Suzuki GSX1300BKA Supplementary Service Manual
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Suzuki GSX1300BKA Supplementary Service Manual

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GSX1300BKA
USE THIS MANUAL WITH:
GSX1300BK SERVICE MANUAL (99500-39320-01E)
9 9 5 0 1 - 3 9 5 8 0 - 0 1 E

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Summary of Contents for Suzuki GSX1300BKA

  • Page 1 GSX1300BKA USE THIS MANUAL WITH: GSX1300BK SERVICE MANUAL (99500-39320-01E) 9 9 5 0 1 - 3 9 5 8 0 - 0 1 E...
  • Page 2 * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.
  • Page 3 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........00-1 General Precautions ..........00-* Precautions for Electrical Circuit Service .....00-* Precautions............
  • Page 6 00-1 Precautions: Precautions Precautions Precautions Precautions for ABS (GSX1300BKAK8) • Never subject the ABS control unit/HU to strong B823H30000004 impacts or allow them to be dropped. ABS Wiring The ABS parts are connected to various lead wires. The coupler and lead wire connections, as well as the lead wire and wire harness routings must be done correctly.

  • Page 7: General Information

    Abbreviations (GSX1300BKAK8)......0A-1 Drive Chain Inspection and Adjustment ....0B-* Vehicle Side View (GSX1300BKAK8)....0A-1 Drive Chain Cleaning and Lubricating....0B-* SUZUKI GSX1300BKA (2008-model)....0A-1 Brake System Inspection ........0B-* Country and Area Codes (GSX1300BKAK8) ..0A-1 Tire Inspection............. 0B-* Component Location ...........
  • Page 8 Vehicle Side View (GSX1300BKAK8) Left Side B823H30101013 NOTE Difference between illustrations and actual motorcycles may exist depending on the markets. SUZUKI GSX1300BKA (2008-model) B823H30101014 Right Side I823H3010002-01 I823H3010001-01 Country and Area Codes (GSX1300BKAK8) B823H30101015 The following codes stand for the applicable country(-ies) and area(-s).
  • Page 9 General Information: 0A-2 Specifications Specifications (GSX1300BKAK8) B823H30107002 NOTE • These specifications are subject to change without notice. • Any differences between the GSX1300BKK8 (’08-model) and GSX1300BKAK8 (’08-model) in specifications are indicated an asterisk mark (*). Dimensions and dry mass Item Specification Remark 2 245 mm (88.4 in)
  • Page 10 0A-3 General Information: Special Tools and Equipment Special Tool B823H30108001 09900–20803 09900–20806 09900–25008 09900–25009 09904–41010 Thickness gauge Thickness gauge Multi-circuit tester set Needle pointed probe SDS set 09930–82710 99565–01010–015 Mode select switch CD-ROM Ver.15...

  • Page 11: Service Data

    Service Data: 0C-1 Service Data General Information Specifications Service Data (GSX1300BKAK8) B823H30307004 Electrical Unit: mm Item Specification Note ABS motor 40 A Fuse size ABS valve 25 A Wattage Unit: W Item Specification ABS indicator light Tightening Torque List (GSX1300BKAK8) B823H30307005 Chassis Item...
  • Page 12 0C-2 Service Data:...
  • Page 13 Table of Contents 1- i Section 1 Engine CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* DTC “C24” (P0351), “C25” (P0352), “C26” (P0353) or “C27”...
  • Page 14 1-ii Table of Contents Crankcase Emission Control System IAT Sensor Inspection......... 1C-* Description ............1B-* AP Sensor Inspection.......... 1C-* Exhaust Emission Control System AP Sensor Removal and Installation....1C-* Description ............1B-* TO Sensor Inspection ......... 1C-* Noise Emission Control System Description..1B-* TO Sensor Removal and Installation ....
  • Page 15 Table of Contents 1-iii Cam Chain Tensioner Inspection......1D-* Recommended Service Material ......1E-* Cylinder Head Disassembly and Assembly ..1D-* Special Tool ............1E-* Cylinder Head Related Parts Inspection ..... 1D-* Engine Cooling System ......1F-* Valve Guide Replacement ........1D-* Valve Seat Repair ..........
  • Page 16 1-iv Table of Contents Fuel Hose Inspection .......... 1G-* Starter Motor Removal and Installation ....1I-* Fuel Level Gauge Inspection ......1G-* Starter Motor Disassembly and Assembly ....1I-* Fuel Tank Construction ........1G-* Starter Motor Inspection........1I-* Fuel Tank Heat Shield Construction ....1G-* Starter Relay Removal and Installation ....1I-* Fuel Tank Removal and Installation....
  • Page 17 Table of Contents 1-v EXCV Cable Removal and Installation....1K-* EXCV Inspection ..........1K-* EXCVA Removal and Installation ......1K-* Specifications ............1K-* EXCVA Inspection ..........1K-* Service Data............1K-* EXCVA Pulley Inspection........1K-* Tightening Torque Specifications......1K-* EXCVA Adjustment ..........1K-* Special Tools and Equipment ......1K-* Muffler / Muffler Joint / Exhaust Pipe Removal Recommended Service Material ......
  • Page 18 1B-1 Emission Control Devices: Emission Control Devices Engine Schematic and Routing Diagram EVAP Canister Hose Routing Diagram (Only for E-33) (GSX1300BKAK8) B823H31202002 “B” “B” “D” “C” “B” “B” “C” “A” “E” “B” I823H3120001-02 1. EVAP canister 7. Clutch hose 2. Fuel shut-off valve “A”: The ends of the clamp should face outside.
  • Page 19 Table of Contents 2- i Section 2 Suspension CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........2-* Special Tools and Equipment ......2C-* Recommended Service Material ......

