Suzuki GSF650A Service Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Motorcycle
  5. GSF650A
  6. Service manual

Suzuki GSF650A Service Manual

Hide thumbs Also See for GSF650A:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
Table of Contents

Advertisement

Quick Links

GSF650/A/S/SA
GSX650F
9 9 5 0 0 - 3 6 1 7 2 - 0 1 E

Advertisement

Table of Contents
loading

Related Manuals for Suzuki GSF650A

Summary of Contents for Suzuki GSF650A

  • Page 1 GSF650/A/S/SA GSX650F 9 9 5 0 0 - 3 6 1 7 2 - 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 Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Lubrication ......... 0B-1 Service Data............0C-1 Engine ................. 1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Emission Control Devices ........1B-1 Engine Electrical Devices........1C-1 Engine Mechanical..........1D-1 Engine Lubrication System ........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 General Precautions ........... 00-1 Precautions for Electrical Circuit Service .... 00-2 Precautions............00-1 Precautions for ABS..........00-7 Warning / Caution / Note........00-1...
  • Page 6 CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent. Indicates a potential hazard that could result • When removing parts that are to be reused, in death or injury.
  • Page 7 Precautions: 00-2 • Inspect each lead wire circuit for poor connection by • Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease shaking it by hand lightly. If any abnormal condition is and oil if a thread is smeared with them. found, repair or replace.
  • Page 8 00-3 Precautions: Clamp • Be careful not to touch the electrical terminals of the electronic parts (ECM, etc.). The static electricity from • Clamp the wire harness at such positions as indicated your body may damage these. in “Wiring Harness Routing Diagram (GSF650/S/A/ SAK7) in Section 9A (Page 9A-8)”.
  • Page 9 Precautions: 00-4 When checking system circuits including an electronic • Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, control unit such as ECM, etc., it is important to perform damaging counter electromotive force will be applied careful check, starting with items which are easier to to the ECM which may result in serious damage.
  • Page 10 00-5 Precautions: 4) Using continuity inspect or voltage check procedure Voltage check as described below, inspect the wire harness If voltage is supplied to the circuit being checked, voltage terminals for open circuit and poor connection. check can be used as circuit check. Locate abnormality, if any.
  • Page 11 “A” and “C”. Using The Multi-Circuit Testers • Use the Suzuki multi-circuit tester set. “A” • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range.
  • Page 12 00-7 Precautions: Precautions for ABS • After using the tester, turn the power off. B817H20000004 Special tool ABS Wiring : 09900–25008 (Multi-circuit tester set) • 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 13: General Information

    Adjustment ............0B-14 Warning, Caution and Information Labels Throttle Valve Synchronization ......0B-14 Location (GSF650/S/A/SAK7)......0A-6 PAIR System Inspection ........0B-14 Vehicle Side View (GSF650A/UA/SA/ASUK7) ..0A-7 Cooling System Inspection........0B-14 Country and Area Codes (GSF650A/UA/SA/ Clutch System Inspection........0B-16 ASUK7) ............. 0A-7 Clutch Hose Replacement ........0B-16 Country and Area Codes (GSF650/A/S/SA/ Clutch Fluid Replacement .........0B-16...
  • Page 14 Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent. 99000-25010 Apply SUZUKI MOLY PASTE or equivalent. 99000-25140 Apply SUZUKI SILICONE GREASE or equivalent.
  • Page 15 PCV: Positive Crankcase Ventilation (Crankcase Breather) RH: Right Hand ROM: Read Only Memory I717H1010002-02 SAE: Society of Automotive Engineers SDS: Suzuki Diagnosis System STC System: Secondary Throttle Control System (STCS) STP Sensor: Secondary Throttle Position Sensor (STPS) ST Valve: Secondary Throttle Valve (STV)

  • Page 16: Fuel And Oil Recommendation

    B817H20101005 JASO. The frame serial number or V.I.N. (Vehicle Identification Suzuki recommends the use of SAE 10W-40 engine oil. Number) “A” is stamped on the right side of the steering If SAE 10W-40 engine oil is not available, select and head pipe.

  • Page 17: Cylinder Identification

    Suzuki recommends the use of SUZUKI COOLANT anti- freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.
  • Page 18 0A-5 General Information: Country and Area Codes (GSF650/S/U/SUK7) B817H20101010 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSF650 K7 (E-02) U.K. JS1CJ122200100001 – GSF650 K7 (E-19) E.U. JS1CJ122100100001 – GSF650S K7 (E-02) U.K.
  • Page 19 General Information: 0A-6 Warning, Caution and Information Labels Location (GSF650/S/A/SAK7) B817H20101012 [ A ] [ B ] [ C ] 9, 10 [ D ] I717H1010006-02 GSF650/A GSF650U/UA GSF650S/SA GSF650SU/ASU 1. Information label — — For E-28 — 2. Fuel caution label For E-02 —...
  • Page 20 SUZUKI GSF650A/UA (2007-model) Right Side I717H2010003-01 Left Side I717H2010001-01 Left Side I717H2010004-01 I717H2010002-01 Country and Area Codes (GSF650A/UA/SA/ASUK7) B817H20101015 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSF650A K7 (E-02) U.K.
  • Page 21 Effective Frame No. GSF650 K8 (E-02) U.K. JS1CJ122200100465 – GSF650 K8 (E-19) E.U. JS1CJ122100103082 – GSF650 K8 (P-37) Brazil XXXXXXXXXXXXXXXXX – GSF650A K8 (E-19) E.U. JS1CJ124100100964 – GSF650S K8 (E-02) U.K. JS1CJ111200100068 – GSF650S K8 (E-19) E.U. JS1CJ111100101804 – GSF650S K8 (E-28) Canada JS1GP74A82100001 –...
  • Page 22 0A-9 General Information: Country and Area Codes (GSX650FK8) B817H20101017 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No. GSX650F K8 (E-02) U.K. JS1CJ135200100001 – GSX650F K8 (E-03) U.S.A (Except for California) JS1GP74A 82100001 – GSX650F K8 (E-19) E.U.
  • Page 23 General Information: 0A-10 Component Location Electrical Components Location B817H20103001 I717H1010007-02 1. Fuel pump relay 6. Fuel level gauge 11. Mode selection switch coupler 2. Starter relay/Main fuse 7. Ignition coil/plug cap 12. ISC valve 3. Cooling fan relay 8. PAIR control solenoid valve 13.
  • Page 24 0A-11 General Information: I717H1010008-04 15. IAP sensor (# 1) 21. Turn signal/side-stand relay 27. GP switch 16. Fuel injector 22. Horn 28. Starter motor 17. IAP/TP (# 2) /IAT sensor 23. Cooling fan 29. Speed sensor 18. STP sensor 24. CKP sensor 30.
  • Page 25 General Information: 0A-12 Specifications Specifications (GSF650/S/U/SUK7) B817H20107001 NOTE These specifications are subject to change without notice. Dimensions and dry mass Item Specification Remark Overall length 2 130 mm (83.9 in) Overall width 780 mm (30.1 in) Low/High 1 085/1 095 mm (42.7/43.1 in) Overall height GSF650/U 1 225 mm (48.2 in)
  • Page 26 0A-13 General Information: Chassis Item Specification Remark Front suspension Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 130 mm (5.1 in) Rear wheel travel 128 mm (5.0 in) Steering angle 35° (right & left) Caster 26°...
  • Page 27 General Information: 0A-14 Specifications (GSF650A/UA/SA/ASUK7) B817H20107002 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650/SK7 (’07-model) and GSF650A/UA/SA/ASUK7 (’07-model) in specifications are indicated an asterisk mark (*). Dimensions and dry mass Item Specification Remark Overall length 2 130 mm (83.9 in)
  • Page 28 0A-15 General Information: Specifications (GSF650/S/U/SUK8) B817H20107003 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650/SK7 (’07-model) and GSF650/S/U/SUK8 (’08-model) in specifications are indicated an asterisk mark (*). Electrical Item Specification Remark Ignition type Electronic ignition (Transistorized) Ignition timing 2°...
  • Page 29 General Information: 0A-16 Specifications (GSF650A/UA/SA/ASUK8) B817H20107004 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650A/UA/SA/ASUK7 (’07-model) and GSF650A/UA/SA/ASUK8 (’08- model) in specifications are indicated an asterisk mark (*). Electrical Item Specification Remark Ignition type...
  • Page 30 0A-17 General Information: Specifications (GSX650FK8) B817H20107005 NOTE • These specifications are subject to change without notice. • Any differences between the GSF650/SK7 (’07-model) and GSX650FK8 (’08-model) in specifications are indicated an asterisk mark (*). Dimensions and dry mass Item Specification Remark Overall length 2 130 mm (83.9 in)
  • Page 31 General Information: 0A-18 Special Tools and Equipment Special Tool B817H20108002 09900–06107 09900–06108 09900–20102 09900–20202 09900–20203 Snap ring pliers Snap ring pliers Vernier calipers (1/20 Micrometer (1/100 Micrometer (1/100 mm, 200 mm) mm, 25 – 50 mm) mm, 50 – 75 mm) 09900–20205 09900–20530 09900–20602...
  • Page 32 0A-19 General Information: 09915–40610 09915–63311 09915–64512 09915–74521 09915–74540 Oil filter wrench Compression gauge Compression gauge Oil pressure gauge Oil pressure gauge attachment hose attachment 09915–77331 09916–10911 09916–14510 09916–14521 09916–33210 Meter (for high Valve lapper set Valve lifter Valve spring Valve guide reamer pressure) compressor (4.5 mm)
  • Page 33 General Information: 0A-20 09923–74511 09924–84510 09924–84521 09930–10121 09930–11920 Bearing remover Bearing installer set Bearing installer set Spark plug wrench set Torx bit (JT40H) 09930–11940 09930–11950 09930–30104 09930–34970 09930–44530 Bit holder Torx wrench Rotor remover sliding Rotor remover set Rotor holder shaft 09930–82710 09930–82720...

  • Page 34: Maintenance And Lubrication

    0B-1 Maintenance and Lubrication: Maintenance and Lubrication General Information Precautions Precautions for Maintenance B817H20200001 The “Periodic Maintenance Schedule Chart” 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 for your convenience.
  • Page 35 Maintenance and Lubrication: 0B-2 Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months Steering — — Front forks — — — Rear suspension — — — Chassis bolts and nuts Lubrication Points (GSF650/S/A/SAK7) B817H20205002 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
  • Page 36 0B-3 Maintenance and Lubrication: Periodic Maintenance Schedule Chart (GSX650FK8) B817H20205003 NOTE I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace. T = Tighten. Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500...
  • Page 37 Maintenance and Lubrication: 0B-4 I817H2020001-01 1. Clutch lever holder 6. Brake lever holder 2. Gearshift lever pivot 7. Brake pedal pivot and footrest pivot 3. Side-stand pivot and spring hook : Apply oil. 4. Footrest pivot : Apply grease. 5. Drive chain Repair Instructions Air Cleaner Element Replacement 2) Inspect the air cleaner element for clogging.
  • Page 38 0B-5 Maintenance and Lubrication: Cleaning Tightening torque Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 1) Remove the air cleaner element. Refer to “Air Exhaust pipe mounting bolt (b): 23 N·m (2.3 kgf-m, Cleaner Element Removal and Installation in Section 16.5 lbf-ft) 1D (Page 1D-7)”.
  • Page 39 Maintenance and Lubrication: 0B-6 Valve Clearance Inspection and Adjustment Carbon Deposits B817H20206006 1) Remove the spark plugs. Refer to “Ignition Coil / Inspect valve clearance Plug Cap and Spark Plug Removal and Installation in Initially every 24 000 km (14 500 miles, 48 months). Section 1H (Page 1H-3)”.
  • Page 40 0B-7 Maintenance and Lubrication: 7) Remove the cylinder head cover. Refer to “Engine 9) Turn the crankshaft clockwise and align the match Top Side Disassembly in Section 1D (Page 1D-24)”. mark “C” on the crankshaft with the mating surfaces “D” of the crankcases. Also, position the notches “E” NOTE on the right end of each camshaft as shown.
  • Page 41 Maintenance and Lubrication: 0B-8 10) Insert the thickness gauge between the tappet and Adjustment the cam. If the clearance is out of specification, The clearance is adjusted by replacing the existing adjust it into the specified range. tappet shim by a thicker or thinner shim. 1) Remove the intake or exhaust camshafts.
  • Page 42 0B-9 Maintenance and Lubrication: 5) Fit the selected shim (2) to the valve stem end, with numbers toward tappet. Be sure to check shim size with micrometer to ensure its size. NOTE • Be sure to apply engine oil to tappet shim top and bottom faces.
  • Page 43 Maintenance and Lubrication: 0B-10 (INTAKE SIDE) I718H1020003-02...
  • Page 44 0B-11 Maintenance and Lubrication: (EXHAUST SIDE) I718H1020004-02...

  • Page 45: Fuel Line Inspection

    Maintenance and Lubrication: 0B-12 6) Install the cam chain tension adjuster and Engine Oil Replacement camshafts. Refer to “Engine Top Side Assembly in 1) Keep the motorcycle upright with the center stand. Section 1D (Page 1D-26)”. 2) Place an oil pan below the engine, and drain engine 7) Rotate the engine so that the tappet is depressed oil by removing the oil drain plug (1) and filler cap fully.
  • Page 46 Also, do not use a genuine Suzuki 3) Turn off the engine and wait about three minutes, automobile oil filter on this motorcycle.
  • Page 47 Maintenance and Lubrication: 0B-14 Throttle Valve Synchronization 5) Add new engine oil and check the oil level is as described in the engine oil replacement procedure. B817H20206010 Inspect throttle valve synchronization Necessary amount of engine oil Every 12 000 km (7 500 miles, 24 months) Oil change: 3 000 ml (3.2/2.6 US/lmp qt) Oil and filter change: 3 500 ml (3.7/3.1 US/lmp qt) Inspect the throttle valve synchronization periodically.
  • Page 48 0B-15 Maintenance and Lubrication: Engine Coolant Change 7) Bleed air from the cooling circuit. Refer to “Engine Coolant Description in Section 1F 8) After changing engine coolant, reinstall the removed (Page 1F-1)”. parts. WARNING Air Bleeding From the Cooling Circuit Do not open the radiator cap when the engine 1) Support the motorcycle upright with the center stand.
  • Page 49 Maintenance and Lubrication: 0B-16 Radiator Hose Inspection Check the radiator hoses for crack, damage or engine coolant leakage. If any defect is found, replace the radiator hose with a new one. I718H1020034-01 Clutch Hose Inspection 1) Remove the seat and left frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/ I717H1020014-01 A/SAK7) in Section 9D (Page 9D-6)”.
  • Page 50 0B-17 Maintenance and Lubrication: Drive Chain Inspection and Adjustment 3) Count out 21 pins (20 pitches) on the chain and B817H20206016 measure the distance between the two points. If the distance exceeds the service limit, the chain must be Inspect drive chain replaced.
  • Page 51 CAUTION • Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is a RK 525SMOZ7Y. SUZUKI recommends to use this standard drive chain as a replacement. I717H1020019-01...
  • Page 52 0B-19 Maintenance and Lubrication: Brake Fluid Level Check 1) Keep the motorcycle upright and place the handlebars straight. 2) Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit “A”...
  • Page 53 Maintenance and Lubrication: 0B-20 Tire Inspection Brake Pedal Height Inspection and Adjustment B817H20206019 1) Inspect the brake pedal height “a” between the pedal Inspect tire top face and footrest. Every 6 000 km (4 000 miles, 12 months) Adjust the brake pedal height if necessary. Tire Tread Condition Brake pedal height “a”...
  • Page 54 It is highly recommended to use a Replace any defective parts, if necessary. Refer to SUZUKI Genuine Tire. “Front Fork Parts Inspection in Section 2B (Page 2B-9)”. Tire type BRIDGESTONE •...
  • Page 55 Maintenance and Lubrication: 0B-22 Chassis Bolt and Nut Inspection B817H20206023 Tighten chassis bolt and nut Initially at 1 000 km (600 miles, 2 months) and every 6 000 km (4 000 miles, 12 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque.
  • Page 56 0B-23 Maintenance and Lubrication: I717H1020035-02 I717H1020038-01 Front fork lower clamp bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Front footrest bolt 35 N⋅m (3.5 kgf-m, 25.5 lb-ft) Rear brake master cylinder mounting bolt 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) Rear brake master cylinder rod lock-nut 18 N⋅m (1.8 kgf-m, 13.0 lb-ft)
  • Page 57 For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H20208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) /...
  • Page 58 0C-1 Service Data: Service Data General Information Specifications Service Data (GSF650/S/U/SUK7) B817H20307001 Valve + Guide Unit: mm (in) Item Standard Limit 23 (0.91) — Valve diam. 20 (0.79) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 –...
  • Page 59 Service Data: 0C-2 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 900 kPa Compression pressure 1 200 – 1 600 kPa (12 – 16 kgf/cm , 171 – 226 psi) (9 kgf/cm , 128 psi) 200 kPa Compression pressure difference —...
  • Page 60 0C-3 Service Data: Transmission + Drive Chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 1.700 (85/50) — Final reduction ratio 3.200 (48/15) — 3.076 (40/13) — 2.058 (35/17) — 1.600 (32/20) — Gear ratios 1.363 (30/22) —...
  • Page 61 Service Data: 0C-4 FI Sensors + Secondary Throttle Valve Actuator Item Standard/Specification Note 90 – 150 Ω CKP sensor resistance CKP sensor peak voltage 2.0 V and more When cranking IAP sensor (# 1) input voltage 4.5 – 5.5 V IAP sensor (# 1) output voltage Approx.
  • Page 62 0C-5 Service Data: Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR9E Type Spark plug DENSO: U27ESR-N 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 90 –...
  • Page 63 133 (5.2) — outer tube fully compressed) GSF650S/SU 132 (5.2) — Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil — GSF650/U 458 ml (15.5/16.1 US/lmp oz) — Front fork oil capacity (Each leg) GSF650S/SU 459 ml (15.5/16.2 US/lmp oz) —...
  • Page 64 0C-7 Service Data: Fuel + Oil Item Specification Note Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less E-28 Fuel type than 10% ethanol, or less than 5% methanol with...
  • Page 65 Service Data: 0C-8 Item N⋅m kgf-m lb-ft (Initial) 13.0 Crankshaft journal bolt [M9] (Final) 23.0 (Cylinder head) [M6] Oil gallery plug [M8] [M12] 11.0 [M16] 25.5 Oil gallery bolt Oil gallery jet 16.0 Oil drain plug 16.5 Piston cooling oil jet bolt Oil pump mounting bolt Initial 11.0...
  • Page 66 0C-9 Service Data: Chassis Item N⋅m kgf-m lb-ft Steering stem head nut 47.0 Tighten 45 N⋅m (4.5 kgf-m, 32.5 Ib-ft) then turn back 1/2 – Steering stem nut 1/4. Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5...
  • Page 67 16.0 115.5 24.0 173.5 “ a ” “a” “a ” I649G1030001-04 1. Conventional bolt 2. “4” marked bolt 3. “7” marked bolt Service Data (GSF650A/UA/SA/ASUK7) B817H20307003 Electrical Unit: mm Item Specification Note ABS motor 20 A Fuse size 15 A...
  • Page 68 0C-11 Service Data: Service Data (GSF650A/UA/SA/ASUK8) B817H20307006 Electrical Unit: mm Item Specification Note NGK: CR8E Spark plug Type DENSO: U24ESR-N ABS motor 20 A Fuse size 15 A Wattage Unit: W Specification Item GSF650A/UA GSF650SA/ASU ← ABS indicator light Service Data (GSX650FK8)
  • Page 69 Front fork oil level (Without spring, * 132 (5.2) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil — Front fork oil capacity (Each leg) * 459 ml (15.5/16.2 US/lmp oz) —...
  • Page 70 0C-13 Service Data:...

  • Page 71: Table Of Contents

    Table of Contents 1- i Section 1 Engine CONTENTS Precautions ..........1-1 DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction....1A-75 Precautions............. 1-1 DTC “C29” (P1654-H/L): Secondary Throttle Precautions for Engine.......... 1-1 Position Sensor (STPS) Circuit Malfunction..1A-79 Engine General Information and DTC “C31”...

  • Page 72: Table Of Contents

    1-ii Table of Contents PAIR Reed Valve Removal and Installation..1B-6 Throttle Cable Routing Diagram PAIR Control Solenoid Valve Removal and (GSX650FK8)............1D-3 Installation ............1B-6 Diagnostic Information and Procedures ....1D-4 PAIR System Inspection ........1B-7 Engine Mechanical Symptom Diagnosis .....1D-4 Crankcase Breather (PCV) Hose Inspection..
  • Page 73 Table of Contents 1-iii Engine Lubrication System ....1E-1 Water pump Components ......... 1F-11 Water Pump Construction ......... 1F-12 Precautions............1E-1 Water Pump Removal and Installation....1F-12 Precautions for Engine Oil ........1E-1 Water Pump Disassembly and Assembly ..1F-13 Schematic and Routing Diagram......
  • Page 74 1-iv Table of Contents Repair Instructions ..........1H-3 Special Tools and Equipment ......1I-13 Ignition Coil / Plug Cap and Spark Plug Recommended Service Material ......1I-13 Removal and Installation........1H-3 Special Tool ............1I-13 Spark Plug Inspection and Cleaning ....1H-4 Charging System ........1J-1 Ignition Coil / Plug Cap Inspection ......1H-4 CKP Sensor Inspection ........1H-6 Schematic and Routing Diagram ......

  • Page 75: Precautions

    Precautions: Precautions Engine Precautions Precautions for Engine B817H21000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”.

  • Page 76: Engine General Information And Diagnosis

    1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B817H21101001 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

  • Page 77: Self-Diagnosis Function (Gsf650/S/A/Sak7)

    Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased.
  • Page 78 1A-3 Engine General Information and Diagnosis: For Example: The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”. If CHEC is indicated, the LCD does not indicate the trouble code.

  • Page 79: Self-Diagnosis Function (Gsx650Fk8)

    Engine General Information and Diagnosis: 1A-4 Self-Diagnosis Function (GSX650FK8) B817H21101003 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided.
  • Page 80 1A-5 Engine General Information and Diagnosis: Dealer Mode The defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices.

  • Page 81: Schematic And Routing Diagram

    Engine General Information and Diagnosis: 1A-6 Schematic and Routing Diagram FI System Wiring Diagram B817H21102001 I717H1110002-02...

  • Page 82: Terminal Alignment Of Ecm Coupler

    1A-7 Engine General Information and Diagnosis: Terminal Alignment of ECM Coupler B817H21102002 I718H1110004-02 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT STVA signal (STVA, 2A) CKP sensor signal (CKP-) STVA signal (STVA, 1A) Serial data for self-diagnosis — Power source for fuel injector (VM) ECM ground (E1) ISC signal (ISC, 2A) Serial data for speedometer...

  • Page 83: Fi System Parts Location

    Engine General Information and Diagnosis: 1A-8 Component Location FI System Parts Location B817H21103001 “B” “J” “I” “C” “H” “D” “E” “F” I717H1110003-02 “A”: ECM “C”: Cooling fan relay “E”: ISC valve “G”: Cooling fan “I”: PAIR control solenoid valve “B”: TO sensor “D”: STV actuator “F”: HO2 sensor “H”: Ignition coil...

  • Page 84: Diagnostic Information And Procedures

    1A-9 Engine General Information and Diagnosis: Diagnostic Information and Procedures Engine Symptom Diagnosis B817H21104001 Condition Possible cause Correction / Reference Item Engine will not start or is Valve clearance out of adjustment. Adjust. hard to start Worn valve guides or poor seating of Repair or replace.
  • Page 85 Engine General Information and Diagnosis: 1A-10 Condition Possible cause Correction / Reference Item Engine stalls often (Fuel Defective fuel injectors. Replace. injector improperly No injection signal from ECM. Repair or replace. operating) Open or short circuited wiring Repair or replace. connection.
  • Page 86 1A-11 Engine General Information and Diagnosis: Condition Possible cause Correction / Reference Item Engine runs poorly in Weakened valve springs. Replace. high speed range Worn camshafts. Replace. (Defective engine internal/ Valve timing out of adjustment. Adjust. electrical parts) Too narrow spark plug gap. Adjust.
  • Page 87 Engine General Information and Diagnosis: 1A-12 Condition Possible cause Correction / Reference Item Engine lacks power Low fuel pressure. Repair or replace. (Defective control circuit Defective TP sensor. Replace. or sensor) Defective IAT sensor. Replace. Defective CKP sensor. Replace. Defective GP sensor. Replace.

  • Page 88: Self-Diagnostic Procedures (Gsf650/S/A/Sak7)

    1A-13 Engine General Information and Diagnosis: Self-Diagnostic Procedures (GSF650/S/A/SAK7) 5) Check the DTC to determine the malfunction part. B817H21104002 Refer to “DTC Table (Page 1A-21)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble...
  • Page 89 Engine General Information and Diagnosis: 1A-14 Use of SDS NOTE • Do not disconnect the coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory.

  • Page 90: Use Of Sds Diagnosis Reset Procedures

    1A-15 Engine General Information and Diagnosis: 4) Start the engine or crank the engine for more the 4 3) Check the DTC. seconds. 4) The previous malfunction history code (Past DTC) 5) Check the DTC to determine the malfunction part. still remains stored in the ECM.
  • Page 91 Engine General Information and Diagnosis: 1A-16 Show Data When Trouble (DTC) B817H21104004 Use of SDS ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.

  • Page 92: Sds Check

    1A-17 Engine General Information and Diagnosis: 2) Click the drop down button (2), either “Failure #1” or “Failure #2” can be selected. I718H1110009-01 SDS Check B817H21104005 Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user.
  • Page 93 Engine General Information and Diagnosis: 1A-18 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) Special tool : 09904–41010 (SDS set) : 99565–01010–010 (CD-ROM Ver.10)
  • Page 94 1A-19 Engine General Information and Diagnosis: Data at the time of racing Throttle: Quick wide open Throttle: Slowly open Secondary throttle valve opens closes in according with the throttle valve opening PAIR control solenoid valve OFF in according with the throttle valve opens closes I718H1110151-01 Data of intake negative pressure during idling (100 °C)
  • Page 95 Engine General Information and Diagnosis: 1A-20 Example of Trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the passing of time and identify what problem is currently occurring.

  • Page 96: Dtc Table

    1A-21 Engine General Information and Diagnosis: DTC Table B817H21104006 Code Malfunction Part Remarks None No defective part C12 (P0335) Crankshaft position sensor (CKPS) Pick-up coil signal, signal generator (Page 1A-27) C13 (P0105-H/L) Intake air pressure sensor #1 (IAPS) (Page 1A-30) C14 (P0120-H/L) Throttle position sensor (TPS) (Page 1A-39)

  • Page 97: Fail-Safe Function Table

    Engine General Information and Diagnosis: 1A-22 Fail-Safe Function Table B817H21104007 FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition. Item Fail-Safe Mode Starting Ability Running Ability Intake air pressure is fixed to 101 kPa (760...

  • Page 98: Fi System Troubleshooting

    1A-23 Engine General Information and Diagnosis: FI System Troubleshooting B817H21104008 Customer Complaint Analysis Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as following will facilitate collecting information to the point required for proper analysis and diagnosis.

  • Page 99: Malfunction Code And Defective Condition Table

    Engine General Information and Diagnosis: 1A-24 Visual Inspection Prior to diagnosis using the mode select switch or SDS, perform the following visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be displayed on the screen with the use of mode select switch or SDS.
  • Page 100 1A-25 Engine General Information and Diagnosis: Malfunction Detected Item Detected Failure Condition Check For Code The sensor voltage should be the following. 0.15 V ≤ sensor voltage < 4.85 V ECT sensor, lead wire/coupler In other than the above range, C15 (P0115) is connection indicated.
  • Page 101 Engine General Information and Diagnosis: 1A-26 Malfunction Detected Item Detected Failure Condition Check For Code ISC valve circuit open or C40/P0505 The circuit voltage of motor drive is unusual. shorted to the ground Air passage clogged Idle speed is lower than the desired idle ISC valve fixed C40/P0506 speed.

