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Start the engine, turn the throttle stop screw and set the en- gine idle speed between 1 100 and 1 300 r/min.
2-12 PERIODIC MAINTENANCE 3rd step: • While holding the throttle grip at the fully closed position, slowly turn out the adjuster 3 of the throttle returning cable 2 until resistance is felt. • Tighten the locknut 1 while holding the adjuster 3. % Throttle cable play A: 2 –...
PERIODIC MAINTENANCE 2-13 CLUTCH (CLUTCH FLUID) Inspect every 12 000 km (12 months). Replace fluid every 2 years. (CLUTCH HOSE) Inspect every 6 000 km (6 months). Replace hose every 4 years. CLUTCH FLUID LEVEL • Keep the motorcycle upright and place the handlebars straight. •...
2-14 PERIODIC MAINTENANCE DRIVE CHAIN Inspect initially at 1 000 km (600 miles, 1 month) and ev- Grease ery 6 000 km (4 000 miles, 6 months) thereafter. “O” ring Lubricate every 1 000 km (600 miles). With the transmission in neutral, support the motorcycle using the center-stand and turn the rear wheel slowly by hand.
* Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. * The standard drive chain is a RKGB50MFOZ1. SUZUKI recommends to use this standard drive chain as a re- placement.
2-16 PERIODIC MAINTENANCE BRAKES (BRAKE) Inspect initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 6 months) thereafter. (BRAKE HOSE AND BRAKE FLUID) Inspect every 6 000 km (4 000 miles, 6 months). Replace hoses every 4 years.
PERIODIC MAINTENANCE 2-17 BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line 1 on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ($5-44 and -54) Replace the brake pads as a set, otherwise braking per- formance will be adversely affected.
2-18 PERIODIC MAINTENANCE AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin- der and thus interferes with the full braking performance of the brake caliper.
PERIODIC MAINTENANCE 2-19 • Rear brake: The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal. TIRES Inspect every 6 000 km (4 000 miles, 6 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation.
2-20 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be ad- versely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.
PERIODIC MAINTENANCE 2-21 FRONT FORKS Inspect every 12 000 km (7 500 miles, 12 months). Inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. ($5-12) REAR SUSPENSION Inspect every 12 000 km (7 500 miles, 12 months).
2-22 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (600 miles, 1 month) and ev- ery 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-23 for the locations of the following nuts and bolts.) kgf .
2-24 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK 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. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
PERIODIC MAINTENANCE 2-25 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION Above 300 kPa (3.0 kgf/cm , 43 psi) at 3 000 r/min., oil temp. at 60°C (140°F) Below 600 kPa (6.0 kgf/cm , 85 psi) If the oil pressure is lower or higher than the specification, the following causes may be considered.
ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ................3- 2 ENGINE REMOVAL AND REINSTALLATION ........3- 3 ENGINE REMOVAL ................3- 3 ENGINE REINSTALLATION ............. 3- 8 ENGINE DISASSEMBLY AND REASSEMBLY ........3-12 ENGINE DISASSEMBLY ..............3-12 ENGINE REASSEMBLY ..............
ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the page listed in each section for removal and reinstallation instructions. ENGINE CENTER See page Exhaust pipe/muffler ......
ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. • Remove the seat and frame side covers. (!5-5 and -6) •...
ENGINE • Disconnect the PAIR valve hoses 1, 2 and 3. 1 Air cleaner hose 2 Vacuum hose 3 PAIR hoses • Loosen the respective carburetor clamp screws 4. • Disconnect the throttle position sensor lead wire coupler 5. • Slightly move the air cleaner box backward. •...
ENGINE • Remove the two wire clamps. • Disconnect the starter motor lead wire 1. • Disconnect the generator lead wire 2 and coupler 3. • Remove the gearshift lever by removing its mounting bolt. • Remove the engine sprocket cover by removing the bolts. •...
ENGINE • Remove the eight exhaust pipe bolts. • Remove the muffler mounting bolts. • Remove the exhaust pipe/muffler. • Remove the oil cooler hose union bolts 1. • Remove the oil cooler by removing the mounting bolts 2.
ENGINE • Suppport the engine with a proper engine jack. • Remove the frame down tube mounting bolts and nuts. • Remove the frame down tube 1. • Remove the engine mounting bolts, nuts, spacer and brackets. • Gradually lower the engine. NOTE: Only for E-28 model;...
ENGINE ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. • Insert the two long bolts from left side. Install the brackets, spacer, bolts and nuts properly, as shown in the following illustration. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
ENGINE • Tighten the oil cooler mounting bolts to the specified torque. " Oil cooler mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) • Tighten the oil cooler hose union bolts to the specified torque. " Oil cooler hose union bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) Use a new gasket washer to prevent oil leakage.
" Speed sensor rotor bolt 2: 20 N . m (2.0 kgf . m, 14.5 lb-ft) • Before installing the engine sprocket cover, apply a small quan- tity of SUZUKI SUPER GREASE “A” to the clutch release mechanism. & 99000-25010: SUZUKI SUPER GREASE “A”...
ENGINE 3-11 • After remounting the engine, route the wire harness, cables and hoses properly. (!7-12) • Install the gearshift lever to the gearshift shaft in the correct position. ' Gearshift lever height A Standard: 55 mm (2.2 in) • Tighten the oil drain plug 1 to the specified torque. "...
3-12 ENGINE ENGINE DISASSEMBLY AND REASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake, exhaust) so that they can be reinstalled in their original positions. ENGINE DISASSEMBLY • Remove each PAIR valve pipe and hose. •...
ENGINE 3-13 • Remove the signal generator cover 1. ( 09911-73730: 5 mm “T” type hexagon wrench • Remove all of the spark plugs. • Turn the crankshaft clockwise and align the “T” mark on the signal generator rotor with the center of the pickup coil. Also, position the notches 2 on the right end of each camshaft as shown.
3-14 ENGINE • Remove the cam chain guide 1. • Remove the cylinder head bolt 2. • The cylinder head can be removed when its twelve 10-mm nuts are removed. NOTE: When loosening the cylinder head nuts, loosen each nut little by little, in descending order, according to the numbers cast on the cylinder head.
ENGINE 3-15 • Remove the left and right oil pipes 1. • Remove the cylinder base nut 2. • Firmly grip the cylinder block at both ends and lift it straight up. If the cylinder block does not come off, lightly tap on the finless portions of it using a plastic mallet.
3-16 ENGINE • Remove the starter motor 1. • Remove the generator 2. • Remove the signal generator rotor 3 using the special tool. ( 09900-00410: Hexagon wrench set • Disconnect the oil pressure switch lead wire 4. • Remove the signal generator stator (along with the pickup coil) 5 and oil pressure switch 6.
ENGINE 3-17 • Remove the clutch pressure plate lifter 1 by removing the circlip. ( 09900-06108: Snap ring pliers • After removing the clutch pressure plate lifter, remove the thrust washer 2, bearing 3 and clutch push piece 4, and pull out the clutch push rods, 5 and 6.
3-18 ENGINE • Remove the clutch diaphragm springs 1, clutch diaphragm spring seat 2 and clutch pressure plate 3. • Remove the clutch drive and driven plates along with the clutch sleeve hub. • Remove the thrust washer 4. • With the spacer and bearing removed, the primary driven gear (integral with the clutch housing) is free to disengage from the primary drive gear.
ENGINE 3-19 • Draw out the gearshift shaft 1, and then remove the gearshift cam driven gear 2. ( 09900-09004: Impact driver set NOTE: When removing the gearshift cam driven gear, do not lose the gearshifting pawl 3 , pin 4 and spring 5 . •...
3-20 ENGINE • Hold the starter clutch assembly using the special tool and then loosen the starter clutch mounting bolt. ( 09920-34840: Starter clutch holder NOTE: Do not remove the starter clutch mounting bolt at this stage, only loosen it. You will need to use it in conjunction with the special tool when removing the starter clutch assembly.
ENGINE 3-21 • Remove the countershaft bearing retainer 1. • Remove the plug 2. • Remove the upper crankcase bolts and nut. • Remove the oil pan 3. • Remove the shim 4 and O-ring 5. • Remove the oil sump filter 6. •...
3-22 ENGINE • Remove the main oil gallery plug 1 and O-ring. ( 09900-00410: Hexagon wrench set • Loosen the crankcase bolts in descending numerical order and then remove them. NOTE: Two allen bolts are located at position A to tighten the crank- shaft.
ENGINE 3-23 • Remove the dampers 1 and cam chain tensioner guide 2. • Remove the O-rings (3 and 4). NOTE: * Do not remove the crankshaft journal bearings unless abso- lutely necessary. * Make a note of where the crankshaft journal bearings are re- moved from so that they can be reinstalled in their original po- sitions.
3-24 ENGINE • Unhook the gearshift cam stopper spring 1 from the lower crankcase. • Remove the circlip 2 from the gearshift cam, then draw out the gearshift cam 3 from the opposite side. ( 09900-06107: Snap ring pliers • Remove the circlip 4 and gearshift cam stopper 5. ( 09900-06107: Snap ring pliers NOTE: Rotate the bearing 6 in the crankcase by hand to inspect for...
