Suzuki GSX1300RK8 Manual
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Suzuki GSX1300RK8 Manual

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Assembly and Pre-Delivery
Service Guide
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This service guide has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this service guide carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2)
categories could lead to serious problems.  and 
areas are denoted to emphasize certain areas and carry the following meanings:
 . . . . . . . Indicates a potential hazard that could result in
 . . . . . . . . . . Indicates a potential hazard that could result in
Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the
dealer shall be deemed by your Suzuki distributor to be performed at the dealer's
sole risk and responsibility. The Suzuki distributor disclaims any and all liability,
obligation or responsibility for any defects resulting from said assembly and pre-
delivery set-up, and for any claims, demands or causes of action for damage to
property or for personal injuries resulting from the Dealer's assembly and pre-
delivery set-up of Suzuki motorcycle.
This Assembly and Pre-Delivery Service Guide may contain photographs of
products sold in other markets. The assembly and pre-delivery service procedures
in this guide, however, apply to this market.
K8
FOREWORD
death or injury.
motorcycle damage.
99505-01028-03E
September '07 Printed in Japan (TK) 03

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Summary of Contents for Suzuki GSX1300RK8

  • Page 1 Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the dealer shall be deemed by your Suzuki distributor to be performed at the dealer’s sole risk and responsibility. The Suzuki distributor disclaims any and all liability,...
  • Page 2 PREPARATION WORKSHOP  The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION  The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
  • Page 3 Remove the bolts A used to mount the steel frame on the crate base.  Don’t remove the bolt B of the motorcycle sup- porting bracket C. Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle.

  • Page 4: Location Of Parts

    LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Windscreen Handlebar balancer Right and Left weight Allen screw 5 × 14 mm Allen bolt 6 ×...
  • Page 5 The certification of vehicle pre-delivery form must be filled out in duplicate for every motorcycle. Use of this form is mandatory and serves as pro- tection for yourself and your customer, as well as assuring that all necessary assembly and service functions have been completed.

  • Page 6: Front Brake Lever

    ASSEMBLY RIGHT FRONT BRAKE LEVER Set the front brake lever to the lever holder and tighten the flange stepped bolt. Then tighten the self-lock nut securely. NOTE: Before installing the brake lever, grease the sliding surface. A: Front brake lever B: 6 ×...
  • Page 7 Set the clutch lever to the lever holder and tighten the flange stepped bolt. Then tighten the flange nut securely. NOTE: Before installing the clutch lever, grease the sliding surface. A: Clutch lever B: 6 × 35 mm flange stepped bolt C: 6 mm flange nut ...

  • Page 8: Removing The Bracket

    Place the motorcycle on the side-stand, then remove the hoist hook. REMOVING THE BRACKET Remove the bolt and bracket. Remove the steel nut.  Be careful not to scratch the fuel tank. NOTE: The bracket, bolt and steel nut are no longer needed and may be discarded.

  • Page 9: Rear View Mirror

    WINDSCREEN Assemble the windscreen fitting parts. NOTE: Don’t tighten the screw excessively. A: Windscreen fitting parts B: 5 × 14 mm Allen screw C: Washer OD:12.0 mm ID:5.5 mm D: Rubber cushion (with nut) 5 mm L:17.0 mm Set the windscreen to the upper cowling and attach the fitting parts.

  • Page 10: Handlebar Balancer

    HANDLEBAR BALANCER Install the right and left handlebar balancers to each of handlebar end. NOTE: Apply SUZUKI THREAD LOCK SUPER “1342” to the attaching screw of handlebar balancer.  Check to ensure that the throttle operates freely and closes automatically.

  • Page 11: License Plate

    LICENSE PLATE NOTE: When installing the license plate, use the wash- ers as shown in the photograph. A: Washer OD:13.0 mm ID:6.5 mm B: Rear fender OWNER’S MANUAL Remove the rear seat using the key. A: Key B: Rear seat Store the owner’s manual in place.

  • Page 12: Seat Tail Cover

    SEAT TAIL COVER When installing the seat tail cover to the motorcycle, follow the procedures below. 1. Remove the rear seat using the key. 2. Remove the bolts to take off the pillion handle assembly. A: Pillion handle B: Allen bolt 3.
  • Page 13 SERVICING BATTERY Filling electrolyte Remove the aluminium tape sealing the battery elec- trolyte filler holes. A: Aluminium tape B: Electrolyte filler hole Remove the caps from the electrolyte container. NOTE: Use the removed caps as the sealing cap of battery filler holes. Do not remove or pierce the sealed areas of the electrolyte container.
  • Page 14 Make sure air bubbles are coming up in each electro- lyte container, and leave in this position for about 20 minutes. A: Air bubbles NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the container two or three times.
  • Page 15 Charge the battery with a battery charger.  For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life. Do not remove the cap during charging. Position the battery with the cap facing upward during charging.
  • Page 16  Check the rubber cushions are installed in the correct position before installing the battery. A: Rubber cushion B: Battery box 1. Install the battery in the motorcycle. 2. First connect the + lead to the + positive terminal of the battery. 3.

  • Page 17: Brake Fluid

    FRONT REAR BRAKE FLUID Keep the motorcycle upright and place the handlebars straight. Check the brake fluid level in both the front and rear UPPER UPPER master cylinder reservoirs. If the fluid level is below the “LOWER” level indicated in the figure, add the correct type of brake fluid.