  • Page 102: Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction

    1A-27 Engine General Information and Diagnosis: DTC “C12” (P0335): CKP Sensor Circuit Malfunction B817H21104010 Detected Condition and Possible Cause Detected Condition Possible Cause The signal does not reach ECM for 3 sec. or more, after • Metal particles or foreign material being stuck on the receiving the starter signal.
  • Page 103 Engine General Information and Diagnosis: 1A-28 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the CKP sensor with a new one. 2) Check the CKP sensor coupler for loose or poor contacts. If OK, then measure the CKP sensor resistance. I717H1110008-01 3) Disconnect the CKP sensor coupler and measure the resistance.
  • Page 104 1A-29 Engine General Information and Diagnosis: Step Action 1) Crank the engine a few seconds with the starter motor, • B/Y or B/R wire open • Inspect that metal and measure the CKP sensor peak voltage at the or shorted to the particles or foreign coupler.

  • Page 105: Dtc "C13" (P0105-H/L): Iap Sensor (#1) Circuit Malfunction

    Engine General Information and Diagnosis: 1A-30 DTC “C13” (P0105-H/L): IAP Sensor (#1) Circuit Malfunction B817H21104011 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
  • Page 106 1A-31 Engine General Information and Diagnosis: C13 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Lift and support the fuel tank. Refer to “Fuel Tank coupler.
  • Page 107 Engine General Information and Diagnosis: 1A-32 P0105-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 1 data. I718H1110161-02 Approx. 146 kPa (1.46 kgf/cm , 21 psi) and more OK? 1) Turn the ignition switch OFF.
  • Page 108 1A-33 Engine General Information and Diagnosis: Step Action 4) Disconnect the IAP sensor coupler. Go to Step 4. W/Bl wire shorted to Vcc, or B/Br wire open. 5) Check the continuity between the B wire and W/Bl wire. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 109 Engine General Information and Diagnosis: 1A-34 P0105-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 1 data. I718H1110163-02 Approx. –20 kPa (–0.2 kgf/cm , –2.8 psi) and less OK? 1) Turn the ignition switch OFF.
  • Page 110 1A-35 Engine General Information and Diagnosis: Step Action 4) Disconnect the IAP sensor coupler. Go to Step 3. B and W/Bl wire open, W/Bl wire shorted to the 5) Check the continuity between the W/Bl wire “C” and ground. ground. Also, check the continuity between the W/Bl wire and B/Br wire.
  • Page 111 Engine General Information and Diagnosis: 1A-36 Step Action 1) Connect the ECM coupler. Refer to “ECM Removal and Go to Step 4. Open or short circuit in Installation in Section 1C (Page 1C-1)”. the B wire or B/Br wire. 2) Turn the ignition switch ON. 3) Measure the input voltage at the B wire and ground with the needle pointed probes.
  • Page 112 1A-37 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 5. • Check the vacuum hose for crack or 2) Connect the ECM coupler and IAP sensor coupler. damage. 3) Insert the needle pointed probes to the lead wire coupler. •...
  • Page 113 Engine General Information and Diagnosis: 1A-38 Step Action 1) Turn the ignition switch OFF. • B, W/Bl or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Remove the IAP sensor. Refer to “ECM Removal and the ground, or poor IAP sensor with a new Installation in Section 1C (Page 1C-1)”.

  • Page 114: Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction

    1A-39 Engine General Information and Diagnosis: DTC “C14” (P0120-H/L): TP Sensor Circuit Malfunction B817H21104012 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not within the following • TP sensor maladjusted. range. • TP sensor circuit open or short. Difference between actual throttle opening •...
  • Page 115 Engine General Information and Diagnosis: 1A-40 C14 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Check the TP sensor coupler for loose or poor contacts. coupler.
  • Page 116 1A-41 Engine General Information and Diagnosis: P0120-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the throttle position data. I718H1110169-01 ° Throttle position approx. 125 and more OK? 1) Turn the ignition switch OFF.
  • Page 117 Engine General Information and Diagnosis: 1A-42 Step Action 3) Disconnect the TP sensor coupler. Go to Step 4. P/B wire shorted to Vcc, or B/Br wire open. 4) Insert the needle pointed probes to the lead wire coupler. 5) Check the continuity between the P/B wire and R wire. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 118 1A-43 Engine General Information and Diagnosis: P0120-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the throttle position data. I718H1110172-01 ° Throttle position approx. 0 1) Turn the ignition switch OFF.
  • Page 119 Engine General Information and Diagnosis: 1A-44 Step Action 4) Insert the needle pointed probes to the lead wire coupler. Go to Step 3. R and P/B wire open, or P/B wire shorted to the 5) Check the continuity between the P/B wire and ground. ground.
  • Page 120 1A-45 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Refer to “ECM Removal and Turn the ignition switch Open or short circuit in Installation in Section 1C (Page 1C-1)”. OFF and go to Step 4. the R or B/Br wire. 2) Turn the ignition switch ON.
  • Page 121 Engine General Information and Diagnosis: 1A-46 Step Action 1) Turn the ignition switch OFF. • P/B, R or B/Br wire If check result is not open or shorted to satisfactory, replace TP 2) Connect the ECM coupler and TP sensor coupler. the ground, or poor 8, sensor with a new one.

  • Page 122: Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction

    1A-47 Engine General Information and Diagnosis: DTC “C15” (P0115-H/L): ECT Sensor Circuit Malfunction B817H21104013 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • ECT sensor circuit open or short. range. • ECT sensor malfunction. 0.15 V ≤...
  • Page 123 Engine General Information and Diagnosis: 1A-48 C15 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the ECT sensor coupler for loose or poor coupler.
  • Page 124 1A-49 Engine General Information and Diagnosis: P0115-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the engine coolant/oil temperature data. I718H1110175-01 ° ° Approx. –30 C (–22 F) and less OK?
  • Page 125 Engine General Information and Diagnosis: 1A-50 Step Action 1) Turn the ignition switch OFF. Go to Step 3. B/Bl or B/Br wire open. 2) Check the ECT sensor coupler for loose or poor contacts. If OK, then check the ECT sensor lead wire continuity. I717H1110014-01 3) Disconnect the ECT coupler.
  • Page 126 1A-51 Engine General Information and Diagnosis: P0115-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the engine coolant/oil temperature data. I718H1110176-01 ° ° Approx. 120 C (248 F) and more OK? 1) Turn the ignition switch OFF.
  • Page 127 Engine General Information and Diagnosis: 1A-52 Step Action 4) Check the continuity between the B/Bl wire and ground. Go to Step 3. • B/Bl wire shorted to If the sound is not heard from the tester, the circuit the ground. condition is OK.
  • Page 128 1A-53 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • B/Bl or B/Br wire Replace the ECT open or shorted to sensor with a new one. 2) Connect the ECM coupler. the ground, or poor Refer to “ECT Sensor 3) Remove the regulator/rectifier.

  • Page 129: Dtc "C17" (P1750-H/L): Iap Sensor (#2) Circuit Malfunction

    Engine General Information and Diagnosis: 1A-54 DTC “C17” (P1750-H/L): IAP Sensor (#2) Circuit Malfunction B817H21104014 Detected Condition and Possible Cause Detected Condition Possible Cause IAP sensor voltage is not within the • Clogged vacuum passage between throttle body and following range. IAP sensor.
  • Page 130 1A-55 Engine General Information and Diagnosis: NOTE • After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”. • IAP sensor #2 is incorporated in the TP sensor/IAT sensor. C17 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF.
  • Page 131 Engine General Information and Diagnosis: 1A-56 P1750-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 2 data. I718H1110181-03 Approx. 126 kPa (1.26 kgf/cm , 18 psi) and more OK? 1) Turn the ignition switch OFF.
  • Page 132 1A-57 Engine General Information and Diagnosis: Step Action 4) Disconnect the IAP sensor coupler. Go to Step 4. W/Bl wire shorted to Vcc, or B/Br wire open. 5) Insert the needle pointed probes to the lead wire coupler. 6) Check the continuity between the R and G/B wire. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 133 Engine General Information and Diagnosis: 1A-58 P1750-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the manifold absolute pressure 2 data. I718H1110183-02 Approx. 0 kPa (0 kgf/cm , 0 psi) and less OK? 1) Turn the ignition switch OFF.
  • Page 134 1A-59 Engine General Information and Diagnosis: Step Action 5) Check the continuity between the G/B wire and ground. Go to Step 3. R and G/B wire open, Also, check the continuity between the G/B wire and B/ W/Bl wire shorted to the Br wire.
  • Page 135 Engine General Information and Diagnosis: 1A-60 Step Action 1) Connect the ECM coupler. Refer to “ECM Removal and Go to Step 4. Open or short circuit in Installation in Section 1C (Page 1C-1)”. the R wire or B/Br wire. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the lead wire coupler.
  • Page 136 1A-61 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • G/B, R or B/Br wire • Open or short circuit open or shorted to in the G/B wire. 2) Connect the ECM coupler and IAP sensor coupler. the ground, or poor 9, •...

  • Page 137: Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction

    Engine General Information and Diagnosis: 1A-62 DTC “C21” (P0110-H/L): IAT Sensor Circuit Malfunction B817H21104015 Detected Condition and Possible Cause Detected Condition Possible Cause Output voltage is not with in the following • IAT sensor circuit open or short. range. • IAT sensor malfunction. 0.15 V ≤...
  • Page 138 1A-63 Engine General Information and Diagnosis: C21 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 3. • Loose or poor contacts on the ECM 2) Check the IAT sensor coupler for loose or poor contacts. coupler.
  • Page 139 Engine General Information and Diagnosis: 1A-64 P0110-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the intake air temperature data. I717H1110019-01 ° ° Approx. –30 C (–22 F) and less OK?
  • Page 140 1A-65 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Connect the ECM Dg or B/Br wire open. coupler and go to Step 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. I717H1110013-02 3) Disconnect the IAT sensor coupler.
  • Page 141 Engine General Information and Diagnosis: 1A-66 P0110-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 3. I718H1110251-01 2) Check the intake air temperature data. I717H1110020-01 ° ° Approx. 125 C (257 F) and more OK? 1) Turn the ignition switch OFF.
  • Page 142 1A-67 Engine General Information and Diagnosis: Step Action 3) Disconnect the IAT sensor coupler. Go to Step 3. • Dg wire shorted to the ground. 4) Insert the needle pointed probes to the lead wire coupler. • If wire is OK, go to 5) Check the continuity between the Dg wire and ground.
  • Page 143 Engine General Information and Diagnosis: 1A-68 Step Action 1) Turn the ignition switch OFF. • Dg or B/Br wire open Replace the IAT sensor or shorted to the with a new one. Refer to 2) Disconnect the IAT sensor coupler. ground, or poor 27 or “IAP / TP / IAT Sensor 3) Measure the IAT sensor resistance.

  • Page 144: Dtc "C23" (P1651-H/L): To Sensor Circuit Malfunction

    1A-69 Engine General Information and Diagnosis: DTC “C23” (P1651-H/L): TO Sensor Circuit Malfunction B817H21104016 Detected Condition and Possible Cause Detected Condition Possible Cause The sensor voltage should be the • TO sensor circuit open or short. following for 2 sec. and more, after ignition •...
  • Page 145 Engine General Information and Diagnosis: 1A-70 C23 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the TO sensor with a new one. Refer to 2) Remove the seat. Refer to “Exterior Parts Removal and “TO Sensor Removal Installation (GSF650/S/A/SAK7) in Section 9D and Installation in...
  • Page 146 1A-71 Engine General Information and Diagnosis: P1651-H (Use of SDS) Step Action 1) Turn the ignition switch OFF. Go to Step 2. B wire shorted to Vcc, or B/Br wire open. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”.
  • Page 147 Engine General Information and Diagnosis: 1A-72 Step Action 8) Check the continuity between the B wire “B” and terminal Go to Step 2. B wire shorted to Vcc, or 22. Also, check the continuity between B/Br wire “C” and B/Br wire open. terminal 29.
  • Page 148 1A-73 Engine General Information and Diagnosis: Step Action 4) Disconnect the TO sensor coupler. Go to Step 2. R or B wire open, or B wire shorted to the 5) Check the continuity between the B wire “B” and ground. ground.
  • Page 149 Engine General Information and Diagnosis: 1A-74 Step Action 1) Connect the ECM coupler and TO sensor coupler. • R, B or B/Br wire • Loosen or poor open or shorted to contacts on the ECM 2) Dismount the TO sensor from its bracket. the ground, or poor coupler.

  • Page 150: Dtc "C24" (P0351), "C25" (P0352), "C26" (P0353) Or "C27" (P0354): Ignition System Malfunction

    1A-75 Engine General Information and Diagnosis: DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27” (P0354): Ignition System Malfunction B817H21104017 NOTE Refer to “No Spark or Poor Spark in Section 1H (Page 1H-2)” for details. DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction B817H21104018 Detected Condition and Possible Cause Detected Condition...
  • Page 151 Engine General Information and Diagnosis: 1A-76 Step Action 1) Remove the regulator/rectifier. Refer to “Regulator / Go to Step 2. • Loose or poor Rectifier Inspection in Section 1J (Page 1J-8)”. contacts on the coupler. 2) Check the STVA lead wire coupler for loose or poor contacts.
  • Page 152 1A-77 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • W/B, P/W, G and B/ • Loose or poor Lg wire open or contacts on the ECM 2) Move the throttle body right side. Refer to “Throttle Body shorted to the coupler.
  • Page 153 Engine General Information and Diagnosis: 1A-78 Active Control Inspection 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” (1). I718H1110247-01 4) Click each button (2). At this time, if an operation sound is heard from the STVA, the function is normal.

  • Page 154: Dtc "C29" (P1654-H/L): Secondary Throttle Position Sensor (Stps) Circuit Malfunction

    1A-79 Engine General Information and Diagnosis: DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction B817H21104019 Detected Condition and Possible Cause Detected Condition Possible Cause Signal voltage is not within the following • STP sensor maladjusted. range. • STP sensor circuit open or short. Difference between actual throttle opening •...
  • Page 155 Engine General Information and Diagnosis: 1A-80 C29 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. Go to Step 4. • Loose or poor contacts on the ECM 2) Check the STP sensor coupler for loose or poor coupler.
  • Page 156 1A-81 Engine General Information and Diagnosis: P1654-H (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the secondary throttle actuator position sensor data. I718H1110198-01 Secondary throttle position approx. 100% and more OK? 1) Turn the ignition switch OFF.
  • Page 157 Engine General Information and Diagnosis: 1A-82 Step Action 3) Disconnect the STP sensor coupler. Go to Step 4. Y/W wire shorted to Vcc, or B/Br wire open. 4) Check the continuity between the Y/W wire and R wire. If the sound is not heard from the tester, the circuit condition is OK.
  • Page 158 1A-83 Engine General Information and Diagnosis: P1654-L (Use of SDS) Step Action 1) Click the data monitor button (1). Go to Step 2. Go to Step 4. I718H1110251-01 2) Check the secondary throttle actuator position sensor data. I718H1110199-01 Secondary throttle position approx. 0% OK? 1) Turn the ignition switch OFF.
  • Page 159 Engine General Information and Diagnosis: 1A-84 Step Action 3) Disconnect the STP sensor coupler. Go to Step 3. R or Y/W wire open, or Y/W wire shorted to the 4) Check the continuity between the Y/W wire and ground. ground. Also, check the continuity between the Y/W wire and B/ Br wire.
  • Page 160 1A-85 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler. Refer to “ECM Removal and Go to Step 4. Open or short circuit in Installation in Section 1C (Page 1C-1)”. the R or B/Br wire. 2) Disconnect the STP sensor coupler. 3) Turn the ignition switch ON.
  • Page 161 Engine General Information and Diagnosis: 1A-86 Step Action 1) Turn the ignition switch OFF. • R, Y/W or B/Br wire If check result is not open or shorted to satisfactory, replace the 2) Connect the ECM coupler and STP sensor coupler. the ground, or poor STP sensor with a new 3) Move the air cleaner box backward.

  • Page 162: Dtc "C31" (P0705): Gp Switch Circuit Malfunction

    1A-87 Engine General Information and Diagnosis: DTC “C31” (P0705): GP Switch Circuit Malfunction B817H21104020 Detected Condition and Possible Cause Detected Condition Possible Cause No Gear Position switch voltage • Gear position switch circuit open or short. Switch voltage is not within the following range. •...
  • Page 163 Engine General Information and Diagnosis: 1A-88 Step Action 1) Turn the ignition switch OFF. • P wire open or • P or B/W wire open, shorted to the or P wire shorted to 2) Remove the left frame cover. Refer to “Exterior Parts ground.

  • Page 164: Dtc "C32" (P0201), "C33" (P0202), "C34" (P0203) Or "C35" (P0204): Fuel Injector Circuit Malfunction

    1A-89 Engine General Information and Diagnosis: DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Fuel Injector Circuit Malfunction B817H21104021 Detected Condition and Possible Cause Detected Condition Possible Cause CKP signal is produced but fuel injector signal is • Injector circuit open or short. interrupted by 4 times or more continuity.
  • Page 165 Engine General Information and Diagnosis: 1A-90 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the injector with a new one. Refer to 2) Lift and support the fuel tank. Refer to “Fuel Tank “Throttle Body Removal and Installation in Section 1G (Page 1G-9)”.
  • Page 166 1A-91 Engine General Information and Diagnosis: Step Action 5) If OK, then check the continuity between each terminal Go to Step 2. Replace the injector and ground. with a new one. Refer to “Throttle Body Special tool Disassembly and (A): 09900–25008 (Multi-circuit tester set) Assembly in Section 1D Injector continuity (Page 1D-11)”.
  • Page 167 Engine General Information and Diagnosis: 1A-92 Step Action 1) Turn the ignition switch ON. • Gr/W wire open or Open circuit in the Y/R shorted to the wire. 2) Measure the injector voltage between the Y/R wire and ground, or poor 44 ground.

  • Page 168: Dtc "C40" (P0505, P0506 Or P0507): Isc Valve Circuit Malfunction

    1A-93 Engine General Information and Diagnosis: DTC “C40” (P0505, P0506 or P0507): ISC Valve Circuit Malfunction B817H21104022 Detected Condition and Possible Cause Detected Condition Possible Cause The circuit voltage of motor drive is • ISC valve circuit open or shorted to the ground. (P0505) unusual.
  • Page 169 Engine General Information and Diagnosis: 1A-94 Step Action 1) Turn the ignition switch OFF. Go to Step 2. Lbl, W/Y, Dgr or Lg wire open. 2) Check the ISC valve coupler for loose or poor contacts. If OK, then check the ISC valve lead wire continuity. I717H1110027-01 3) Disconnect the ISC valve coupler and ECM coupler.
  • Page 170 1A-95 Engine General Information and Diagnosis: Step Action 1) Move the throttle body right side. Refer to “Throttle Body If wire is OK, Replace the ISC valve Removal and Installation in Section 1D (Page 1D-10)”. intermittent trouble or with a new one. Refer to faulty ECM.
  • Page 171 Engine General Information and Diagnosis: 1A-96 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control”...
  • Page 172 1A-97 Engine General Information and Diagnosis: Check 2 1) Click the button (4) and decrease the “Spec” (2) to 1 100 rpm slowly. 2) Check that the “Desired idle speed” (3) is nearly equal to the “Spec” (2). At the same time, check that the number of steps (5) in the ISC valve position decreases.
  • Page 173 Engine General Information and Diagnosis: 1A-98 Check 4 1) Click the button (6) and increase the “Spec” (2) to 1 400 rpm. 2) Check that the “Desired idle speed” (3) is approx. 1 400 rpm. 3) Check that the “Engine speed” (7) is close to 1 400 rpm. NOTE Be careful not to increase the “Spec”...

  • Page 174: Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction

    1A-99 Engine General Information and Diagnosis: DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction B817H21104023 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to fuel pump • Fuel pump relay circuit open or short. although fuel pump relay is turned ON, or •...
  • Page 175 Engine General Information and Diagnosis: 1A-100 C41 (Use of mode select switch) Step Action 1) Turn the ignition switch OFF. • Y/B or B/R wire open Replace the FP relay or short or poor 38 with a new one. Refer to 2) Remove the seat.
  • Page 176 1A-101 Engine General Information and Diagnosis: P0230-L (Use of SDS) Step Action 1) Turn the ignition switch OFF. • Y/B wire open or poor Replace the FP relay 38 connection. with a new one. Refer to 2) Remove the seat. Refer to “Exterior Parts Removal and “Fuel Pump Relay Installation (GSF650/S/A/SAK7) in Section 9D •...

  • Page 177: Dtc "C41" (P2505): Ecm Power Input Signal Malfunction

    Engine General Information and Diagnosis: 1A-102 DTC “C41” (P2505): ECM Power Input Signal Malfunction B817H21104024 Detected Condition and Possible Cause Detected Condition Possible Cause No voltage is applied to the ECM/PCM, • Lead wire/coupler connection of ECM terminal to fuel although fuel pump relay is turned ON.
  • Page 178 1A-103 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • R/Bl wire open or Open or short circuit in short or poor 16 the R/Bl wire. 2) Remove the seat. Refer to “Exterior Parts Removal and connection.

  • Page 179: Dtc "C42" (P1650): Ig Switch Circuit Malfunction

    Engine General Information and Diagnosis: 1A-104 DTC “C42” (P1650): IG Switch Circuit Malfunction B817H21104025 Detected Condition and Possible Cause Detected Condition Possible Cause Ignition switch signal is not input in the ECM. • Ignition system circuit open or short. • ECM malfunction. Troubleshooting NOTE •...
  • Page 180 1A-105 Engine General Information and Diagnosis: Troubleshooting (When Indicating C44/P0130:) CAUTION When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend. NOTE After repairing the trouble, clear the DTC using SDS tool.
  • Page 181 Engine General Information and Diagnosis: 1A-106 Step Action 6) Disconnect the ECM coupler. Refer to “ECM Removal Go to Step 2. W/G wire shorted to the and Installation in Section 1C (Page 1C-1)”. power source, or W/G or B/Br wire open. 7) Check the continuity between the W/G wire “A”...
  • Page 182 1A-107 Engine General Information and Diagnosis: Step Action 1) Connect the ECM coupler and HO2 sensor coupler. • W/G or B/Br wire Replace the HO2 open or shorted to sensor with a new one. 2) Warm up the engine enough. the power source, or Refer to “Heated 3) Insert the needle pointed probes to the lead wire coupler.
  • Page 183 Engine General Information and Diagnosis: 1A-108 Troubleshooting (When Indicating C44/P0135:) NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “Use of SDS Diagnosis Reset Procedures (Page 1A-15)”. Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the HO2 sensor with a new one.
  • Page 184 1A-109 Engine General Information and Diagnosis: Step Action 1) Connect the HO2 sensor coupler. • O/W or W/B wire • Open or short circuit open or shorted to in the W/B wire or O/ 2) Insert the needle pointed probes to the lead wire coupler. the ground, or poor W wire.

  • Page 185: Dtc "C49" (P1656): Pair Solenoid Valve Circuit Malfunction

    Engine General Information and Diagnosis: 1A-110 DTC “C49” (P1656): PAIR Solenoid Valve Circuit Malfunction B817H21104027 Detected Condition and Possible Cause Detected Condition Possible Cause PAIR control solenoid valve voltage is not input to ECM. • PAIR control solenoid valve circuit open or short. •...
  • Page 186 1A-111 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the PAIR control solenoid with a 2) Remove the fuel tank. Refer to “Fuel Tank Removal and new one. Refer to “PAIR Installation in Section 1G (Page 1G-9)”.
  • Page 187 Engine General Information and Diagnosis: 1A-112 Step Action 1) Turn the ignition switch ON. • B/G wire open or Open or short circuit in shorted to the the O/W wire. 2) Measure the voltage between the O/W wire and ground. ground, or poor 39 Special tool connection failure.
  • Page 188 1A-113 Engine General Information and Diagnosis: Active Control Inspection 1) Set up the SDS tool. Refer to “SDS operation manual” for further details. 2) Turn the ignition switch ON. 3) Click “PAIR Sol operating control” (1). I718H1110245-01 4) Click each button (2). At this time, if and operation sound is heard from the PAIR control solenoid valve, the function is normal.

  • Page 189: Dtc "C60" (P0480): Cooling Fan Relay Circuit Malfunction

    Engine General Information and Diagnosis: 1A-114 DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction B817H21104028 Detected Condition and Possible Cause Detected Condition Possible Cause Cooling fan relay signal is not input to ECM. • Cooling fan relay circuit open or short. •...
  • Page 190 1A-115 Engine General Information and Diagnosis: Step Action 1) Turn the ignition switch OFF. • O/W and O/R wire Replace the cooling fan open or shorted to relay with a new one. 2) Remove the seat. Refer to “Exterior Parts Removal and the ground, or poor Refer to “Cooling Fan Installation (GSF650/S/A/SAK7) in Section 9D...
  • Page 191 Engine General Information and Diagnosis: 1A-116 Active Control Inspection NOTE Cooling fan relay and cooling fan motor operation can be checked until the engine coolant temperature is less than 100 °C (212 °F) after starting the engine. 1) Set up the SDS tool. Refer to “SDS operation manual” for further details. 2) Start the engine and run it idling condition.

  • Page 192: Self-Diagnostic Procedures (Gsx650Fk8)

    1A-117 Engine General Information and Diagnosis: Self-Diagnostic Procedures (GSX650FK8) 5) Check the DTC to determine the malfunction part. B817H21104029 Refer to “DTC Table (Page 1A-21)”. Use of Mode Select Switch Special tool NOTE (A): 09930–82720 (Mode select switch) • Do not disconnect coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble...

  • Page 193: Specifications

    Engine General Information and Diagnosis: 1A-118 Specifications Service Data B817H21107001 Injector Item Specification Note 11 – 13 Ω at 20 °C (68 F°) Injector resistance — FI Sensors Item Specification Note 90 – 150 Ω CKP sensor resistance CKP sensor peak voltage 2.0 V and more When cranking IAP sensor (#1) input voltage...

  • Page 194: Special Tools And Equipment

    1A-119 Engine General Information and Diagnosis: Special Tools and Equipment Special Tool B817H21108001 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 1A-28) / (Page 1A-109) / (Page 1A-29) / (Page 1A-33) / (Page 1A-109) / (Page 1A-35) / (Page 1A-111) / (Page 1A-37) / (Page 1A-112) /...

  • Page 195: Emission Control Devices

    Emission Control Devices: 1B-1 Emission Control Devices Engine Precautions Precautions for Emission Control Devices B817H21200001 Refer to “General Precautions in Section 00 (Page 00-1)”. General Description Fuel Injection System Description B817H21201001 GSF650 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is precision designed, manufactured and adjusted to comply with the applicable emission limits.

  • Page 196: Crankcase Emission Control System Description

    1B-2 Emission Control Devices: Crankcase Emission Control System Description B817H21201002 The engine is equipped with a PCV system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas in the engine is constantly drawn into the crankcase, which is returned to the combustion chamber through the PCV (breather) hose, air cleaner and throttle body.

  • Page 197: Exhaust Emission Control System Description

    Emission Control Devices: 1B-3 Exhaust Emission Control System Description B817H21201003 The exhaust emission control system is composed of the PAIR system, HO2 sensor, catalyst system and ISC system. The fresh air is drawn into the exhaust port through the PAIR control solenoid valve and PAIR reed valve. The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TPS, ECTS, IATS, IAPS and CKPS.

  • Page 198: Schematic And Routing Diagram

    1B-4 Emission Control Devices: Schematic and Routing Diagram PAIR System Hose Routing Diagram B817H21202001 “B” “ a ” “C” “B” “a” “B” “A” “a” “A” “A” “ a” “a” “C” I717H1120001-01 1. PAIR control solenoid valve “A”: Marking (Yellow) “C”: To air cleaner box 2.