ENGINE 3-25 • Remove the oil pump 1. ( 09900-00410: Hexagon wrench set • Remove the O-rings and dowel pins.
3-26 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary mea- sures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. • Install the O-rings (1 and 2) and dowel pins 3 in the correct position as shown.
ENGINE 3-27 NOTE: When installing the gearshift cam stopper plate 1 , align the pin groove A with the pin B as shown. • Install the gearshift cam 2 and its related parts. 3 Gearshift cam stopper 4 Circlip 5 Spring 6 Circlip Always use new circlips (4 4 4 4 4 and 6 6 6 6 6 ).
3-28 ENGINE • Hold the gearshift forks 1 by hand when installing the gear- shift fork shaft 2. • Install the bearing pins 3 and C-rings 4 into the upper crank- case. • Install the countershaft assembly 5 and driveshaft assembly 6 into the upper crankcase.
• Before installing the crankshaft assembly, apply molybdenum oil solution to each crankshaft journal bearing. ) 99000-25140: SUZUKI MOLY PASTE • Install the crankshaft assembly along with the cam chain into the upper crankcase. • Insert the right-and left-thrust bearings with the oil grooves fac- ing towards the crankshaft web.
3-30 ENGINE BOND “1207B” should be applied to the following locations. The line of BOND...
ENGINE 3-31 • Install the right oil pipe A with the bolt 1. • Install the copper washers onto bolts 9 and A. • Install the two allen bolts at position B. • Install the ten crankcase bolts (8 mm). •...
3-32 ENGINE • Install the left oil pipe 1. • Install a new O-ring 2 and shim 3. • Install a new gasket and the oil sump filter 4. Replace the gasket and O-ring with new ones to prevent oil leakage. •...
• Apply a light coat of the recommended bond to the starter clutch cover gasket mating surface as shown. * 99000-31140: SUZUKI BOND “1207B” • Install the dowel pin, a new gasket and the starter clutch cover, and tighten the cover bolts securely.
3-34 ENGINE • Install each pawl 1 into the gearshift cam driven gear 2. • The large shoulder A must face to the outside. • Install the cam guide 3 and pawl lifter 4. • Apply a small quantity of THREAD LOCK “1342” to the screws. ( 09900-09004: Impact driver set # 99000-32050: THREAD LOCK “1342”...
ENGINE 3-35 • Install the generator/oil pump drive gears 1 onto the primary driven gear assembly as shown. • Install the primary driven gear assembly onto the countershaft, and apply engine oil onto the needle bearing and spacer. • Install the thrust washer 2 onto the countershaft. •...
3-36 ENGINE No. 1 and No. 2 drive plates resemble each other very closely in external appearance. Make sure to check the number of facing before installing them. No.1: 40 pcs Drive plate No. 1: 40 pcs No.2: 48 pcs Drive plate No.
• Apply a light coat of the recommended bond to the clutch cover gasket mating surface A as shown. * 99000-31140: SUZUKI BOND “1207B” • Install the dowel pins, a new gasket and the clutch cover. • Tighten the clutch cover bolts securely.
3-38 ENGINE Diaphragm springs Diaphragm spring holder 150 N . m (15.0 kgf . m, 108.5 lb-ft)
• Install the oil pressure switch, apply the recommended bond to its thread and tighten it to the specified torque. * 99000-31140: SUZUKI BOND “1207B” " Oil pressure switch: 14 N . m (1.4 kgf . m, 10.0 lb-ft) • Install the signal generator stator (along with the pickup coil) •...
" Starter motor mounting bolt: 6 N . m (0.6 kgf . m, 4.5 lb-ft) NOTE: * Apply SUZUKI SUPER GREASE “A” to the starter motor O- ring. * Apply a small quantity of THREAD LOCK “1342” to the two bolts.
Refer to the scribe marks on each piston. • Before installing the piston pins, apply molybdenum oil solu- tion to their surfaces. ) 99000-25140: SUZUKI MOLY PASTE • Place a cloth beneath the piston, and install the circlips 3. NOTE: * Install the pistons with the arrow mark facing towards the ex- haust side.
Replace the O-rings and gasket with new ones to pre- vent oil leakage. • Install the new O-rings 2 onto the oil pipes and apply SUZUKI SUPER GREASE “A” to the O-rings. • Install the right and left oil pipes.
6-mm T-type wrench. NOTE: Before installing the camshafts onto the cylinder head, apply mixed engine oil/moly paste onto the camshaft journals and do not leave any dry spots. Also, apply engine oil onto the camshaft journal holders. ) 99000-25140: SUZUKI MOLY PASTE...
3-44 ENGINE • The exhaust camshaft has the embossed letters “EX” and the intake camshaft has the embossed letters “IN”. Also, the right end of each camshaft has a notch A. • When the “T” mark on the signal generator rotor is aligned with the center of the pickup coil, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the crankshaft sprocket and the exhaust camshaft sprocket.
3-46 ENGINE • Each camshaft journal holder is identified with an embossed letter. Install the dowel pins into each cam- shaft journal holder. • Fasten the camshafts (IN and EX) evenly by tightening the camshaft journal holder bolts sequentially and in a crisscross pattern.
ENGINE 3-47 • After removing the spring holder bolt 1 and spring, unlock the ratchet mechanism 2 and push the push rod 3 all the way into the cam chain tensioner. NOTE: Before installing the cam chain tensioner, turn the crankshaft clock- wise to remove any cam chain slack between the crankshaft sprocket and exhaust camshaft sprocket.
ENGINE • Apply a light coat of the recommended bond to the signal gen- erator gasket mating surface A as shown. * 99000-31140: SUZUKI BOND “1207B” • Install a new gasket and the signal generator cover. NOTE: * Install the gasket washer onto the signal generator cover bolt B as shown.
ENGINE 3-49 • Install the left and right oil hoses and tighten their mounting bolts to the specified torque. Replace the O-rings (A and B) with new ones to prevent oil leakage. " Oil hose mounting bolt: 10 N . m (1.0 kgf . m, 7.0 lb-ft) •...
3-50 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE CAMSHAFT/CYLINDER HEAD INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake, exhaust, #1 or #2) so that they can be installed in their original loca- tions.
ENGINE 3-51 NOTE: Do not rotate the camshafts with the plastigauge in place. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the compressed plastigauge.
If it is necessary to replace the cam chain tensioner guide, re- move the engine and separate the upper and lower crankcases. ($3-23) NOTE: When replacing the cam chain guides A and B , apply SUZUKI THREAD LOCK SUPER ‘‘1303’’ to threads of bolt and screws. & &...
ENGINE 3-53 CYLINDER HEAD DISASSEMBLY • Remove the rocker arm shaft set bolt 1 and cylinder head plug " 09900-00410: Hexagon wrench set • Remove the rocker arm shaft 1, rocker arm 2 and spring 3. NOTE: To remove the rocker arm shaft, screw a 8-mm bolt into the rocker arm shaft end and then pull out the shaft.
3-54 ENGINE • Remove the valve spring seat. • Remove the valve from the combustion chamber side. • Remove the oil seal. CYLINDER HEAD DISTORTION Decarbonize the combustion chambers. Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge.
ENGINE 3-55 VALVE FACE WEAR Visually inspect each valve face for wear. Replace any valve with an abnormally worn face. The thickness of the valve face de- creases as the face wears. Measure the valve face T. If it is out of specification replace the valve with a new one.
3-56 ENGINE VALVE GUIDE SERVICING • Using the valve guide remover 1, drive the valve guide out toward the intake or exhaust camshaft side. " 09916-44310: Valve guide remover/installer NOTE: * Discard the removed valve guide subassemblies. * Only oversized valve guides are available as replacement parts. (Part No.
ENGINE 3-57 VALVE SEAT WIDTH • Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.
3-58 ENGINE • When installing the solid pilot 1, rotate it slightly. • Seat the pilot snugly. Install the 45° cutter 2, attachment 3 and T-handle 4. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns.
ENGINE 3-59 15° FINAL SEAT CUT Contact area too low and too narrow on face of valve • If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. NOTE: After cutting the 15°...
3-60 ENGINE VALVE SEAT SEALING CONDITION INSPECTION Clean and assemble the cylinder head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
ENGINE 3-61 # Valve spring tension (IN & EX) For outer Standard: INNER: 53 – 65 N, 5.3 – 6.5 kgf/28 mm 13.1 – 15.1 kgf spring (11.7 – 14.3 lbs/1.10 in) OUTER: 131 – 151 N, 13.1 – 15.1 kgf/31.5 mm 31.5 mm (28.9 –...
Coat the entire stem making sure that there are no gaps. When inserting each valve, take care not to damage the lip of the oil seal. ( 99000-25140: SUZUKI MOLY PASTE • Install the valve springs with the smaller pitch A facing the cylinder head.