  • Page 18: Clutch Fluid

    RIGHT LEFT Bleed the air from the front brake caliper.  Front brake caliper air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) A: Bleeder valve REAR Bleed the air from the rear brake caliper.  Rear brake caliper air bleeder valve: 7.5 N·m (0.75 kgf-m, 5.5 lb-ft) B: Bleeder valve CLUTCH FLUID...
  • Page 19 CLUTCH AIR BLEEDING Any air which may have been trapped in the clutch fluid circuit must be bled completely. If the clutch lever feels spongy or weak, then most likely there is air in the hydraulic circuit. To bleed the air from the clutch fluid, use the following procedure: Remove the meter lower panel.
  • Page 20 Remove the side cowling (Left). A: Side cowling (Left) B: 6 × 20 mm stepped Allen screw C: 5 × 18 mm stepped Allen screw D: Fastener E: Boss Bleed the clutch fluid circuit in the same manner as the brake air bleeding procedure.

  • Page 21: Throttle Cable

    CLUTCH LEVER Make sure the clutch lever position is correct. The standard setting of this motorcycle is as indicated in the table below. Standard setting Position 2 A: Adjuster THROTTLE CABLE This motorcycle has a twin throttle cable system. Cable A is for pulling cable and cable B is for return- ing.

  • Page 22: Rear Brake Pedal

    REAR BRAKE PEDAL Check the rear brake pedal height. Rear brake pedal height: 50–60 mm (2.0–2.4 in) If the rear brake pedal height is not correct, adjust in the following manner: 1. Loosen the lock nut A. 2. Rotate the push rod B to locate the pedal to the correct height below the top face of the footrest C.

  • Page 23: Front Suspension

    FRONT SUSPENSION Checking spring setting Adjust the setting of the spring setting to the standard position. Standard setting: 4 turns back To adjust, turn the adjuster A clockwise until it stops and then turn it counterclockwise until 4 turns.  Do not force the adjuster A past the stopped position or you may damage the adjuster.

  • Page 24: Rear Suspension

    REAR SUSPENSION Compression Damping Force Adjustment Adjust the setting of the compression damping force to the standard position. Standard setting: 8 clicks turn back To adjust, turn the adjuster A clockwise until it stops and then turn it counterclockwise until approximately 8 clicks are felt and the two punch marks align.

  • Page 25: Headlight Beam Adjustment

    HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted both horizontally and vertically if necessary. Remove the six fasteners to take off the bracket lower cover. A: Bracket lower cover B: Fastener To adjust the beam vertically: Turn the adjuster A clockwise or counterclockwise. To adjust the beam horizontally: Turn the adjuster B clockwise or counterclockwise.
  • Page 26 Remove the meter lower cover and meter upper cover. Remove the upper panel (Right). A: Upper panel (Right) B: Tapping screw C: Stepped Allen screw D: Hook RIGHT Remove the fastener. A: Fastener B: Bracket lower cover C: Under cowling Remove the screw and fastener.

  • Page 27: Engine Oil

    API: American Petroleum Institute JASO: Japanese Automobile Standards Organization ENGINE OIL VISCOSITY RATING SELECTION CHART SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the left chart.

  • Page 28: Idle Speed Adjustment

    IDLE SPEED ADJUSTMENT Check the engine idle speed. Engine idle speed: 1 050–1 250 r/min NOTE: If the engine idle speed is not within the speci- fied range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle.
  • Page 29 FUEL  Use only premium unleaded gasoline of at least 90 pump octane (R/2+M/2 method) or 95 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less that 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

  • Page 30: Tightening Torque

    TIGHTENING TORQUE Item Part Name N·m kgf-m lb-ft Item Part Name N·m kgf-m lb-ft FRONT FORK Brake caliper air bleeder valve 0.75 Handlebar holder nut 25.5 Clutch air bleeder valve 0.60 Handlebar set bolt AXLE Steering stem head nut 65.0 Front axle bolt 10.0 72.5...

  • Page 31: Cable Routing

    CABLE ROUTING Cable guide Throttle cable (Pulling) Pass the throttle cable (Pulling) and throttle cable (Returning) between the air cleaner box and guide of the screw Pass the throttle cable (Pulling) over the throttle cable (Returning) Pass the throttle cable (Pulling) over the throttle cable (Returning) Throttle cable (Pulling) Front brake hose Throttle cable (Returning)

  • Page 32: Harness Routing

    HARNESS ROUTING Secondary fuel injector Combination meter coupler Secondary throttle position sensor Intake air pressure sensor Tape Clamp Handlebar switch lead wire (R,L) Throttle position sensor Ignition switch lead wire Secondary throttle valve actuator Clamp Battery - lead wire There should be no slacking the lead wires. Clamp Clamp Starter motor lead wire...
  • Page 33 Clamp Handlebar switch lead wire (R,L) Ignition switch lead wire Rear turn signal light lead wire Clamp REAR COMBINATION LIGHT Clamp Wiring harness Clamp Clamp Starter motor lead wire Battery + lead wire Wiring harness Generator lead wire Handlebar switch lead wire (R) Gear position switch lead wire sensor lead wire Intake air temperature sensor...

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