  • Page 20: Wheels And Tires

    2D-1 Wheels and Tires: Wheels and Tires Suspension Repair Instructions Front Wheel Components (GSX1300BKAK8) B823H32406015 I823H3240010-01 1. Front axle 7. Front wheel 13. Wheel speed sensor rotor 2. Brake disc bolt 8. Collar : 23 N⋅m (2.3 kgf-m, 16.5 lb-ft) 3.
  • Page 21 Wheels and Tires: 2D-2 Front Wheel Assembly Construction (GSX1300BKAK8) B823H32406016 “ a ” “ b ” I823H3240008-03 1. Brake disc bolt 5. ABS speed sensor : 39 N⋅m (3.9 kgf-m, 28.0 lb-ft) 2. Brake caliper mounting bolt “a”: Clearance : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3.
  • Page 22 2D-3 Wheels and Tires: Front Wheel Assembly Removal and Installation Installation (GSX1300BKAK8) 1) Install the front wheel assembly. Refer to “Front B823H32406017 Wheel Assembly Removal and Installation in related manual”. Removal 2) Check the clearance between the front wheel speed 1) Remove the front wheel speed sensor (1).
  • Page 23 Wheels and Tires: 2D-4 Rear Wheel Components (GSX1300BKAK8) B823H32406018 I823H3240011-02 1. Spacer 8. Spacer 15. Wheel speed sensor rotor 2. Rear sprocket 9. Rear wheel : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3. Dust seal 10. Tire : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 4.
  • Page 24 2D-5 Wheels and Tires: Rear Wheel Assembly Construction (GSX1300BKAK8) B823H32406019 “ a ” “ b ” “A” I823H3240009-02 1. Rear sprocket nut : 60 N⋅m (6.0 kgf-m, 43.5 lb-ft) 2. Rear axle nut : 100 N⋅m (10.0 kgf-m, 72.5 lb-ft) 3.
  • Page 25 Wheels and Tires: 2D-6 Rear Wheel Assembly Removal and Installation Installation (GSX1300BKAK8) 1) Install the rear wheel assembly. Refer to “Rear B823H32406020 Wheel Assembly Removal and Installation in related manual”. Removal 2) Check the clearance between the rear wheel speed 1) Remove the rear wheel speed sensor (1).
  • Page 26 2D-7 Wheels and Tires: Special Tools and Equipment Recommended Service Material B823H32408001 NOTE Required service material is also described in the following. “Front Wheel Components (GSX1300BKAK8) (Page 2D-1)” “Front Wheel Assembly Construction (GSX1300BKAK8) (Page 2D-2)” “Rear Wheel Components (GSX1300BKAK8) (Page 2D-4)” “Rear Wheel Assembly Construction (GSX1300BKAK8) (Page 2D-5)”...
  • Page 27 Table of Contents 4- i Section 4 Brake CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* Rear Brake Pedal Removal and Installation ..4A-* Front Brake Hose and Pipe Removal and Precautions..............