  • Page 199: Repair Instructions

    Emission Control Devices: 1B-5 Repair Instructions Heated Oxygen Sensor (HO2S) Removal and 6) Remove the HO2 sensor (3). Installation B817H21206001 Removal WARNING Do not remove the HO2 sensor while it is hot. CAUTION • Be careful not to expose the HO2 sensor to excessive shock.

  • Page 200: Heated Oxygen Sensor (Ho2S) Inspection

    1B-6 Emission Control Devices: Heated Oxygen Sensor (HO2S) Inspection Tightening torque B817H21206002 PAIR reed valve cover bolt (a): 11 N·m (1.1 kgf-m, Refer to “DTC “C44” (P0130/P0135): HO2 Sensor 8.0 lbf-ft) (HO2S) Circuit Malfunction in Section 1A (Page 1A- 104)”. PAIR Reed Valve Removal and Installation B817H21206003 Removal...

  • Page 201: Pair System Inspection

    Emission Control Devices: 1B-7 PAIR System Inspection PAIR Reed Valve Cover B817H21206005 1) Remove the PAIR reed valve covers. Refer to “PAIR PAIR Hose Reed Valve Removal and Installation (Page 1B-6)”. 1) Remove the fuel tank. Refer to “Fuel Tank Removal 2) Inspect the PAIR reed valve for carbon deposit.

  • Page 202: Crankcase Breather (Pcv) Hose Inspection

    1B-8 Emission Control Devices: Crankcase Breather (PCV) Hose / Cover 4) Check the resistance between the terminals of the PAIR control solenoid valve. Removal and Installation B817H21206007 Special tool Removal : 09900–25008 (Multi-circuit tester set) 1) Remove the throttle body. Refer to “Throttle Body Removal and Installation in Section 1D (Page 1D- Tester knob indication 10)”.

  • Page 203: Crankcase Breather (Pcv) Cover Inspection

    • Apply bond to the mating surface of the breather 1) Remove the crankcase breather cover. Refer to cover. “Crankcase Breather (PCV) Hose / Cover Removal : Sealant 99000–31110 (SUZUKI BOND and Installation (Page 1B-8)”. No.1215 or equivalent) 2) Inspect the crankcase breather cover in the carbon deposit.

  • Page 204: Service Data

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H21208001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110 (Page 1B-9)

  • Page 205: Engine Electrical Devices

    Engine Electrical Devices: 1C-1 Engine Electrical Devices Engine Precautions Precautions for Engine Electrical Device B817H21300001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Engine Electrical components Location B817H21303001 Refer to “Electrical Components Location in Section 0A (Page 0A-10)”.

  • Page 206: Iap Sensor (#1) Removal And Installation

    1C-2 Engine Electrical Devices: IAP Sensor (#1) Removal and Installation ECT Sensor Removal and Installation B817H21306005 B817H21306008 Removal Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal 1) Drain engine coolant. Refer to “Cooling System and Installation in Section 1G (Page 1G-9)”. Inspection in Section 0B (Page 0B-14)”.

  • Page 207: Ect Sensor Inspection

    Engine Electrical Devices: 1C-3 ECT Sensor Inspection TO Sensor Removal and Installation B817H21306009 B817H21306010 Refer to “DTC “C15” (P0115-H/L): ECT Sensor Circuit Removal Malfunction in Section 1A (Page 1A-47)”. 1) Remove the seat. Refer to “Exterior Parts Removal Inspect the ECT sensor in the following procedures: and Installation (GSF650/S/A/SAK7) in Section 9D 1) Remove the ECT sensor.

  • Page 208: Stp Sensor Adjustment

    1C-4 Engine Electrical Devices: STP Sensor Adjustment 7) Loosen the STP sensor mounting screw adjust the B817H21306013 STP sensor (2) until the output voltage comes within Adjust the STP sensor in the following procedures: the specified value and tighten the STP sensor 1) Move the air cleaner box backward.

  • Page 209: Stv Actuator Inspection

    “A” if necessary. coupler at least 5 seconds after ignition switch is turned to OFF. If the ECM coupler or : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) ISC valve coupler is disconnected within 5 seconds after ignition switch is turned to...

  • Page 210: Ho2 Sensor Inspection

    1C-6 Engine Electrical Devices: 4) Click the “ISC learned value reset” (1). 6) Close the SDS tool and turn the ignition to OFF position. NOTE The ISC valve opening initialization is automatically started after the ignition switch is turned OFF position. HO2 Sensor Inspection B817H21306020 Refer to “DTC “C44”...

  • Page 211: Service Data

    Engine Electrical Devices: 1C-7 Specifications Service Data B817H21307001 FI Sensors Item Specification Note 90 – 150 Ω CKP sensor resistance CKP sensor peak voltage 2.0 V and more When cranking IAP sensor (#1) input voltage 4.5 – 5.5 V IAP sensor (#1) output voltage Approx.

  • Page 212: Special Tools And Equipment

    1C-8 Engine Electrical Devices: Special Tools and Equipment Recommended Service Material B817H21308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1C-5) equivalent Special Tool B817H21308002 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set...

  • Page 213: Engine Mechanical

    Engine Mechanical: 1D-1 Engine Mechanical Engine Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B817H21402001 I717H1140211-01...

  • Page 214: Throttle Cable Routing Diagram (Gsf650/S/A/Sak7)

    1D-2 Engine Mechanical: Throttle Cable Routing Diagram (GSF650/S/A/SAK7) B817H21402002 “A” “ a” “ a ” I718H1140308-03 1. Wiring harness 4. Throttle cable No.2 7. Ignition switch lead wire 2. Cable guide (GSF650S only) 5. Handlebar switch lead wire (L) “a”: 0 mm (0 in) 3.

  • Page 215: Throttle Cable Routing Diagram (Gsx650Fk8)

    Engine Mechanical: 1D-3 Throttle Cable Routing Diagram (GSX650FK8) B817H21402003 “A” “a” “ a ” I817H2140001-01 1. Wiring harness 4. Throttle cable No. 2 7. Ignition switch lead wire 2. Cable guide 5. Handlebar switch lead wire (L) “a”: 0 mm (0 in) 3.

  • Page 216: Diagnostic Information And Procedures

    1D-4 Engine Mechanical: Diagnostic Information and Procedures Engine Mechanical Symptom Diagnosis 6) Keep the throttle grip in the fully-opened position. B817H21404001 Refer to “Engine Symptom Diagnosis in Section 1A (Page 1A-9)”. Compression Pressure Check B817H21404002 The compression pressure reading of a cylinder is a good indicator of its internal condition.

  • Page 217: Repair Instructions

    Engine Mechanical: 1D-5 Repair Instructions Engine Components Removable with the Engine in Place B817H21406001 Engine components which can be removed while the engine is installed on the frame are as follows. For the installing and removing procedures, refer to respective paragraphs describing each component. Center of Engine Item Removal...
  • Page 218 1D-6 Engine Mechanical: Engine Right Side Item Removal Inspection Installation Refer to “Clutch Removal in Refer to “Clutch Installation Clutch cover — Section 5C (Page 5C-12)”. in Section 5C (Page 5C-14)”. Refer to “Clutch Parts Refer to “Clutch Removal in Refer to “Clutch Installation Clutch plates Inspection in Section 5C...

  • Page 219: Air Cleaner Element Removal And Installation

    Engine Mechanical: 1D-7 Air Cleaner Element Removal and Installation 3) Release the drain hose from the clamp (1). B817H21406002 Removal 1) Remove the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. 2) Remove the air cleaner cover screws. 3) Remove the air cleaner cover (1).

  • Page 220: Throttle Cable Inspection

    1D-8 Engine Mechanical: Throttle Cable Inspection Throttle Cable Play Inspection and Adjustment B817H21406006 B817H21406007 Check that the throttle grip moves smoothly from full Refer to “Throttle Cable Play Inspection and Adjustment open to full close. If it does not smoothly, lubricate the in Section 0B (Page 0B-14)”.

  • Page 221: Throttle Body Construction

    Engine Mechanical: 1D-9 Throttle Body Construction B817H21406009 Upper Upper Air cleaner side Engine side “A” “B” I717H1140014-01 1. Clamp (Air cleaner side) “B”: Clamp the drain hose at mark position. : After tighten the clamp band #3, 4 and tighten the clamp band #1, 4. “A”: White mark downward.

  • Page 222: Throttle Body Removal And Installation

    1D-10 Engine Mechanical: Throttle Body Removal and Installation 6) Loosen the throttle body clamp screws. B817H21406010 7) Move the air cleaner box backward. Removal 1) Disconnect the battery (–) read wire. Refer to “Battery Removal and Installation in Section 1J (Page 1J-12)”.

  • Page 223: Throttle Body Disassembly And Assembly

    Engine Mechanical: 1D-11 Installation 1) Remove the injector covers (1) and disconnect the Install the throttle body in the reverse order of removal. respective vacuum hoses (2) from each throttle Pay attention to the following points: body. • Connect the throttle pulling cable (1) and throttle returning cable (2) to the throttle cable drum.
  • Page 224 1D-12 Engine Mechanical: 4) Remove the fuel injectors (8) and fuel delivery pipes 8) Remove the joint pipes (12) from the ISC valve (9) from the T-joint (7). assembly (11). I718H1140323-02 I717H1140208-01 5) Disconnect the ISC valve hoses (9). 9) Remove the STP sensor (13). NOTE Prior to disassembly, mark sensor’s original position with a paint or scribe for accurate...
  • Page 225 • Align the secondary throttle shaft end “A” with the groove “B” of STP sensor. • Apply grease to the secondary throttle shaft end “A” if necessary. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1140332-01 Special tool CAUTION : 09930–11950 (Torx wrench)
  • Page 226 1D-14 Engine Mechanical: • Apply thin coat of the engine oil to the O-rings and • Apply thin coat of the engine oil to the new cushion install the ISC valve assembly. seal (2) and the O-ring (3). CAUTION CAUTION Replace the O-rings with new ones.

  • Page 227: Throttle Body Inspection And Cleaning

    Engine Mechanical: 1D-15 • Install the fuel injector (5) by pushing it straight to the • Tighten the fuel delivery pipe mounting screws to the delivery pipe (6). specified torque. Tightening torque CAUTION Fuel delivery pipe mounting screw (a): 3.5 N·m ( Never turn the injector while pushing it.

  • Page 228: Throttle Valve Synchronization

    1D-16 Engine Mechanical: Inspection 2) Disconnect the IAP sensor (#1) vacuum hoses (1) Check following items for any defects or clogging. from the throttle body. Replace the throttle body if necessary. • O-ring • Throttle valve • Secondary throttle valve •...
  • Page 229 Engine Mechanical: 1D-17 4) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 5) Start the engine. 6) Click “Data monitor”. 7) Warm up the engine (Water temp. more than 80 °C (176 °F)). I717H1140034-01 8) Click “Active control”.

  • Page 230: Engine Assembly Removal

    1D-18 Engine Mechanical: 11) Check for the synchronization of vacuum from #1 to Use of Mode Select Switch #4 cylinders. The following procedure describes only difference between use of SDS tool and use of mode select switch. 1) 1), 2) and 3) are the same as the using SDS tool. 2) Connect the special tool (Mode select switch) and turn ON.
  • Page 231 Engine Mechanical: 1D-19 4) Remove the fuel tank. Refer to “Fuel Tank Removal 12) Remove the throttle body assembly (6). Refer to and Installation in Section 1G (Page 1G-9)”. “Throttle Body Removal and Installation (Page 1D- 10)”. 5) Drain engine coolant. Refer to “Cooling System Inspection in Section 0B (Page 0B-14)”.
  • Page 232 1D-20 Engine Mechanical: 16) Disengage the gearshift lever link arm by removing 23) Remove the engine sprocket (17). the bolt. NOTE Mark the gearshift shaft head at which the gearshift link arm slit set for correct reinstallation. 17) Move the engine sprocket inner cover (10). I717H1140048-01 24) Disconnect the ECT sensor coupler (18), CKP sensor coupler (19) and generator coupler (20).

  • Page 233: Engine Assembly Installation

    Engine Mechanical: 1D-21 27) Support the engine with a proper jack. 30) Remove the engine mounting bolts and nuts. I717H1140052-01 I717H1140055-02 28) Remove the engine mounting bracket (25). 31) Gradually lower the front side of the engine and remove the engine. WARNING Care should be taken not to drop the engine accidentally when the engine mounting bolts...
  • Page 234 1D-22 Engine Mechanical: • Install the frame down tube and engine mounting brackets. • Tighten the bolts and nuts to the specified torque. NOTE The frame down tube nuts are self-locking. Once the nuts have been removed, they are no longer of any use. Tightening torque Frame down tube bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
  • Page 235 1D-23 • Connect the oil pressure switch lead wire as shown. • Before installing the engine sprocket inner cover, apply a small quantity of SUZUKI SUPER GREASE to Tightening torque the clutch push rod. Oil pressure switch lead wire mounting bolt (e): 1.5 N·m (0.15 kgf-m, 1.1 lbf-ft)

  • Page 236: Engine Top Side Disassembly

    1D-24 Engine Mechanical: • After remounting the engine, route the wiring harness, Cylinder Head Cover cable and hoses properly. Refer to “Wiring Harness Remove the cylinder head cover (1) and its gasket. Routing Diagram (GSF650/S/A/SAK7) in Section 9A (Page 9A-8)”, “Throttle Cable Routing Diagram (GSF650/S/A/SAK7) (Page 1D-2)”...
  • Page 237 Engine Mechanical: 1D-25 3) Turn the crankshaft clockwise and align the match 6) Remove the oil pipe (4) and camshaft journal holders mark “A” on the crankshaft with the mating surfaces (5). “B” of the crankcases. Also position each of the CAUTION camshaft as shown.

  • Page 238: Engine Top Side Assembly

    1D-26 Engine Mechanical: 2) Remove the cylinder head gasket (1) and dowel 3) Remove the cylinder gasket (3) and dowel pins. pins. I717H1140074-01 I717H1140071-01 Piston 3) Remove the cam chain No.1 guide (2) and O-ring (3). 1) Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase.
  • Page 239 Engine Mechanical: 1D-27 • Install the pistons and piston pins. CAUTION NOTE When turning the crankshaft, pull the cam chain upward, or the chain will be caught • Be sure to install the pistons in the between the crankcase and the cam drive cylinders from which they were removed in sprocket.
  • Page 240 1D-28 Engine Mechanical: • Apply molybdenum oil solution to the sliding surface • After inserting the #2 and #3 pistons in place, insert of the pistons. the #1 and #4 pistons in the same manner of the #2 and #3 pistons. M/O: Molybdenum oil (MOLYBDENUM OIL SOLUTION) NOTE...
  • Page 241 Engine Mechanical: 1D-29 Cylinder Head • After firmly tightening the cylinder head bolts (M10), install the cylinder head bolts (M6) (4). • Install the O-ring (1), dowel pins and cylinder head gasket (2). • Tighten the cylinder head bolts (4) to the specified torque.
  • Page 242 1D-30 Engine Mechanical: • Before replacing the camshafts on cylinder head, • Engage the 16th roller pin “E” on the cam chain with apply engine oil to their journals and cam faces. the marked “3” on the intake sprocket. • Apply engine oil to the camshaft journal holders. NOTE NOTE The cam chain should now be on all three...
  • Page 243 Engine Mechanical: 1D-31 • Install the camshaft journal holders. • Install the oil pipe (1) and tighten the mounting bolts to specified torque. CAUTION NOTE Damage to head or camshaft journal holder Fit the washer to each oil pipe mounting bolt. thrust surfaces may result if the camshaft journal holders are not drawn down evenly.
  • Page 244 Right Crankshaft Cover works properly by checking the slack of cam • Apply SUZUKI BOND lightly to the mating surfaces at chain. the parting line between the upper and lower crankcases as shown.

  • Page 245: Valve Clearance Inspection And Adjustment

    • Install a new gasket to the cylinder head cover. CAUTION Use the new gasket to prevent oil leakage. • Apply SUZUKI BOND to the cam end caps of the gasket as shown. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent)

  • Page 246: Cylinder Head Cover Inspection

    1D-34 Engine Mechanical: Cylinder Head Cover Inspection Cam Wear B817H21406019 Check the camshaft for wear or damage. Inspect the cylinder head cover in the following Measure the cam height “a” with a micrometer. procedures: Replace a camshaft if the cams are worn to the service 1) Remove the cylinder head cover.
  • Page 247 Engine Mechanical: 1D-35 2) Use the plastigauge to read the clearance at the widest portion, which is specified as follows. Special tool (A): 09900–22301 (Plastigauge (0.025 - 0.076 mm)) (B): 09900–22302 (Plastigauge (0.051 - 0.152 mm)) I718H1140085-01 7) If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the (A), (B)

  • Page 248: Camshaft Sprocket Inspection

    1D-36 Engine Mechanical: Camshaft Sprocket Inspection Installation B817H21406021 1) Set the camshaft sprocket to the camshafts. Inspect the camshaft sprocket in the following procedures: NOTE 1) Remove the intake and exhaust camshafts. Refer to Align the arrow mark “3” on camshaft “Engine Top Side Disassembly (Page 1D-24)”.

  • Page 249: Cam Chain Guide Removal And Installation

    Engine Mechanical: 1D-37 2) Check that the push rod slides smoothly when Installation releasing stopper (1). If it does not slide smoothly, Install the cam chain guides in the reverse order of replace the cam chain tension adjuster with a new removal.

  • Page 250: Cylinder Head Disassembly And Assembly

    1D-38 Engine Mechanical: 4) Check the contacting surface of the cam chain 2) When compressing the valve spring use a sleeve tensioner. If it is worn or damaged, replace it with a protector. new one. Cut the sleeve protector as shown in the illustration. Special tool (A): 09919–28610 (Sleeve protector) I718H1140097-01...
  • Page 251 • Apply grease to O-ring of the intake pipe. CAUTION I717H1140106-01 Replace the O-rings with new ones. 10) Remove the intake pipes (10). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1140107-01 11) Remove the oil gallery plugs (cylinder head) (11). I718H1140109-01...
  • Page 252 1D-40 Engine Mechanical: NOTE • Install the valve spring seat. • Apply engine oil to the oil seal (1), and press-fit it into • When replacing the intake pipes, identify position. the different intake pipes according to each I.D. code “A”. CAUTION (1-17H0 for cylinder #1) Do not reuse the removed oil seal.

  • Page 253: Cylinder Head Related Parts Inspection

    Engine Mechanical: 1D-41 • Put on the valve spring retainer (2), and using the NOTE special tools, press down the spring, fit the cotter • Apply engine oil to the stem end, shim and halves to the stem end, and release the lifter to allow tappet before fitting them.
  • Page 254 1D-42 Engine Mechanical: Valve Stem Runout Valve Face Wear Support the valve using V-blocks, as shown, and check Visually inspect each valve face for wear. Replace any its runout using the dial gauge. If the runout exceeds the valve with an abnormally worn face. The thickness of the service limit, replace the valve.
  • Page 255 Engine Mechanical: 1D-43 Valve Stem Wear Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, recheck the deflection.

  • Page 256: Valve Guide Replacement

    1D-44 Engine Mechanical: Valve Guide Replacement 4) Check that the transferred red lead (blue) on the valve face is uniform all around and in center of the B817H21406029 1) Remove the cylinder head. Refer to “Engine Top valve face. Side Disassembly (Page 1D-24)”. If the seat width “a”...

  • Page 257: Valve Seat Repair

    Engine Mechanical: 1D-45 5) Cool down the new valve guides in a freezer for 8) After installing the valve guides, refinish their guiding about one hour and heat the cylinder head to 100 – bores using the reamer. Be sure to clean and oil the 150 °C (212 –...

  • Page 258: Cylinder Disassembly And Assembly

    1D-46 Engine Mechanical: Assembly CAUTION Assembly is in the reverse order of disassembly. Pay • The valve seat contact area must be attention to the following points: inspected after each cut. • Apply engine coolant to O-ring of water inlet •...

  • Page 259: Cylinder Inspection

    Engine Mechanical: 1D-47 • Apply engine oil to O-ring and install the oil jet. Cylinder Bore Measure the cylinder bore diameter at six places. If any • Tighten the ECT sensor to the specified torque. one of the measurements exceed the limit, overhaul the CAUTION cylinder and replace the piston with an oversize piston.

  • Page 260: Piston Ring Removal And Installation

    1D-48 Engine Mechanical: Piston Ring Removal and Installation CAUTION B817H21406033 Removal When installing the spacer, be careful so that the both edges are not overlapped. 1) Draw out the piston pin and remove the piston. Refer to “Engine Top Side Disassembly (Page 1D-24)”. 2) Carefully spread the ring opening with your thumbs and then push up the opposite side of the 1st ring (2) “A”...

  • Page 261: Piston And Piston Ring Inspection

    Engine Mechanical: 1D-49 2) Position the gaps of the three rings and side rails as Piston-to-cylinder Clearance shown. Before inserting piston into the cylinder, Subtract the piston diameter from the cylinder bore check that the gaps are so located. diameter. If the piston-to-cylinder clearance exceeds the service limit, replace both the cylinder and the piston.
  • Page 262 1D-50 Engine Mechanical: Piston Ring Free End Gap and Piston Ring End Gap Piston Pin and Pin Bore Measure the piston ring free end gap using vernier Measure the piston pin bore inside diameter using the calipers. Next, fit the piston ring squarely into the small bore gauge.

  • Page 263: Engine Bottom Side Disassembly

    Engine Mechanical: 1D-51 Engine Bottom Side Disassembly Clutch B817H21406035 1) Remove the clutch component parts (1). Refer to NOTE “Clutch Removal in Section 5C (Page 5C-12)”. The crankcase must be separated to service the crankshaft and conrod. Engine Top Side 1) Remove the engine assembly.
  • Page 264 1D-52 Engine Mechanical: 4) Remove the snap ring (6). 2) Remove the gearshift shaft assembly (3) and washer (4). NOTE Do not drop the snap ring (6) into the crankcase. Special tool : 09900–06107 (Snap ring pliers) 5) Remove the oil pump driven gear (7). I717H1140131-01 3) Remove the gearshift cam plate bolt (5) and gearshift cam plate (6).
  • Page 265 Engine Mechanical: 1D-53 Starter Gear Position Switch Remove the idle gear shaft (1), idle gear (2) and starter Remove the gear position switch (1). driven gear (3). Refer to “Starter Clutch Removal and Installation in Section 1I (Page 1I-10)”. I717H1140137-01 Crankcase Breather Cover I717H1140134-01 Remove the crankcase breather cover (1).
  • Page 266 1D-54 Engine Mechanical: Oil Filter Crankcase Remove the oil filter (1) with the special tool. 1) Remove the crankcase bolts (M6). Special tool 2) Remove the crankcase bolts (M8). (A): 09915–40610 (Oil filter wrench) I717H1140143-01 I717H1140140-01 Oil Pan Remove the oil pan (1). I717H1140144-02 3) Loosen the crankcase bolts evenly by shifting the wrench in the descending order of numbers.
  • Page 267 Engine Mechanical: 1D-55 4) Make sure that all of the bolts are removed. Then, 3) Remove the cam chain (3) from the crankshaft. tap the sides of the lower crankcase using a plastic NOTE hammer to separate the upper and lower crankcase halves and then lift the lower crankcase off of the Remove the conrod if necessary.
  • Page 268 1D-56 Engine Mechanical: Oil Jet Crankshaft Journal Bearing Remove the crankshaft journal bearings, upper and 1) Remove the oil jet (1) (for engine top side) from the lower. upper crankcase. CAUTION • When removing the crankshaft journal bearings, be careful not to scratch the crankcase and the crankshaft journal bearings.
  • Page 269 Engine Mechanical: 1D-57 Oil Gallery Plug Oil seal /Bearing Remove the oil seals and bearings if necessary. Refer to 1) Remove the oil gallery plug (1) from the upper “Transmission Removal in Section 5B (Page 5B-2)”. crankcase. I718H1140197-01 I717H1140153-01 2) Remove the oil gallery plugs (2) from the lower crankcase.

  • Page 270: Engine Bottom Side Assembly

    1D-58 Engine Mechanical: Engine Bottom Side Assembly B817H21406036 Assembly the engine bottom side in the reverse of disassembly. Pay attention to the following points: NOTE Apply engine oil to each running and sliding part before reassembling. Oil Seal / Bearing •...
  • Page 271 Engine Mechanical: 1D-59 Oil Jet • Fit the new O-ring (1) to each piston cooling oil jet as shown and apply engine oil to them. CAUTION Use the new O-ring to prevent oil pressure leak. I718H1140206-02 • Install the oil jets, (2) and (3). I718H1140204-01 •...
  • Page 272 1D-60 Engine Mechanical: • Before installing the crankshaft assembly, apply • Apply SUZUKI BOND to the mating surface of the engine oil to each crankshaft journal bearing. lower crankcase as follows. • Install the crankshaft assembly along with the cam NOTE chain into the upper crankcase.
  • Page 273 19.0 lbf-ft) “B” I717H1140163-01 I717H1140164-03 Oil Pressure Regulator / Oil Strainer / Oil Pan • Apply SUZUKI SUPER GREASE to the O-rings and press in the oil pressure regulator (1) to the lower crankcase. CAUTION Replace the O-rings with new ones.
  • Page 274 (Page 0B-12)”. Special tool (A): 09915–40610 (Oil filter wrench) I717H1140167-01 Oil Pan • Apply SUZUKI BOND to the mating surface of the oil pan. NOTE • Make surfaces free from moisture, oil, dust and other foreign materials. • Spread on surfaces thinly to from an even layer, and assemble the oil pan within few minutes.
  • Page 275 Engine Mechanical: 1D-63 Oil Pressure Switch • Tighten the breather cover bolts. • Apply SUZUKI BOND to the thread part of oil pressure switch and tighten oil pressure switch to the specified torque. NOTE Be careful not to apply SUZUKI BOND to the hole of thread end.
  • Page 276 1D-64 Engine Mechanical: Starter Water Pump • Apply SUZUKI SUPER GREASE to the O-ring. • Install the starter component parts (1). Refer to “Starter Clutch Removal and Installation in Section 1I CAUTION (Page 1I-10)”. Replace the O-ring with a new one.
  • Page 277 Engine Mechanical: 1D-65 • Check the gearshift cam stopper moves smoothly. • Apply a small quantity of THREAD LOCK to the gearshift cam stopper plate bolt and tighten it to the • Locate the gearshift cam in the neutral position. specified torque.
  • Page 278 • Install the snap ring (4). CAUTION I717H1140182-01 Never reuse a snap ring. Oil Pump • Install the O-ring to the oil pump and apply SUZUKI SUPER GREASE to it. CAUTION Replace the O-ring with a new one. NOTE Set the oil pump shaft end “A” to the water pump shaft.

  • Page 279: Conrod Removal And Installation

    Engine Mechanical: 1D-67 Starter Motor • Install the washer (5) and thrust washer (6) onto the countershaft. • Install the starter motor (1). Refer to “Starter Motor Removal and Installation in Section 1I (Page 1I-4)”. NOTE The chamfer side “B” of thrust washer should face the crankcase side.
  • Page 280 1D-68 Engine Mechanical: 4) Remove the bearings (1). 3) When fitting the conrod cap, make sure that I.D. code “B” on each conrod faces intake side. NOTE • Do not remove the bearings (1) unless absolutely necessary. • Make a note of where the bearings are removed from so that they can be “B”...

  • Page 281: Conrod And Crankshaft Inspection

    Engine Mechanical: 1D-69 Conrod and Crankshaft Inspection 2) If the clearance exceeds the limit, remove the conrod B817H21406038 and measure the conrod big end width and crank pin Refer to “Conrod Removal and Installation (Page 1D- width. Refer to “Conrod Removal and Installation 67)”.

