Suzuki GSX650FA Service Manual
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Suzuki GSX650FA Service Manual

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GSX650FA
SUPPLEMENTARY SERVICE MANUAL
USE THIS MANUAL WITH:
GSF650/A/S/SA GSX650F SERVICE MANUAL (99500-36172-01E)
9 9 5 0 1 - 3 6 1 9 0 - 0 1 E

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Summary of Contents for Suzuki GSX650FA

  • Page 1 GSX650FA SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH: GSF650/A/S/SA GSX650F SERVICE MANUAL (99500-36172-01E) 9 9 5 0 1 - 3 6 1 9 0 - 0 1 E...
  • Page 2 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
  • Page 3 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 Precautions for Electrical Circuit Service .....00-* Precautions for ABS..........00-* Precautions............
  • Page 6 00-1 Precautions: Precautions Precautions Precautions Precautions for ABS (GSX650FAK9) • Never subject the ABS control unit/HU to strong B917H20000005 impacts or allow them to be dropped. ABS Wiring • The ABS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly.

  • Page 7: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. General Information ........ 0A-1 General Description ..........
  • Page 8 0-ii Table of Contents Service Data..........0C-1 Service Data (GSF650/S/U/SUK8) ..... 0C-* Service Data (GSF650A/UA/SA/ASUK8) .... 0C-* Specifications............0C-1 Service Data (GSX650FK8) ........ 0C-* Service Data (GSF650/S/U/SUK7) ..... 0C-* Service Data (GSX650FAK9)......0C-1 Tightening Torque List ........0C-* Tightening Torque List (GSX650FAK9) ....0C-2 Service Data (GSF650A/UA/SA/ASUK7)....
  • Page 9 Vehicle Side View (GSX650FAK9) Left Side B917H20101019 NOTE Difference between illustration and actual motorcycles may exist depending on the markets. SUZUKI GSX650FA (2009-model) Right Side I917H2010002-01 I917H2010001-01 Country and Area Codes (GSX650FAK9) B917H20101020 The following codes stand for the applicable country(-ies) and area(-s).

  • Page 10: Specifications

    0A-2 General Information: Specifications Specifications (GSX650FAK9) B917H20107007 NOTE • These specifications are subject to change without notice. • Any differences between the GSX650FK9 (’09-model) and GSX650FAK9 (’09-model) in specifications are indicated an asterisk mark (*). Dimensions and curb mass Item Specification Remark Overall length...
  • Page 11 General Information: 0A-3 Special Tools and Equipment Special Tool B917H20108001 09900–20803 09900–20806 09900–25008 09900–25009 09904–41010 Thickness gauge Thickness gauge Multi circuit tester set Needle-point probe SUZUKI Diagnostic system set 09930–82710 99565–01010–020 Mode select switch CD-ROM Ver.20...

  • Page 12: Service Data

    0C-1 Service Data: Service Data General Information Specifications Service Data (GSX650FAK9) B917H20307007 NOTE • These specifications are subject to change without notice. • Any differences between the GSX650FK9 (’09-model) and GSX650FAK9 (’09-model) in service data are indicated an asterisk mark (*). Electrical Unit: mm (in) Item...
  • Page 13 Front fork oil level (Without spring, * 136 (5.4) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil — Front fork oil capacity (Each leg) * 455 ml (15.4/16.0 US lmp oz) —...
  • Page 14 0C-3 Service Data:...
  • Page 15 Table of Contents 2- i Section 2 Suspension CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........2-* Recommended Service Material ......2C-* Special Tool ............
  • Page 16 2-ii Table of Contents Front Wheel Assembly Construction Specifications ............2D-7 (GSX650FAK9) ..........2D-3 Service Data............2D-* Rear Wheel Components (GSX650FAK9)..2D-4 Tightening Torque Specifications......2D-7 Rear Wheel Assembly Construction Special Tools and Equipment ......2D-8 (GSX650FAK9) ..........2D-5 Recommended Service Material ......2D-8 Rear Wheel Assembly Removal and Installation (GSX650FAK9) .......2D-6...