% Rocker arm shaft set bolt 4: 9 N . m (0.9 kgf . m, 6.5 lb-ft) Cylinder head plug 5: 28 N . m (2.8 kgf . m, 20.0 lb-ft) INTAKE PIPES • When installing the intake pipe, apply SUZUKI SUPER GREASE “A” to the O-ring. ) 99000-25010: SUZUKI SUPER GREASE “A”...
3-64 ENGINE • When installing the intake pipe bolts, apply a small quantity of THREAD LOCK “1342” to these thread. * 99000-32050: THREAD LOCK “1342” Use a new O-ring to prevent the joint from sucking in any air. NOTE: * When replacing the intake pipes, identify the different intake pipes according to each I.D.
ENGINE 3-65 CYLINDER BLOCK/PISTON INSPECTION CYLINDER BLOCK DISTORTION Check the gasket surface of the cylinder block for distortion. Use a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder block. "...
3-66 ENGINE PISTON-TO-CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylin- der and the piston. # Piston-to-cylinder clearance Service Limit: 0.12 mm (0.0047 in) Piston oversize: 0.5, 1.0 mm PISTON-RING-TO-GROOVE CLEARANCE...
ENGINE 3-67 Oversize piston ring The following two types of oversize piston rings are used. They bear the following identification numbers. 0.5 mm O.S. 0.5 mm Oversize oil ring The following two types of oversize oil rings are available as op- 0.5 mm tional parts.
3-68 ENGINE • The 1st 1 and 2nd 2 piston rings should be installed with the mark facing up. • First, install a spacer 3 into the oil ring groove and then install the two side rails 4. The spacer and side rails do not have a designated top and bottom.
ENGINE 3-69 CLUTCH INSPECTION CLUTCH DIAPHRAGM SPRING Measure the free height of each diaphragm spring with a vernier calipers. If each diaphragm spring height is not within the speci- fied limit, replace it with a new one. " 09900-20102: Vernier calipers Spring height # Clutch spring free height Service Limit: 3.1 mm (0.12 in)
3-70 ENGINE CLUTCH RELEASE CYLINDER DISASSEMBLY • Remove the gearshift lever and engine sprocket cover. ( $ 3-5) • Remove the clutch hose by removing the union bolt 1. • Remove the air bleeder valve 2. • Remove the clutch release cylinder by removing the mounting bolts 3 and piston retainer screws 4.
" 09943-88211: Pinion bearing installer The removed oil seal must be replaced with a new one. NOTE: Apply SUZUKI SUPER GREASE “A” onto the oil seal lip to pre- vent oil seal damage when installing the lower crankcase. ) 99000-25010: SUZUKI SUPER GREASE “A”...
3-72 ENGINE GEARSHIFT SHAFT HOLE INSPECTION Check the gearshift shaft hole for damage or wear. GEARSHIFT SHAFT REASSEMBLY When installing the gearshift shaft return spring, position the stop- per between the ends of the gearshift shaft return spring.
ENGINE 3-73 TRANSMISSION INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., drive or driven) so that they can be reinstalled in their original positions. GEARSHIFT FORK-TO-GEARSHIFT FORK GROOVE CLEARANCE Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge.
3-74 ENGINE DISASSEMBLY Countershaft assembly • Remove the left end bearing 1 and oil seal 2. • Remove the 5th (top) drive gear circlip 3 from its groove and slide it towards the 3rd drive gear 4. " 09900-06107: Snap ring pliers •...
* Before installing the gears, lightly coat the driveshaft, counter- shaft and bushings with molybdenum oil solution. * Before installing the oil seal, apply SUZUKI SUPER GREASE “A” to the oil seal lip. ( 99000-25140: SUZUKI MOLY PASTE ) 99000-25010: SUZUKI SUPER GREASE “A”...
3-76 ENGINE Driveshaft assembly • Align the bushing oil hole 1 with the shaft oil hole 2. • With the lock washer turned in its groove A, align the cutout B of the lock washer with the tab C on the gear bushing. •...
ENGINE 3-77 Install the oil seal as shown in the illustration. 1 Left end bearing 2 Oil seal 3 2nd drive gear 4 Countershaft A 115 N . m (11.5 kgf . m, 83.0 ib-ft) B 13 N . m (1.3 kgf . m, 9.5 lb-ft) 1 1st (low) driven gear 2 4th driven gear 3 3rd driven gear...
ENGINE 3-79 CONROD/CRANKSHAFT INSPECTION CONROD SMALL END I.D. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. " 09900-20602: Dial gauge (1/1000 mm) 09900-22403: Small bore gauge (18 –...
3-80 ENGINE • Remove the conrods and mark them to identify their respective cylinders. • Inspect the bearing surfaces for any signs of fusion, pitting, burns, or flaws. If there is any damage, replace them with the specified set of bearings. CONROD-CRANK PIN BEARING SELECTION •...
ENGINE 3-81 • Check the corresponding crank pin O.D. code numbers (“1”, “2” or “3”) 3. Bearing selection table Crank pin O.D. 3 Code Green Black Brown Conrod I.D. 2 Black Brown Yellow Conrod I.D. specification Code I.D. specification 41.000 – 41.008 mm (1.6142 –...
• Apply molybdenum oil solution to the crank pin and bearing surface. ( 99000-25140: SUZUKI MOLY PASTE • When mounting the conrod on the crankshaft, make sure that the numbers 1 on the conrod faces towards the intake side.
ENGINE 3-83 • Mate the lower crankcase with the upper crankcase and tighten the crankshaft bolts to the specified torque and in the proper tightening sequence. % Crankcase bolt (Initial): 13 N . m (1.3 kgf . m, 9.5 lb-ft) (Final): 23 N .
ENGINE 3-85 CRANKSHAFT THRUST CLEARANCE ADJUSTMENT • With the crankshaft’s right-side and left-side thrust bearings inserted into the upper crankcase, measure the thrust clear- ance between the left-side thrust bearing and the crankshaft using the thickness gauge. R: Right-side thrust bearing L: Left-side thrust bearing A: Front side NOTE:...
ENGINE 3-87 ENGINE LUBRICATION SYSTEM OIL PUMP REMOVAL The crankcase must be separated to service the oil pump. The oil pump service requires engine removal and disassembly. Refer to the engine removal and the engine disassembly sec- tions for oil pump removal. ($3-25) INSPECTION Rotate the oil pump by hand and check that it moves smoothly.
3-88 ENGINE • Oil pressure regulator • Oil sump filter OIL PRESSURE REGULATOR INSPECTION Check the operation of the oil pressure regulator by pushing on the piston with an appropriately shaped tool. If the piston does not operate, replace the oil pressure regulator with a new one. OIL SUMP FILTER CLEANING Clean the oil sump filter using compressed air.
ENGINE 3-89 OIL SUMP FILTER/OIL PRESSURE REGULATOR INSTALLATION Installation is in the reverse order of removal. NOTE: Refer to the following pages for the details of each step. Install: • Oil sump filter NOTE: * When installing the oil sump filter, make sure that the arrow mark A points towards the front of the motorcycle.
3-90 ENGINE OIL PRESSURE SWITCH/OIL COOLER REMOVAL After draining the engine oil, remove the oil pressure switch and the oil cooler. NOTE: Refer to the following pages for the details of each step. Drain: • Engine oil ($2-9) Remove: • Signal generator cover. •...
ENGINE 3-91 OIL COOLER HOSE INSPECTION Inspect the oil cooler hoses for damage and oil leaks. If any de- fects are found, replace the oil cooler hose(-s) with a new one. OIL COOLER INSPECTION AND CLEANING Remove any foreign matter that is stuck in the oil cooler fins us- ing compressed air.
3-92 ENGINE • Signal generator cover ($3-48) Adjust the following item to specification. * Engine oil ............$2-9 OIL FILTER $2-10 OIL PRESSURE $2-25 OIL JET OIL JET (for the cylinder head) REMOVAL • The oil jet (for the cylinder head) can be removed after remov- ing the cylinder block.
ENGINE 3-93 OIL JET (for piston cooling and the transmission) REMOVAL • The oil jet (for piston cooling and the transmission) can be re- moved after separating the crankcase. Remove: • Oil jet (for piston cooling) 1 • Oil jet (for the transmission) 2 INSPECTION Make sure that the oil jets are not clogged.
3-94 ENGINE ENGINE LUBRICATION SYSTEM CHART...
3-98 ENGINE PAIR (AIR SUPPLY) SYSTEM PAIR SYSTEM REMOVAL • Remove the fuel tank. ($4-3) • Disconnect all of the PAIR valve hoses. 1 Vacuum hose 2 Air cleaner hose 3 PAIR hose No. 1 4 PAIR hose No. 2 5 PAIR hose No.
ENGINE 3-99 PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES AND PIPES • Inspect the hoses and pipes for wear or damage. • Inspect that the hoses and pipes are securely connected. PAIR VALVE • Remove the PAIR valve. ($3-98) • Inspect the PAIR valve body for damage. REED VAVLE •...
3-100 ENGINE PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...