  • Page 282: Conrod Crank Pin Bearing Inspection And Selection

    1D-70 Engine Mechanical: Conrod Crank Pin Bearing Inspection and 4) Remove the conrod caps and measure the width of the compressed plastigauge using the envelope Selection scale. This measurement should be taken at the B817H21406039 Refer to “Conrod Removal and Installation (Page 1D- widest part of the compressed plastigauge.

  • Page 283: Crankshaft Journal Bearing Inspection And Selection

    Engine Mechanical: 1D-71 2) Check the corresponding crank pin O.D. code Bearing thickness specification numbers ([1], [2] or [3]) “B”. Color “C” (Part No.) Thickness Green 1.480 – 1.484 mm (12164-26E01-0A0) (0.0583 – 0.0584 in) Black 1.484 – 1.488 mm (12164-26E01-0B0) (0.0584 –...
  • Page 284 1D-72 Engine Mechanical: 2) Install the plastigauge onto each crankshaft journal 5) Remove the lower crankcase and measure the width as shown. of compressed plastigauge using the envelope scale. This measurement should be taken at the Special tool widest part of the compressed plastigauge. If the oil (A): 09900–22301 (Plastigauge (0.025 –...

  • Page 285: Crankshaft Thrust Clearance Inspection And Selection

    Engine Mechanical: 1D-73 2) Check the corresponding crankshaft journal O.D. 4) Select the specified bearings from the bearing codes ([A], [B] or [C]) “B”, which are stamped on the selection table. crankshaft. Bearing selection table Crankshaft O.D. “B” Code Green Black Brown Crankcase...
  • Page 286 1D-74 Engine Mechanical: 2) Measure the thrust clearance “a” between the left- Selection side thrust bearing and crankshaft using the 1) Remove the right-side thrust bearing and measure thickness gauge. If the thrust clearance exceeds the its thickness using the micrometer. If the thickness of standard range, adjust the thrust clearance.
  • Page 287 Engine Mechanical: 1D-75 4) Select a left-side thrust bearing from the selection table. NOTE Right-side thrust bearing has the same specification as the GREEN (12228-17E00-0D0) of left-side thrust bearing. Left-side thrust bearing selection table Clearance before inserting Color “A” (Part No.) Thrust bearing thickness Thrust clearance the left-side thrust bearing...

  • Page 288: Service Data

    1D-76 Engine Mechanical: Specifications Service Data B817H21407001 Valve + Guide Unit: mm (in) Item Standard Limit 23 (0.91) — Valve diam. 20 (0.79) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —...
  • Page 289 Engine Mechanical: 1D-77 Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 900 kPa Compression pressure 1 200 – 1 600 kPa (12 – 16 kgf/cm , 171 – 226 psi) (9 kgf/cm , 128 psi) 200 kPa Compression pressure difference —...

  • Page 290: Tightening Torque Specifications

    1D-78 Engine Mechanical: Tightening Torque Specifications B817H21407002 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft STP sensor mounting screw 0.35 (Page 1D-13) ISC valve mounting screw 0.35 (Page 1D-14) Fuel delivery pipe mounting screw 0.35 2.45 (Page 1D-15) Frame down tube bolt 36.0 (Page 1D-22) Engine mounting bracket bolts...

  • Page 291: Special Tools And Equipment

    Engine Mechanical: 1D-79 Special Tools and Equipment Recommended Service Material B817H21408001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1D-13) / equivalent (Page 1D-23) / (Page 1D-39) / (Page 1D-61) / (Page 1D-62) /...
  • Page 292 1D-80 Engine Mechanical: 09900–20205 09900–20530 Micrometer (0 – 25 mm) Cylinder gauge set (Page 1D-35) / (Page 1D-47) (Page 1D-43) / (Page 1D-49) / (Page 1D-50) / (Page 1D-69) / (Page 1D-74) 09900–20602 09900–20605 Dial gauge (1/1000 mm, 1 Dial calipers (1/100 mm, 10 –...
  • Page 293 Engine Mechanical: 1D-81 09915–64512 09916–10911 Compression gauge Valve lapper set (Page 1D-4) (Page 1D-43) 09916–14510 09916–14521 Valve lifter Valve spring compressor attachment (Page 1D-38) / (Page 1D-38) / (Page 1D-41) (Page 1D-41) 09916–33210 09916–34542 Valve guide reamer (4.5 Reamer handle (Page 1D-45) (Page 1D-44) / (Page 1D-45)

  • Page 294: Engine Lubrication System

    1E-1 Engine Lubrication System: Engine Lubrication System Engine Precautions Precautions for Engine Oil B817H21500001 Refer to “Fuel and Oil Recommendation in Section 0A (Page 0A-3)”.

  • Page 295: Schematic And Routing Diagram

    Engine Lubrication System: 1E-2 Schematic and Routing Diagram Engine Lubrication System Chart Diagram B817H21502001 EXHAUST CAMSHAFT EXHAUST CAMSHAFT JOURNAL HOLDER (B) CAMSHAFT JOURNALS, CAMFACES, TAPPETS INTAKE CAMSHAFT INTAKE CAMSHAFT JOURNAL HOLDER (D) EXHAUST CAMSHAFT JOURNAL HOLDERS (A) OIL JET (#8) CAMSHAFT JOURNALS, CAMFACES, TAPPETS CAM CHAIN...

  • Page 296: Diagnostic Information And Procedures

    1E-3 Engine Lubrication System: Diagnostic Information and Procedures Engine Lubrication Symptom Diagnosis B817H21504001 Condition Possible cause Correction / Reference Item Engine overheats. Insufficient amount of engine oil. Check level and add. Defective oil pump. Replace. Clogged oil circuit. Clean. Clogged oil cooler Clean or replace.

  • Page 297: Repair Instructions

    Engine Lubrication System: 1E-4 6) Stop the engine and remove the oil pressure gauge and attachment. 7) Reinstall the main oil gallery plug and tighten it to the specified torque. CAUTION Use a new gasket to oil leakage. Tightening torque Main Oil gallery plug (M16) (a): 35 N·m (3.5 kgf- m, 25.5 lbf-ft) I717H1150003-01...
  • Page 298 • Apply GREASE to the O-rings and install them. CAUTION I718H1150024-02 8) Remove the O-rings (7), oil pressure regulator (8) Use new O-rings to prevent oil leakage. and oil strainer (9). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1150007-01 I717H1150009-01 I718H1150028-01...

  • Page 299: Oil Pressure Regulator / Oil Strainer Inspection

    • Apply to distorted surfaces as it forms a 14)”. comparatively thick film. Oil Pressure Regulator / Oil Strainer Inspection : Sealant 99000–31110 (SUZUKI BOND B817H21506004 No.1215 or equivalent) Refer to “Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation (Page 1E-4)”.

  • Page 300: Oil Pressure Switch Removal And Installation

    Inspect the oil strainer body for damage. If necessary, thread and tighten it to the specified torque. replace it with a new one. : Sealant 99000–31140 (SUZUKI BOND No.1207B or equivalent) Tightening torque Oil pressure switch (a): 14 N·m (1.4 kgf-m, 10.0...

  • Page 301: Oil Jet Removal And Installation

    Engine Lubrication System: 1E-8 Oil Jet Removal and Installation Oil Jet (For Cylinder Head) B817H21506007 Removal Oil Jet (For Cam Chain Tension Adjuster) 1) Remove the cylinder. Refer to “Engine Top Side Removal Disassembly in Section 1D (Page 1D-24)”. 1) Remove the cam chain tension adjuster. Refer to 2) Remove the oil jet (1).

  • Page 302: Oil Gallery Jet Removal And Installation

    1E-9 Engine Lubrication System: Oil Gallery Jet Removal and Installation 5) Remove the oil jet (2) (for transmission) from the lower crankcase. B817H21506008 Removal 1) Remove the generator cover. Refer to “Generator Removal and Installation in Section 1J (Page 1J-4)”. 2) Remove the oil gallery jet (1).

  • Page 303: Oil Jet / Oil Gallery Jet Inspection

    Engine Lubrication System: 1E-10 Oil Jet / Oil Gallery Jet Inspection 3) Remove the spacer (1). B817H21506009 4) Remove the oil pump drive sprocket (2) and chain Refer to “Oil Jet Removal and Installation (Page 1E-8)”. (3). Refer to “Oil Gallery Jet Removal and Installation (Page 1E-9)”.
  • Page 304 Special tool : 09900–06107 (Snap ring pliers) CAUTION Use a new O-ring to prevent oil leakage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • Install the oil pump. NOTE Set the oil pump shaft end “A” to the water pump shaft.

  • Page 305: Oil Pump Inspection

    Engine Lubrication System: 1E-12 2) Rotate the oil pump by hand and check that it moves • Pass the chain between the oil pump drive and driven sprockets. smoothly. If it does not move smoothly, replace the oil pump assembly. •...

  • Page 306: Special Tools And Equipment

    1E-13 Engine Lubrication System: Special Tools and Equipment Recommended Service Material B817H21508001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1E-5) / (Page 1E- equivalent Sealant SUZUKI BOND No.1215 or P/No.: 99000–31110...

  • Page 307: Engine Cooling System

    Engine Cooling System: 1F-1 Engine Cooling System Engine Precautions Engine Cooling System Warning B817H21600001 WARNING • You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.

  • Page 308: Schematic And Routing Diagram

    1F-2 Engine Cooling System: Schematic and Routing Diagram Cooling Circuit Diagram B817H21602001 RESERVOIR TANK THERMOSTAT CONNEECTOR CYLINDER HEAD THERMOSTAT ECT SENSOR CYLINDER RADIATOR WATER PUMP I717H1160001-01...

  • Page 309: Water Hose Routing Diagram

    Engine Cooling System: 1F-3 Water Hose Routing Diagram B817H21602002 “R” “Q” “L ” “O” “K” “S ” “H” “J ” “U ” “P” “C” “C” “C” “G” “T” “V” “D” “F” “D” “D” “C” “I” “F” “D” “M” “a” “N” “F”...

  • Page 310: Diagnostic Information And Procedures

    1F-4 Engine Cooling System: Diagnostic Information and Procedures Engine Cooling Symptom Diagnosis B817H21604001 Condition Possible cause Correction / Reference Item Engine overheats Not enough engine coolant. Add engine coolant. Radiator core clogged with dirt or scale. Clean. Faulty cooling fan. Repair or replace.

  • Page 311: Radiator Cap Inspection

    Engine Cooling System: 1F-5 Radiator Cap Inspection 4) Disconnect the cooling fan motor coupler (2), water B817H21606002 bypass hose (3) and radiator outlet hose (4). Inspect the radiator cap in the following procedures: 1) Remove the radiator cap. Refer to “Cooling Circuit Inspection (Page 1F-4)”.

  • Page 312: Radiator Inspection And Cleaning

    1F-6 Engine Cooling System: 9) Remove the radiator covers (9), left and right. Radiator Cleaning Blow out any foreign matter that is stuck in the radiator fins using compressed air. CAUTION • Make sure not to bend the fins when using compressed air.

  • Page 313: Radiator Reservoir Tank Inspection

    Engine Cooling System: 1F-7 2) Pour engine coolant and bleed air from the cooling circuit. Refer to “Cooling System Inspection in Section 0B (Page 0B-14)”. 3) Reinstall the fuel tank. Refer to “Fuel Tank Removal and Installation in Section 1G (Page 1G-9)”. Radiator Reservoir Tank Inspection B817H21606006 Inspect the radiator reservoir tank in the following...

  • Page 314: Cooling Fan Inspection

    1F-8 Engine Cooling System: Installation 2) Test the cooling fan motor for load current with an Install radiator reservoir tank in the reverse order of ammeter connected as shown in the figure. removal. Pay attention to the following points: If the fan motor does not turn, replace the cooling fan assembly with a new one.

  • Page 315: Ect Sensor Removal And Installation

    Engine Cooling System: 1F-9 3) First check the insulation between “A” and “B” 4) Remove the thermostat connector (1) along with terminals with tester. Then apply 12 volts to “C” and bracket (7). “D” terminals, (+) to “C” and (–) to “D”, and check the continuity between “A”...

  • Page 316: Thermostat Inspection

    1F-10 Engine Cooling System: Thermostat Inspection Installation Install the thermostat in the reverse order of removal. B817H21606014 Inspect the thermostat in the following procedures: Pay attention to the following points: 1) Remove the thermostat. Refer to “Thermostat • Install the thermostat. Connector / Thermostat Removal and Installation (Page 1F-9)”.

  • Page 317: Water Pump Components

    Engine Cooling System: 1F-11 6) Read the thermometer just when opening the thermostat. If this reading, which is the temperature level at which the thermostat valve begins to open, is out of the standard value, replace the thermostat with a new one. Thermostat valve opening temperature Standard: Approx.

  • Page 318: Water Pump Construction

    CAUTION inner. Refer to “Engine Sprocket Removal and Installation in Section 3A (Page 3A-2)”. Replace the O-ring with the a new one. 3) Disconnect the water pump inlet hose (1). : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1160022-01...

  • Page 319: Water Pump Disassembly And Assembly

    Engine Cooling System: 1F-13 Water Pump Disassembly and Assembly • Install the water pump assembly with the slot on the pump shaft end “A” securely engaged with the flat “B” B817H21606018 Refer to “Water Pump Removal and Installation on the oil pump shaft. (Page 1F-12)”.
  • Page 320 Special tool (A): 09921–20240 (Bearing remover set) I718H1160056-01 2) Apply a small quantity of GREASE to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1160055-01 8) Remove the oil seal. NOTE If there is no abnormal condition, the oil seal removal is not necessary.
  • Page 321 “D” of washer face the impeller securing bolt head. I718H1160059-01 4) Apply GREASE to the impeller shaft. : Grease 99000–25010 (SUZUKI SUPER “C” “D” GREASE A or equivalent) 5) Install the impeller shaft and washer (1) to the water I718H1160019-02 pump body.

  • Page 322: Water Pump Related Parts Inspection

    1F-16 Engine Cooling System: 10) Install a new O-ring (7) and apply engine coolant to Water Pump Related Parts Inspection B817H21606019 Refer to “Water Pump Disassembly and Assembly (Page 1F-13)”. CAUTION Use a new O-ring to prevent engine coolant Mechanical Seal leakage.

  • Page 323: Specifications

    Engine Cooling System: 1F-17 Impeller / Shaft Impeller Shaft Journal Visually inspect the impeller and its shaft for damage. Visually inspect the journal for damage or scratch. Replace the impeller or shaft if necessary. Replace the water pump body if necessary. I718H1160015-01 I718H1160027-01 Specifications...

  • Page 324: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H21608001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1F-12) /...

  • Page 325: Fuel System

    Fuel System: 1G-1 Fuel System Engine Precautions Precautions for Fuel System B817H21700001 WARNING • Keep away from fire or spark. • During disassembling, use care to minimize spillage of gasoline. • Spilled gasoline should be wiped off immediately. • Work in a well-ventilated area. CAUTION •...

  • Page 326: General Description

    1G-2 Fuel System: General Description Fuel System Description B817H21701001 Fuel System The fuel delivery system consists of the fuel tank (1), fuel pump (2), fuel mesh filter (3), fuel feed hose (4), fuel delivery pipe (5) (including fuel injectors) and fuel pressure regulator (6). There is no fuel return hose. The fuel in the fuel tank (1) is pumped up by the fuel pump (2) and pressurized fuel flows into the injector (8) installed in the fuel delivery pipe (5).

  • Page 327: Schematic And Routing Diagram

    Fuel System: 1G-3 Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram B817H21702001 “a” “C” “A” “ b ” “B” “D” I717H1170016-04 1. Fuel tank drain hose 8. Clamp : Clamp end should face inside. Tip of clamp should face downward. 2.

  • Page 328: Diagnostic Information And Procedures

    1G-4 Fuel System: Diagnostic Information and Procedures Fuel System Diagnosis B817H21704001 Condition Possible cause Correction / Reference Item Engine will not start or is Clogged fuel filter or fuel hose. Clean or replace. hard to start (No fuel Defective fuel pump. Replace.

  • Page 329: Repair Instructions

    Fuel System: 1G-5 Repair Instructions Fuel Pressure Inspection 4) Turn the ignition ON and check for fuel pressure. B817H21706001 Fuel pressure WARNING Approx. 300 kPa (3.0 kgf/cm , 43.5 psi) • Keep away from fire or spark. If the fuel pressure is lower than the specification, •...

  • Page 330: Fuel Discharge Amount Inspection

    1G-6 Fuel System: Fuel Discharge Amount Inspection 6) Connect a proper lead wire into the fuel pump lead B817H21706003 wire coupler (fuel pump side) and apply 12 V to the WARNING fuel pump (between (+) Y/R wire and (–) B/W wire) for 10 seconds and measure the amount of fuel •...

  • Page 331: Fuel Hose Leakage Inspection

    Fuel System: 1G-7 Fuel Hose Leakage Inspection 3) First, check for insulation with the tester between terminals “A” and “B”. Next, check for continuity B817H21706005 Refer to “Fuel Line Inspection in Section 0B (Page 0B- between “A” and “B” with 12 V voltage applied, 12)”.

  • Page 332: Fuel Tank Construction

    1G-8 Fuel System: Fuel Tank Construction B817H21706009 “A” I717H1170005-04 1. Fuel tank rear cushion : Be careful not to mistake the assembling position and direction. 2. Rear bracket cushion : Be careful not to mistake the assembling position and direction. “A”: Apply adhesive agent to the cushion rubber.

  • Page 333: Fuel Tank Removal And Installation

    Fuel System: 1G-9 Fuel Tank Removal and Installation 4) Disconnect the fuel tank air breather hose (2) and B817H21706010 water drain hose (3). 5) Disconnect the fuel pump lead wire coupler (4). Removal 6) Remove the fuel tank. WARNING • Keep away from fire or spark. •...

  • Page 334: Fuel Pump Components

    1G-10 Fuel System: Fuel Pump Components B817H21706011 I718H1170002-03 1. Vessel 5. Thermistor : Apply grease. 2. Fuel mesh filter 6. Fuel level gauge : Do not reuse. 3. Fuel pump 7. O-ring : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 4. Fuel pressure regulator assembly : Apply engine oil.

  • Page 335: Fuel Pump Assembly / Fuel Level Gauge Removal And Installation

    Fuel System: 1G-11 Fuel Pump Assembly / Fuel Level Gauge 4) Remove the fuel level gauge (3) while pushing the pawl end “A”. Removal and Installation B817H21706012 CAUTION Removal Do not pull the lead wire when removing the fuel gauge. WARNING •...

  • Page 336: Fuel Level Gauge And Fuel Level Indicator Switch Inspection

    Refer to “Fuel Level Gauge Inspection in Section 9C Replace the O-ring with a new one. (Page 9C-9)” and “Fuel Level Indicator Switch (Thermistor) Inspection in Section 9C (Page 9C-8)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Fuel Pump Disassembly and Assembly B817H21706014 Refer to “Fuel Pump Assembly / Fuel Level Gauge...
  • Page 337 Fuel System: 1G-13 5) Remove the cup cover (6) and fuel pump (7) from 8) Disconnect the lead wire (BI) (11) and remove the the reservoir cup. fuel level gauge coupler (12). I717H1170011-01 I717H1170014-01 6) Remove the fuel pressure regulator holder (8). 9) Disconnect the lead wire (W) (13) and remove the thermistor (14).

  • Page 338: Fuel Mesh Filter Inspection And Cleaning

    1G-14 Fuel System: Fuel Mesh Filter Inspection and Cleaning Assembly Refer to “Fuel Mesh Filter Inspection and Cleaning B817H21706015 Inspect the fuel mesh filter in the following procedures: (Page 1G-14)”. 1) Remove the fuel mesh filter. Refer to “Fuel Pump Assemble the fuel tank pump in the reverse order of the Disassembly and Assembly (Page 1G-12)”.

  • Page 339: Fuel Injector Inspection And Cleaning

    Fuel System: 1G-15 Fuel Injector Inspection and Cleaning B817H21706018 Inspect the fuel injector in the following procedures: 1) Remove the fuel injector. Refer to “Throttle Body Disassembly and Assembly in Section 1D (Page 1D- 11)”. 2) Check the fuel injector filter for evidence of dirt and contamination.

  • Page 340: Special Tools And Equipment

    1G-16 Fuel System: Special Tools and Equipment Recommended Service Material B817H21708001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1G-12) equivalent NOTE Required service material is also described in the following. “Fuel Pump Components (Page 1G-10)”...

  • Page 341: Ignition System

    Ignition System: 1H-1 Ignition System Engine Schematic and Routing Diagram Ignition System Diagram B817H21802001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Engine stop switch Side-stand relay Fuse sensor Ignition switch Fuse Battery sensor sensor switch I718H1180001-02 Ignition System Components Location B817H21802002 Refer to “Electrical Components Location in Section 0A (Page 0A-10)”.

  • Page 342: No Spark Or Poor Spark

    1H-2 Ignition System: Condition Possible cause Correction / Reference Item Spark plug quickly Worn piston rings. Replace. becomes fouled with oil Worn pistons. Replace. or carbon. Worn cylinders. Rebore or replace. Excessive valve-stem to valve-guide Replace. clearance. Worn valve stem oil seals. Replace.

  • Page 343: Repair Instructions

    Ignition System: 1H-3 Repair Instructions Ignition Coil / Plug Cap and Spark Plug Removal 6) Remove the spark plugs with a spark plug wrench. and Installation Special tool B817H21806001 (A): 09930–10121 (Spark plug wrench set) Removal WARNING The hot engine can burn you. Wait until the engine is cool enough to touch.

  • Page 344: Spark Plug Inspection And Cleaning

    1H-4 Ignition System: • Install the ignition coil/plug caps and connect their lead wire couplers. CAUTION Do not hit the ignition coil/plug cap with a plastic hammer when installing it. I717H1180005-01 3) Connect new spark plug to each ignition coil/spark plug cap.
  • Page 345 Ignition System: 1H-5 Tester knob indication: Voltage ( 8) Repeat the b) procedure a few times and measure the highest peak voltage. ((+) Probe) ((–) Probe) If the voltage is lower than standard range, inspect Green wire Ignition coil/Plug cap #1 Ground the ignition coil/plug cap and the CKP sensor.

  • Page 346: Ckp Sensor Inspection

    1H-6 Ignition System: CKP Sensor Inspection 4) Repeat the b) procedure a few times and measure B817H21806004 the highest CKP sensor peak voltage. Refer to “Electrical Components Location in Section 0A CKP sensor peak voltage (Page 0A-10)”. 2.0 V and more (B/BI – Y/W) CKP Sensor Peak Voltage 5) If the peak voltage is within the specification, check 1) Disconnect the CKP sensor coupler (1).

  • Page 347: Ckp Sensor Removal And Installation

    Ignition System: 1H-7 CKP Sensor Removal and Installation Ignition Switch Removal and Installation B817H21806005 B817H21806008 Refer to “Generator Removal and Installation in Section Removal 1J (Page 1J-4)”. 1) Support the motorcycle with the center stand. 2) Remove the right frame head cover (GSF650). Refer Engine Stop Switch Inspection to “Exterior Parts Removal and Installation (GSF650/ B817H21806006...
  • Page 348 1H-8 Ignition System: 7) Loosen the front fork upper clamp bolts (4). • First tighten the steering stem head nut (1), then tighten the front fork upper clamp bolts (2). 8) Remove the steering stem head nut and washer. 9) Remove the steering stem upper bracket (5) along Tightening torque with the ignition switch (6).

  • Page 349: Specifications

    Ignition System: 1H-9 Specifications Service Data B817H21807001 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 ⋅ 4 ⋅ 3 Firing order NGK: CR9E Type DENSO: U27ESR-N Spark plug 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 90 –...

  • Page 350: Starting System

    1I-1 Starting System: Starting System Engine Schematic and Routing Diagram Starting System Diagram B817H21902001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. Ignition Engine stop switch switch Fuse (30 A) Bl/B Gear B/Bl Fuse position Starter Starter (15 A) switch button motor...

  • Page 351: Starter Motor Will Not Run

    Starting System: 1I-2 Starter motor will not run B817H21904002 NOTE Make sure the fuses are not blown and the battery is fully-charged before diagnosing. Troubleshooting Step Action 1) Shift the transmission into neutral. Go to step 2. Go to step 3. 2) Grasp the clutch lever, turn on the ignition switch with the engine stop switch in the “RUN”...

  • Page 352: Repair Instructions

    1I-3 Starting System: Repair Instructions Starter Motor Components B817H21906001 I717H1190026-03 1. O-ring 6. Starter motor case : Apply grease to sliding surface. 2. Housing end (Inside) 7. O-ring : Apply moly past to sliding surface. 3. O-ring 8. Housing end assembly (Outside) : Do not reuse.

  • Page 353: Starter Motor Removal And Installation

    Install the starter motor in the reverse order of removal. Pay attention to the following points: • Apply grease to the starter motor O-ring. I717H1190004-01 : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Starter Motor Disassembly and Assembly B817H21906003 Refer to “Starter Motor Removal and Installation...

  • Page 354: Starter Motor Inspection

    Service limit: 3.5 mm (0.14 in) Special tool : 09900–20102 (Vernier calipers (1/20 mm, 200 mm)) I717H1190007-01 • Apply a small quantity of moly paste to the armature shaft. : Moly paste 99000–25140 (SUZUKI Moly “a” paste or equivalent) I717H1190010-01 I717H1190008-01...

  • Page 355: Starter Relay Removal And Installation

    Starting System: 1I-6 Starter Relay Removal and Installation Commutator Inspect the commutator for discoloration, abnormal wear B817H21906005 Refer to “Electrical Components Location in Section 0A or undercut “A”. (Page 0A-10)”. If the commutator is abnormally worn, replace the armature. Removal If the commutator surface is discolored, polish it with 1) Turn the ignition switch OFF position.

  • Page 356: Starter Relay Inspection

    1I-7 Starting System: Starter Relay Inspection B817H21906006 Inspect the starter relay in the following procedures: 1) Remove the starter relay. Refer to “Starter Relay Removal and Installation (Page 1I-6)”. 2) Apply 12 V to “A” and “B” terminals and check for continuity between the positive and negative terminals using the multi-circuit tester.

  • Page 357: Side-Stand / Ignition Interlock System Parts Inspection

    Starting System: 1I-8 Side-stand / Ignition Interlock System Parts 5) Connect the side-stand switch coupler. Inspection 6) Install the left frame cover. Refer to “Exterior Parts B817H21906008 Removal and Installation (GSF650/S/A/SAK7) in Refer to “Electrical Components Location in Section 0A Section 9D (Page 9D-6)”.
  • Page 358 1I-9 Starting System: Diode inspection 1) Remove the turn signal/side-stand relay. Refer to “Turn Signal / Side-stand Relay Removal and Installation (Page 1I-7)”. 2) Measure the voltage between the “A”, “B” and “C” terminals using the multi-circuit tester. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication Diode test (...

  • Page 359: Starter Clutch Removal And Installation

    Starting System: 1I-10 8) Turn the ignition switch OFF. 5) Remove the one way clutch (4) from the guide (5). 9) Install the left frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. Starter Clutch Removal and Installation B817H21906009 Removal 1) Drain engine oil.

  • Page 360: Starter Clutch Inspection

    1I-11 Starting System: • Install the guide (2) to the generator rotor. • Fit the key (3) in the key slot on the crankshaft. NOTE The arrow mark “B” must face to the generator rotor side. “B” I717H1190024-01 • Install the generator rotor assembly onto crankshaft. Refer to “Generator Removal and Installation in Section 1J (Page 1J-4)”.

  • Page 361: Starter Button Inspection

    Starting System: 1I-12 Starter Driven Gear Bearing Inspect the starter driven gear bearing for wear or damage. I717H1190025-01 3) Inspect the starter button for continuity with a tester. If any abnormality is found, replace the right handle switch assembly with a new one. Refer to I718H1190036-01 “Handlebars Removal and Installation in Section 6B Starter Button Inspection...

  • Page 362: Special Tools And Equipment

    1I-13 Starting System: Special Tools and Equipment Recommended Service Material B817H21908001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 1I-4) / (Page 1I-5) equivalent Moly paste SUZUKI Moly paste or equivalent P/No.: 99000–25140...