  • Page 17: Wheels And Tires

    Wheels and Tires: 2D-1 Wheels and Tires Suspension Precautions Precautions for Wheel and Tire (GSX650FAK9) B917H22400002 WARNING • Proper tire inflation pressure and loading are important factors to ensure riding safety. Overloading can lead not only to tire damage but also to loss of control. •...
  • Page 18 2D-2 Wheels and Tires: Repair Instructions Front Wheel Components (GSX650FAK9) B917H22406021 I917H2240001-04 1. Front axle 6. Spacer 11. Tire : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake disc bolt 7. Wheel speed sensor rotor bolt 12. Front wheel : 6.5 N⋅m (0.65 kgf-m, 4.7 lbf-ft) 3.
  • Page 19 Wheels and Tires: 2D-3 Front Wheel Assembly Construction (GSX650FAK9) B917H22406022 Left Right “a ” “b ” I917H2240002-01 1. Brake disc bolt 6. Wheel speed sensor rotor bolt : 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) 2. Brake caliper mounting bolt “a”: Clearance : 6.5 N⋅m (0.65 kgf-m, 4.7 lbf-ft) 3.
  • Page 20 2D-4 Wheels and Tires: Rear Wheel Components (GSX650FAK9) B917H22406024 I917H2240013-01 1. Rear axle 8. Spacer 15. Spacer : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 2. Brake disc 9. Bearing 16. Air valve : 6.5 N⋅m (0.65 kgf-m, 4.7 lbf-ft) 3. Collar 10.
  • Page 21 Wheels and Tires: 2D-5 Rear Wheel Assembly Construction (GSX650FAK9) B917H22406025 Left Right “b” “ a ” I917H2240014-01 1. Rear sprocket nut 6. Wheel speed sensor rotor bolt : 22 N⋅m (2.2 kgf-m, 16.0 lbf-ft) 2. Rear axle nut “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 3.
  • Page 22 2D-6 Wheels and Tires: Rear Wheel Assembly Removal and Installation (GSX650FAK9) B917H22406026 Removal 1) Remove the rear wheel speed sensor (1) by removing the mounting bolts (2). Refer to “Rear Wheel Speed Sensor Removal and Installation in Section 4E in related manual”. I917H2240017-01 7) Remove the spacer (6) and collar (7).
  • Page 23 Wheels and Tires: 2D-7 4) Tighten the rear axle nut (3) to the specified torque. Tightening torque Rear axle nut (a): 100 N·m (10.0 kgf-m, 72.5 lbf- WARNING After remounting the rear wheel, pump the brake pedal several times to check for proper brake operation.
  • Page 24 2D-8 Wheels and Tires: Special Tools and Equipment Recommended Service Material B917H22408001 NOTE Required service material is also described in the following. “Front Wheel Components (GSX650FAK9) (Page 2D-2)” “Front Wheel Assembly Construction (GSX650FAK9) (Page 2D-3)” “Rear Wheel Components (GSX650FAK9) (Page 2D-4)” “Rear Wheel Assembly Construction (GSX650FAK9) (Page 2D-5)”...
  • Page 25 Table of Contents 4- i Section 4 Brake CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* Special Tools and Equipment ......4A-* Recommended Service Material ......
  • Page 26 4-ii Table of Contents ABS Information (GSX650FAK9) ......4E-1 DTC “43” (C1643): Wheel Speed Sensor Circuit Short (F)..........4E-* General Description ..........4E-1 DTC “44” (C1644): Wheel Speed Sensor Wheel Speed Sensor Description ....... 4E-* Signal Malfunction (R)........4E-* ABS Control Unit Description ......4E-* DTC “45”...