FUEL SYSTEM FUEL SYSTEM CONTENTS FUEL SYSTEM ..................4- 2 FUEL TANK .................... 4- 3 REMOVAL ..................4- 3 REMOUNTING .................. 4- 3 FUEL VALVE ..................4- 4 REMOVAL ..................4- 5 INSPECTION AND CLEANING ............4- 5 REMOUNTING .................. 4- 5 FUEL LEVEL GAUGE ................
FUEL SYSTEM FUEL SYSTEM The fuel system consists of a fuel tank, 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.
FUEL SYSTEM FUEL TANK REMOVAL • Remove the seat. (!5-5) • Remove the fuel tank mounting bolts 1. • Turn the fuel valve knob to the “ON” position. • Remove the fuel valve knob 2 by removing its mounting screw. •...
FUEL SYSTEM 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.
FUEL SYSTEM REMOVAL • Remove the fuel tank. (!4-3) • Remove the fuel valve 1. " * Gasoline is very explosive. Extreme care must be taken. * The gaskets 2 and O-ring 3 must be replaced with new ones to prevent fuel leakage. INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result.
FUEL SYSTEM FUEL LEVEL GAUGE REMOVAL • Remove the fuel tank. (!4-3) • Remove the fuel level gauge 1. " Gasoline is very explosive. Extreme care must be taken. INSPECTION Measure the resistance between the lead wire terminals when the float is at the position listed below. $ 09900-25008: Multi-circuit tester Float position Resistance between terminals...
FUEL SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 2 O-ring 3 Spring 4 Jet needle stopper 5 O-ring 6 Spring 7 Washer 8 E-ring 9 Spacer 0 Jet needle A Diaphragm B Piston valve C Pilot air jet D Starter (enricher) plunger E Needle valve assy F Float G Float pin...
4-10 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. Negative pressure is admitted into the diaphragm chamber 2 through an orifice 3 provided in the piston valve 1.
FUEL SYSTEM 4-11 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.
4-12 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.
FUEL SYSTEM 4-13 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.
4-14 FUEL SYSTEM REMOVAL • Remove the fuel tank. (!4-3) • Remove the frame side covers. (!5-6) • Remove the fuel tank bracket bolts 1. • Remove the air cleaner box mounting bolts 2. • Disconnect the throttle position sensor coupler 3. •...
FUEL SYSTEM 4-15 DISASSEMBLY Before disassembly, prepare a clean and well lit work place where carburetor components can be laid out neatly and will not get lost. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor.
4-16 FUEL SYSTEM • Remove the top cap 1. Do not use compressed air on the carburetor body, be- fore removing the diaphragm; this may damage the dia- phragm. • Remove the spring 2 and the piston valve along with its dia- phragm 3.
FUEL SYSTEM 4-17 • Remove the float pin 1 and then remove the float 2 and needle valve 3. • Remove the following parts. 4 Main jet 5 Needle jet 6 Pilot jet 7 Pilot screw 8 Starter (enricher) jet 9 Valve seat NOTE: Before removing the pilot screw 7 , its setting must be determined.
4-18 FUEL SYSTEM • Remove the throttle valve. PILOT SCREW REMOVAL (For with plug type) Because harsh cleaning solvents can damage the O-ring seals in the pilot system, the pilot system components should be re- moved before cleaning. • Use a 1/8“ size drill bit with a drill-stop to remove the pilot screw plug.
FUEL SYSTEM 4-19 CARBURETOR CLEANING " Some carburetor cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
4-20 FUEL SYSTEM CARBURETOR INSPECTION Check the following items for any damage or clogging. * Pilot jet * Valve seat * Main jet * Piston valve * Main air jet * Starter (enricher) jet * Pilot air jet * Gasket and O-ring * Needle jet air bleeding hole * Throttle shaft oil seal * Float * Diaphragm...
Face the stamped side of the throttle valve out. O-RING • Apply thin coat of the grease “A” to each new O-ring. ( 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-ring with a new one. • Install the new O-ring to its groove properly.
• Apply thin coat of the grease “A” to the fuel joint pipe O-rings. ( 99000-25010: SUZUKI SUPER GREASE “A” Replace the O-ring with a new one. • Place the carburetor assembly on the surface plate (engine side downward) and tighten the upper and lower carburetor set shafts to the specified torque.
FUEL SYSTEM 4-23 THROTTLE POSITION SENSOR POSITIONING Install the throttle position sensor as described below. • Measure the resistance between the throttle position sen- sor terminals as shown. $ 09900-25008: Multi circuit tester set & Throttle position sensor resistance : 3.5 – 6.5 kΩ Ω Ω Ω Ω •...
4-24 FUEL SYSTEM THROTTLE CABLE ADJUSTMENT (MAJOR ADJUSTMENT) NOTE: Minor adjustment can be made by the throttle grip side adjuster. ( ! 2-11) • Remove the fuel tank. (!4-3) • Loosen the lock nut 1 of the throttle returning cable. •...
FUEL SYSTEM 4-25 • Remove the vacuum inlet cap from the carburetor (for cylinders #1 or #4). • Connect one of the carburetor balancer’s rubber hoses to this inlet. $ 09913-13121: Carburetor balancer NOTE: If it is difficult to connect the carburetor balancer’s rubber hoses to the vacuum inlets, slightly move the carburetor assembly back- ward after loosening the carburetor clamps.
4-26 FUEL SYSTEM CARBURETOR SYNCHRONIZATION Remove all of the vacuum inlet caps, before synchronizing the carburetors. Connect the carburetor balancer hoses to these vacuum inlets and then adjust the carburetors as follows. • Start the engine and keep it running at 1 750 r/min. Observe the tachometer reading.
CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ............................5- 2 CONSTRUCTION ..........................5- 2 REMOVAL ............................. 5- 3 REMOUNTING ............................5- 6 FRONT WHEEL ............................5- 7 CONSTRUCTION ..........................5- 7 REMOVAL ............................. 5- 9 INSPECTION AND DISASSEMBLY ..................... 5- 9 REASSEMBLY ............................5-10 REMOUNTING ............................
CHASSIS REMOVAL COWLING AND COWLING BRACE (Except for GSF1200) • Remove the two screws. • Remove the rear view mirrors 1 and the front cowling 2. Hooked part • Remove the center cowling 3. • Remove the side cowlings 4, left and right. •...
CHASSIS • Disconnect the headlight and position light lead wire couplers. • Remove the headlight assy 6. (Remove the nuts at both left and right sides.) • Remove the combination meter 7. (!6-33) • Remove the three screws and the upper panel 8. •...
CHASSIS SEAT • Remove the seat 1 by using the ignition key. DOCUMENT TRAY • Remove the seat. (! 5-5) • Remove the document tray 1. FRAME COVER • Remove the seat. (! 5-5) • Remove the passenger grab handle 1. •...
CHASSIS REMOVAL • Remove the reflectors. (For E-03, E-28, E-33) • Remove the brake caliper mounting bolts 1. • Loosen the front axle pinch bolts 2. • Loosen the front axle 3. • Raise the front wheel off the ground using a jack or wooden block.
09900-20701: Magnetic stand 09900-21304: V-block set (100 mm) $ Wheel axle runout Service Limit: 0.25 mm (0.010 in) REASSEMBLY • Apply SUZUKI SUPER GREASE “A” to the bearings before installation. For USA & 99000-25030: SUZUKI SUPER GREASE “A” For the other countries &...
CHASSIS 5-11 REMOUNTING Remount the front wheel in the reverse order of removal. Pay attention to the following points: • Install the front wheel. Face the arrow mark A on the tire to the direction of wheel rotation, when remounting the wheel. •...
5-12 CHASSIS FRONT FORK CONSTRUCTION Front fork protecter Dust seal Oil seal stopper ring Oil seal Oil seal retainer Outer tube slide metal Oil lock piece Outer tube (R) Gasket O-ring Spring adjuster Collar O-ring Spring seat Spacer Washer " Spring Damper rod N .
CHASSIS 5-13 REMOVAL AND DISASSEMBLY • Remove the center cowling. (! 5-3) • Remove the front wheel. (! 5-9) • Remove the front fender mounting bolts 1, left and right. • Remove the front fender 2. • Remove the brake hose clamp bolts 3, left and right. •...
5-14 CHASSIS • Remove the front fork cap bolt with spring adjuster 1 by loos- ening the inner rod lock nut. • Remove the spring seat 2. • Remove the spacer, washer and spring. • Invert the fork and stroke it several times to drain out fork oil. •...
CHASSIS 5-15 • Remove the oil seal stopper ring. • Remove the damper rod bolt. • Remove the inner rod cylinder. • Remove the oil seal by slowly pulling out the inner tube. NOTE: Be careful not to damage the inner tube. The outer and inner tube’s slide metals must be replaced along with the oil seal and dust seal when assembling the front fork.
5-16 CHASSIS INSPECTION INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding surface for scuffing. FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it with a new one. $ Front fork spring free length Service Limit: 366 mm (14.4 in) ..