  • Page 363: Charging System

    Charging System: 1J-1 Charging System Engine Schematic and Routing Diagram Charging System Diagram B817H21A02001 Regulator/Rectifier Ignition switch Generator I718H11A0001-01 Component Location Charging System Components Location B817H21A03001 Refer to “Electrical Components Location in Section 0A (Page 0A-10)”. Diagnostic Information and Procedures Charging System Symptom Diagnosis B817H21A04001 Condition...

  • Page 364: Battery Runs Down Quickly

    1J-2 Charging System: Condition Possible cause Correction / Reference Item Battery overcharges Faulty regulator/rectifier. Replace. Faulty battery. Replace. Poor contact of generator lead wire Repair. coupler. “Sulfation”, acidic white Cracked battery case. Replace the battery. powdery substance or Battery has been left in a run-down Replace the battery.

  • Page 365: Repair Instructions

    Charging System: 1J-3 Repair Instructions Battery Current Leakage Inspection 3) Measure the DC voltage between the (+) and (–) B817H21A06001 battery terminals using the multi-circuit tester. If the Inspect the battery current leakage in the following voltage is not within the specified value, inspect the procedures: generator and regulator/rectifier.

  • Page 366: Generator Removal And Installation

    1J-4 Charging System: 2) Measure the resistance between the three lead 3) Using the multi-circuit tester, measure the voltage wires. between three lead wires. If the resistance is out of specified value, replace the If the tester reads under the specified value, replace stator with a new one.
  • Page 367 Charging System: 1J-5 4) Remove the generator cover (4). 8) Loosen the generator rotor bolt. NOTE When loosen the rotor bolt, do not remove it. The rotor bolt is used in conjunction with the rotor remover when removing the rotor. I717H11A0004-01 5) Remove the gasket (5) and dowel pins.
  • Page 368 • Install the generator rotor onto crankshaft. I717H11A0013-01 • Apply BOND lightly to the mating surfaces at the parting line between the upper and lower crankcases as shown. : Sealant 99000–31140 (SUZUKI BOND “A” No.1207B or equivalent) “B” I717H11A0011-01 I717H11A0014-01...
  • Page 369 Charging System: 1J-7 • Install the dowel pins and new gasket (2). • Install the generator cover and tighten the generator cover bolts. CAUTION WARNING Use a new gasket to prevent oil leakage. Be careful not to pinch the finger between the generator cover and the crankcase.

  • Page 370: Regulator / Rectifier Construction

    1J-8 Charging System: Regulator / Rectifier Construction B817H21A06005 I718H11A0002-01 1. Regulator/rectifier 3. Regulator/rectifier bracket No.2 5. Engine sprocket inner cover 2. Regulator/rectifier bracket No.1 4. Breather cover : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) Regulator / Rectifier Inspection B817H21A06006 Inspect the regulator/rectifier in the following procedures: 1) Turn the ignition switch OFF.

  • Page 371: Battery Components

    Charging System: 1J-9 4) Measure the voltage between the terminals using the multi-circuit tester as indicated in the following table. If the voltage is not within the specified value, replace the regulator/rectifier with a new one. NOTE If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery. Special tool : 09900–25008 (Multi-circuit tester set) Tester knob indication...
  • Page 372 1J-10 Charging System: 2) Remove the caps (2) from the electrolyte container. NOTE If no air bubbles are coming up from a filler NOTE port, tap the bottom of the electrolyte • Do not remove or pierce the sealed areas container two or three times.
  • Page 373 Charging System: 1J-11 2) Measure the battery voltage using the multi-circuit tester. Correct If the voltage reading is less than the 12 V (DC), recharge the battery with a battery charger. Recharging time 0.9 A for 5 to 10 hours or 4 A for 1 hour. CAUTION Be careful not to permit the charging current to exceed 4 A at any time.

  • Page 374: Battery Removal And Installation

    1J-12 Charging System: Battery Removal and Installation Installation B817H21A06009 Install the battery in the reverse order of removal. Refer to “Electrical Components Location in Section 0A Pay attention to following points: (Page 0A-10)”. CAUTION Removal Never use anything except the specified 1) Remove the seat.

  • Page 375: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H21A08001 Material SUZUKI recommended product or Specification Note Sealant SUZUKI BOND No.1207B or P/No.: 99000–31140 (Page 1J-6)

  • Page 376: Special Tool

    1J-14 Charging System: Special Tool B817H21A08002 09900–25008 09930–34970 Multi-circuit tester set Rotor remover set (Page 1J-3) / (Page 1J- (Page 1J-5) 3) / (Page 1J-4) / (Page 1J-4) / (Page 1J- 09930–44530 Rotor holder (Page 1J-5) / (Page 1J-...

  • Page 377: Exhaust System

    Exhaust System: 1K-1 Exhaust System Engine Precautions Precautions for Exhaust System B817H21B00001 WARNING To avoid the danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting.

  • Page 378: Repair Instructions

    1K-2 Exhaust System: Repair Instructions Exhaust System Construction B817H21B06001 “A” “B” I718H11B0001-03 1. Exhaust pipe 5. Exhaust pipe mounting bolt “A”: Chamfer : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) 2. Muffler 6. Muffler connecting bolt “B”: Apply exhaust gas sealer. : Do not reuse.

  • Page 379: Exhaust Pipe / Muffler Removal And Installation

    Exhaust System: 1K-3 Exhaust Pipe / Muffler Removal and Installation 5) Remove the exhaust pipe (5) by removing the B817H21B06002 exhaust pipe bolts and mounting bolt (6). Removal NOTE 1) Loosen the muffler connecting bolts (1). Support the exhaust pipe to prevent it from falling.
  • Page 380 1K-4 Exhaust System: Installation Installation is in the reverse order of removal. Pay attention to the following points: • Tighten the HO2 sensor to the specified torque. Tightening torque “A” HO2 sensor (a): 25 N·m (2.5 kgf-m, 18.0 lbf-ft) CAUTION •...

  • Page 381: Exhaust System Inspection

    Exhaust System: 1K-5 Exhaust System Inspection • Route the HO2 sensor lead wire. Refer to “Throttle Body Construction in Section 1D (Page 1D-9)”. B817H21B06003 Inspect the exhaust pipe connection and muffler • Tighten the muffler mounting nut and muffler connection for exhaust gas leakage and mounting connecting bolts to the specified torque.

  • Page 382: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H21B08001 Material SUZUKI recommended product or Specification Note Exhaust gas sealer PERMATEX 1372 (commercially — (Page 1K-4)
  • Page 383 Installation ............2C-3 Air Valve Removal and Installation ....2D-17 Rear Suspension Inspection .......2C-4 Wheel Balance Check and Adjustment.....2D-17 Rear Shock Absorber Inspection ......2C-4 Front Wheel Components (GSF650A/UA/SA/ Rear Suspension Adjustment ......2C-4 ASUK7) ............2D-18 Rear Shock Absorber Disposal ......2C-5 Front Wheel Assembly Construction Cushion Lever Removal and Installation.....2C-6...
  • Page 384 2-ii Table of Contents Special Tools and Equipment ......2D-27 Special Tool ............2D-27 Recommended Service Material .......2D-27...

  • Page 385: Precautions

    Precautions: Precautions Suspension Precautions Precautions for Suspension B817H22000001 Refer to “General Precautions in Section 00 (Page 00-1)”. WARNING All suspensions, bolts and nuts are an important part in that it could affect the performance of vital parts. They must be tightened to the specified torque periodically and if the suspension effect is lost, replace it with a new one.

  • Page 386: 2A-1 Suspension General Diagnosis

    2A-1 Suspension General Diagnosis: Suspension General Diagnosis Suspension Diagnostic Information and Procedures Suspension and Wheel Symptom Diagnosis B817H22104001 Condition Possible cause Correction / Reference Item Wobbly front wheel Distorted wheel rim. Replace. Worn front wheel bearings. Replace. Defective or incorrect tire. Replace.

  • Page 387: Front Suspension

    Front Suspension: 2B-1 Front Suspension Suspension Repair Instructions Front Fork Components B817H22206001 I717H1220036-03 1. Front fork protector 11. Cylinder bolt 21. Spacer 2. Dust seal 12. Front axle pincj bolt 22. Washer 3. Oil seal stopper ring 13. Ring 23. Spring 4.

  • Page 388: Front Fork Removal And Installation

    2B-2 Front Suspension: Front Fork Removal and Installation 6) Loosen the front fork lower clamp bolts (6) and B817H22206002 remove the front fork. Removal NOTE 1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (GSF650/ Hold the front fork by the hand to prevent S/U/SUK7) in Section 2D (Page 2D-4)”.

  • Page 389: Front Fork Disassembly And Assembly

    Front Suspension: 2B-3 4) Tighten the front fork lower clamp bolts (1). 7) Remount the front fender along with the fender plate nut. Tightening torque 8) Install the front wheel assembly. Refer to “Front Front fork lower clamp bolt (b): 23 N·m (2.3 kgf- Wheel Assembly Removal and Installation (GSF650/ m, 16.5 lbf-ft) S/U/SUK7) in Section 2D (Page 2D-4)”.
  • Page 390 2B-4 Front Suspension: 2) Remove the front fork cap bolt (2). 7) Remove the oil seal stopper ring (8). CAUTION Hold the front fork cap bolt when removing it, or it will jump out due to the spring pressure. 3) Remove the spring seat (3), spacer (4), washer (5) and spring (6).
  • Page 391 Front Suspension: 2B-5 10) Remove the oil seal by slowly pulling out the inner Assembly tube. Assemble the front fork in the reverse order of disassembly. Pay attention to the following points: NOTE CAUTION Be careful not to damage the inner tube. •...
  • Page 392 • Apply fork oil to the inner tube slide metal. • Install the inner tube into the outer tube with care not to drop the oil lock piece out. : Fork Oil 99000–99044–10G (SUZUKI FORK OIL G-10 or equivalent) NOTE...
  • Page 393 Front fork cylinder bolt: 30 N·m (3.0 kgf-m, 21.5 • Install the rebound spring (2) to the cylinder (3). lbf-ft) • Apply fork oil to the cylinder ring. : Fork Oil 99000–99044–10G (SUZUKI FORK OIL G-10 or equivalent) • Insert the cylinder (3) into the inner tube. I718H1220012-03...
  • Page 394 • Pour specified front fork oil up to the top level of the When adjusting the fork oil level, remove the inner tube. fork spring and compress the inner tube fully. : Fork Oil 99000–99044–10G (SUZUKI FORK Special tool OIL G-10 or equivalent) (A): 09943–74111 (Fork oil level gauge) Capacity (each leg) Fork oil level “a”...

  • Page 395: Front Fork Inspection

    • Apply fork oil lightly to the O-ring (1). sliding surface for scuffing. CAUTION Use a new O-ring (1) to prevent oil leakage. : Fork Oil 99000–99044–10G (SUZUKI FORK OIL G-10 or equivalent) • Install the front fork cap bolt to the inner tube temporarily.

  • Page 396: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H22208001 Material SUZUKI recommended product or Specification Note Fork Oil SUZUKI FORK OIL G-10 or P/No.: 99000–99044– (Page 2B-6) /...

  • Page 397: Special Tool

    Front Suspension: 2B-11 Special Tool B817H22208002 09940–34520 09940–34531 T handle Attachment A (Page 2B-4) / (Page 2B- (Page 2B-4) / (Page 2B- 09940–52861 09943–74111 Front fork oil seal installer Fork oil level gauge (Page 2B-6) (Page 2B-8)

  • Page 398: Rear Suspension

    2C-1 Rear Suspension: Rear Suspension Suspension Repair Instructions Rear Suspension Components B817H22306001 From November 2008 production I817H2230001-01 1. Rear shock absorber 7. Chain case : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Rear shock absorber mounting nut 8. Swingarm : 78 N⋅m (7.8 kgf-m, 56.5 lb-ft) 3.

  • Page 399: Rear Suspension Assembly Construction

    Rear Suspension: 2C-2 Rear Suspension Assembly Construction B817H22306002 Left Right From November 2008 production I817H2230002-02 1. Rear shock absorber mounting nut (Upper) 5. Cushion lever mounting nut : 100 N m (10.0 kgf-m 72.5 lb-ft) 2. Rear shock absorber mounting nut (Lower) 6.

  • Page 400: Rear Shock Absorber Removal And Installation

    2C-3 Rear Suspension: Rear Shock Absorber Removal and Installation 6) Remove the shock absorber upper mounting bolt B817H22306003 and nut. Removal 1) Place the motorcycle on the center stand and support the motorcycle with a jack to be no load for the rear shock absorber.

  • Page 401: Rear Suspension Inspection

    Rear Suspension: 2C-4 Rear Shock Absorber Inspection • Tighten the cushion lever mounting bolt and nut. B817H22306005 Tightening torque Inspect the rear shock absorber in the following Cushion lever mounting nut (b): 78 N·m (7.8 kgf- procedures: m, 56.5 lbf-ft) 1) Remove the rear shock absorber.

  • Page 402: Rear Shock Absorber Disposal

    2C-5 Rear Suspension: Damping Force Adjustment 1) Mark the drill center at the location “A” using a center Turn the damping force adjuster (1) to the desired punch. position. NOTE Turn the adjuster clockwise to stiffen the damping force and turn it counterclockwise “a”...

  • Page 403: Cushion Lever Removal And Installation

    Rear Suspension: 2C-6 Cushion Lever Removal and Installation Installation B817H22306008 Install the cushion lever in the reverse order of removal. Pay attention to the following point: Removal • Tighten each nut to the specified torque. 1) Place the motorcycle on the center stand and Tightening torque support the motorcycle with a jack to be no load for Cushion lever mounting nut (a): 78 N·m (7.8 kgf-...

  • Page 404: Cushion Lever Inspection

    2C-7 Rear Suspension: Cushion Lever Inspection Cushion Rod B817H22306009 Refer to “Swingarm Related Parts Inspection (Page 2C- Refer to “Cushion Lever Removal and Installation 10)”. (Page 2C-6)”. Cushion Lever Bearing Removal and Spacer Installation 1) Remove the spacers from the cushion lever. B817H22306010 2) Inspect the spacers for any flaws or other damage.

  • Page 405: Swingarm / Cushion Rod Removal And Installation

    3) Remove the brake hose from the brake hose clamps. I718H1230014-02 2) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1230019-01 4) Remove the cushion lever (2) and rear shock absorber (3). Refer to “Rear Shock Absorber Removal and Installation (Page 2C-3)”...
  • Page 406 2C-9 Rear Suspension: 5) Remove the pivot shaft end caps (4), left and right. 10) Remove the cushion rods (8). 6) Remove the swingarm by removing the pivot shaft and nut (5) and washer. I717H1230025-01 Installation I717H1230021-01 Install the swingarm in the reverse order of removal. Pay 7) Remove the chain adjusters (6).

  • Page 407: Swingarm Related Parts Inspection

    Rear Suspension: 2C-10 • Tighten the cushion lever, cushion rod and rear shock Chain Buffer absorber mounting nut to the specified torque. Inspect the chain buffer for wear and damage. If any defect is found, replace the chain buffer with a new one. Tightening torque Cushion rod mounting nut (b): 78 N·m (7.8 kgf-m, 56.5 lbf-ft)

  • Page 408: Swingarm Bearing Removal And Installation

    2C-11 Rear Suspension: Cushion Rod 3) Draw out the swingarm pivot bearings (1) using the Inspect the cushion rods for damage and bend. If any special tool. defects are found, replace the cushion rods with new Special tool ones. (A): 09921–20240 (Bearing remover set) I717H1230034-01 I717H1230035-01 4) Remove the center spacer (2).
  • Page 409 Special tool (A): 09924–84521 (Bearing installer set) I717H1230039-01 4) Apply grease to the bearings. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1230038-01 I717H1230040-01 5) Install the swingarm. Refer to “Swingarm / Cushion Rod Removal and Installation (Page 2C-8)”.

  • Page 410: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H22308001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 2C-8) /...

  • Page 411: Special Tool

    Rear Suspension: 2C-14 Special Tool B817H22308002 09900–20607 09900–20701 Dial gauge (1/100 mm, 10 Magnetic stand (Page 2C-11) (Page 2C-11) 09900–21304 09913–70210 V-block (100 mm) Bearing installer set (Page 2C-11) (Page 2C-7) 09921–20240 09923–73210 Bearing remover set Bearing remover (Page 2C-11) (Page 2C-7) / (Page 2C- 09924–84521...

  • Page 412: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Precautions Precautions for Wheel and Tire B817H22400001 WARNING • Proper tire pressure and proper tire loading are important factors. Over loading tire can lead to tire failure and loss of motorcycle control. •...

  • Page 413: Repair Instructions

    Wheels and Tires: 2D-2 Repair Instructions Front Wheel Components (GSF650/S/U/SUK7) B817H22406001 I717H1240040-04 1. Front axle 6. Dust seal : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 2. Brake disc bolt 7. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Brake disc 8.

  • Page 414: Front Wheel Assembly Construction (Gsf650/S/U/Suk7)

    2D-3 Wheels and Tires: Front Wheel Assembly Construction (GSF650/S/U/SUK7) B817H22406002 Left Right “a ” I717H1240001-03 1. Brake disc bolt “a”: Clearance : Apply grease. 2. Brake caliper mounting bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Apply thread lock to thread part. 3.

  • Page 415: Front Wheel Assembly Removal And Installation (Gsf650/S/U/Suk7)

    Wheels and Tires: 2D-4 Front Wheel Assembly Removal and Installation 5) Draw out the front axle and remove the front wheel. (GSF650/S/U/SUK7) NOTE B817H22406003 After removing the front wheel, fit the Removal calipers temporarily to the original positions. 1) Remove the brake calipers. Refer to “Front Brake Caliper Removal and Installation in Section 4B (Page 4B-2)”.
  • Page 416 2D-5 Wheels and Tires: 2) Install the front wheel with the front axle and tighten 4) Tighten the front axle (2) to the specified torque. the front axle temporarily. Special tool : 09944–28320 (Hexagon socket (19 mm)) WARNING Tightening torque The directional arrow on the tire should point Front axle (b): 100 N·m (10.0 kgf-m, 72.5 lbf-ft) to the wheel rotation, when remounting the...

  • Page 417: Front Wheel Related Parts Inspection

    Wheels and Tires: 2D-6 Front Wheel Related Parts Inspection Wheel B817H22406004 Inspect the wheel in the following procedures: Refer to “Front Wheel Assembly Removal and 1) Remove the brake pads. Refer to “Front Brake Pad Installation (GSF650/S/U/SUK7) (Page 2D-4)” Replacement in Section 4B (Page 4B-2)”. 2) Make sure that the wheel runout checked as shown Tire does not exceed the service limit.

  • Page 418: Front Wheel Dust Seal / Bearing Removal And Installation

    1) Remove the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (GSF650/ 1) Apply grease to the wheel bearings. S/U/SUK7) (Page 2D-4)”. : Grease 99000–25010 (SUZUKI SUPER 2) Remove the dust seals (1) on both sides using the GREASE A or equivalent) special tool.
  • Page 419 Right Special tool (C): 09913–70210 (Bearing installer set) I717H1240020-01 Right Left 4) Apply grease to the lip of dust seals. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “ a ” I717H1240019-03 1. Spacer “a”: Clearance I717H1240021-01 5) Install the front wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (GSF650/ S/U/SUK7) (Page 2D-4)”.

  • Page 420: Rear Wheel Components (Gsf650/S/U/Suk7)

    2D-9 Wheels and Tires: Rear Wheel Components (GSF650/S/U/SUK7) B817H22406006 I717H1240041-02 1. Rear axle 9. Sprocket mounting drum 17. Wheel balancer 2. Brake disc 10. Bearing : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Spacer 11. Dust seal : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 4.

  • Page 421: Rear Wheel Assembly Construction (Gsf650/S/U/Suk7)

    Wheels and Tires: 2D-10 Rear Wheel Assembly Construction (GSF650/S/U/SUK7) B817H22406007 Left Right “a” I717H1240022-01 1. Rear sprocket nut “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) : Apply grease. 3.

  • Page 422: Rear Wheel Assembly Removal And Installation (Gsf650/S/U/Suk7)

    2D-11 Wheels and Tires: Rear Wheel Assembly Removal and Installation 5) Remove the spacer (2) and collar (3). (GSF650/S/U/SUK7) B817H22406008 Removal 1) Support the motorcycle with the center stand. CAUTION Make sure that the motorcycle is supported securely. 2) Remove the rear axle nut (1) and draw out the rear axle.

  • Page 423: Rear Wheel Related Parts Inspection

    Wheels and Tires: 2D-12 3) Adjust the drive chain slack after installing the rear Dust Seal wheel. Refer to “Drive Chain Inspection and Inspect the dust seal lip for wear or damage. If any Adjustment in Section 0B (Page 0B-17)”. defects is found, replace the dust seal with a new one.

  • Page 424: Rear Wheel Dust Seal / Bearing Removal And Installation

    Wheel Assembly Removal and Installation (GSF650/ S/U/SUK7) (Page 2D-11)”. 1) Apply grease to the wheel bearings. 2) Remove the rear sprocket mounting drum assembly : Grease 99000–25010 (SUZUKI SUPER (1) from the rear wheel. GREASE A or equivalent) I649G1240019-02 I717H1240030-01...
  • Page 425 (B): 09913–70210 (Bearing installer set) CAUTION The sealed cover of the bearing must face outside. I717H1240035-01 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1240034-01 Right Left I717H1240036-01 5) Install the rear sprocket mounting drum assembly (2).

  • Page 426: Tire Removal And Installation

    2D-15 Wheels and Tires: Tire Removal and Installation B817H22406011 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.

  • Page 427: Wheel / Tire / Air Valve Inspection And Cleaning

    Wheels and Tires: 2D-16 Tire 6) If the distance between the rim line and wheel rim varies, this indicates that the bead is not properly Tire must be checked for the following points: seated. If this is the case, deflate the tire completely •...

  • Page 428: Air Valve Removal And Installation

    2D-17 Wheels and Tires: Air Valve Removal and Installation B817H22406013 Removal 1) Remove the wheel assembly. Refer to “Front Wheel Assembly Removal and Installation (GSF650/S/U/ SUK7) (Page 2D-4)” and “Rear Wheel Assembly Removal and Installation (GSF650/S/U/SUK7) (Page 2D-11)”. 2) Remove the tire. Refer to “Tire Removal and I718H1240055-01 Installation (Page 2D-15)”.

  • Page 429: Front Wheel Components (Gsf650A/Ua/Sa/Asuk7)

    Wheels and Tires: 2D-18 Front Wheel Components (GSF650A/UA/SA/ASUK7) B817H22406015 I717H2240001-01 1. Front axle 6. Spacer 11. Tire : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc bolt 7. Sensor rotor bolt 12. Front wheel : Apply grease. 3. Brake disc 8.

  • Page 430: Front Wheel Assembly Construction (Gsf650A/Ua/Sa/Asuk7)

    2D-19 Wheels and Tires: Front Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) B817H22406016 Left Right “ a ” “ b ” I717H2240002-03 1. Brake disc bolt “a”: Clearance : Apply grease. 2. Brake caliper mounting bolt “b”: 0.3 – 1.5 mm (0.012 – 0.059 in.) : Apply thread lock to thread part.

  • Page 431: Front Wheel Assembly Removal And Installation (Gsf650A/Ua/Sa/Asuk7)

    Wheels and Tires: 2D-20 Front Wheel Assembly Removal and Installation 5) Raise the front wheel off the ground and support the motorcycle with a jack or a wooden block. (GSF650A/UA/SA/ASUK7) B817H22406017 CAUTION Removal Do not carry out the work with the 1) Remove the front wheel speed sensor by removing motorcycle resting on the side-stand.
  • Page 432 2D-21 Wheels and Tires: Installation 3) Install the front wheel with the front axle and tighten the front axle temporarily. 1) Install the collar (1) and front wheel speed sensor bracket (2) into the right side of the wheel. WARNING The directional arrow on the tire should point to the wheel rotation, when remounting the wheel.
  • Page 433 Wheels and Tires: 2D-22 5) Tighten the front axle to the specified torque. 7) Tighten the axle pinch bolt to the specified torque. Special tool Tightening torque (A): 09944–28320 (Hexagon socket (19 Front axle pinch bolt (b): 23 N·m (2.3 kgf-m, 16.5 mm)) lbf-ft) Tightening torque...

  • Page 434: Rear Wheel Components (Gsf650A/Ua/Sa/Asuk7)

    2D-23 Wheels and Tires: Rear Wheel Components (GSF650A/UA/SA/ASUK7) B817H22406018 I717H2240003-01 1. Rear axle 8. Spacer 15. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Brake disc 9. Bearing 16. Air valve : Apply grease. 3. Spacer 10. Wheel damper 17.

  • Page 435: Rear Wheel Assembly Construction (Gsf650A/Ua/Sa/Asuk7)

    Wheels and Tires: 2D-24 Rear Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) B817H22406019 Left Right “b ” “a” I717H2240004-01 1. Rear sprocket nut “a”: Clearance : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Rear axle nut “b”: 0.3 – 1.5 mm (0.012 – 0.059 in) : Apply grease.
  • Page 436 2D-25 Wheels and Tires: 3) Remove the rear axle nut (1) and draw out the rear Installation axle. Refer to “Wheel Speed Sensor and Sensor Rotor Inspection in Section 4E (Page 4E-73)”. 1) Install the collar (1) and spacer (2). I717H2240017-01 4) Remove the rear axle and disengage the drive chain from the rear sprocket.

  • Page 437: Specifications

    “Rear Wheel Components (GSF650/S/U/SUK7) (Page 2D-9)” “Rear Wheel Assembly Construction (GSF650/S/U/SUK7) (Page 2D-10)” “Front Wheel Components (GSF650A/UA/SA/ASUK7) (Page 2D-18)” “Front Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) (Page 2D-19)” “Rear Wheel Components (GSF650A/UA/SA/ASUK7) (Page 2D-23)” “Rear Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) (Page 2D-24)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C...
  • Page 438 “Rear Wheel Components (GSF650/S/U/SUK7) (Page 2D-9)” “Rear Wheel Assembly Construction (GSF650/S/U/SUK7) (Page 2D-10)” “Front Wheel Components (GSF650A/UA/SA/ASUK7) (Page 2D-18)” “Front Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) (Page 2D-19)” “Rear Wheel Components (GSF650A/UA/SA/ASUK7) (Page 2D-23)” “Rear Wheel Assembly Construction (GSF650A/UA/SA/ASUK7) (Page 2D-24)” Special Tool B817H22408002 09900–20607...
  • Page 439 Table of Contents 3- i Section 3 Driveline / Axle CONTENTS Precautions ..........3-1 Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation ......3A-4 Precautions............. 3-1 Drive Chain Related Parts Inspection ....3A-5 Precautions for Driveline / Axle ......3-1 Sprocket Mounting Drum Dust Seal / Bearing Drive Chain / Drive Train / Drive Shaft...

  • Page 440: Precautions

    • Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant. Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings. • The standard drive chain is RK 525SMOZ7Y. Suzuki recommends to use this standard drive chain as a replacement.

  • Page 441: Drive Chain / Drive Train / Drive Shaft

    Drive Chain / Drive Train / Drive Shaft: 3A-1 Drive Chain / Drive Train / Drive Shaft Driveline / Axle Diagnostic Information and Procedures Drive Chain and Sprocket Symptom Diagnosis B817H23104001 Condition Possible cause Correction / Reference Item Noisy Drive Chain Worn sprocket.

  • Page 442: Engine Sprocket Removal And Installation

    3A-2 Drive Chain / Drive Train / Drive Shaft: Engine Sprocket Removal and Installation 5) Remove the speed sensor (4). B817H23106002 6) Remove the engine sprocket cover along with the clutch release cylinder. Removal 1) Support the motorcycle with the center stand. 2) Remove the engine sprocket outer cover (1).
  • Page 443 Tightening torque Speed sensor rotor bolt (b): 25 N·m (2.5 kgf-m, 18.0 lbf-ft) • Before installing the engine sprocket inner cover, apply a small quantity of suzuki super grease to the clutch push rod. I717H1310008-01 : Grease 99000–25010 (SUZUKI SUPER 11) Remove the spacer (9) engine sprocket (10).

