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GSF650SA
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Suzuki GSF650SA Service Manual
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Service manual
(66 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Section 1 Engine
General Information
Vehicle Identification Number
Fuel and Oil Recommendation
Cylinder Identification
Maintenance and Lubrication
Scheduled Maintenance
Fuel Line Inspection
Table of Contents
Table of Contents
Precautions
Precautions for Engine
Section
Engine General Information and Diagnosis
General Description
Injection Timing Description
Self-Diagnosis Function (GSF650/S/A/SAK7)
Self-Diagnosis Function (GSX650FK8)
Schematic and Routing Diagram
FI System Wiring Diagram
Terminal Alignment of ECM Coupler
FI System Parts Location
Diagnostic Information and Procedures
Engine Symptom Diagnosis
Self-Diagnostic Procedures (GSF650/S/A/SAK7)
Use of SDS Diagnosis Reset Procedures
Show Data When Trouble (DTC)
SDS Check
DTC Table
Fail-Safe Function Table
FI System Troubleshooting
Malfunction Code and Defective Condition Table
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
DTC "C13" (P0105-H/L): IAP Sensor (#1) Circuit Malfunction
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
DTC "C17" (P1750-H/L): IAP Sensor (#2) Circuit Malfunction
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
DTC "C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354): Ignition System Malfunction
DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction
DTC "C31" (P0705): GP Switch Circuit Malfunction
DTC "C32" (P0201), "C33" (P0202), "C34" (P0203) or "C35" (P0204): Fuel Injector Circuit Malfunction
DTC "C40" (P0505, P0506 or P0507): ISC Valve Circuit Malfunction
DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction
DTC "C41" (P2505): ECM Power Input Signal Malfunction
DTC "C42" (P1650): IG Switch Circuit Malfunction
DTC "C44" (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction
DTC "C49" (P1656): PAIR Solenoid Valve Circuit Malfunction
DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction
Self-Diagnostic Procedures (GSX650FK8)
Specifications
Service Data
Special Tools and Equipment
Special Tool
Emission Control Devices
Precautions
Precautions for Emission Control Devices
General Description
Fuel Injection System Description
Crankcase Emission Control System Description
Exhaust Emission Control System Description
Noise Emission Control System Description
Schematic and Routing Diagram
PAIR System Hose Routing Diagram
Repair Instructions
Heated Oxygen Sensor (HO2S) Removal and Installation
Heated Oxygen Sensor (HO2S) Inspection
PAIR Reed Valve Removal and Installation
PAIR Control Solenoid Valve Removal and Installation
PAIR System Inspection
Crankcase Breather (PCV) Hose Inspection
Crankcase Breather (PCV) Hose / Cover Removal and Installation
Crankcase Breather (PCV) Cover Inspection
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Engine Electrical Devices
Precautions
Precautions for Engine Electrical Device
Engine Electrical Components Location
Diagnostic Information and Procedures
Engine Symptom Diagnosis
Repair Instructions
ECM Removal and Installation
CKP Sensor Inspection
CKP Sensor Removal and Installation
IAP Sensor (#1) Removal and Installation
IAP / TP / IAT Sensor Inspection
IAP / TP / IAT Sensor Removal and Installation
ECT Sensor Removal and Installation
ECT Sensor Inspection
TO Sensor Removal and Installation
TO Sensor Inspection
STP Sensor Inspection
STP Sensor Adjustment
STP Sensor Removal and Installation
STV Actuator Inspection
STV Actuator Removal and Installation
ISC Valve Inspection
ISC Valve Removal and Installation
ISC Valve Preset and Opening Initialization
HO2 Sensor Inspection
HO2 Sensor Removal and Installation
GP Switch Inspection
GP Switch Removal and Installation
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Engine Mechanical
Schematic and Routing Diagram
Camshaft and Sprocket Assembly Diagram
Throttle Cable Routing Diagram (GSF650/S/A/SAK7)
Throttle Cable Routing Diagram (GSX650FK8)
Diagnostic Information and Procedures
Engine Mechanical Symptom Diagnosis
Compression Pressure Check
Repair Instructions
Engine Components Removable with the Engine in Place
Air Cleaner Element Removal and Installation
Air Cleaner Element Inspection and Cleaning
Air Cleaner Box Removal and Installation
Throttle Cable Removal and Installation
Throttle Cable Inspection
Adjustment
Throttle Body Components
Throttle Body Construction
Throttle Body Removal and Installation
Throttle Body Disassembly and Assembly
Throttle Body Inspection and Cleaning
Throttle Valve Synchronization
Engine Assembly Removal
Engine Assembly Installation
Engine Top Side Disassembly
Engine Top Side Assembly
Valve Clearance Inspection and Adjustment
Cylinder Head Cover Inspection
Camshaft Inspection
Camshaft Sprocket Inspection
Camshaft Sprocket Removal and Installation
Cam Chain Tension Adjuster Inspection
Cam Chain Guide Removal and Installation
Cam Chain Guide Inspection
Cam Chain Tensioner Inspection
Cylinder Head Disassembly and Assembly
Cylinder Head Related Parts Inspection
Valve Guide Replacement
Valve Seat Repair
Cylinder Disassembly and Assembly
Cylinder Inspection
Piston Ring Removal and Installation
Piston and Piston Ring Inspection
Engine Bottom Side Disassembly
Engine Bottom Side Assembly
Conrod Removal and Installation
Conrod and Crankshaft Inspection
Conrod Crank Pin Bearing Inspection and Selection
Crankshaft Journal Bearing Inspection and Selection