CHASSIS 5-17 • Insert the inner tube into the outer tube and install the oil seal 1 using the special tool. % 09940-52861: Front fork oil seal installer • Install the oil seal stopper ring 2. Make sure that the oil seal stopper ring is fitted securely. •...
$ Fork oil level: 107 mm (4.2 in) ..For E-03, 28, 33 105 mm (4.1 in) ..For the others ) 99000-99001-SS8: SUZUKI FORK OIL SS-08 99000-99044-10G: SUZUKI FORK OIL #10 or an equiva- lent fork oil $ Capacity (each leg): 507 ml (17.1/17.9 US/lmp oz) ..
CHASSIS 5-19 FORK SPRING • Install the fork spring as shown. NOTE: The smaller pitch A should face to the bottom of the front fork. INNER ROD AND LOCK NUT • Install the special tool and pull up the inner rod. % 09940-52840: Front fork inner rod holder •...
5-20 CHASSIS • Install the front fork protecter. NOTE: Fit the projection of the front fork protecter to the depression of the front fork outer tube. • Set the upper surface A of the inner tube at the height C from the upper surface B of the steering stem upper bracket and tighten the front fork lower clamp bolts to the specified torque.
CHASSIS 5-21 • Install the front fender. NOTE: Face the triangle mark on the front fender plate to front side. • Install the front wheel. (!5-11) • Remount the center cowling. (!5-3) NOTE: Before tightening the front axle and front axle pinch bolts, move the front fork up and down four or five times.
5-22 CHASSIS STEERING CONSTRUCTION 1 Steering stem upper bracket 2 Dust seal 3 Steering stem upper bearing set 4 Steering stem lower bearing set 5 Steering stem 6 Dust seal 7 Handlebar 8 Handlebar balancer 9 Handlebar switch assy (L) 0 Handlebar switch assy (R) A Steering stem head nut B Handlebar holder bolt...
CHASSIS 5-23 • Remove the handlebars 1. NOTE: Place the rag on the fuel tank to prevent the fuel tank scratches. • Remove the steering stem upper bracket 2. • Remove the steering stem nut using the special tool. % 09940-14911: Steering stem nut wrench •...
5-24 CHASSIS • Remove the ignition switch 6 using a Torx wrench. % 09930-11920: Torx bit 09930-11940: Bit holder INSPECTION AND DISASSEMBLY Inspect the removed parts for the following abnormalities. *Handlebar distortion *Race wear or damage *Bearing wear or damage *Abnormal bearing noise *Distortion of the steering stem •...
• Press in the lower inner race using the special tool % 09941-74911: Steering bearing installer BEARINGS • Apply SUZUKI SUPER GREASE “A” to the upper and lower bearings and the lip of the dust seals before remounting the steering stem.
5-26 CHASSIS • Tighten the steering stem head nut to the specified torque. " " Steering stem head nut: 65 N . m (6.5 kgf . m, 47.0 lb-ft) " " " NOTE: Before tightening the steering stem head nut, temporarily install the front forks.
CHASSIS 5-27 STEERING TENSION ADJUSTMENT Check the steering tension as follows • Support the motorcycle using a jack and raise the front wheel off the floor 20 – 30 mm (0.8 – 1.2 in). • Make sure that the cables and wire harness are properly routed. •...
5-30 CHASSIS REMOVAL • Support the motorcycle with center stand. • Remove the cotter pin. (For E-03, 28, 33) • Remove the axle nut 1. • Remove the rear axle and disengage the drive chain from the rear sprocket. • Remove the rear wheel. Do not operate the brake pedal during or after rear wheel removal.
CHASSIS 5-31 INSPECTION AND DISASSEMBLY TIRE ............. (! 5-61) REAR WHEEL ..........(! 5-9) WHEEL BEARING ........(! 5-9) Rear wheel and its bearing inspection manner is the same as the front one. REAR SPROCKET MOUNTING DRUM BEARING Play Inspect the play of the bearing by hand while it is in the rear Play sprocket mounting drum.
A Normal wear B Excessive wear REASSEMBLY WHEEL BEARINGS • Apply SUZUKI SUPER GREASE “A” to the bearings before installation. For USA & 99000-25030: SUZUKI SUPER GREASE “A” For the other countries &...
• Install the new bearing and new dust seal using the special tool. % 09913-75520: Bearing installer NOTE: Apply SUZUKI SUPER GREASE “A” to the bearing and dust seal lip before assembling the rear sprocket mounting drum. For USA & 99000-25030: SUZUKI SUPER GREASE “A”...
5-34 CHASSIS REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Rear cushion lever 3 Rear cushion lever rod 4 Bearing 5 Spacer 6 Bearing 7 Spacer 8 Bearing 9 Spacer 0 Spacer A Chain adjuster plate B Washer C Spacer D Bearing E Spacer F Pivot shaft...
CHASSIS 5-35 Right side Left side 50 N . m 5.0 kgf . m 36.0 lb-ft 50 N . m 5.0 kgf . m 36.0 lb-ft 78 N . m 7.8 kgf . m 56.5 lb-ft 78 N . m 7.8 kgf .
5-36 CHASSIS REMOVAL • Remove the rear wheel. (! 5-30) • Remove the drive chain case 1. • Remove the rear torque link nut 2. • Remove the brake hose union bolt 3. • Remove the brake hose from the brake hose guide and hose clamps.
CHASSIS 5-37 • Remove the right and left pivot shaft end caps 6. • Remove the swingarm by removing the pivot shaft nut and pivot shaft. • Remove the rear shock absorber 7, cushion lever 8, cushion lever rods 9. INSPECTION AND DISASSEMBLY DUST SEALS AND SPACERS •...
5-38 CHASSIS • Remove the swingarm needle bearings and spacer using the special tools. % 09923-74510: Bearing remover 09930-30102: Sliding shaft The removed needle bearings should be replaced with new ones. SWINGARM Inspect the swingarm for damage. CUSHION LEVER NEEDLE BEARINGS Insert the spacers into the needle bearings, move the spacer up and down and check for any play.
% 09941-34513: Steering outer race installer NOTE: Install the needle bearings with the stamped mark facing out. • Apply SUZUKI SUPER GREASE “A” to the spacers, dust seals and needle bearings. For USA & 99000-25030: SUZUKI SUPER GREASE “A”...
CUSHION LEVER NEEDLE BEARINGS • Press the needle bearings into the cushion lever using the special tool. % 09941-34513: Steering outer race installer • Apply SUZUKI SUPER GREASE “A” to the spacers and needle bearings. For USA & 99000-25030: SUZUKI SUPER GREASE “A”...
CHASSIS 5-41 REMOUNTING Remount the swingarm and rear shock absorber in the reverse order of removal. Pay attention to the following points: • When remount the rear shock absorber and cushion lever, set the index punched mark rearward. • Tighten the cushion lever rod mounting nuts 1 and rear shock absorber lower mounting nut 2 to the specified torque.
5-42 CHASSIS • Tighten the brake hose union bolt 6 to the specified torque. " Brake hose union bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) • Tighten the rear torque link nut 7 to the specified torque. "...
5-44 CHASSIS BRAKE PAD REPLACEMENT • Remove the spring 1. • Remove the brake pads by removing the clip 2 and pad mount- ing pin 3. * Do not operate the brake lever while dismounting the pads. * Replace the brake pads as a set, otherwise braking performance will be adversely affected.
CHASSIS 5-45 CALIPER REMOVAL AND DISASSEMBLY • Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle. NOTE: Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid.
5-46 CHASSIS • Remove the dust seals and piston seals. Do not reuse the dust seals and piston seals to prevent fluid leakage. CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks, scratches or other damage. BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any scratches or other damage.
CHASSIS 5-47 • Tighten each bolt to the specified torque. " Front brake caliper housing bolt 1: 21 N . m (2.1 kgf . m, 15.0 lb-ft) Front brake caliper mounting bolt 2: 39 N . m (3.9 kgf . m, 28.0 lb-ft) Front brake hose union bolt 3: 23 N .
5-48 CHASSIS BRAKE DISC INSPECTION • Remove the front and rear wheels. (! 5-9 and -30) Check the brake disc for damage or cracks. Measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if damage is found.
CHASSIS 5-49 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Disconnect the front brake light switch lead wires 1. • Place a rag underneath the brake hose union bolt on the master cylinder to catch any spilt brake fluid. Remove the brake hose union bolt and disconnect the brake hose.
5-50 CHASSIS • Pull out the dust boot 1 and remove the circlip 2. % 09900-06108: Snap ring pliers • Remove the piston/secondary cup, primary cup and spring. 3 Secondary cup 4 Piston 5 Primary cup 6 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other damage.
CHASSIS 5-51 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: * Wash the master cylinder components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components.
5-52 CHASSIS • Tighten the brake hose union bolt to the specified torque. " Brake hose union bolt: 23 N . m (2.3 kgf . m, 16.5 lb-ft) Bleed air from the brake system after reassembling the master cylinder. (! 2-18)
CHASSIS 5-53 REAR BRAKE CONSTRUCTION " E O-ring 1 Brake caliper F Brake hose 2 Brake caliper pistons N . m kgf . m ITEM lb-ft G Master cylinder 3 Piston seals H Piston/cup set 4 Dust seals I Push rod 5 Inner shim J Circlip 6 Brake pads...