  • Page 28: Table Of Contents

    4-ii Table of Contents Special Tools and Equipment ......4C-* ABS Control Unit/HU Removal and Recommended Service Material ......4C-* Installation (GSX1300BKAK8) ......4E-13 Special Tool ............4C-* Diagnostic Information and Procedures ..4E-14 ABS Troubleshooting (GSX1300BKAK8)..4E-14 ABS............4E-1 Pre-diagnosis Inspection (GSX1300BKAK8) ..4E-16 Precautions............

  • Page 29: Brake Control System And Diagnosis

    Brake Control System and Diagnosis: 4A-1 Brake Control System and Diagnosis Brake Schematic and Routing Diagram Front Brake Hose Routing Diagram (GSX1300BKAK8) B823H34102003...
  • Page 30 4A-2 Brake Control System and Diagnosis: “ a ” “ b ” “ c ” “ e” “ d ” “ c ” “ d ” I823H3410001-02 1. Stopper “b”: 42° : After the brake hose union has contacted the stopper, tighten the union bolt. 2.
  • Page 31 Brake Control System and Diagnosis: 4A-3 Front Wheel Speed Sensor Routing Diagram (GSX1300BKAK8) B823H34102006 “A” I823H3410004-02 1. Clamp 3. Clamp : Bind the ABS sensor lead with the clamp. Cut off the excess end of : Fix the ABS sensor lead and brake hose with the clamp at the white the clamp.
  • Page 32 4A-4 Brake Control System and Diagnosis: Rear Brake Hose Routing Diagram (GSX1300BKAK8) B823H34102004 “B” “ a ” “ a ” “A” “b” “ a ” I823H3410005-01 1. Stopper “b”: 21° : After the brake hose union has contacted the stopper, tighten the union bolt. 2.
  • Page 33 Brake Control System and Diagnosis: 4A-5 Rear Wheel Speed Sensor Routing Diagram (GSX1300BKAK8) B823H34102005 “A” I823H3410006-02 1. Rear wheel speed sensor 4. Clamp : Cut off the excess end of the clamp. 2. Clamp “A”: Outside marking : Bind the sensor lead wire and brake hose with the clamp at the white paint marking on the sensor lead wire.
  • Page 34 4A-6 Brake Control System and Diagnosis: Repair Instructions Front Brake Hose and Pipe Removal and 2) Bleed air from the front brake system. Refer to “Air Bleeding from Brake Fluid Circuit in related manual”. Installation (GSX1300BKAK8) B823H34106021 3) Reinstall the removed parts. CAUTION Rear Brake Hose and Pipe Removal and •...
  • Page 35 Brake Control System and Diagnosis: 4A-7 Installation CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage. 1) Install the rear brake hoses and pipes as shown in the rear brake hose routing diagram. Refer to “Rear Brake Hose Routing Diagram (GSX1300BKAK8) (Page 4A-4)”...

  • Page 36: Abs

    4E-1 ABS: 3Brake Precautions Precautions for ABS (GSX1300BKAK8) • Be sure to route the brake hoses correctly. B823H34500001 • The ABS does not shorten the motorcycle’s braking Refer to “Precautions for Electrical Circuit Service in distance. When riding down slopes or on wet or Section 00 in related manual”...

  • Page 37: Abs Control Unit Description (Gsx1300Bkak8)

    ABS: 4E-2 ABS Control Unit Description (GSX1300BKAK8) B823H34501002 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 38: Hydraulic Unit (Hu) Description (Gsx1300Bkak8)

    4E-3 ABS: Hydraulic Unit (HU) Description (GSX1300BKAK8) B823H34501003 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 39: Self-Diagnosis Function And Abs Indicator Light Description (Gsx1300Bkak8)

    ABS: 4E-4 Self-diagnosis Function and ABS Indicator • If an ABS malfunction has occurred, the ABS indicator light keeps lighting up. Light Description (GSX1300BKAK8) B823H34501006 The ABS control unit performs the self-diagnosis and can store any electronically detected malfunctions as diagnostic trouble codes.