Crankshaft Thrust Clearance Inspection and Selection
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Engine Lubrication System
Precautions
Precautions for Engine Oil
Schematic and Routing Diagram
Engine Lubrication System Chart Diagram
Oil Pan
Diagnostic Information and Procedures
Engine Lubrication Symptom Diagnosis
Oil Pressure Check
Repair Instructions
Engine Oil and Filter Replacement
Engine Oil Level Inspection
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation
Oil Pressure Regulator / Oil Strainer Inspection
Oil Pressure Switch Removal and Installation
Oil Pressure Switch Inspection
Oil Jet Removal and Installation
Oil Gallery Jet Removal and Installation
Oil Jet / Oil Gallery Jet Inspection
Oil Pump Removal and Installation
Oil Pump Inspection
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Engine Cooling System
Precautions
Engine Cooling System Warning
Precautions for Engine Coolant
General Description
Engine Coolant Description
Schematic and Routing Diagram
Cooling Circuit Diagram
Water Hose Routing Diagram
Diagnostic Information and Procedures
Engine Cooling Symptom Diagnosis
Repair Instructions
Cooling Circuit Inspection
Radiator Cap Inspection
Radiator / Cooling Fan Motor Removal and Installation
Radiator Inspection and Cleaning
Radiator Hose Removal and Installation
Radiator Reservoir Tank Inspection
Water Hose Inspection
Radiator Reservoir Tank Removal and Installation
Cooling Fan Inspection
Cooling Fan Relay Inspection
ECT Sensor Removal and Installation
ECT Sensor Inspection
Thermostat Connector / Thermostat Removal and Installation
Thermostat Inspection
Water Pump Components
Water Pump Construction
Water Pump Removal and Installation
Water Pump Disassembly and Assembly
Water Pump Related Parts Inspection
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Fuel System
Precautions
Precautions for Fuel System
General Description
Fuel System Description
Schematic and Routing Diagram
Fuel Tank Drain Hose and Breather Hose Routing Diagram
Diagnostic Information and Procedures
Fuel System Diagnosis
Repair Instructions
Fuel Pressure Inspection
Fuel Pump Inspection
Fuel Discharge Amount Inspection
Fuel Pump Relay Inspection
Fuel Hose Leakage Inspection
Fuel Level Gauge Inspection
Fuel Level Indicator Inspection
Fuel Level Indicator Switch (Thermistor) Inspection
Fuel Tank Construction
Fuel Tank Removal and Installation
Fuel Pump Components
Fuel Pump Assembly / Fuel Level Gauge Removal and Installation
Fuel Level Gauge and Fuel Level Indicator Switch Inspection
Fuel Pump Disassembly and Assembly
Fuel Mesh Filter Inspection and Cleaning
Fuel Hose Inspection
Fuel Injector / Fuel Delivery Pipe / T-Joint Removal and Installation
Fuel Injector Inspection and Cleaning
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Ignition System
Schematic and Routing Diagram
Ignition System Diagram
Ignition System Components Location
Diagnostic Information and Procedures
Ignition System Symptom Diagnosis
No Spark or Poor Spark
Repair Instructions
Ignition Coil / Plug Cap and Spark Plug Removal and Installation
Spark Plug Inspection and Cleaning
Ignition Coil / Plug Cap Inspection
CKP Sensor Inspection
CKP Sensor Removal and Installation
Engine Stop Switch Inspection
Ignition Switch Inspection
Ignition Switch Removal and Installation
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Special Tool
Starting System
Schematic and Routing Diagram
Starting System Diagram
Component Location
Starting System Components Location
Diagnostic Information and Procedures
Starting System Symptom Diagnosis
Starter Motor will Not Run
Starter Motor Runs but Does Not Crank the Engine
Repair Instructions
Starter Motor Components
Starter Motor Removal and Installation
Starter Motor Disassembly and Assembly
Starter Motor Inspection
Starter Relay Removal and Installation
Starter Relay Inspection
Turn Signal / Side-Stand Relay Removal and Installation
Side-Stand / Ignition Interlock System Parts Inspection
Starter Clutch Removal and Installation
Starter Clutch Inspection
Starter Button Inspection
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Charging System
Schematic and Routing Diagram
Charging System Diagram
Component Location
Charging System Components Location
Diagnostic Information and Procedures
Charging System Symptom Diagnosis
Battery Runs down Quickly
Repair Instructions
Battery Current Leakage Inspection
Regulated Voltage Inspection
Generator Inspection
Generator Removal and Installation
Regulator / Rectifier Construction
Regulator / Rectifier Inspection
Battery Components
Battery Charging
Battery Removal and Installation
Battery Visual Inspection
Specifications
Service Data
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Special Tool
Exhaust System
Precautions
Precautions for Exhaust System
Repair Instructions
Exhaust System Construction
Exhaust Pipe / Muffler Removal and Installation
Exhaust System Inspection
Specifications
Tightening Torque Specifications
Special Tools and Equipment
Recommended Service Material
Advertisement
Quick Links
1
Fuel and Oil Recommendation
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GSF650/A/S/SA
GSX650F
9 9 5 0 0 - 3 6 1 7 2 - 0 1 E
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Chapters
Section 1 Engine
71
Section 2 Suspension
383
Section 3 Driveline / Axle
439
Section 4 Brake
453
Section 5 Transmission / Transaxle
565
Section 6 Steering
609
Section 9 Body and Accessories
625
Table of Contents
Troubleshooting
FI System Troubleshooting
98
Diagnostic Information and Procedures
500
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