5-54 CHASSIS BRAKE PAD REPLACEMENT • Remove the brake pad cover. • Remove the clip 1. • Remove the brake pads along with the shims by removing the brake pad mounting pins 2 and springs 3. * Do not operate the brake pedal during or after brake pad removal.
CHASSIS 5-55 BRAKE CALIPER REMOVAL AND DISASSEMBLY • Remove the brake hose union bolt 1 and allow the brake fluid to drain into a suitable receptacle. • Remove the brake caliper mounting bolts 2 and rear torque link nut 3. NOTE: Slightly loosen the brake caliper housing bolts 4 to facilitate later disassembly before removing the brake caliper mounting bolts.
5-56 CHASSIS • Place a rag over the brake caliper piston to prevent it from popping out and then force out the piston using compressed air. Do not use high pressure air to prevent brake caliper piston damage. • Remove the dust seals and piston seals. Do not reuse the dust seals and piston seals to prevent fluid leakage.
CHASSIS 5-57 • Tighten each bolt to the specified torque. " Brake caliper housing bolt 1: 30 N . m (3.0 kgf . m, 21.5 lb-ft) Brake caliper mounting bolt 2: 25 N . m (2.5 kgf . m, 18.0 lb-ft) Brake hose union bolt 3: 23 N .
5-58 CHASSIS • Remove the brake hose connector by removing the screw. • Remove the O-ring 1. Replace the O-ring with a new one. • Pull out the dust boot 2 and remove the circlip 3. % 09900-06108: Snap ring pliers •...
CHASSIS 5-59 MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: * Wash the master cylinder components with new brake fluid before reassembly. * Do not wipe the brake fluid off after washing the components.
5-60 CHASSIS CLUTCH MASTER CYLINDER CONSTRUCTION 1 Piston/cup set 2 Clutch hose A Master cylinder bolt B Union bolt " N . m kgf . m ITEM lb-ft 16.5 REMOVAL • Disconnect the clutch lever position switch lead wires. • Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid.
CHASSIS 5-61 TIRE AND WHEEL TIRE REMOVAL The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.
5-62 CHASSIS NOTE: When repairing a flat tire, follow the repair instructions and use only recommended repairing materials. VALVE INSPECTION Inspect the valve 1 after the tire is removed from the rim, and replace the valve with a new one if the seal rubber has any splits or scratches.
CHASSIS 5-63 • The tire is designed to have specified rotational direction. Never use oil, grease or gasoline on the tire bead in place of tire lubricant. • When installing the tire, the arrow 1 on the side wall should point the direction of wheel rotation.
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTORS • When disconnecting a connector, be sure to hold the ter- Click minals; do not pull the lead wires. • When connecting a connector, push it in so it is firmly attached. • Inspect the connector for corrosion, contamination and any breakage in the cover.
ELECTRICAL SYSTEM BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replen- ishing). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER • Properly use the multi circuit tester (+) and (-) probes. Im- proper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range.
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Turn signal/side-stand relay 2 Fuse box 3 Ignition switch 4 Handlebar switch (R) 5 Front brake light switch 6 Battery 7 Rear brake light switch 8 Throttle position sensor 9 Signal generator 0 Oil pressure switch...
ELECTRICAL SYSTEM A Clutch lever position switch B Handlebar switch (L) C Ignition coil D Main fuse E Starter relay F Ignitor G Horn H Starter motor I Generator J Speed sensor K Side-stand switch L Gear position switch M Speed sensor rotor...
ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION (GENERATOR WITH IC REGULATOR) The generator features a solid-state regulator that is mounted inside the generator. All regulator com- ponents are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator voltage setting cannot be adjusted.
ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use Accessories Remove accessories excessive amounts of electricity. are installed No accessories Check the battery for current leaks. Current leaks Short circuit of the wire harness 6-9) Loose or disconnected wires Faulty battery No current leaks Measure the charging voltage between...
ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAK INSPECTION • Turn the ignition switch to the “OFF” position. • Remove the seat. (!5-5) • Remove the document tray. (!5-5) • Disconnect the battery - lead wire. • Connect the multi circuit tester between the battery - ter- minal and the battery - lead wire.
6-10 ELECTRICAL SYSTEM GENERATOR 1 Generator driven gear C Slip ring side bearing N . m kgf . m ITEM lb-ft 2 Damper (4 pcs) D Bearing cover #1 3 Damper housing E Generator housing 40.0 4 Oil seal F Rectifier 5 O-ring G IC regulator 18.0...
ELECTRICAL SYSTEM 6-11 REMOVAL AND DISASSEMBLY • Remove the engine sprocket cover. (!3-5) • Disconnect the generator lead wire 1 and coupler 2. NOTE: Before disconnecting the generator lead wire, disconnect the battery - lead wire. • Remove the generator 3. •...
6-12 ELECTRICAL SYSTEM • Remove the brush holder 1 and IC regulator 2. • Remove the stator coil lead wires mounting screws 3. • Remove the rectifier 4. NOTE: Straighten the stator coil lead wires using long-nose pliers, then remove the rectifier. •...
ELECTRICAL SYSTEM 6-13 • Remove the bearing retainer 1. • Remove the bearing 2, washer 3 and spacer 4. • Remove the oil seal 5. INSPECTION Play ROTOR BEARINGS Play Inspect the rotor bearings for abnormal noise. Also, rotate the rotor bearings by hand and make sure that they rotate smoothly.
If any defects are found, replace the generator driven gear dampers as a set. NOTE: When installing the generator driven gear dampers, apply SUZUKI MOLY PASTE to the damper surface. ) 99000-25140: SUZUKI MOLY PASTE STATER COIL CONTINUITY CHECK Measure the continuity between the lead wires of the stator coil using a tester.
ELECTRICAL SYSTEM 6-15 CARBON BRUSHES Measure the length of the carbon brushes as shown. If the mea- surement is less then the service limit, replace the carbon brushes with new ones. # 09900-20102: Vernier calipers (200 mm) $ Brush length Service Limit: 4.5 mm (0.18 in) RECTIFIER Measure the voltage among the terminal 1 and the other termi-...
Pay attention to the following points: " The removed oil seal should be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. For USA . 99000-25030: SUZUKI SUPER GREASE “A”...
ELECTRICAL SYSTEM 6-17 NOTE: Before reinstalling the slip ring side bearing onto the generator Expander ring lug end housing, turn the expander ring and align the expander ring lug with the center of the chamfered edge of the bearing outer race.
6-18 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE-STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components: the starter motor, starter relay, clutch lever posi- tion switch, turn signal/side-stand relay, side-stand switch, gear position switch, starter button, engine stop switch, ignition switch and battery.
ELECTRICAL SYSTEM 6-19 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. The gear position and side-stand switches work together in this system. The ignition coils work only in two situations as follows.
6-20 ELECTRICAL SYSTEM TROUBLE SHOOTING Starter motor will not run. The transmission is in neutral. Grasp the Check if the starter motor runs clutch lever. Turn on the ignition switch with when its terminal is connected to the engine stop switch in the “RUN" position. Clicks the battery terminal (Do not use...
ELECTRICAL SYSTEM 6-21 STARTER MOTOR REMOVAL AND DISASSEMBLY • Remove the starter motor. (!3-16) • Disassemble the starter motor, as shown. ( 5 N . m 0.5 kgf . m 3.5 lb-ft ( 6 N . m 0.6 kgf . m 4.5lb-ft 1 O-ring 2 Housing end (inside)
Pay attention to the following points: " Replace the O-rings with new ones to prevent oil leak- age and moisture. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. For USA . 99000-25030: SUZUKI SUPER GREASE “A” For the other countries .
ELECTRICAL SYSTEM 6-23 • Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft. ) 99000-25140: SUZUKI MOLY PASTE • Align the match mark on the starter motor case with the match mark on the housing end. • Apply a small quantity of THREAD LOCK “1342” to the starter motor housing bolts.
6-24 ELECTRICAL SYSTEM Apply 12 volts to terminals A and B and measure for continuity between the positive and negative terminals. If the starter relay clicks and continuity is found, the relay is ok. # 09900-25008: Multi circuit tester set * Tester knob indication: Continuity test (+) "...
ELECTRICAL SYSTEM 6-25 GEAR POSITION SWITCH The gear position switch coupler is located behind the frame side cover (left side). • Remove the frame side cover (left side). (!5-6) • Disconnect the gear position switch coupler and measure the continuity between Blue and Ground with the transmission in neutral.
6-26 ELECTRICAL SYSTEM SIDE-STAND RELAY First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C (+ to D and - to C) and check the continuity between D and E. If there is no continuity, replace the turn signal/side-stand relay with a new one.