  • Page 40: Fail-Safe Function Description (Gsx1300Bkak8)

    4E-5 ABS: Stored DTCs (Diagnostic Trouble Codes) The maximum of six DTCs can be recorded. In these records, duplication of the same DTC will not occur. If the system detects the 7th DTC, it overwrites the record of the oldest DTC. Check and see if any diagnostic trouble code remains, by actually running the machine to activate ABS and by carrying out the self-diagnosis after deleting the diagnostic trouble code once the malfunctioned part is repaired.

  • Page 41: Schematic And Routing Diagram

    ABS: 4E-6 Schematic and Routing Diagram ABS Wiring Diagram (GSX1300BKAK8) B823H34502001 Refer to “Wire Color Symbols in Section 0A in related manual”. I823H3450068-04...

  • Page 42: Abs Unit Diagram (Gsx1300Bkak8)

    4E-7 ABS: ABS Unit Diagram (GSX1300BKAK8) B823H34502002 Refer to “Wire Color Symbols in Section 0A in related manual”. I823H3450011-05 “A”: Front brake solenoid inlet valve “C”: Rear brake solenoid inlet valve “B”: Front brake solenoid outlet valve “D”: Rear brake solenoid outlet valve...

  • Page 43: Component Location

    ABS: 4E-8 Component Location ABS Components Location (GSX1300BKAK8) B823H34503001 I823H3450012-01 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 44: Repair Instructions

    4E-9 ABS: Repair Instructions ABS Control Unit Coupler Disconnect and Removal Connect (GSX1300BKAK8) 1) Turn the ignition switch OFF. B823H34506003 2) Lift and support the fuel tank with the prop stay. Disconnect Refer to “Fuel Tank Removal and Installation in 1) Turn the ignition switch OFF.

  • Page 45: Rear Wheel Speed Sensor Removal And Installation (Gsx1300Bkak8)

    ABS: 4E-10 • Check the clearance between the front wheel speed 4) Disconnect the rear wheel speed sensor coupler (2). 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 46: Front Wheel Speed Sensor Rotor Removal And Installation (Gsx1300Bkak8)

    4E-11 ABS: • Tighten the front footrest bracket mounting bolts to the Removal specified torque. Refer to “Front Footrest Bracket 1) Remove the front wheel assembly. Refer to “Front Construction in Section 9E in related manual”. Wheel Assembly Removal and Installation in Section 2D in related manual”.

  • Page 47: Rear Wheel Speed Sensor Rotor Removal And Installation (Gsx1300Bkak8)

    ABS: 4E-12 • Check the clearance between the front wheel speed Installation sensor and sensor rotor using the thickness gauge. Install the rear wheel speed sensor rotor in the reverse order of removal. Pay attention to the following points: Special tool •...

  • Page 48: Wheel Speed Sensor And Sensor Rotor Inspection (Gsx1300Bkak8)

    4E-13 ABS: Wheel Speed Sensor and Sensor Rotor ABS Control Unit/HU Removal and Installation Inspection (GSX1300BKAK8) (GSX1300BKAK8) B823H34506008 B823H34506009 Wheel Speed Sensor WARNING 1) Remove the wheel speed sensor. Refer to “Front When storing the brake fluid, seal the Wheel Speed Sensor Removal and Installation container completely and keep away from (GSX1300BKAK8) (Page 4E-9)”...

  • Page 49: Diagnostic Information And Procedures

    ABS: 4E-14 7) Loosen the flare nuts (1) and disconnect the brake • Temporarily tighten the ABS control unit/HU holder pipes. nuts (1). 8) Remove the ABS control unit/HU (2) by removing the • Temporarily tighten the brake pipe flare nuts (2) and holder nuts (3).
  • Page 50 4E-15 ABS: 5) Perform appropriate troubleshooting procedures 7) Delete the DTCs and check the brake operation. according to the DTCs output. Refer to “DTC Table Refer to “DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) (Page 4E-33)”. (GSX1300BKAK8) (Page 4E-25)”. If troubleshooting procedures cannot be performed, Basic Troubleshooting Diagram try to determine the cause of the malfunction according to the information gathered in 1) through...