  • Page 444: Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation

    • Adjust the drive chain slack. Refer to “Drive Chain the following points: Inspection and Adjustment in Section 0B (Page 0B- • Apply grease to the retainer. 17)”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation B817H23106003...

  • Page 445: Drive Chain Related Parts Inspection

    I717H1310019-01 • Apply grease to the contacting surface between the rear wheel hub and the mounting drum. I717H1310022-01 : Grease 99000–25010 (SUZUKI SUPER Bearing GREASE A or equivalent) Inspect the play of the sprocket mounting drum bearings by hand while they are in the wheel and drum. Rotate the inner race by hand to inspect for abnormal noise and smooth rotation.

  • Page 446: Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation

    (Page 2D-13)”. 3) Remove the retainer (1). I717H1310026-02 Installation CAUTION The removed dust seal and bearing must be replaced with new ones. 1) Apply grease to the bearing before installing. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I717H1310024-01 I649G1310020-02...

  • Page 447: Drive Chain Replacement

    : 09922–22711 (Drive chain cutting and joining (A): 09913–70210 (Bearing installer set) tool) 4) Apply grease to the dust seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I649G1310023-02 Drive Chain Cutting 1) Set up the special tool as shown in the illustration.
  • Page 448 3A-8 Drive Chain / Drive Train / Drive Shaft: NOTE 6) Remove the joint pin (9) of the other side of joint plate. The tip of pin remover (1) should be positioned inside “a” approximately 5 mm CAUTION (0.2 in) from the end face of pressure bolt [A] Never reuse joint pins, O-rings and plates.
  • Page 449 Drive Chain / Drive Train / Drive Shaft: 3A-9 Joint plate installation 5) Set the drive chain on the tool as illustrated and turn in the adjuster bolt (5) to secure the wedge holder & 1) Set up the special tool as shown in the illustration. wedge pin (4).

  • Page 450: Specifications

    3A-10 Drive Chain / Drive Train / Drive Shaft: Joint pin staking CAUTION 1) Set up the special tool as shown in the illustration. • After joining of the chain has been completed, check to make sure that the link is smooth and no abnormal condition is found.

  • Page 451: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H23108001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 3A-3) /...
  • Page 452 3A-12 Drive Chain / Drive Train / Drive Shaft:...
  • Page 453 Table of Contents 4- i Section 4 Brake CONTENTS Precautions ..........4-1 Front Brakes ..........4B-1 Precautions............. 4-1 Repair Instructions ..........4B-1 Precautions for Brake System ......4-1 Front Brake Components ........4B-1 Brake Fluid Information ......... 4-1 Front Brake Pad Inspection.........4B-1 Front Brake Pad Replacement......4B-2 Brake Control System and Diagnosis ...
  • Page 454 4-ii Table of Contents Self-diagnosis Function and ABS Indicator DTC “43” (C1643): Wheel Speed Sensor Light Description ..........4E-5 Circuit Short (F)..........4E-52 Fail-safe Function Description......4E-6 DTC “44” (C1644): Wheel Speed Sensor Signal Malfunction (R)........4E-54 Schematic and Routing Diagram......4E-7 DTC “45”...

  • Page 455: Precautions

    Precautions: Precautions Brake Precautions Precautions for Brake System B817H24000001 Refer to “General Precautions in Section 00 (Page 00-1)”. Brake Fluid Information B817H24000002 WARNING • This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid, such as silicone-based or petroleum-based.

  • Page 456: Brake Control System And Diagnosis

    4A-1 Brake Control System and Diagnosis: Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram (GSF650) B817H24102001 (c ) I717H1410027-01 1. Front brake hose No.1 6: Clamp : Insert the clamp to the hole of the front fender fully. 2.

  • Page 457: Front Brake Hose Routing Diagram (Gsf650S)

    Brake Control System and Diagnosis: 4A-2 Front Brake Hose Routing Diagram (GSF650S) B817H24102002 I717H1410028-01 1. Front brake hose No.1 6: Clamp : Insert the clamp to the hole of the front fender fully. 2. Front brake hose No.2 7: Front brake hose No.1 : Pass the front brake hose No.1 to the brake hose guide.

  • Page 458: Rear Brake Hose Routing Diagram

    4A-3 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram B817H24102003 42˚ “B” “A” 28˚ I717H1410001-03 1. Brake hose clamp “B” : White paint : Brake hose clamp ends should face forward. 2. Brake hose clamp : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) : Brake hose clamp ends should face backward.

  • Page 459: Diagnostic Information And Procedures

    Brake Control System and Diagnosis: 4A-4 Diagnostic Information and Procedures Brake Symptom Diagnosis B817H24104001 Condition Possible cause Correction / Reference Item Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace. system. Worn pads. Replace. Oil adhesion on friction surface of pads. Clean disc and pads. Worn disc and disk.

  • Page 460: Rear Brake Light Switch Inspection

    4A-5 Brake Control System and Diagnosis: Rear Brake Light Switch Inspection Brake Fluid Level Check B817H24106003 B817H24106005 Inspect the rear brake light switch in the following Refer to “Brake System Inspection in Section 0B procedures: (Page 0B-18)”. 1) Disconnect the rear brake light switch lead coupler Brake Hose Inspection (1).
  • Page 461 Brake Control System and Diagnosis: 4A-6 9) Install the reservoir cap. 4) Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever Rear Brake causing it to touch the handlebar grip.

  • Page 462: Brake Fluid Replacement

    4A-7 Brake Control System and Diagnosis: Brake Fluid Replacement 7) Close the air bleeder valve and disconnect the clear B817H24106008 hose. CAUTION Tightening torque Handle brake fluid with care: the fluid reacts Air bleeder valve (Front brake) (a): 8.5 N·m (0.85 chemically with paint, plastic, rubber kgf-m, 6.1 lbf-ft) materials, etc.

  • Page 463: Brake Hose Removal And Installation

    Brake Control System and Diagnosis: 4A-8 Brake Hose Removal and Installation 7) Loosen the air bleeder valve and pump the brake pedal until the old brake fluid flows out of the brake B817H24106009 Removal system. 1) Drain brake fluid. Refer to “Brake Fluid Replacement (Page 4A-7)”.

  • Page 464: Front Brake Master Cylinder Components

    4A-9 Brake Control System and Diagnosis: Front Brake Master Cylinder Components B817H24106010 I718H1410070-01 1. Reservoir cap 7. Brake lever : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Plate 8. Brake lever pivot bolt : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 3.

  • Page 465: Front Brake Master Cylinder / Brake Lever Disassembly And Assembly

    Brake Control System and Diagnosis: 4A-10 Installation • Bleed air from the brake system. Refer to “Air Install the front brake master cylinder in the reverse Bleeding from Brake Fluid Circuit (Page 4A-5)”. order of removal. Pay attention to the following points: Front Brake Master Cylinder / Brake Lever •...
  • Page 466 Pay attention to the following points: • Apply grease to the contact point between piston and brake lever. CAUTION : Grease 99000–25100 (SUZUKI Silicone • Wash the master cylinder components with Grease or equivalent) new brake fluid before reassembly.

  • Page 467: Front Brake Master Cylinder Parts Inspection

    Brake Control System and Diagnosis: 4A-12 Front Brake Master Cylinder Parts Inspection Piston B817H24106013 Inspect the piston surface for any scratches or other Refer to “Front Brake Master Cylinder / Brake Lever damage. Disassembly and Assembly (Page 4A-10)”. Rubber Parts Master Cylinder Inspect the primary cup, secondary cup and dust boot Inspect the master cylinder bore for any scratches or...

  • Page 468: Rear Brake Master Cylinder Assembly Removal And Installation

    4A-13 Brake Control System and Diagnosis: Rear Brake Master Cylinder Assembly Removal Installation Install the rear brake master cylinder in the reverse order and Installation of removal. Pay attention to the following points: B817H24106015 Removal CAUTION 1) Remove the right frame cover. Refer to “Exterior The seal washers should be replaced with the Parts Removal and Installation (GSF650/S/A/SAK7) new ones to prevent fluid leakage.

  • Page 469: Rear Brake Master Cylinder Disassembly And Assembly

    4) Pull out the dust boot (5) and remove the snap ring (6). Special tool : 09900–06108 (Snap ring pliers) I649G1410036-02 • Apply grease to the push rod end. : Grease 99000–25100 (SUZUKI Silicone Grease or equivalent) I718H1410060-01 5) Remove the push rod (7), piston/cup set (8) and spring (9). I649G1410041-03...

  • Page 470: Rear Brake Master Cylinder Parts Inspection

    4A-15 Brake Control System and Diagnosis: • Install the O-ring (1). Master Cylinder Inspect the master cylinder bore for any scratches or CAUTION other damage. Replace the O-ring (1) with a new one. I649G1410038-02 Piston Inspect the piston surface for any scratches or other damage.

  • Page 471: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H24108001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4A-7) /...

  • Page 472: Front Brakes

    4B-1 Front Brakes: Front Brakes Brake Repair Instructions Front Brake Components B817H24206001 I649G1420001-05 1. O-ring 6. Front brake disc : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 2. Piston seal : 8.5 N⋅m (0.85 kgf-m, 6.1 lb-ft) : Apply thread lock to thread part. 3.

  • Page 473: Front Brake Pad Replacement

    Front Brakes: 4B-2 Front Brake Pad Replacement B817H24206003 1) Remove the spring (1). I718H1420003-01 5) Tighten the pad mounting pin to the specified torque. Tightening torque I717H1420003-01 Front brake pad mounting pin (a): 16 N·m (1.6 2) Remove the brake pads (2) by removing the pad kgf-m, 11.5 lbf-ft) mounting pin (3).

  • Page 474: Front Brake Caliper Disassembly And Assembly

    4B-3 Front Brakes: 3) Remove the brake caliper by removing the caliper • Bleed air from the brake system after installing the mounting bolts (2). caliper. Refer to “Brake System Inspection in Section 0B (Page 0B-18)”. • Check the brake fluid leakage and brake operation. WARNING Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces.
  • Page 475 Front Brakes: 4B-4 4) Place a rag over the pistons to prevent it from popping out and then force out the pistons using compressed air. CAUTION Do not use high pressure air to prevent piston damage. I649G1420012-02 • Apply the brake fluid to piston seals (1) and dust seals (2).

  • Page 476: Front Brake Caliper Parts Inspection

    4B-5 Front Brakes: • Temporarily tighten the brake caliper housing bolts Brake Caliper Piston (3). Inspect the brake caliper piston surface for any scratches or other damage. If any damage is found, CAUTION replace the piston with a new one. After installing the brake caliper to the front fork, tighten the brake caliper housing bolts to the specified torque.

  • Page 477: Front Brake Disc Removal And Installation

    Front Brakes: 4B-6 Front Brake Disc Removal and Installation Front Brake Disc Inspection B817H24206007 B817H24206008 Brake Disc Thickness Removal Check the brake disc for damage or cracks and measure the thickness using the micrometer. 1) Remove the front wheel assembly. Refer to “Front Replace the brake disc if the thickness is less than the Wheel Assembly Removal and Installation (GSF650/ service limit or if defect is found.

  • Page 478: Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H24208001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4B-4) /...

  • Page 479: Special Tool

    Front Brakes: 4B-8 Special Tool B817H24208002 09900–20205 09900–20607 Micrometer (0 – 25 mm) Dial gauge (1/100 mm, 10 (Page 4B-6) (Page 4B-6) 09900–20701 09930–11920 Magnetic stand Torx bit (JT40H) (Page 4B-6) (Page 4B-2) / (Page 4B- 3) / (Page 4B-5) 09930–11940 Bit holder (Page 4B-2) /...

  • Page 480: Rear Brakes

    4C-1 Rear Brakes: Rear Brakes Brake Repair Instructions Rear Brake Components B817H24306001 I649G1430001-05 1. Rear caliper bracket : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) : Apply silicone grease to sliding surface. 2. Piston : 27 N⋅m (2.7 kgf-m, 19.5 lb-ft) : Apply thread lock to thread part.

  • Page 481: Rear Brake Pad Inspection

    Rear Brakes: 4C-2 Rear Brake Pad Inspection B817H24306002 The extent of brake pads wear can be checked by observing the grooved limit line “A” on the pads. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Rear Brake Pad Replacement (Page 4C-2)”.

  • Page 482: Rear Brake Caliper Removal And Installation

    4C-3 Rear Brakes: 7) Install the new brake pads. NOTE Make sure that the detent of the pad is seated onto the retainer on the caliper bracket. I717H1430007-01 Rear Brake Caliper Removal and Installation B817H24306004 Removal 1) Drain brake fluid. Refer to “Brake Fluid Replacement I717H1430005-01 in Section 4A (Page 4A-7)”.

  • Page 483: Rear Brake Caliper Disassembly And Assembly

    Rear Brakes: 4C-4 Rear Brake Caliper Disassembly and Assembly Installation Install the brake caliper in the reverse order of removal. B817H24306005 Refer to “Rear Brake Caliper Removal and Installation Pay attention to the following points: (Page 4C-3)”. • Tighten the sliding pin (1) to the specified torque. Disassembly Tightening torque Rear brake caliper sliding pin (a): 27 N·m (2.7 kgf-...
  • Page 484 I649G1430017-02 I649G1420013-02 • Apply grease to the inside of the boot. Assembly : Grease 99000–25100 (SUZUKI Silicone Assemble the caliper in the reverse order of Grease or equivalent) disassembly. Pay attention to the following points: • Wash the caliper bore and piston with specified brake •...

  • Page 485: Rear Brake Caliper Parts Inspection

    Rear Brakes: 4C-6 Rear Brake Caliper Parts Inspection Boot and Spacer B817H24306006 Inspect the boots and spacer for damage and wear. If Refer to “Rear Brake Caliper Disassembly and any defects are found, replace them with new ones. Assembly (Page 4C-4)”. Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks, scratches or other damage.

  • Page 486: Rear Brake Disc Inspection

    4C-7 Rear Brakes: Installation Install the rear brake disc in the reverse order of removal. Pay attention to the following points: • Make sure that the brake discs are clean and free of any grease. • Apply thread lock to the brake disc bolts and tighten them to the specified torque.

  • Page 487: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H24308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 4C-5) /...

  • Page 488: Abs

    4E-1 ABS: Brake Precautions Precautions for ABS • Be sure to route the brake hoses correctly. B817H24500001 • 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 (Page 00-2)”.

  • Page 489: Abs Control Unit Description

    ABS: 4E-2 ABS Control Unit Description B817H24501002 ABS control unit (1) calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to Hydraulic Unit (HU) (2). This ABS control unit/HU can not be disassembled.
  • Page 490 4E-3 ABS: ABS Control Unit Calculating Process The ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the ABS control unit calculating process. ABS control is performed in one cycle every 10/1 000 seconds. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlled by the ABS and a diagnostic trouble code is stored.

  • Page 491: Hydraulic Unit (Hu) Description

    ABS: 4E-4 Hydraulic Unit (HU) Description B817H24501003 The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by operating separate components for the front and the rear, except for the pump drive motor, which is shared by both systems.

  • Page 492: Self-Diagnosis Function And Abs Indicator Light Description

    4E-5 ABS: Self-diagnosis Function and ABS Indicator • If an ABS malfunction has occurred, the ABS indicator light keeps lighting up. Light Description B817H24501004 The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic trouble codes. If a malfunction has occurred, the indicator light lights up to inform the rider of the malfunction.

  • Page 493: Fail-Safe Function Description

    ABS: 4E-6 ABS Operation and ABS Indicator Light The ABS indicator light 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). If a malfunction has occurred, the ABS indicator light keeps lighting up.

  • Page 494: Schematic And Routing Diagram

    4E-7 ABS: Schematic and Routing Diagram ABS Wiring Diagram B817H24502001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. I718H1450020-06...

  • Page 495: Abs Unit Diagram

    ABS: 4E-8 ABS Unit Diagram B817H24502002 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. I718H1450021-04 “A”: Rear brake solenoid OUT “C”: Front brake solenoid OUT “E”: Fail safe (+) B “G”: Motor (+) B “B”: Rear brake solenoid IN “D”: Front brake solenoid IN “F”: Motor relay (+) B...

  • Page 496: Front Wheel Speed Sensor Routing Diagram

    4E-9 ABS: Front Wheel Speed Sensor Routing Diagram B817H24502003 GSF650A/UA “B” “C” “D” “E” “F” “I” “H” “A” “G” I717H2450006-01 1. Clamp “B”: Pass through the sensor lead wire between brake hose No.2 and brake hose No.2 (L). 2. Guide “C”: Pass through the sensor lead wire in front of the brake hose.
  • Page 497 ABS: 4E-10 8. Front wheel speed sensor “I”: Clamp the sensor lead wire at front side of the brake hose. “A”: Outside mark GSF650SA/ASU “B” “C” “D” “E” “F” “I” “H” “A” “G” I717H2450007-03 1. Clamp “B”: Pass through the sensor lead wire between brake hose No.2 and brake hose No.2 (L). 2.

  • Page 498: Rear Wheel Speed Sensor Routing Diagram

    4E-11 ABS: 7: Clamp “H”: Clamp the sensor lead wire on the protector of brake hose. : Clamp the sensor lead wire at the white marking. 8. Front wheel speed sensor “I”: Clamp the sensor lead wire at front side of the brake hose. Rear Wheel Speed Sensor Routing Diagram B817H24502004 “G”...

  • Page 499: Component Location

    ABS: 4E-12 Component Location ABS Components Location B817H24503001 I717H2450005-01 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 500: Diagnostic Information And Procedures

    4E-13 ABS: Diagnostic Information and Procedures ABS Troubleshooting 5) Perform appropriate troubleshooting procedures B817H24504001 according to the DTCs output. Refer to “DTC Table Many of the ABS malfunction diagnosing operations are (Page 4E-33)”. performed by checking the wiring continuity. Quick and If troubleshooting procedures cannot be performed, accurate detection of malfunctions within the complex try to determine the cause of the malfunction...
  • Page 501 ABS: 4E-14 Information Gathering To properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without duplicating the malfunction, even an experienced service technician may make a misdiagnosis and not perform the servicing procedure correctly, resulting in the malfunction not being repaired.

  • Page 502: Pre-Diagnosis Inspection

    Brake fluid circuit air bleeding Refer to “Air Bleeding from Brake Fluid Circuit in Section 4A (Page 4A-5)”. Tire Tire type Tire type Front: BRIDGESTONE BT011F G (GSF650A/UA) Front: BRIDGESTONE BT011F M (GSF650SA/ASU) I717H2450010-01 4) Reinstall the seat. Rear: BRIDGESTONE BT020R G ABS Component Tire pressure Wheel speed sensor –...
  • Page 503 ABS: 4E-16 Rear 6) Disconnect the ABS control unit coupler (2). (A), (B) I717H2450011-01 I718H1450115-01 7) Check for continuity between “24” (B/W) at the ABS control unit/HU ground wire inspection coupler and the battery (–) terminal, also “25” (B/W) 1) Turn the ignition switch OFF. at the coupler and the battery (–) terminal.

  • Page 504: Abs Indicator Light Inspection

    4E-17 ABS: ABS Indicator Light Inspection B817H24504003 Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Check if the ABS indicator light lights up when turning Go to Step 2. Go to Step 3. the ignition switch ON. I718H1450122-04 Does the ABS indicator light up? (The ABS indicator light lights up)
  • Page 505 ABS: 4E-18 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 (Page 9D-6)”. 2) Remove the fuse box (1) by removing the mounting bolt. I718H1450034-01 3) Open the fuse box and inspect the ignition fuse (2).
  • Page 506 4E-19 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 coupler. Refer to “ABS or ground wire) Control Unit Coupler Disconnect and Connect (Page 4E- 69)”.
  • Page 507 ABS: 4E-20 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 508 4E-21 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 coupler. Refer to “ABS or ground wire) Control Unit Coupler Disconnect and Connect (Page 4E- 69)”...
  • Page 509 ABS: 4E-22 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 (Page 9D-6)”.

  • Page 510: Dtc (Diagnostic Trouble Code) Output

    4E-23 ABS: DTC (Diagnostic Trouble Code) Output 4) Switch the special tool to ON. B817H24504004 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 511 ABS: 4E-24 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 512 4E-25 ABS: Use of SDS NOTE • Don’t disconnect couplers from ABS HU, the battery cable from the battery, ABS HU ground wire harness from the engine or main fuse before confirming the malfunction code (self-diagnostic trouble code) stored in memory. Such disconnection will erase the memorized information in ABS HU memory.

  • Page 513: Dtc (Diagnostic Trouble Code) Deleting

    ABS: 4E-26 DTC (Diagnostic Trouble Code) Deleting 3) While the DTCs are being output, set the special tool B817H24504005 to OFF. Use of Mode Select Switch CAUTION 1) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in The DTC deletion mode starts 12.5 seconds Section 9D (Page 9D-6)”.
  • Page 514 4E-27 ABS: 5) After deleting the DTCs, repeat the code output 4) Click the ABS button (1). procedure and make sure that no DTCs remain (the ABS indicator light no longer flashes). NOTE If any DTCs remain, perform the appropriate procedures, then delete the codes.
  • Page 515 ABS: 4E-28 6) Check the DTC. 9) Check that both “Current DTC” (4) and “Past DTC” (5) are deleted (NIL). NOTE The previous malfunction history code (Past DTC) still remains stored in the ABS HU. Therefore, erase the history code memorized in the ABS HU using SDS tool.

  • Page 516: Sds Check

    4E-29 ABS: SDS Check B817H24504006 Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealer. Save the data in the computer or by printing and filing the hard copies. The saved or filed data are useful for troubleshooting as they can be compared periodically with changes over time or failure conditions of the motorcycle.

  • Page 517: Active Control Inspection

    ABS: 4E-30 Active Control Inspection 4) Click “Active control” (2). B817H24504007 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Click “ABS”...
  • Page 518 4E-31 ABS: 6) Click “Next” according to the screen indication. Return Next Cancel Help Return Next Cancel Help I718H1450060-02 NOTE Skip this screen as this vehicle is not equipped with parking brake. Return Next Cancel Help I718H1450121-01...
  • Page 519 ABS: 4E-32 NOTE • If the front wheel is selected, place the motorcycle on the center stand and lift the front wheel off the ground using a jack. • Two operators are needed in this work; One should apply a rotational force to the front wheel. Return Next Cancel...

  • Page 520: Dtc Table

    4E-33 ABS: Return Finish Cancel Help I718H1450062-01 NOTE • Inspect the rear brake in the same manner of front brake. • If the ABS does not function, the cause may lie in the ABS control unit/HU. • In checking the rear brake at the time of pressure reduction drive (4/7), “brake lever” appears on the screen.
  • Page 521 ABS: 4E-34 Indicator Malfunction cause Reference status Refer to “DTC “43” (C1643): Wheel 43 (C1643) Wheel speed sensor circuit short (F) * Speed Sensor Circuit Short (F) (Page 4E-52)”. Refer to “DTC “44” (C1644): Wheel 44 (C1644) Wheel speed sensor signal malfunction (R) * Speed Sensor Signal Malfunction (R) (Page 4E-54)”.

  • Page 522: Dtc "13" (C1613): Wheel Speed Sensor Rotor Malfunction

    4E-35 ABS: DTC “13” (C1613): Wheel Speed Sensor Rotor Malfunction (F) B817H24504009 Possible Cause • Front wheel speed sensor rotor distortion • Faulty front wheel speed sensor or wiring discontinuity, etc. Troubleshooting Step Action 1) Inspect the clearance between the front wheel speed Go to Step 2.
  • Page 523 Replace the ABS Adjust or replace the control unit/HU. front tire and wheel. Tire type and size GSF650A/UA: BRIDGESTONE BT011F G 120/ 70ZR17M/C (58W) GSF650SA/ASU: BRIDGESTONE BT011F M 120/ 70ZR17M/C (58W) Cold inflation tire pressure (Solo riding) 250 kPa (2.50 kgf/cm...

  • Page 524: Dtc "14" (C1614): Wheel Speed Sensor Rotor Malfunction

    4E-37 ABS: DTC “14” (C1614): Wheel Speed Sensor Rotor Malfunction (R) B817H24504010 Possible Cause • Rear wheel speed sensor rotor distortion • Faulty rear wheel speed sensor or wiring discontinuity, etc. Troubleshooting Step Action 1) Inspect the clearance between the rear wheel speed Go to Step 2.
  • Page 525 ABS: 4E-38 Step Action 1) Check that the rear wheel speed sensor is mounted Go to Step 4. Tighten the mounting securely. bolts or replace the bracket if necessary. I717H2450017-01 Is the sensor mounted securely? 1) Inspect the rear tire and wheel. Replace the ABS Adjust or replace the control unit/HU.

  • Page 526: Dtc "22" (C1622): Abs Actuator Circuit Malfunction

    4E-39 ABS: DTC “22” (C1622): ABS Actuator Circuit Malfunction (F) B817H24504011 Possible Cause • Wire harness discontinuity • Front wheel locking, etc. Troubleshooting Step Action 1) Raise the front wheel off the ground and support the Inspect the front brake Go to step 2.

  • Page 527: Dtc "23" (C1623): Abs Actuator Circuit Malfunction

    ABS: 4E-40 Step Action 1) Check that the front wheel speed sensor is mounted Replace the ABS Tighten the mounting securely. control unit/HU. bolts or replace the bracket if necessary. I717H2450015-01 Is the sensor mounted securely? DTC “23” (C1623): ABS Actuator Circuit Malfunction (R) B817H24504012 Possible Cause •...
  • Page 528 4E-41 ABS: Step Action 1) Inspect the clearance between the rear wheel speed Go to Step 3. Adjust the clearance. sensor and sensor rotor using the thickness gauge. Special tool (A): 09900–20803 (Thickness gauge) (B): 09900–20806 (Thickness gauge) Wheel speed sensor – sensor rotor clearance 0.3 –...

  • Page 529: Dtc "25" (C1625): Wheel Speed Sensor Related Malfunction

    1) Check that the specified tires are installed. Go to Step 2. Use the specified tires. Tire type and size Front: BRIDGESTONE BT011F G 120/70 ZR17M/C (58W) (GSF650A/UA) Front: BRIDGESTONE BT011F M 120/70 ZR17M/C (58W) (GSF650SA/ASU) Rear: BRIDGESTONE BT020R G 160/60ZR17M/C (69W)
  • Page 530 4E-43 ABS: Step Action 1) Inspect both wheel speed sensor rotors for damage and Go to Step 4. Clean or replace the check that no foreign objects are caught in the rotor rotor. openings. I718H1450064-01 Are the rotors OK? 1) Inspect the clearances of the front and rear wheel speed Replace the ABS Adjust the clearance.

  • Page 531: Dtc "35" (C1635): Abs Motor Malfunction

    ABS: 4E-44 DTC “35” (C1635): ABS Motor Malfunction B817H24504014 Possible Cause • Faulty HU motor • Faulty wiring, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Inspect if the pump motor makes turning noise by setting •...
  • Page 532 4E-45 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty motor 2) Remove the left frame cover. Refer to “Exterior Parts power supply or ground Removal and Installation (GSF650/S/A/SAK7) in Section wire) 9D (Page 9D-6)”.

  • Page 533: Dtc "41" (C1641): Wheel Speed Sensor Signal Malfunction

    ABS: 4E-46 DTC “41” (C1641): Wheel Speed Sensor Signal Malfunction (F) B817H24504015 Possible Cause • Poor contact in the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Troubleshooting Step Action 1) Inspect the clearance between the front wheel speed Go to Step 2.