ELECTRICAL SYSTEM 6-27 IGNITION SYSTEM (DIGITAL IGNITOR) DESCRIPTION The fully transistorized ignition system consists of the following components: a signal generator (which is made up of the signal generator rotor and pickup coil), ignitor (including a 8-bit microcomputer and a 10 MHz ceramic vibrator), throttle position sensor, two ignition coils and four spark plugs.
6-28 ELECTRICAL SYSTEM TROUBLE SHOOTING * Check that the transmission is in neutral and the No spark or poor spark engine stop switch is in the “RUN” position. Grasp the clutch lever. Check that the main fuse is not blown and the battery is fully-charged before diagnosing.
ELECTRICAL SYSTEM 6-29 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. (!4-3) • Remove all of the spark plug caps and spark plugs. • Connect four new spark plugs to each spark plug cap and ground them to the crankcase. NOTE: Make sure that all of the spark plug caps and spark plugs are connected properly and the battery is fully-charged.
6-30 ELECTRICAL SYSTEM Measure ignition coil primary peak voltage (for #2 and #3 cylinders) in the same manner as for cylinders #1 and #4. Ignition coil (for #2 and #3 cylinders): B/Y terminal (+ Probe) – Ground (- Probe) B/Y: Black with Yellow tracer NOTE: Do not disconnect the ignition coil primary wire.
ELECTRICAL SYSTEM 6-31 SIGNAL GENERATOR PEAK VOLTAGE • Remove the frame cover. (!5-5) • Remove the frame side cover (left side). (!5-6) NOTE: Make sure that all of the couplers are connected properly and the battery is fully-charged. • Disconnect the ignitor coupler 1 at the ignitor. Measure the signal generator peak voltage between the Yel- low/White and Black/Blue lead wires on the ignitor coupler.
6-32 ELECTRICAL SYSTEM • Remove the frame side cover (left side). (!5-6) • Disconnect the signal generator coupler and connect the multi circuit tester with the peak volt adaptor. Blue terminal (+ Probe) – Yellow terminal (- Probe) • Measure the signal generator peak voltage in the same man- ner as on the ignitor coupler.
ELECTRICAL SYSTEM 6-33 COMBINATION METER REMOVAL • Remove the cowling. (!5-3) • Remove the headlight assy. (!5-4) • Disconnect the combination meter couplers 1 and clamps. • Remove the combination meter mounting nuts 2. • Remove the combination meter 3. DISASSEMBLY •...
6-34 ELECTRICAL SYSTEM SPEEDOMETER TACHOMETER NEUTRAL TURN SIGNAL (L) TURN SIGNAL (R) HIGH BEAM 1: SPEEDOMETER 9: Blank + Probe of - Probe of 2: TACHOMETER 10: GROUND (PILOT LAMP) ITEM tester to: tester to: 3: OIL - 11: NEUTRAL - ILLUMINATION 12: HIGH BEAM + 4: SPEEDOMETER...
ELECTRICAL SYSTEM 6-35 SPEEDOMETER INSPECTION If the speedometer, odometer or tripmeter does not function prop- erly, inspect the speed sensor and the coupler connections. If the speed sensor and coupler connections are OK, replace the com- bination meter with a new one. SPEED SENSOR INSPECTION •...
6-36 ELECTRICAL SYSTEM FUEL LEVEL METER INSPECTION • Remove the fuel tank. (!4-3) • Disconnect the fuel level gauge coupler. (!4-3) Check that the fuel level meter indicates properly when the jumper wire A is connected between the fuel level gauge coupler termi- nals coming from the main wiring harness.
ELECTRICAL SYSTEM 6-37 LAMPS HEADLIGHT Headlight bulb: 12 V 51 + 60/51 W (Except for E-03, 24, 28, 33) Position light bulb: 12 V 5 W (Except for E-03, 24, 28, 33) NOTE: Adjust the headlight (vertically and horizontally) after reassembling BULB REPLACEMENT •...
6-38 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT AND LICENSE PLATE LIGHT Brake light/taillight bulb: 12 V 21/5 W License plate bulb: 12 V 5 W " If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
ELECTRICAL SYSTEM 6-39 RELAYS STARTER RELAY The starter relay is located behind the frame side cover (left side). (!6-23) TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay, which is located under the seat, is composed of the turn signal relay, and the side-stand relay and diode.
6-40 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH HORN BUTTON Color Color O/Y B/W B/Bl Position Position PUSH LOCK FRONT BRAKE LIGHT SWITCH Color B/Bl Position...
6-42 ELECTRICAL SYSTEM INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 which seals the battery filler holes 2. • Remove the caps 3 from the electrolyte container. NOTE: * Do not remove or pierce the sealed areas 4 of the electrolyte container.
ELECTRICAL SYSTEM 6-43 • After the electrolyte container is completely empty, remove it from the battery and wait about 20 minutes. • Insert the caps 1 firmly into the filler holes so that the top of the caps do not protrude above the upper surface of the battery’s top cover.
6-44 ELECTRICAL SYSTEM RECHARGING OPERATION Charging period • Measure the battery voltage using a tester. If the voltage read- Stop charging ing is less than 12.5 V (DC), recharge the battery with a battery charger. " When recharging the battery, remove the battery from the motorcycle.
SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start or Compression too low is hard to start. 1. Worn cylinder. Rebore or replace. 2. Worn piston ring. Replace. 3. Worn valve guide or improper valve seating. Repair or replace.
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive valve clearance. Adjust. 2. Weak or broken valve spring. Replace. 3. Worn rocker arm or rocker arm shaft. Replace. 4. Worn or burnt camshaft journal. Replace.
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission will not 1. Broken gearshift shaft return spring. Replace. shift back. 2. Rubbing or stuck gearshift shaft. Repair or replace. 3. Worn or distorted gearshift fork. Replace. 1. Worn gear. Transmission jumps out Replace.
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. 1. Insufficient valve clearance. Adjust. 2. Weak valve spring. Replace. 3. Mistimed valves. Adjust. 4. Worn cylinder. Rebore or replace. 5. Worn piston ring. Replace. 6. Improper valve seating Repair or replace.
SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy 1. Clogged starter jet. Starting difficulty. Clean. 2. Clogged starter jet passage. Clean. 3. Air leaking from joint between starter body and car- Tighten, adjust or replace buretor. gasket. 4. Air leaking from carburetor joint or vacuum hose joint. Tighten or replace defective part.
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Replace. Front suspension too 1. Weak spring. Check level and add. soft. 2. Insufficient fork oil. Replace. Front suspension too 1. Excessively viscous fork oil. Check level and drain. stiff. 2. Excessive fork oil. Front suspension too 1.
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Clean and lubricate. Brake drags. 1. Rusty part. Lubricate. 2. Insufficient brake lever or brake pedal pivot lubrication. ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor Replace. 1. Defective ignition coil. sparking.
SERVICING INFORMATION BATTERY (MF BATTERY) Complaint Symptom and possible causes Remedy Sulfation or spots on 1. Cracked battery case. Replace the battery. surfaces of cell plates. 2. Battery has been left in a run-down condition for a long Replace. time. Battery runs down 1.
7-14 SERVICING INFORMATION Signal generator lead wire Engine oil hose Engine ground wire must be faced to the inside. Engine ground wire Generator lead wire Starter motor lead wire Clamp Clamp Side-stand switch lead wire VIEW OF A Clamp Speed sensor Gear position switch lead wire 30˚...
7-18 SERVICING INFORMATION CLUTCH HOSE ROUTING Clamp After touching the clutch hose union to the stopper, tighten the union bolt to the specified torque. Clamp NOTE: Starter motor lead wire must be Cable guide passed outside of the clutch hose. Clamp Clamp Starter motor...
7-20 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING Master cylinder After touching the brake hose union Throttle to the stopper, tighten the union bolt cables to the specified torque. 42˚ 42˚ 42˚ 21˚ Throttle cable Brake hose No. 1 21˚ Brake hose No. 2 21˚...
SERVICING INFORMATION 7-21 REAR BRAKE HOSE ROUTING After touching the brake hose union to the stopper, tighten the union bolt to the specified torque. 42˚ Assemble the clamp Assemble the clamp as shown. as shown. Assemble the clamp as shown. Reservoir tank After touching the brake hose union to the stopper, tighten the union bolt to the...
SERVICING INFORMATION 7-23 FUEL TANK SET UP Fuel tank cap Adhesive agent Fuel tank Fuel tank molding 4.4 N . m 0.44 kgf . m 3.0 lb-ft Fuel tank front cushion Fuel valve Frame Fuel tank side cushion Fuel tank bracket 4.0 mm 4.0 mm 3.4 mm...
7-28 SERVICING INFORMATION COWLING CUSHION AND TAPE VIEW A Cushion meter panel Meter panel Meter panel tape No.2 Meter panel tape No.1 Front cowling (Reverse face) Cushion Side cowling (Reverse face) 1 mm Cushion Front cowling Cushion Tape Center cowling (Reverse face)
7-32 SERVICING INFORMATION SPECIAL TOOLS 09900-06107 09900-09004 09900-00410 09900-06106 09900-06108 Hexagon wrench set Snap ring pliers Snap ring pliers Snap ring pliers Impact driver set 09900-20205 09900-20508 09900-20102 09900-20202 09900-20204 Micrometer Cylinder gauge set Vernier calipers Micrometer Micrometer (1/1000 mm, 0 – 25 mm) (1/100 mm, 40 –...