  • Page 51: Pre-Diagnosis Inspection (Gsx1300Bkak8)

    ABS: 4E-16 EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM User name: Model: VIN: Date of issue: Date Reg. Date of problem: Mileage: PROBLEM SYMPTOMS ABS operation Past malfunctions and repairs ABS does not work ABS works so often with Too long stopping distance Other CONDITION WHEN MALFUNCTION OCCURRED ABS indicator light...
  • Page 52 (B): 09900–20806 (Thickness gauge) instability. It is highly recommended to use Wheel speed sensor – Sensor rotor clearance a SUZUKI Genuine Tire. 0.3 – 1.5 mm (0.012 – 0.059 in) • Replace the tire as a set, otherwise the DTC “25” (C1625) may be stored.
  • Page 53 ABS: 4E-18 3) Disconnect the battery (–) lead wire. 6) Check for continuity between “1” (B/W) at the coupler and the battery (–) terminal, also “4” (B/W) at the coupler and the battery (–) terminal. Special tool (A): 09900–25008 (Multi-circuit tester set) Tester knob indication Continuity ( ABS control unit coupler (Harness end)

  • Page 54: Abs Indicator Light Inspection (Gsx1300Bkak8)

    4E-19 ABS: ABS Indicator Light Inspection (GSX1300BKAK8) B823H34504020 Wiring Diagram Refer to “ABS Unit Diagram (GSX1300BKAK8) (Page 4E-7)”. 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.
  • Page 55 ABS: 4E-20 Step Action (The ABS indicator light does not light up) Go to Step 4. Replace the ignition fuse. 1) Turn the ignition switch OFF. 2) Remove the front seat. Refer to “Exterior Parts Removal and Installation in Section 9D in related manual”. 3) Open the fuse box and inspect the signal fuse (1).
  • Page 56 4E-21 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. Refer to harness. (Faulty ground 2) Check for continuity between “4” (B/W) at the coupler “ABS Control Unit/HU wire) and body ground. Removal and Special tool Installation...
  • Page 57 ABS: 4E-22 Step Action 1) Disconnect the ABS control unit coupler. Refer to “ABS Go to Step 8. Inspect the wire Control Unit Coupler Disconnect and Connect harness. (Faulty ignition (GSX1300BKAK8) (Page 4E-9)”. or ground wire) 2) Turn the ignition switch ON with the ABS control unit coupler disconnected, measure the voltage between “18”...

  • Page 58: Dtc (Diagnostic Trouble Code) Output (Gsx1300Bkak8)

    4E-23 ABS: DTC (Diagnostic Trouble Code) Output (GSX1300BKAK8) B823H34504021 Use of Mode Select Switch NOTE • If there is a DTC recorded, the ABS indicator light repeatedly flashes in a cyclic manner. (However, when five minutes have elapsed from the start of self-diagnosis mode, the output of the DTC will be interrupted.) I823H3450009-01...
  • Page 59 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 60: Dtc (Diagnostic Trouble Code) Deleting (Gsx1300Bkak8)

    4E-25 ABS: DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) B823H34504022 Use of Mode Select Switch 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 61 ABS: 4E-26 3) While the DTCs are being output, set the special tool 4) In the DTC deletion mode, switch the ABS test to OFF. switch from OFF to ON three times, each time leaving it at ON for more than 1 second. NOTE NOTE The DTC deletion mode is started after the...
  • Page 62 4E-27 ABS: Use of SDS 4) Click the ABS button (1). 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 63 ABS: 4E-28 6) Check the DTC. 9) Check that both “Current DTC” (4) and “Past DTC” (5) are deleted (NIL). 7) Click “Clear” (3) to delete history code (Past DTC). I718H1450057-01 10) Close the SDS tool and turn the ignition switch OFF. I718H1450056-01 8) Follow the displayed instructions.

  • Page 64: Sds Check (Gsx1300Bkak8)

    4E-29 ABS: SDS Check (GSX1300BKAK8) B823H34504023 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 65: Active Control Inspection (Gsx1300Bkak8)

    ABS: 4E-30 Active Control Inspection (GSX1300BKAK8) 4) Click “Active control” (2). B823H34504031 1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D in related manual”. 2) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 3) Click “ABS”...
  • Page 66 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 67 ABS: 4E-32 NOTE • If the front wheel is selected, 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 Help Return...

  • Page 68: Dtc Table (Gsx1300Bkak8)

    4E-33 ABS: NOTE • In normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the ABS HU operating sound will be heard. • The ABS HU motor operates for 6 seconds and then stops automatically. Return Finish Cancel...
  • Page 69 ABS: 4E-34 Indicator DTC parameter Possible cause Reference status Too great air gap, worn Refer to “DTC “41” (C1641): Wheel or missing teeth, noise, Speed Sensor Signal Malfunction interference between (F) (GSX1300BKAK8) (Page 4E- lines, loose contact in 40)”. Wheel speed sensor wheel speed sensor 41 (C1641) signal malfunction (F) *...