  • Page 534: Dtc "42" (C1642): Wheel Speed Sensor Circuit Open

    4E-47 ABS: Step Action 1) Check that the front wheel speed sensor is mounted Go to DTC “42” Tighten the mounting securely. (C1642). (Refer to “DTC bolts or replace the “42” (C1642): Wheel bracket if necessary. Speed Sensor Circuit Open (F) (Page 4E- 47)”.) I717H2450015-01 Is the sensor mounted securely?
  • Page 535 1) Turn the ignition switch OFF. Go to Step 3. Go to Step 2. 2) Remove the right frame head cover. (GSF650A/UA) Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. 3) Remove the left frame cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”.
  • Page 536 4E-49 ABS: Step Action 1) Disconnect the front wheel speed sensor coupler. Inspect the wire Faulty front wheel harness. (Faulty B/R speed sensor 2) Measure the resistance between “A” (B) and ground at wire) the front wheel speed sensor coupler. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication...
  • Page 537 ABS: 4E-50 Step Action 1) Measure the resistance between “B” (W) and ground at Inspect the wire Faulty front wheel the front wheel speed sensor coupler. harness. (Faulty W/R speed sensor wire) Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Resistance (Ω) Normal value (“B”...
  • Page 538 4E-51 ABS: Step Action 1) Check for continuity between “3” (W/R) on the ABS Go to Step 7. Inspect the wire control unit coupler and “D” (W/R) on the front wheel harness. (Faulty W/R speed sensor coupler. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 539: Dtc "43" (C1643): Wheel Speed Sensor Circuit Short

    ABS: 4E-52 DTC “43” (C1643): Wheel Speed Sensor Circuit Short (F) B817H24504017 Possible Cause • Poor contact in the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action...
  • Page 540 4E-53 ABS: Step Action 1) Check for continuity between “2” (B/Y) and “3” (W/R) at • Inspect the wire Go to Step 3. the coupler. harness. (Faulty sensor wire) Special tool • Faulty front wheel (A): 09900–25008 (Multi-circuit tester set) speed sensor Tester knob indication Continuity (...

  • Page 541: Dtc "44" (C1644): Wheel Speed Sensor Signal Malfunction

    ABS: 4E-54 DTC “44” (C1644): Wheel Speed Sensor Signal Malfunction (R) B817H24504018 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Troubleshooting Step Action 1) Inspect the clearance between the rear wheel speed Go to Step 2.
  • Page 542 4E-55 ABS: Step Action 1) Check that the rear wheel speed sensor is mounted Go to DTC “45” Tighten the mounting securely. (C1645). (Refer to “DTC bolts or replace the “45” (C1645): Wheel bracket if necessary. Speed Sensor Circuit Open (R) (Page 4E- 56)”.) I717H2450017-01 Is the sensor mounted securely?

  • Page 543: Dtc "45" (C1645): Wheel Speed Sensor Circuit Open

    ABS: 4E-56 DTC “45” (C1645): Wheel Speed Sensor Circuit Open (R) B817H24504019 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action...
  • Page 544 4E-57 ABS: Step Action 1) Disconnect the rear wheel speed sensor coupler. Inspect the wire Replace the rear wheel harness. (Faulty B/Y speed sensor. 2) Measure the resistance between “A” (B) and ground at wire) the rear wheel speed sensor coupler. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication...
  • Page 545 ABS: 4E-58 Step Action 1) Measure the resistance between “B” (W) and ground at Inspect the wire Replace the rear wheel the rear wheel speed sensor coupler. harness. (Faulty W/Y speed sensor. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Resistance (Ω) Normal value (“B”...
  • Page 546 4E-59 ABS: Step Action 1) Check the continuity between “18” (W/Y) on the ABS Go to Step 7. Inspect the wire control unit coupler and “D” (W/Y) on the rear wheel harness. (Faulty W/Y speed sensor coupler. wire) Special tool (A): 09900–25008 (Multi-circuit tester set) (B): 09900–25009 (Needle pointed probe set) Tester knob indication...

  • Page 547: Dtc "46" (C1646): Wheel Speed Sensor Circuit Short

    ABS: 4E-60 DTC “46” (C1646): Wheel Speed Sensor Circuit Short (R) B817H24504020 Possible Cause • Poor contact in the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action...
  • Page 548 4E-61 ABS: Step Action 1) Check for continuity between “12” (B/R) and “18” (W/Y) • Inspect the wire Go to Step 3. at the coupler. harness. (Faulty sensor wire) Special tool • Faulty wheel speed (A): 09900–25008 (Multi-circuit tester set) sensor Tester knob indication Continuity (...

  • Page 549: Dtc "47" (C1647): Supply Voltage (Increased)

    ABS: 4E-62 DTC “47” (C1647): Supply Voltage (Increased) B817H24504021 Possible Cause • Faulty regulator/rectifier • Faulty ABS control unit • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Remove the seat. Refer to “Exterior Parts Removal and Go to Step 2.
  • Page 550 4E-63 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ignition 2) Remove the left frame cover. Refer to “Exterior Parts or ground wire) Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”.

  • Page 551: Dtc "48" (C1648): Supply Voltage (Decreased)

    ABS: 4E-64 DTC “48” (C1648): Supply Voltage (Decreased) B817H24504022 Possible Cause • Faulty generator or regulator/rectifier • Faulty ABS control unit • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (Page 4E-8)”. Troubleshooting Step Action 1) Remove the seat. Refer to “Exterior Parts Removal and Go to Step 2.
  • Page 552 4E-65 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. harness. (Faulty ignition 2) Remove the left frame cover. Refer to “Exterior Parts or ground wire) Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”.

  • Page 553: Dtc "55" (C1655): Abs Control Unit Malfunction

    ABS: 4E-66 DTC “55” (C1655): ABS Control Unit Malfunction B817H24504023 Possible Cause Faulty ABS control unit Troubleshooting Step Action 1) Inspect the clearances of the front and rear wheel speed Go to Step 2. Adjust the clearance. sensor – sensor rotor using the thickness gauge. Special tool (A): 09900–20803 (Thickness gauge) (B): 09900–20806 (Thickness gauge)
  • Page 554 4E-67 ABS: Step Action 1) Check that the front and rear wheel speed sensors are Go to Step 4. Tighten the mounting mounted securely. bolts or replace the bracket if necessary. I717H2450022-01 Are the sensors mounted securely? 1) Delete DTCs and repeat the code output procedure. Replace the ABS Intermittent trouble.

  • Page 555: Dtc "61" (C1661): Abs Solenoid Malfunction

    ABS: 4E-68 DTC “61” (C1661): ABS Solenoid Malfunction B817H24504024 Possible Cause Faulty solenoid valve or relay Troubleshooting Step Action 1) Turn the ignition switch OFF. Go to Step 2. Replace the ABS solenoid valve fuse. 2) Remove the seat. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”.

  • Page 556: Repair Instructions

    4E-69 ABS: Step Action 1) Check the ABS control unit coupler for loose or poor Replace the ABS Inspect the wire contacts. control unit/HU. harness. (Faulty If OK, then disconnect the ABS control unit coupler. solenoid or ground wire) 2) Measure the voltage between “8” (R/Bl) and “24” (B/W) at the coupler.

  • Page 557: Front Wheel Speed Sensor Removal And Installation

    Removal Special tool 1) Turn the ignition switch OFF. (A): 09900–20803 (Thickness gauge) 2) Remove the right frame head cover. (GSF650A/UA) (B): 09900–20806 (Thickness gauge) Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. Wheel speed sensor – sensor rotor clearance 0.3 –...

  • Page 558: Front Wheel Speed Sensor Rotor Removal And Installation

    4E-71 ABS: Removal • Check the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge. 1) Turn the ignition switch OFF. 2) Remove the right frame cover. Refer to “Exterior Special tool Parts Removal and Installation (GSF650/S/A/SAK7) (A): 09900–20803 (Thickness gauge) in Section 9D (Page 9D-6)”.

  • Page 559: Rear Wheel Speed Sensor Rotor Removal And Installation

    ABS: 4E-72 Installation Removal Refer to “Wheel Speed Sensor and Sensor Rotor 1) Remove the rear wheel assembly. Refer to “Rear Inspection (Page 4E-73)”. Wheel Assembly Removal and Installation (GSF650/ Install the front wheel speed sensor rotor in the reverse S/U/SUK7) in Section 2D (Page 2D-11)”.

  • Page 560: Wheel Speed Sensor And Sensor Rotor Inspection

    4E-73 ABS: • Check the clearance between the rear wheel speed Wheel Speed Sensor Rotor sensor and sensor rotor using the thickness gauge. 1) Raise the wheel off the ground and support the motorcycle with a jack or wooden block. Special tool (A): 09900–20803 (Thickness gauge) CAUTION...
  • Page 561 ABS: 4E-74 1) Remove the seat and frame covers. Refer to “Exterior Parts Removal and Installation (GSF650/S/ A/SAK7) in Section 9D (Page 9D-6)”. 2) Remove the battery (1). Refer to “Battery Removal and Installation in Section 1J (Page 1J-12)”. 3) Remove the starter relay (2) from the battery case. 4) Remove the cooling fan relay (3) and fuel pump relay (4) from the battery case.

  • Page 562: Specifications

    4E-75 ABS: Specifications Tightening Torque Specifications B817H24507001 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Brake pipe flare nut 11.5 (Page 4E-74) Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”.
  • Page 563 ABS: 4E-76 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 4E-15) / (Page 4E-48) / (Page 4E-16) / (Page 4E-49) / (Page 4E-19) / (Page 4E-50) / (Page 4E-19) / (Page 4E-51) / (Page 4E-20) / (Page 4E-51) / (Page 4E-21) / (Page 4E-56) / (Page 4E-21) /...
  • Page 564 4E-77 ABS:...
  • Page 565 Table of Contents 5- i Section 5 Transmission / Transaxle CONTENTS Precautions ..........5-1 Clutch ............5C-1 Precautions............. 5-1 Precautions............5C-1 Precautions for Transmission / Transaxle..... 5-1 Precautions for Clutch System......5C-1 Clutch Fluid (Brake Fluid) Information....5C-1 Manual Transmission......5B-1 Schematic and Routing Diagram ......5C-2 Diagnostic Information and Procedures....5B-1 Clutch Hose Routing Diagram......5C-2 Manual Transmission Symptom Diagnosis ..

  • Page 566: Precautions

    5-1 Precautions: Precautions Transmission / Transaxle Precautions Precautions for Transmission / Transaxle B817H25000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 567: Manual Transmission

    Manual Transmission: 5B-1 Manual Transmission Transmission / Transaxle Diagnostic Information and Procedures Manual Transmission Symptom Diagnosis B817H25204001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn or rubbing gear. Replace. seems to come from the Worn countershaft spline. Replace countershaft.

  • Page 568: Repair Instructions

    5B-2 Manual Transmission: Repair Instructions Transmission Components B817H25206001 I717H1520024-03 1. 1st driven gear 9. 5th drive gear 17. Gearshift cam plate 2. 5th driven gear 10. 3rd/4th drive gear 18. Gear position switch 3. 4th driven gear 11. 6th drive gear 19.
  • Page 569 Manual Transmission: 5B-3 3) Separate the upper and lower crankcases. Refer to Gearshift Cam / Gearshift Fork “Engine Bottom Side Disassembly in Section 1D 1) Remove the retainer screws (1). (Page 1D-51)”. I718H1520007-01 I717H1520001-01 2) Remove the gearshift fork shafts (2) and No.1 gearshift forks (3).
  • Page 570 5B-4 Manual Transmission: Countershaft Assembly 2) Remove the countershaft bearing (3) with the special tool. 1) Remove the bearing retainer (1). Special tool (A): 09913–70210 (Bearing installer set) I718H1520010-01 2) By using suitable size bolts (2), pull out the countershaft assembly (3). I718H1520013-01 3) Remove the snap ring (4).

  • Page 571: Transmission Installation

    (A): 09913–70210 (Bearing installer set) Pay attention to the following points: • Apply grease to the oil seal lip. Bearing / Oil Seal : Grease 99000–25010 (SUZUKI SUPER CAUTION GREASE A or equivalent) Replace the removed oil seal, bearings and snap ring with new ones.
  • Page 572 • Apply grease to the O-ring. • Install the No.3 gearshift fork (1) as shown. CAUTION Replace the O-ring (1) with new one. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1520022-03 • Install the gearshift cam (2) with the bearing (3) fitted.
  • Page 573 Manual Transmission: 5B-7 • With engaging each forks (5) end to the cam groove, • Install the driveshaft assembly on the upper insert the fork shaft (6). crankcase. NOTE • Align the gearshift forks (2) with their grooves (3). • Align the C-ring with the groove of bearing and the bearing pin with the indent on the bearing.

  • Page 574: Transmission Construction

    5B-8 Manual Transmission: Transmission Construction B817H25206004 0.2 mm I717H1520011-03 1. Counter shaft 2. Drive shaft 3. Snap ring :Assemble snap ring with sharp edge side out.

  • Page 575: Countershaft Gear / Driveshaft Gear Disassembly And Assembly

    Manual Transmission: 5B-9 Countershaft Gear / Driveshaft Gear • Remove the countershaft bearing (8) from the housing (9), using the special tool. Disassembly and Assembly B817H25206005 Special tool Refer to “Transmission Removal (Page 5B-2)” and (A): 09913–70210 (Bearing installer set) “Transmission Installation (Page 5B-5)”.
  • Page 576 • Before installing the oil seal, apply grease to the oil seal lip. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) • When installing a new snap ring (1), pay attention to I717H1520016-01 its direction.

  • Page 577: Transmission Related Parts Inspection

    Manual Transmission: 5B-11 • When installing the gear bushing onto the countershaft (3), align the shaft oil hole “A” with the bushing oil hole “B”. “A” “B” “A” “B” I718H1520037-01 Countershaft • Install the countershaft bearing (1) into the housing I718H1520040-01 (2), using the special tool.

  • Page 578: Gear Position Switch Inspection

    5B-12 Manual Transmission: Gearshift Fork Groove Width Gearshift Cam Bearing Measure the gearshift fork groove width using the Inspect the gearshift cam bearings, left and right for vernier calipers. abnormal noise and smooth rotation. Replace the bearing if there is anything unusual. Refer Special tool to “Transmission Removal (Page 5B-2)”...

  • Page 579: Gearshift Lever Construction

    • Apply grease to the O-ring. B817H25206009 CAUTION Replace the O-ring with a new one. NOTE Align the gear position switch pin “A” with the gearshift cam hole “B”. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) “A” “a ” “B” “A” I718H1520044-01 •...

  • Page 580: Gearshift Lever Removal And Installation

    5B-14 Manual Transmission: Gearshift lever Removal and Installation Gearshift Shaft / Gearshift Cam Plate B817H25206010 Components Removal B817H25206012 1) Place the motorcycle on the center stand. 2) Remove the gearshift lever as shown in the gearshift lever construction. Refer to “Gearshift lever Construction (Page 5B-13)”.

  • Page 581: Gearshift Shaft / Gearshift Cam Plate Removal And Installation

    Manual Transmission: 5B-15 Gearshift Shaft / Gearshift Cam Plate Removal 5) Remove the gearshift shaft assembly (2) and washers (3). and Installation B817H25206014 Removal 1) Remove the engine sprocket outer cover. Refer to “Engine Sprocket Removal and Installation in Section 3A (Page 3A-2)”. 2) Disengage the gearshift lever link by removing the bolt.
  • Page 582 5B-16 Manual Transmission: 9) Remove the gearshift arm stopper (14). I718H1520003-03 I718H1520051-01 Installation Install the gearshift shaft and gearshift cam plate in the reverse order of removal. Pay attention to the following “A” points: CAUTION The removed snap rings must be replaced with new ones.
  • Page 583 Manual Transmission: 5B-17 • Apply a small quantity of thread lock to the gearshift • Install the gearshift shaft assembly (6) and washers cam stopper plate bolt and tighten it to the specified (7) as shown. torque. NOTE : Thread lock cement 99000–32110 Pinch the gearshift arm stopper (8) with (THREAD LOCK CEMENT SUPER 1322 or return spring ends “F”.

  • Page 584: Gearshift Linkage Inspection

    5B-18 Manual Transmission: Gearshift Linkage Inspection Gearshift Shaft Oil Seal / Bearing Removal and B817H25206015 Installation Refer to “Gearshift Shaft / Gearshift Cam Plate Removal B817H25206016 and Installation (Page 5B-15)”. Removal 1) Remove the gearshift shaft. Refer to “Gearshift Shaft Gearshift Shaft / Gearshift Cam Plate Removal and Installation Check the gearshift shaft for bend or wear.

  • Page 585: Specifications

    (A): 09913–70210 (Bearing installer set) The stamped mark side of gearshift shaft • Apply grease to the oil seal lip. bearing faces outside. : Grease 99000–25010 (SUZUKI SUPER Special tool GREASE A or equivalent) (A): 09913–70210 (Bearing installer set) I718H1520067-01...

  • Page 586: Tightening Torque Specifications

    For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”. Special Tools and Equipment Recommended Service Material B817H25208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5B-5) /...

  • Page 587: Special Tool

    Manual Transmission: 5B-21 Special Tool B817H25208002 09900–06107 09900–06108 Snap ring pliers Snap ring pliers (Page 5B-15) / (Page 5B-4) (Page 5B-15) / (Page 5B-17) 09900–20102 09900–20803 Vernier calipers (1/20 mm, Thickness gauge 200 mm) (Page 5B-12) / (Page 5B-11) (Page 5B-12) 09913–70210 09921–20210 Bearing installer set...

  • Page 588: Clutch

    5C-1 Clutch: Clutch Transmission / Transaxle Precautions Precautions for Clutch System B817H25300001 Refer to “General Precautions in Section 00 (Page 00-1)”. Clutch Fluid (Brake Fluid) Information B817H25300002 WARNING • This clutch system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based.

  • Page 589: Schematic And Routing Diagram

    Clutch: 5C-2 Schematic and Routing Diagram Clutch Hose Routing Diagram B817H25302001 “A” “B” “C” “D” I718H1530005-05 1. Wiring harness 9. Clutch hose No.3 clamp : After positioning the clamp with stopper, tighten the bolt. 2. Clutch hose 10. Grommet : Install the grommet of the clutch hose to the clutch hose guide properly.

  • Page 590: Diagnostic Information And Procedures

    5C-3 Clutch: Diagnostic Information and Procedures Clutch System Symptom Diagnosis B817H25304001 Condition Possible cause Correction / Reference Item Engine is noisy (Noise Worn countershaft spline. Replace countershaft. seems to come from the Worn clutch hub spline. Replace clutch hub. clutch). Worn clutch plate teeth.

  • Page 591: Clutch Fluid Replacement

    Clutch: 5C-4 11) Reinstall the removed parts. 3) Remove the engine sprocket outer cover (1). Clutch Fluid Replacement B817H25306005 CAUTION Handle brake fluid with care: the fluid reacts chemically with paint, plastic, rubber materials, etc. 1) Place the motorcycle on a level surface and keep the handlebars straight.

  • Page 592: Clutch Hose Removal And Installation

    5C-5 Clutch: 7) Loosen the air bleeder valve and pump the clutch Clutch Hose Removal and Installation lever until old clutch fluid flows out of the bleeder B817H25306006 Removal system. 1) Drain clutch fluid. Refer to “Clutch Fluid Replacement (Page 5C-4)”. 2) Remove the fuel tank.

  • Page 593: Clutch Control System Components

    Clutch: 5C-6 Clutch Control System Components B817H25306007 I718H1530065-02 1. Push rod 7. Push rod : 6 N⋅m (0.6 kgf-m, 4.5 lb-ft) 2. Piston/Cup set 8. Clutch release cylinder set : Apply brake fluid. 3. Clutch hose 9. Air bleeder : Apply grease. 4.
  • Page 594 5C-7 Clutch: 3) Place a rag underneath the clutch hose union bolt (2) on the master cylinder to catch any spilt brake fluid. 4) Remove the clutch hose union bolt (2) and disconnect the clutch hose. “ c ” “B” “A”...

  • Page 595: Clutch Master Cylinder / Clutch Lever Disassembly And Assembly

    Clutch: 5C-8 Clutch Master Cylinder / Clutch Lever 5) Remove the following parts from the master cylinder. Disassembly and Assembly • Washer (9) B817H25306009 • Secondary cup (10) Refer to “Clutch Master Cylinder Assembly Removal and Installation (Page 5C-6)”. • Piston (11) •...

  • Page 596: Clutch Master Cylinder Parts Inspection

    Clutch Master Cylinder Parts Inspection • Apply SILICONE GREASE to the push rod end. B817H25306010 Refer to “Clutch Master Cylinder / Clutch Lever : Grease 99000–25100 (SUZUKI Silicone Disassembly and Assembly (Page 5C-8)”. Grease or equivalent) Master Cylinder Inspect the master cylinder bore for any scratches or other damage.

  • Page 597: Clutch Push Rod (Left) Inspection

    • Apply a small quantity of GREASE “A” to the push Do not use high pressure air to prevent rod. piston damage. : Grease 99000–25010 (SUZUKI SUPER GREASE A or equivalent) I718H1530026-01 I717H1530034-01 • Install the clutch hose as shown in the clutch hose routing diagram.

  • Page 598: Clutch Release Cylinder Inspection

    5C-11 Clutch: Clutch Release Cylinder Inspection Assembly Assemble the clutch cylinder in the reverse order of B817H25306014 Refer to “Clutch Release Cylinder Disassembly and disassembly. Pay attention to the following points: Assembly (Page 5C-10)”. • Wash the cylinder bore and piston with specified Inspect the clutch cylinder bore wall for nicks, scratches brake fluid.

  • Page 599: Clutch Components

    Clutch: 5C-12 Clutch Components B817H25306015 I717H1530001-01 1. Clutch pressure plate 6. No.1 driven plate (0 – 2 pcs) 11. Primary driven gear assembly : The No.1 and No.2 driven plates are 7 in total. 2. Clutch push piece 7. No.2 driven plate (5 – 7 pcs) : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft) : The No.1 and No.2 driven plates are 7 in total.
  • Page 600 5C-13 Clutch: 3) Remove the gasket (2) and dowel pins. 6) Remove the spring washer (6) and its seat (7). I717H1530003-01 I717H1530006-02 4) Remove the clutch spring set bolts, clutch springs 7) Remove the thrust washer (8), bearing (9) and clutch and pressure plate (3).

  • Page 601: Clutch Installation

    Clutch: 5C-14 10) Hold the clutch sleeve hub with the special tools. Clutch Installation B817H25306017 Special tool 1) Install the primary driven gear assembly (1). (A): 09920–53740 (Clutch sleeve hub holder) NOTE (B): 09920–31020 (Extension handle) • If it is difficult to install the primary driven 11) Remove the clutch sleeve hub nut.
  • Page 602 5C-15 Clutch: 4) Install the clutch sleeve hub (5), washer (6) and 7) Lock the clutch sleeve hub nut with a center punch. spring washer (7) NOTE The conical curve side of spring washer (7) faces outside. I717H1530017-01 8) Install the clutch push rod (8) into the countershaft. I717H1530015-01 I717H1530018-01 9) Install the clutch push piece (9), bearing (10) and...
  • Page 603 Clutch: 5C-16 10) Install the spring washer seat (12) and spring washer NOTE (13) onto the clutch sleeve hub correctly. For drive plate Three kinds of the drive plate (No.1, No.2 and No.3) are equipped in the clutch system, they can be distinguished by the inside diameter and paint “D”.

  • Page 604: Clutch Parts Inspection

    13) Apply a light coat of the BOND to the clutch cover gasket mating surface as shown. B817H25306018 Refer to “Clutch Removal (Page 5C-12)” and “Clutch : Sealant 99000–31140 (SUZUKI BOND Installation (Page 5C-14)”. No.1207B or equivalent) Clutch Drive and Driven Plate...
  • Page 605 Clutch: 5C-18 Measure each driven plate for distortion with a thickness Push Rod (Right) gauge and surface plate. Inspect the push rod for wear and damage. Replace driven plates which exceed the limit. If any defects are found, replace the push rod with a new one.

  • Page 606: Specifications

    5C-19 Clutch: Specifications Service Data B817H25307001 Clutch Unit: mm (in) Item Standard Limit Clutch drive plate thickness No.1, 2, 3 2.92 – 3.08 (0.115 – 0.121) 2.62 (0.103) Clutch drive plate claw width No.1, 2, 3 13.7 – 13.8 (0.539 – 0.543) 13.0 (0.51) Clutch driven plate distortion —...

  • Page 607: Special Tools And Equipment

    Clutch: 5C-20 Special Tools and Equipment Recommended Service Material B817H25308001 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 5C-4) / (Page 5C- 8) / (Page 5C-11) Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 5C-10)
  • Page 608 5C-21 Clutch:...
  • Page 609 Table of Contents 6- i Section 6 Steering CONTENTS Precautions ..........6-1 Handlebar Height Adjustment ......6B-4 Steering Components .........6B-5 Precautions............. 6-1 Steering Removal and Installation ......6B-6 Precautions for Steering ........6-1 Steering Related Parts Inspection.......6B-8 Steering General Diagnosis....6A-1 Steering System Inspection ........6B-9 Steering Stem Bearing Removal and Diagnostic Information and Procedures....6A-1 Installation ............6B-9...

  • Page 610: Precautions

    6-1 Precautions: Precautions Steering Precautions Precautions for Steering B817H26000001 Refer to “General Precautions in Section 00 (Page 00-1)”.

  • Page 611: Steering General Diagnosis

    Steering General Diagnosis: 6A-1 Steering General Diagnosis Steering Diagnostic Information and Procedures Steering Symptom Diagnosis B817H26104001 Condition Possible cause Correction / Reference Item Heavy Steering Over tightened steering stem nut. Adjust. Broken bearing in steering stem. Replace. Distorted steering stem. Replace.

  • Page 612: Steering / Handlebar

    6B-1 Steering / Handlebar: Steering / Handlebar Steering Repair Instructions Handlebars Components B817H26206001 “A” I717H1620034-01 1. Throttle grip 5. Handle expander “A”: Apply handle grip bond. 2. Handlebars 6. Handle balancer expander : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Handlebar holder (Upper) 7.

  • Page 613: Handlebar Construction (Gsf650/S/A/Sak7)

    Steering / Handlebar: 6B-2 Handlebar Construction (GSF650/S/A/SAK7) B817H26206002 “A” “A” “a” “B” “B” “A” “A” I718H1620040-01 1. Clutch master cylinder “A”: Punch mark : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft) 2. Front brake master cylinder “B”: UP mark : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3.

  • Page 614: Handlebars Removal And Installation

    6B-3 Steering / Handlebar: Handlebars Removal and Installation 3) Remove the caps and handlebar holder bolts. B817H26206003 Removal 1) Remove the following parts from the left handlebar. a) Rear view mirror (GSF650) b) Clutch master cylinder/clutch lever (1) CAUTION Do not turn the clutch master cylinder upside down.

  • Page 615: Handlebars Inspection

    Steering / Handlebar: 6B-4 Handlebars Inspection • Apply SUZUKI SUPER GREASE to the end of the throttle cables and cable pulley. B817H26206004 Refer to “Handlebars Removal and Installation : Grease 99000–25010 (SUZUKI SUPER (Page 6B-3)”. GREASE A or equivalent) Inspect the handlebars for distortion and damage.

  • Page 616: Steering Components

    6B-5 Steering / Handlebar: 3) Insert the spacers (2) between the steering upper 5) Tighten the handlebar holder set nuts to the bracket and handlebar holders. specified torque. Tightening torque Handlebar holder set nut (a): 45 N·m (4.5 kgf-m, 32.5 lbf-ft) I717H1620009-02 4) Set the handlebars.