SERVICING INFORMATION 7-33 09915-64510 Compression gauge 09914-25811 09913-75520 “T” type hexagon 09913-75830 09915-40610 09913-10750 Bearing installer Bearing remover wrench (6 mm) Oil filter wrench (Adaptor) 09915-74510 Oil pressure gauge 09915-77330 09915-74540 Oil pressure gauge 09916-10911 09916-14510 Meter (for high 09916-14910 Valve lapper set Valve lifter pressure)
7-34 SERVICING INFORMATION 09923-74510 09930-10121 09924-84511 09930-11920 Bearing remover 09925-98221 Spark plug wrench Bearing installer set (20 – 35 mm) Bearing remover Torx bit 09940-14911 09940-52861 09930-30102 09930-30720 09930-11940 Steering stem nut Front fork oil seal Sliding shaft Rotor remover Bit holder wrench installer...
SERVICING INFORMATION 7-35 TIGHTENING TORQUE ENGINE N . m kgf . m ITEM lb-ft Cylinder head cover bolt (10 pcs) 10.0 Cylinder head cover plug 11.0 Cylinder head cover union bolt 11.5 Cylinder head nut [M: 10] 27.5 Cylinder head bolt [M: 6] Cylinder head plug 20.0 Cylinder base nut...
7-36 SERVICING INFORMATION CHASSIS N . m kgf . m ITEM lb-ft Steering stem head nut 47.0 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork damper rod bolt 14.5 Front axle 10.0 72.5...
SERVICING INFORMATION 7-37 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 N . m kgf .
SERVICING INFORMATION 7-43 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 7° B.T.D.C. at 1 500 r/min. Firing order 1•2•4•3 Spark plug Type NGK: JR9B 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Pickup coil resistance Tester range: Approx.
7-44 SERVICING INFORMATION WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 The other countries ← Headlight 60 + 51 ← Parking or position light ← Brake light/Taillight 21/5 × 2 ← Turn signal light 21 × 4 ← Speedometer light ←...
SERVICING INFORMATION 7-45 ITEM STANDARD LIMIT Wheel rim runout ——— Axial (0.08) Radial ——— (0.08) Wheel axle runout 0.25 Front ——— (0.010) 0.25 Rear ——— (0.010) Wheel rim size Front 17 × MT3.50 ——— Rear 17 × MT5.50 ——— SUSPENSION Unit: mm (in) ITEM STANDARD...
7-46 SERVICING INFORMATION FUEL + OIL ITEM SPECIFICATION NOTE Use only unleaded gasoline of at least 87 pump Fuel type R + M octane or 91 octane ( ) or higher rated by the Research Method. Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
GSF1200K1 (2001-MODEL) 8-1 GSF1200K1 (2001-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the GSF1200SK1 (2001-model). NOTE: • Any differences between the GSF1200SK1 (2001-model) and GSF1200K1 (2001- model) in specifications and service data are indicated with an asterisk mark (*). •...
8-4 GSF1200K1 (2001-MODEL) HEADLIGHT/HEADLIGHT HOUSING/ COMBINATION METER REMOVAL • Remove the headlight by removing the two screws. • Disconnect the socket 1 and coupler 2. • Remove the two clamps from the lead wires and disconnect all the lead wire couplers. •...
GSF1200K1 (2001-MODEL) 8-5 • Remove the combination meter 4 by removing the two bolts. • Remove the headlight housing brackets 5 by removing the front forks. (!5-13) • Reassemble and remount the combination meter/headlight housing/headlight in the reverse order of removal and disas- sembly.
8-6 GSF1200K1 (2001-MODEL) HEADLIGHT/HEADLIGHT HOUSING DISASSEMBLY Headlight bulb: 12 V 60/55 W Position light bulb: 12 V 5 W NOTE: Adjust the headlight (vertically and horizontally) after reassembling BULB REPLACEMENT • Remove the headlight by removing the two screws. (!8-4) •...
GSF1200K1 (2001-MODEL) 8-7 • Unlock the bulb holder spring 3 and pull out the bulb 4. • Reassemble the headlight in the reverse order of disassembly. HEADLIGHT BEAM ADJUSTMENT To adjust the beam horizontally: Turn the adjuster 1 clockwise or counterclockwise. To adjust the beam vertically: Turn the adjuster 2 clockwise or counterclockwise.
GSF1200K1 (2001-MODEL) 8-11 FRONT BRAKE HOSE ROUTING Master cylinder After touching the brake hose union Throttle to the stopper, tighten the union bolt cables to the specified torque. 14˚ 14˚ 28˚ 21˚ Throttle cables Brake hose No. 1 21˚ 14˚ Brake hose No.
GSF1200K1 (2001-MODEL) 8-17 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 7° B.T.D.C. at 1 500 r/min. Firing order 1•2•4•3 Spark plug Type NGK: JR9B 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Pickup coil resistance Tester range: Approx.
8-18 GSF1200K1 (2001-MODEL) WATTAGE Unit: W ITEM SPECIFICATION Headlight Parking or position light Brake light/Taillight 21/5 × 2 Turn signal light 21 × 4 Speedometer light Tachometer light Turn signal indicator light LED × 2 High beam indicator light Neutral position indicator light Oil pressure indicator light License plate light BRAKE + WHEEL...
GSF1200K1 (2001-MODEL) 8-19 ITEM STANDARD LIMIT Wheel rim runout Axial ——— (0.08) ——— Radial (0.08) Wheel axle runout 0.25 ——— Front (0.010) 0.25 Rear ——— (0.010) Wheel rim size Front 17 × MT3.50 ——— Rear 17 × MT5.50 ——— SUSPENSION Unit: mm (in) ITEM STANDARD...
8-20 GSF1200K1 (2001-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 91 octane or Fuel type higher. An unleaded gasoline is recommended. Fuel tank capacity 20 L Including reserve (5.3/4.4 US/lmp gal) 4.4 L Reserve only (1.2/1.0 US/lmp gal) Engine oil type SAE 10W/40, API SF or SG Engine oil capacity...
GSF1200K2/SK2 (’02-MODEL) 9-1 GSF1200K2/SK2 (’02-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the GSF1200K1/SK1 (’01-model). CONTENTS SPECIFICATIONS ................9- 2 SERVICE DATA (GSF1200S) ............9- 4 SERVICE DATA (GSF1200) .............. 9-13 WIRING DIAGRAM (GSF1200S) ............9-22 WIRING DIAGRAM (GSF1200) ............
9-2 GSF1200K2/SK2 (’02-MODEL) SPECIFICATIONS GSF1200/GSF1200S DIMENSIONS AND DRY MASS Overall length ............2 070 mm (81.5 in) ..GSF1200S 2 140 mm (84.3 in) ..GSF1200 Overall width ............765 mm (30.1 in) Overall height ............1 220 mm (48.0 in) ..GSF1200S 1 100 mm (43.3 in) ..
GSF1200K2/SK2 (’02-MODEL) 9-3 CHASSIS Front suspension ............ Telescopic, coil spring, oil damped Rear suspension ............. Link type, coil spring, oil damped Front fork stroke ............130 mm (5.1 in) Rear wheel travel ............ 125 mm (4.9 in) Steering angle ............35° (right & left) Caster ..............
GSF1200K2/SK2 (’02-MODEL) 9-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 7° B.T.D.C. at 1 200 r/min. Firing order 1•2•4•3 Spark plug Type NGK: JR9B 0.6 – 0.7 (0.024 – 0.028) Spark performance Over 8 (0.3) at 1 atm. Pickup coil resistance Tester range: Approx.
9-10 GSF1200K2/SK2 (’02-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-03, 24, 28, 33 The other countries ← Headlight 60 + 51 ← Parking or position light ← Brake light/Taillight 21/5 × 2 ← Turn signal light 21 × 4 ← Speedometer light ←...
GSF1200K2/SK2 (’02-MODEL) 9-11 ITEM STANDARD LIMIT Wheel rim runout Axial ——— (0.08) ——— Radial (0.08) Wheel axle runout 0.25 ——— Front (0.010) 0.25 Rear ——— (0.010) Wheel rim size Front 17 × MT3.50, 17 M/C × MT3.50 ——— Rear 17 × MT5.50, 17 M/C × MT5.50 ———...
9-12 GSF1200K2/SK2 (’02-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Use only unleaded gasoline of at least 87 pump Fuel type R + M octane or 91 octane ( ) or higher rated by the Research Method. Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...
GSF1200K2/SK2 (’02-MODEL) 9-19 ITEM SPECIFICATION NOTE Fuse size 15 A Headlight 15 A Turn signal 15 A Ignition 10 A Meter 10 A Main 30 A WATTAGE Unit: W SPECIFICATION ITEM E-03, 33 E-02, 19 ← Headlight ← Parking or position light ←...