  • Page 70: Dtc "25" (C1625): Wheel Speed Sensor Related Malfunction (Gsx1300Bkak8)

    4E-35 ABS: CAUTION When disconnecting couplers and turning the ignition switch ON, disconnect the ABS control unit coupler in order to prevent a DTC from being stored. Each time a resistance is measured, the ignition switch should be set to OFF. DTC “25”...
  • Page 71 ABS: 4E-36 Step Action 1) Make sure the tire pressure for each tire. Refer to “Tire Go to Step 3. Adjust the tire pressure. Inspection in Section 0B in related manual”. Cold inflation tire pressure (Solo riding) Front: 250 kPa (2.50 kgf/cm , 36 psi) Rear: 290 kPa (2.90 kgf/cm , 42 psi)
  • Page 72 4E-37 ABS: Step Action 1) Inspect the clearances of the front and rear wheel speed Replace the ABS Adjust the clearance. sensor – sensor rotor using the thickness gauge. control unit/HU. Refer to “ABS Control Unit/HU Special tool Removal and (A): 09900–20803 (Thickness gauge) Installation (B): 09900–20806 (Thickness gauge)

  • Page 73: Dtc "35" (C1635): Abs Motor Malfunction (Gsx1300Bkak8)

    ABS: 4E-38 DTC “35” (C1635): ABS Motor Malfunction (GSX1300BKAK8) B823H34504008 Possible Cause Motor relay circuit open or short, broken fuse for motor relay, pump motor circuit open or short, faulty motor relay, faulty ABS motor, faulty ABS control unit, etc. Wiring Diagram Refer to “ABS Unit Diagram (GSX1300BKAK8) (Page 4E-7)”.
  • Page 74 4E-39 ABS: Step Action 1) Remove the front seat. Refer to “Exterior Parts Removal Replace the ABS Inspect the wire and Installation in Section 9D in related manual”. control unit/HU. Refer to harness. (Faulty motor “ABS Control Unit/HU power supply or ground 2) Lift and support the fuel tank with the prop stay.

  • Page 75: Dtc "41" (C1641): Wheel Speed Sensor Signal Malfunction (F) (Gsx1300Bkak8)

    ABS: 4E-40 DTC “41” (C1641): Wheel Speed Sensor Signal Malfunction (F) (GSX1300BKAK8) B823H34504009 Possible Cause Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.

  • Page 76: Dtc "42" (C1642): Wheel Speed Sensor Circuit Open (F) (Gsx1300Bkak8)

    4E-41 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) (GSX1300BKAK8) (Page 4E-41)”.) I823H3450037-01...
  • Page 77 ABS: 4E-42 Step Action 5) Check for continuity between “16” terminal and “5” • Inspect the wire Go to Step 2. terminal at the ABS control unit coupler. harness. (Faulty sensor wire) Special tool • Faulty front wheel (A): 09900–25008 (Multi-circuit tester set) speed sensor.
  • Page 78 4E-43 ABS: Step Action 1) Disconnect the front wheel speed sensor coupler. Inspect the wire Faulty front wheel harness. (Faulty W/R speed sensor. Refer to 2) Measure the resistance between “A” (W) and ground at wire) “Front Wheel Speed the front wheel speed sensor coupler. Sensor Removal and Special tool Installation...
  • Page 79 ABS: 4E-44 Step Action 1) Disconnect the front wheel speed sensor coupler. Inspect the wire Faulty front wheel harness. (Faulty B/R speed sensor. Refer to 2) Measure the resistance between “B” (B) and ground at wire) “Front Wheel Speed the front wheel speed sensor coupler. Sensor Removal and Special tool Installation...
  • Page 80 4E-45 ABS: Step Action 1) Check for continuity between “5” (B/R) on the ABS Go to Step 8. Inspect the wire control unit coupler and “D” (B/R) on the front wheel harness. (Faulty B/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 81: Dtc "44" (C1644): Wheel Speed Sensor Signal Malfunction (R) (Gsx1300Bkak8)

    ABS: 4E-46 DTC “44” (C1644): Wheel Speed Sensor Signal Malfunction (R) (GSX1300BKAK8) B823H34504012 Possible Cause Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.