  • Page 617: Steering Removal And Installation

    Steering / Handlebar: 6B-6 Steering Removal and Installation 10) Remove the steering stem nut using the special tool. B817H26206007 NOTE Removal (GSF650) When loosening the stem nuts, hold the 1) Remove the front wheel assembly. Refer to “Front steering stem lower bracket to prevent it from Wheel Assembly Removal and Installation (GSF650/ falling.
  • Page 618 Pay attention to the following points: If necessary, remove the ignition switch from Bearing the upper bracket. Refer to “Ignition Switch • Apply SUZUKI SUPER GREASE to the bearings, Removal and Installation in Section 1H races and dust seals before remounting the steering (Page 1H-7)”.

  • Page 619: Steering Related Parts Inspection

    Steering / Handlebar: 6B-8 Steering stem nut 4) Tighten the steering stem head nut (1). • Tighten the steering stem nut to the specified torque Tightening torque using the special tool. Steering stem head nut (a): 65 N·m (6.5 kgf-m, 47.0 lbf-ft) Special tool (A): 09940–14911 (Steering stem nut wrench)

  • Page 620: Steering System Inspection

    6B-9 Steering / Handlebar: If any abnormal points are found, replace defective parts 3) Remove the steering stem upper and lower bearing with new ones. Refer to “Ignition Switch Removal and races using the special tools. Installation in Section 1H (Page 1H-7)”. Special tool (A): 09941–54911 (Bearing outer race remover)

  • Page 621: Steering Tension Adjustment

    Steering / Handlebar: 6B-10 Inner race 4) Do the same on the other grip end. • Press in the lower inner race and bearing using the 5) If the initial force read on the scale when the special tool. handlebar starts turning is either to heavy or too light, adjust it till it satisfies the specification.

  • Page 622: Handlebar Construction (Gsx650Fk8)

    6B-11 Steering / Handlebar: Handlebar Construction (GSX650FK8) B817H26206012 “A” I817H2620001-01 1. Handlebar switch (LH) : Apply bond. “A”: Apply a small amount of the bond 1207B to inside of the handlebar switchbox. Specifications Tightening Torque Specifications B817H26207001 Tightening torque Fastening part Note N⋅m kgf-m...

  • Page 623: Special Tools And Equipment

    Steering / Handlebar: 6B-12 Special Tools and Equipment Recommended Service Material B817H26208001 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or P/No.: 99000–25010 (Page 6B-4) / (Page 6B- equivalent Handle grip bond Handle Grip Bond (commercially —...
  • Page 624 6B-13 Steering / Handlebar:...
  • Page 625 Passing Light Switch Inspection......9B-11 Wiring Diagram (GSF650K7) ......9A-1 Dimmer Switch Inspection.........9B-11 Wiring Diagram (GSF650SK7)......9A-3 Headlight Components (GSX650FK8) ....9B-12 Wiring Diagram (GSF650A/UAK7)...... 9A-5 Headlight Removal and Installation Wiring Diagram (GSF650SA/ASUK7) ....9A-6 (GSX650FK8)..........9B-13 Wiring Harness Routing Diagram (GSF650/S/ Headlight Bulb Replacement (GSX650FK8) ..9B-13 A/SAK7) ............
  • Page 626 9-ii Table of Contents Fuel Level Gauge Inspection ......9C-9 Front Fender Construction ........9D-4 Speedometer Inspection ........9C-9 Frame Cover Cushion Construction ....9D-4 Speed Sensor Removal and Installation .....9C-9 Engine Sprocket Outer Cover Cushion ....9D-5 Speed Sensor Inspection ........9C-10 Fastener Removal and Installation......9D-5 Oil Pressure Indicator Inspection (GSF650/S/ Exterior Parts Removal and Installation A/SAK7) ............9C-10...

  • Page 627: Precautions

    Precautions: Precautions Body and Accessories Precautions Precautions for Electrical System B817H29000001 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. Component Location Electrical Components Location B817H29003001 Refer to “Electrical Components Location in Section 0A (Page 0A-10)”.

  • Page 628: Wiring Systems

    9A-1 Wiring Systems: Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (GSF650K7) B817H29102001 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”.
  • Page 629 Wiring Systems: 9A-2 For E-02, 19 I717H1910905-01...

  • Page 630: Wiring Diagram (Gsf650Sk7)

    9A-3 Wiring Systems: Wiring Diagram (GSF650SK7) B817H29102002 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02, 19 I717H1910903-02...
  • Page 631 Wiring Systems: 9A-4 For E-28 I717H1910904-01...

  • Page 632: Wiring Diagram (Gsf650A/Uak7)

    9A-5 Wiring Systems: Wiring Diagram (GSF650A/UAK7) B817H29102004 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02, 19 I717H2910901-01...

  • Page 633: Wiring Diagram (Gsf650Sa/Asuk7)

    Wiring Systems: 9A-6 Wiring Diagram (GSF650SA/ASUK7) B817H29102005 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02,19 I717H2910902-01...
  • Page 634 9A-7 Wiring Systems: For E-28 I717H2910903-01...

  • Page 635: Wiring Harness Routing Diagram (Gsf650/S/A/Sak7)

    “E” I717H1910907-03 1. Battery 10. Clamp : Clamp the lead wire and brake hose (ABS) (GSF650A/SA). 2. Clamp (Except GSF650S/SA only) 11. Clamp : Pass through the speed meter lead right side of ignition switch. : Clamp the handle bar lead wires, ignition switch lead wire and front wheel speed sensor lead wire (ABS) (GSF650A/SA).
  • Page 636 3. HO2 sensor coupler 14. Clamp : Clamp the regulator/rectifier lead wire and generator lead wire. 4. ABS control unit/HU bracket (GSF650A/SA only) 15. Clamp : Do not contact the ABS unit wiring harness with the bracket. : Clamp the speed sensor lead wire, HO2 sensor lead wire and side- stand switch lead wire.
  • Page 637 Wiring Systems: 9A-10 “ a ” “ b ” “A” I717H1910902-05 1. Oil pressure lead wire : 6.5 N⋅m (0.65 kgf-m, 4.7 lb-ft) : Be careful not to slacken the oil pressure lead wire. 2. Generator cover : 1.5 N⋅m (0.15 kgf-m, 1.0 lb-ft) 3.

  • Page 638: Wiring Diagram (Gsx650Fk8)

    9A-11 Wiring Systems: Wiring Diagram (GSX650FK8) B817H29102007 Refer to “Wire Color Symbols in Section 0A (Page 0A-5)”. For E-02, 19 I817H2910901-02...
  • Page 639 Wiring Systems: 9A-12 For E-03, 24, 28 I817H2910902-02...

  • Page 640: Wiring Harness Routing Diagram (Gsx650Fk8)

    9A-13 Wiring Systems: Wiring Harness Routing Diagram (GSX650FK8) B817H29102008 “A” “B” “C” I817H2910903-02 1. EVAP purge control valve (E-33 only) “A”: Pass the EVAP purge control valve lead wire lower the clutch hose (E-33 only). 2. Wiring harness No. 1 “B”: Do not make slacked lead wire.

  • Page 641: Specifications

    10 A Headlight 10 A Fuel 10 A Fuse size Ignition 15 A Signal 15 A Main 30 A Service Data (GSF650A/UA/SA/ASUK7) B817H2910S002 Electrical Item Specification Note ABS motor 20 A Fuse size ABS valve 15 A Tightening Torque Specifications...

  • Page 642: Lighting Systems

    9B-1 Lighting Systems: Lighting Systems Body and Accessories Repair Instructions Headlight Components (GSF650/AK7) B817H29206001 I718H1920047-02 1. Headlight rim 3. Headlight bulb (12 V 60/55 W, H4) 5. Position light bulb (12 V 5 W) 2. Headlight unit 4. Headlight housing Headlight Components (GSF650S/SAK7) B817H29206002 I718H1920048-02...

  • Page 643: Headlight Removal And Installation (Gsf650/ S/A/Sak7)

    Lighting Systems: 9B-2 Headlight Removal and Installation (GSF650/S/ Installation Installation is in the reverse order of removal. Pay A/SAK7) attention to the following point: B817H29206003 GSF650/AK7 • After installing, be sure to inspect the headlight beam. Removal Refer to “Headlight Beam Adjustment (GSF650/S/A/ 1) Removal the headlight mounting screws.
  • Page 644 9B-3 Lighting Systems: 2) Disconnect the headlight coupler (1) and position 6) Reassemble the headlight. light coupler (2). 7) Install the headlight assembly so that the hook “A” on the headlight bezel engages with “B” of the housing. “B” “A” I718H1920014-01 3) Remove the position light socket (3) and replace the I718H1920017-03...

  • Page 645: Headlight Beam Adjustment (Gsf650/S/A/ Sak7)

    Lighting Systems: 9B-4 4) Replace the headlight bulb/socket (Low beam) (4) by unhooking the bulb holder spring (5). I717H1920005-01 1. Horizontal adjuster 2. Vertical adjuster I718H1920011-02 5) Disconnect the headlight bulb (7) from the socket GSF650S/SAK7 (6). 1) Insert 5 mm hexagon wrench as shown and adjust 6) Replace the headlight bulb (7) with a new one.

  • Page 646: Rear Combination Light Components

    9B-5 Lighting Systems: Rear Combination Light Components B817H29206006 I649G1920017-03 1. Brake light/Taillight bulb (12 V 21/5 W) 2. Lens Rear Combination Light Construction B817H29206007 I649G1920018-02 1. Seat tail cover 3. Rear combination light 2. Cushion : 2.0 N⋅m (0.2 kgf-m, 1.5 lb-ft)

  • Page 647: Rear Combination Light Removal And Installation

    Lighting Systems: 9B-6 Rear Combination Light Removal and 2) Remove the tool set (1). Installation B817H29206008 Removal 1) Remove the seat tail cover. Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) in Section 9D (Page 9D-6)”. 2) Remove the rear combination light (1) from the seat tail cover.

  • Page 648: License Plate Light Components

    9B-7 Lighting Systems: License Plate Light Components B817H29206010 I649G1920023-03 1. License plate light bulb (12 V 5 W) 2. Lens cover 3. Lens License Plate Light Removal and Installation License Plate Light Bulb Replacement B817H29206011 B817H29206012 Removal 1) Remove the license plate light. Refer to “License 1) Remove the seat.

  • Page 649: Turn Signal Light Components

    Lighting Systems: 9B-8 Turn Signal Light Components B817H29206013 I649G1920028-04 1. Turn signal light bulb (12 V 21 W x 4) 2. Lens Front Turn Signal Light Removal and 2) Disconnect the turn signal light coupler. Installation 3) Remove the front turn signal light (1) by removing B817H29206014 the nut and turn signal lead wire clamp.

  • Page 650: Turn Signal Light Bulb Replacement

    9B-9 Lighting Systems: Turn Signal Light Bulb Replacement 2) Remove the tool set (1) and disconnect the turn signal light coupler (RH: Black, LH: Gray) (2). B817H29206016 CAUTION 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.

  • Page 651: Turn Signal / Side-Stand Relay Inspection

    Lighting Systems: 9B-10 Turn Signal / Side-stand Relay Inspection 2) Disconnect the left handlebar switch coupler (1). B817H29206018 Refer to “Electrical Components Location in Section 0A (Page 0A-10)”. NOTE Make sure that the battery is fully charged. Before removing the turn signal/side-stand relay, check the operation of the turn signal light.

  • Page 652: Passing Light Switch Inspection

    9B-11 Lighting Systems: 3) Inspect the turn signal switch for continuity with a 4) After finishing the passing light switch inspection, tester. If any abnormality is found, replace the left reinstall the removed parts. handlebar switch assembly with a new one. Refer to “Handlebars Removal and Installation in Dimmer Switch Inspection Section 6B (Page 6B-3)”.

  • Page 653: Headlight Components (Gsx650Fk8)

    Lighting Systems: 9B-12 Headlight Components (GSX650FK8) B817H29206024 I817H2920001-01 1. Headlight low beam bulb (12 V 55 W, H7) 3. Position light bulb (12 V 5 W x 2) 2. Headlight high beam bulb (12 V 60 W, HB3) 4. Bulb cap...

  • Page 654: Headlight Removal And Installation (Gsx650Fk8)

    9B-13 Lighting Systems: Headlight Removal and Installation 3) Disconnect the low beam lead wire coupler (2). (GSX650FK8) 4) Replace the low beam bulb (3) by unhooking the B817H29206025 bulb holder spring (4). Removal 1) Remove the body cowling assembly. Refer to “Exterior Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-14)”.

  • Page 655: Headlight Beam Adjustment (Gsx650Fk8)

    Lighting Systems: 9B-14 Headlight Beam Adjustment (GSX650FK8) 3) Replace the high beam bulb (3). B817H29206027 1) Remove the combination meter assembly. Refer to “Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-13)”. 2) Insert 8 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally.

  • Page 656: Reflex Refractor Construction (Gsx650Fk8)

    9B-15 Lighting Systems: Reflex Refractor Construction (GSX650FK8) B817H29206028 I817H2920014-01 1. Front reflex refractor (For E-03, 24, 28, 33) 2. Front fork : 2 N⋅m (0.2 kgf-m, 1.5 lb-ft) Specifications Service Data (GSF650/S/A/SAK7) B817H29207001 Wattage Unit: W Specification Item GSF650/A GSF650S/SA Headlight Parking or position light 5 x 2...

  • Page 657: Tightening Torque Specifications

    Lighting Systems: 9B-16 Tightening Torque Specifications B817H29207004 Tightening torque Fastening part Note N⋅m kgf-m lbf-ft Rear combination light mounting bolt (Page 9B-6) NOTE The specified tightening torque is also described in the following. “Rear Combination Light Construction (Page 9B-5)” “Reflex Refractor Construction (GSF650/S/A/SAK7) (Page 9B-9)” “Reflex Refractor Construction (GSX650FK8) (Page 9B-15)”...

  • Page 658: Combination Meter / Fuel Meter / Horn

    9C-1 Combination Meter / Fuel Meter / Horn: Combination Meter / Fuel Meter / Horn Body and Accessories General Description Combination Meter System Description (GSF650/S/A/SAK7) B817H29301001 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).

  • Page 659: Combination Meter System Description (Gsx650Fk8)

    Combination Meter / Fuel Meter / Horn: 9C-2 Combination Meter System Description (GSX650FK8) B817H29301002 This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The rpm pointer is driven by the stepping motor. The LCDs indicate Speed, Odo / Trip 1 / Trip 2 / Fuel reserve’s trip / Clock / FI (DTC), Gear position, Engine revolution indicator and Fuel level indicator respectively.

  • Page 660: Repair Instructions

    9C-3 Combination Meter / Fuel Meter / Horn: Repair Instructions Combination Meter Components (GSF650/S/A/SAK7) B817H29306001 GSF650/AK7 I718H1930046-03 1. Upper case assembly 2. Combination meter 3. Lower case 4. Cover 5. Bracket...
  • Page 661 Combination Meter / Fuel Meter / Horn: 9C-4 GSF650S/SAK7 I718H1930047-02 1. Upper case assembly 2. Combination meter 3. Lower case...

  • Page 662: Combination Meter Removal And Installation (Gsf650/S/A/Sak7)

    9C-5 Combination Meter / Fuel Meter / Horn: Combination Meter Removal and Installation 2) Disconnect the combination meter coupler and remove the combination meter assembly. (GSF650/S/A/SAK7) B817H29306002 GSF650/AK7 Removal 1) Remove the combination meter mounting bolts from steering stem upper bracket. I717H1930009-01 3) Remove the combination meter (2).

  • Page 663: Combination Meter Inspection (Gsf650/S/A/ Sak7)

    Combination Meter / Fuel Meter / Horn: 9C-6 Combination Meter Inspection (GSF650/S/A/ 2) With the adjuster switch (1) pressed, turn the ignition switch on. SAK7) B817H29306004 3) Release the adjuster switch (1), 3 to 5 seconds after LED Inspection turning the ignition switch on. Check that the LEDs (FI indicator light, Oil pressure, 4) Press the adjuster switch (1) twice (within 1 second).

  • Page 664: Engine Coolant Temperature Indicator Light Inspection (Gsf650/S/A/Sak7)

    9C-7 Combination Meter / Fuel Meter / Horn: Engine Coolant Temperature Indicator Light Engine Coolant Temperature Removal and Inspection (GSF650/S/A/SAK7) Installation B817H29306005 B817H29306006 Inspect the engine coolant temperature indicator light in Refer to “ECT Sensor Removal and Installation in the following procedures: Section 1C (Page 1C-2)”.

  • Page 665: Fuel Level Indicator Switch (Thermistor) Inspection

    Combination Meter / Fuel Meter / Horn: 9C-8 6) Check the display of fuel level indicator (LCD) as 3) Connect 12 V battery and test bulb (12 V, 3.4 W) to shown. the fuel level indicator switch as shown in the figure. If any abnormality is found, replace the combination The bulb should come on after one minutes if the meter with a new one.

  • Page 666: Fuel Level Gauge Inspection

    9C-9 Combination Meter / Fuel Meter / Horn: Fuel Level Gauge Inspection 4) Move the regulator/rectifier assembly (1) by B817H29306009 removing the regulator/rectifier bracket bolts. Inspect the fuel level gauge in the following procedures: 1) Remove the fuel level gauge. Refer to “Fuel Pump Assembly / Fuel Level Gauge Removal and Installation in Section 1G (Page 1G-11)”.

  • Page 667: Speed Sensor Inspection

    Combination Meter / Fuel Meter / Horn: 9C-10 Installation 3) Move a screwdriver back and forth across the pick- Install the speed sensor in the reverse order of removal. up surface of the speed sensor. The voltage readings should cycle as follows (0 V → 12 V or 12 V Pay attention to the following points: →...

  • Page 668: Oil Pressure Switch Removal And Installation

    9C-11 Combination Meter / Fuel Meter / Horn: 2) Turn the ignition switch to ON. 3) Inspect the ignition switch for continuity with a tester. If any abnormality is found, replace the ignition 3) Check if the oil pressure indicator (LED) will light up switch with a new one.

  • Page 669: Horn Removal And Installation (Gsf650/S/A/ Sak7)

    Combination Meter / Fuel Meter / Horn: 9C-12 3) Inspect the horn button for continuity with a tester. 2) Connect a 12 V battery to terminal “A” and terminal If any abnormality is found, replace the left “B”. If the sound is not heard from the horn, replace handlebar switch assembly with a new one.

  • Page 670: Combination Meter Components (Gsx650Fk8)

    9C-13 Combination Meter / Fuel Meter / Horn: Combination Meter Components (GSX650FK8) B817H29306019 I817H2930002-01 1. Combination meter cover 2. Combination meter unit 3. Combination meter case Combination Meter Removal and Installation 2) Disconnect the combination meter coupler (3) and remove the combination meter assembly (4). (GSX650FK8) B817H29306020 Removal...

  • Page 671: Combination Meter Disassembly And Assembly (Gsx650Fk8)

    Combination Meter / Fuel Meter / Horn: 9C-14 Installation If abnormal condition is found, replace the combination Install the combination meter in the reverse order of meter unit with a new one after checking its wire removal. harness/coupler. Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-13)”.

  • Page 672: Engine Coolant Temperature Indicator Light Inspection (Gsx650Fk8)

    9C-15 Combination Meter / Fuel Meter / Horn: 2) With the adjuster switch (1) pressed, turn the ignition 2) Disconnect the ECT sensor coupler (1). switch on. 3) Release the adjuster switch (1), 3 to 5 seconds after turning the ignition switch on. 4) Press the adjuster switch (1) twice (within 1 second).

  • Page 673: Oil Pressure Indicator Inspection (Gsx650Fk8)

    Combination Meter / Fuel Meter / Horn: 9C-16 Oil Pressure Indicator Inspection (GSX650FK8) Horn Inspection (GSX650FK8) B817H29306024 B817H29306025 Inspect the oil pressure indicator in the following Inspect the horn in the following procedures: procedures: 1) Disconnect the couplers (1). NOTE Before inspecting the oil pressure switch, check if the engine oil level is correct.

  • Page 674: Specifications

    9C-17 Combination Meter / Fuel Meter / Horn: Specifications Service Data (GSF650/S/A/SAK7) B817H29307001 Wattage Unit: W Specification Item GSF650/A GSF650S/SA ← Speedometer light ← Tachometer light ← Turn signal indicator light LED x 2 ← High beam indicator light ← Neutral position indicator light ←...

  • Page 675: Exterior Parts

    Exterior Parts: 9D-1 Exterior Parts Body and Accessories Schematic and Routing Diagram Seat Lock Cable Routing Diagram B817H29402001 I718H1940028-01 1. Screw 2. Seat lock cable 3. Seat lock 4. Plate...

  • Page 676: Repair Instructions

    9D-2 Exterior Parts: Repair Instructions Exterior Parts Construction (GSF650S/SAK7) B817H29406001 I717H1940001-01 1. Cowling body 3. Cowling brace 5. Upper panel 7. Head pipe 2. Wind screen 4. Lower panel 6. Meter panel lid...

  • Page 677: Frame Head Cover Construction (Gsf650/Ak7)

    Exterior Parts: 9D-3 Frame head cover construction (GSF650/AK7) B817H29406002 I717H1940013-04...

  • Page 678: Front Fender Construction

    9D-4 Exterior Parts: Front Fender Construction B817H29406003 I718H1940029-01 1. Front fender 2. Fender plate nut 3. Front fork Frame Cover Cushion Construction B817H29406004 I718H1940030-01 1. Frame cover 2. Cushion : Clean an adhesive surface before adhering the tape cushion.

  • Page 679: Engine Sprocket Outer Cover Cushion

    Exterior Parts: 9D-5 Engine Sprocket Outer Cover Cushion B817H29406005 I718H1940031-01 1. Engine sprocket outer cover cushion 2. Engine sprocket outer cover : Clear adhesive surface before adhering the tape cushion. Fastener Removal and Installation Installation B817H29406006 1) Let the center piece stick out toward the head so that Removal the pawls “A”...

  • Page 680: Exterior Parts Removal And Installation (Gsf650/S/A/Sak7)

    9D-6 Exterior Parts: 3) Push in the head of center piece until it becomes Frame Cover flush with the fastener outside face. Removal Remove the frame covers (1), left and right. “A” I649G1940007-02 I718H1940005-02 Exterior Parts Removal and Installation “A”: Hooked point (GSF650/S/A/SAK7) Installation B817H29406007...
  • Page 681 Exterior Parts: 9D-7 5) Disconnect the brake light/taillight lead wire coupler Installation (2). Install the headlight housing cover in the reverse order of removal. 6) Unhook the seat lock cable (3). 7) Remove the seat tail cover (4). Cowling and Cowling Brace (GSF650S/SAK7) Removal 1) Remove the caps.

  • Page 682: Seat Height Adjustment

    9D-8 Exterior Parts: 5) Disconnect the turn signal lead wire couplers and 8) Disconnect the headlight and position light couplers. remove the turn signal lead wire clamps and turn 9) Remove the headlight assembly (7). signal lights (4), left and right. Refer to “Front Turn Signal Light Removal and Installation in Section 9B (Page 9B-8)”.
  • Page 683 Exterior Parts: 9D-9 3) Remove the front seat from the rear seat. 6) Install the seat height adjust dampers. NOTE Dampers are used in two ways “A” or “B”. Pay attention to the direction of dampers when installing them. CAUTION Position of adjuster and direction of dampers must be unified either “A”...

  • Page 684: Cowling Construction (Gsx650Fk8)

    9D-10 Exterior Parts: Cowling Construction (GSX650FK8) B817H29406011 I817H2940014-03 1. Under cowling (R) 3. Cushion 5. Upper panel 2. Body cowling 4. Windscreen 6. Under cowling (L)

  • Page 685: Under Cowl Construction (Gsx650Fk8)

    Exterior Parts: 9D-11 Under Cowl Construction (GSX650FK8) B817H29406012 “ d ” “ a ” “ a ” “b” “ c” “c” I817H2940021-01 1. Heat shield “a”: Max. 5 mm (0.19 in) “c”: 55 mm (2.17 in) 2. Cushion “b”: 0 – 1 mm (0 – 0.039 in) “d”: 3 mm (0.12 in)

  • Page 686: Under Cowl Bracket Cushion Attachment (Gsx650Fk8)

    9D-12 Exterior Parts: Under Cowl Bracket Cushion Attachment (GSX650FK8) B817H29406013 “ a ” “ b ” I817H2940016-01 1. Under cowl F.T.G. cushion “a”: 15 mm (0.59 in) “b”: 0 mm (0 in) Under Cowl Protector Cushion Attachment (GSX650FK8) B817H29406014 “ a ” I817H2940017-01 1.

  • Page 687: Upper Panel Cushion Attachment (Gsx650Fk8)

    Exterior Parts: 9D-13 Upper Panel Cushion Attachment (GSX650FK8) B817H29406015 “ a ” I817H2940018-01 1. Panel cushion “a”: 5 mm (0.19 in) Windscreen Cushion Attachment (GSX650FK8) B817H29406016 I817H2940019-01 1. Cushion 2. Tape...

  • Page 688: Intake Net Cover Construction Attachment (Gsx650Fk8)

    9D-14 Exterior Parts: Intake Net Cover Construction Attachment (GSX650FK8) B817H29406017 I817H2940020-01 1. Cover cushion Exterior Parts Removal and Installation 2) Disconnect the turn signal light couplers (2), left and right. (GSX650FK8) B817H29406010 Under Cowling Refer to “Exterior Parts Removal and Installation (GSF650/S/A/SAK7) (Page 9D-6)”.
  • Page 689 Exterior Parts: 9D-15 3) Remove the left under cowling (3) and right under Upper Panel cowling (4). Removal 1) Remove the combination meter assembly. Refer to “Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-13)”. 2) Remove the upper panel (1). I817H2940006-01 I817H2940007-01 “A”...
  • Page 690 9D-16 Exterior Parts: 3) Disconnect the high beam light coupler (2) and low 6) Remove the screws. beam light coupler (3). I817H2940012-01 7) Remove the body cowling assembly (6). I817H2940010-01 4) Remove the screws (4). 5) Disconnect the position lights (5) and clamps, left and right.

  • Page 691: Body Structure

    Body Structure: 9E-1 Body Structure Body and Accessories Repair Instructions Body Frame Construction B817H29506001 I717H1950001-02 1. Frame : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) 2. Frame down tube bolt : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3. Engine mount No.1 bracket bolt...

  • Page 692: Engine Mounting Bracket Bushing Replacement

    9E-2 Body Structure: Engine Mounting Bracket Bushing Replacement B817H29506002 Replace the engine mounting bracket bushing if necessary, as shown in the body frame construction. Refer to “Body Frame Construction (Page 9E-1)”. Engine Mount Bushing Replacement B817H29506003 Replace the engine mount bushing if necessary, as shown in the body frame construction. Refer to “Body Frame Construction (Page 9E-1)”.

  • Page 693: Side-Stand Construction

    Body Structure: 9E-3 Side-stand Construction B817H29506005 I718H1950005-05 1. Side-stand : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft) : Apply grease to sliding surface. 2. Spring : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft) Side-stand Removal and Installation B817H29506006 Removal 1) Support the motorcycle with the center stand. 2) Remove the side-stand as shown in the side-stand construction.

  • Page 694: Center Stand Construction

    9E-4 Body Structure: Center Stand Construction B817H29506007 “A” I717H1950002-03 1. Center stand 2. Spring 3. Center stand cushion “A”: To the muffler : Apply grease to sliding surface. Center Stand Removal and Installation B817H29506008 Removal 1) Support the motorcycle using a jack. CAUTION Make sure that the motorcycle is supported securely.

  • Page 695: Specifications

    Body Structure: 9E-5 Specifications Tightening Torque Specifications B817H29507001 NOTE The specified tightening torque is also described in the following. “Body Frame Construction (Page 9E-1)” “Front Footrest Bracket Construction (Page 9E-2)” “Side-stand Construction (Page 9E-3)” Reference: For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C (Page 0C-7)”.
  • Page 696 Prepared by 3rd Ed. November, 2007 1st Ed. January, 2007 Part No. 99500-36172-01E Printed in Japan...
  • Page 697 Printed in Japan K7 K8...

This manual is also suitable for:

Gsf650Gsf650sGsf650saGsx650f

Table of Contents