  • Page 27: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram...
  • Page 28 4A-2 Brake Control System and Diagnosis: Front Brake Hose Routing Diagram (GSX650FAK9) B917H24102004 “ b ” “A” “ a ” “ g ” “f” “f” “ e ” “c” “ c” “ d ” “ b ” “ c ” “...
  • Page 29 Brake Control System and Diagnosis: 4A-3 Rear Brake Hose Routing Diagram (GSX650FAK9) B917H24102005 “E” “ b ” “B” “A” “C” “D” “ a ” I917H2410002-03 1. Brake hose clamp “C” : Pass the rear brake hose No. 1 inside of the rear brake hose : Brake hose clamp ends should face forward.
  • Page 30 4A-4 Brake Control System and Diagnosis: Specifications Tightening Torque Specifications B917H24107002 NOTE The specified tightening torque is described in the following. “Front Brake Hose Routing Diagram (GSX650FAK9) (Page 4A-2)” “Rear Brake Hose Routing Diagram (GSX650FAK9) (Page 4A-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C in related manual”.
  • Page 31 ABS: 4E-1 Brake Precautions Precautions for ABS (GSX650FAK9) • Be sure to route the brake hoses correctly. B917H24500003 • The ABS does not shorten the motorcycle’s braking Refer to “Precautions for Electrical Circuit Service in distance. When riding down slopes or on wet or Section 00 in related manual”.
  • Page 32 4E-2 ABS: ABS Operation and ABS Indicator Light The ABS indicator light (1) shows the ABS operating condition. During normal operation, the ABS indicator light lights up when the ignition switch is turned to ON and goes off after the motorcycle is ridden at more than 10 km/h (6.2 mile/ h).
  • Page 33 ABS: 4E-3 Schematic and Routing Diagram ABS Wiring Diagram (GSX650FAK9) B917H24502005 Refer to “Wire Color Symbols in Section 0A in related manual”. I917H2450005-03...
  • Page 34 4E-4 ABS: Rear Wheel Speed Sensor Routing Diagram (GSX650FAK9) B917H24502008 “D” “G” “a” “C” “B” “F” “E” “A” “D” I917H2450045-01 1. Rear wheel speed sensor “C”: Clamp speed sensor lead wire with white tape matched green paint of brake hose. 2.

  • Page 35: Component Location

    ABS: 4E-5 Component Location ABS Components Location (GSX650FAK9) B917H24503002 I917H2450007-03 1. ABS control unit/HU 3. SDS coupler 5. Front wheel speed sensor rotor 7. Rear wheel speed sensor rotor 2. Mode select coupler 4. Front wheel speed sensor 6. Rear wheel speed sensor...
  • Page 36 4E-6 ABS: Diagnostic Information and Procedures ABS Indicator Light Inspection (GSX650FAK9) B917H24504027 Wiring Diagram Refer to “ABS Unit Diagram in related manual”. Troubleshooting Step Action 1) Check if the ABS indicator light (1) lights up when turning Go to Step 2. Go to Step 3.
  • Page 37 ABS: 4E-7 Step Action (The ABS indicator light does not light up) Go to Step 4. Replace the ignition fuse. 1) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D in related manual”. 2) Remove the fuse box (1) by removing the mounting bolt (2).
  • Page 38 4E-8 ABS: Step Action 1) Turn the ignition switch OFF. Go to Step 5. Inspect the wire harness. (Faulty ignition 2) Disconnect the ABS control unit/HU coupler. Refer to or ground wire) “ABS Control Unit Coupler Disconnect and Connect in related manual”.
  • Page 39 ABS: 4E-9 Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ground 2) Check for continuity between “24” (B/W) at the coupler wire) and body ground, also “25” (B/W) at the coupler and body ground.
  • Page 40 4E-10 ABS: Step Action 1) Turn the ignition switch OFF. Go to Step 9. Inspect the wire harness. (Faulty ignition 2) Disconnect the ABS control unit/HU coupler. Refer to or ground wire) “ABS Control Unit Coupler Disconnect and Connect in related manual”...
  • Page 41 ABS: 4E-11 Step Action 10 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty mode 2) Remove the left frame cover. Refer to “Exterior Parts select switch wire) Removal and Installation (GSF650/S/A/SAK7) in Section 9D in related manual”.
  • Page 42 4E-12 ABS: DTC (Diagnostic Trouble Code) Output 4) Switch the special tool to ON. (GSX650FAK9) B917H24504028 NOTE • Even through the ABS is operating correctly, a DTC is memorized in any of the following conditions. – If the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated.
  • Page 43 ABS: 4E-13 Understanding the DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation between the tens and ones are indicated by the light staying off for 1.6 seconds.
  • Page 44 Section 9D in related manual”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool (A): 09904–41010 (SUZUKI Diagnostic system set) (B): 99565–01010–020 (CD-ROM Ver.20) I705H1110116-03 3) Read the DTC (Diagnostic Trouble Code) and show data when trouble (displaying data at the time of DTC) according to instructions displayed on SDS.
  • Page 45 ABS: 4E-15 DTC “55” (C1655): ABS Control Unit Malfunction (GSX650FAK9) B917H24504047 Possible Cause Faulty ABS control unit/HU Troubleshooting NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “DTC (Diagnostic Trouble Code) Deleting in related manual”. Step Action 1) Inspect the clearances of the front and rear wheel speed Go to Step 2.
  • Page 46 4E-16 ABS: Step Action 1) Inspect both of the wheel speed sensor rotors for Go to Step 3. Clean or replace the damage and check that no foreign objects are caught in sensor rotor. the rotor openings. I718H1450064-01 Are the rotors OK? 1) Check that the front and rear wheel speed sensors are Go to Step 4.
  • Page 47 ABS: 4E-17 Repair Instructions Front Wheel Speed Sensor Rotor Removal and Installation Refer to “Wheel Speed Sensor and Sensor Rotor Installation (GSX650FAK9) Inspection in related manual”. B917H24506011 CAUTION Install the front wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: •...
  • Page 48 4E-18 ABS: Rear Wheel Speed Sensor Rotor Removal and Installation Refer to “Wheel Speed Sensor and Sensor Rotor Installation (GSX650FAK9) Inspection in related manual”. B917H24506012 CAUTION Install the rear wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: •...
  • Page 49 8) / (Page 4E-10) / (Page 4E-10) / (Page 4E-10) / (Page 4E-10) / (Page 4E-11) (Page 4E-11) 09904–41010 09930–82710 SUZUKI Diagnostic system Mode select switch (Page 4E-14) (Page 4E-1) / (Page 4E- 11) / (Page 4E-12) 99565–01010–020 CD-ROM Ver.20...
  • Page 50 4E-20 ABS:...
  • Page 51 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........5-* Clutch ............
  • Page 52 5C-1 Clutch: Clutch Transmission / Transaxle Schematic and Routing Diagram Clutch Hose Routing Diagram (GSX650FAK9) B917H25302002 “ b ” “ a ” “ c ” “A” “B” “C” “D” “ d ” I917H2530001-04 1. Wiring harness “A”: Pass the wiring harness through upper the clutch hose No. 3 clamp. 2.
  • Page 53 Clutch: 5C-2 Specifications Tightening Torque Specifications B917H25307002 NOTE The specified tightening torque is described in the following. “Clutch Hose Routing Diagram (GSX650FAK9) (Page 5C-1)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C in related manual”.
  • Page 54 5C-3 Clutch:...
  • Page 55 Table of Contents 9- i Section 9 Body and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* Front Turn Signal Light Removal and Installation ............
  • Page 56 9-ii Table of Contents Engine Coolant Temperature Removal and Repair Instructions ..........9D-* Installation ............9C-* Exterior Parts Construction (GSF650S/SAK7) ..9D-* Fuel Level Indicator Inspection ......9C-* Frame head cover construction (GSF650/ Fuel Level Indicator Switch (Thermistor) AK7) ..............9D-* Inspection............

