Suzuki GSF1200S 2001 Service Manual page 274

Complaint
Engine is noisy.
Clutch slips.
Clutch drags.
Transmission will not
shift.
Symptom and possible causes
Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn rocker arm or rocker arm shaft.
4. Worn or burnt camshaft journal.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain tensioner.
Noise seems to come from the clutch
1. Worn countershaft spline.
2. Worn clutch hub spline.
3. Worn clutch plate teeth.
4. Distorted clutch plate.
5. Worn clutch release bearing.
6. Weak clutch damper.
Noise seems to come from the crankshaft
1. Worn or burnt crank pin bearing.
2. Worn or burnt journal bearing.
3. Excessive thrust clearance.
Noise seems to come from the transmission
1. Worn or rubbing gear.
2. Worn countershaft spline.
3. Worn driveshaft spline.
4. Worn or rubbing primary gear.
5. Worn bearing.
1. Weak or broken clutch spring.
2. Worn or distorted clutch pressure plate.
3. Distorted clutch plate.
1. Leakage of clutch fluid.
2. Worn or damaged clutch cylinder/release cylinder.
3. Some clutch springs are weak, while others are not.
4. Worn or distorted clutch pressure plate.
5. Distorted clutch plate.
1. Broken gearshift cam.
2. Distorted gearshift fork.
3. Worn gearshift pawl.
SERVICING INFORMATION
Remedy
Adjust.
Replace.
Replace.
Replace.
Replace.
Rebore or replace.
Clean.
Replace.
Replace.
Replace cam chain and
sprockets.
Replace cam chain and
sprockets.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace.
Replace primary driven
gear.
Replace.
Replace.
Replace thrust bearing.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
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