  • Page 57: Wiring Systems

    Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (GSX650FAK9) B917H29102009 Refer to “Wire Color Symbols in Section 0A in related manual”.
  • Page 58 9A-2 Wiring Systems: For E-02, 19 I917H2910903-03...
  • Page 59 Wiring Systems: 9A-3 For E-03, 24, 28 I917H2910904-02...
  • Page 60 9A-4 Wiring Systems: For E-33 I917H2910905-03...
  • Page 61 Wiring Systems: 9A-5 Wiring Harness Routing Diagram (GSX650FAK9) B917H29102008 “E” “C” “A” “D” “B” “ a” I917H2910901-07 1. Battery 10. Clamp : Clamp the handle switch lead wires, ignition switch lead wire and front wheel speed sensor lead wire (ABS). 2.
  • Page 62 9A-6 Wiring Systems: “ a ” “A” “B” I917H2910902-02 1. Clamp 10. Headlight high beam bulb cap : Clamp the speed sensor lead wire and HO2 sensor lead wire. 2. Side-stand switch 11. Horn lead wire 3. HO2 sensor coupler 12.
  • Page 63 Wiring Systems: 9A-7 Specifications Service Data (GSX650FAK9) B917H2910S004 Electrical Item Specification Note ABS motor 20 A Fuse size ABS valve 15 A Tightening Torque Specifications B917H2910S005 NOTE The specified tightening torque is described in the following. “Wiring Harness Routing Diagram (GSX650FAK9) (Page 9A-5)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C in related manual”.
  • Page 64 Prepared by March, 2009 Part No. 99501-36190-01E Printed in Japan...
  • Page 65 Printed in Japan...

This manual is also suitable for:

Gsf650Gsf650aGsf650sGsf650saGsx650f

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