  • Page 82: Dtc "45" (C1645): Wheel Speed Sensor Circuit Open (R) (Gsx1300Bkak8)

    4E-47 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) (GSX1300BKAK8) (Page 4E-47)”.) I823H3450046-01...
  • Page 83 ABS: 4E-48 Step Action 4) Check for continuity between “7” terminal and “19” • Inspect the wire Go to Step 2. terminal at the ABS control unit coupler. harness. (Faulty sensor wire) Special tool • Faulty rear wheel (A): 09900–25008 (Multi-circuit tester set) speed sensor.
  • Page 84 4E-49 ABS: Step Action 1) Disconnect the rear wheel speed sensor coupler. Inspect the wire Replace the rear wheel harness. (Faulty W/Y speed sensor. Refer to 2) Measure the resistance between “A” (W) and ground at wire) “Rear Wheel Speed the rear wheel speed sensor coupler.
  • Page 85 ABS: 4E-50 Step Action 1) Disconnect the rear wheel speed sensor coupler. Inspect the wire Replace the rear wheel harness. (Faulty B/Y speed sensor. Refer to 2) Measure the resistance between “B” (B) and ground at wire) “Rear Wheel Speed the rear wheel speed sensor coupler.
  • Page 86 4E-51 ABS: Step Action 1) Check the continuity between “19” (B/Y) on the ABS Go to Step 8. Inspect the wire control unit coupler and “D” (B/Y) on the rear wheel harness. (Faulty B/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 87: Dtc "47" (C1647): Supply Voltage (Increased) (Gsx1300Bkak8)

    ABS: 4E-52 DTC “47” (C1647): Supply Voltage (Increased) (GSX1300BKAK8) B823H34504015 Possible Cause • Faulty regulator/rectifier. • Faulty battery. • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (GSX1300BKAK8) (Page 4E-7)”. Troubleshooting NOTE • After repairing the trouble, clear the DTC using SDS tool. Refer to “DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) (Page 4E-25)”.
  • Page 88 4E-53 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. Refer to harness. (Faulty ignition 2) Lift and support the fuel tank with the prop stay. Refer to “ABS Control Unit/HU or ground wire) “Fuel Tank Removal and Installation in Section 1G in Removal and related manual”.

  • Page 89: Dtc "48" (C1648): Supply Voltage (Decreased) (Gsx1300Bkak8)

    ABS: 4E-54 DTC “48” (C1648): Supply Voltage (Decreased) (GSX1300BKAK8) B823H34504016 Possible Cause • Faulty generator or regulator/rectifier. • Faulty battery. • Faulty wire harness, etc. Wiring Diagram Refer to “ABS Unit Diagram (GSX1300BKAK8) (Page 4E-7)”. Troubleshooting NOTE • After repairing the trouble, clear the DTC using SDS tool. Refer to “DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) (Page 4E-25)”.
  • Page 90 4E-55 ABS: Step Action 1) Turn the ignition switch OFF. Replace the ABS Inspect the wire control unit/HU. Refer to harness. (Faulty ignition 2) Lift and support the fuel tank with the prop stay. Refer to “ABS Control Unit/HU or ground wire) “Fuel Tank Removal and Installation in Section 1G in Removal and related manual”.

  • Page 91: Dtc "55" (C1655): Abs Control Unit Malfunction (Gsx1300Bkak8)

    ABS: 4E-56 DTC “55” (C1655): ABS Control Unit Malfunction (GSX1300BKAK8) B823H34504017 Possible Cause Faulty ABS control unit. Troubleshooting NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) (Page 4E-25)”. Step Action 1) Inspect the clearances of the front and rear wheel speed Go to Step 2.
  • Page 92 4E-57 ABS: Step Action 1) Inspect both of the wheel speed sensor rotors for Go to Step 3. Clean or replace the damage and check that no foreign objects are caught in rotor. the rotor openings. I718H1450064-01 Are the rotors OK? 1) Check that the front and rear wheel speed sensors are Go to Step 4.

  • Page 93: Dtc "61" (C1661): Abs Solenoid Malfunction (Gsx1300Bkak8)

    ABS: 4E-58 DTC “61” (C1661): ABS Solenoid Malfunction (GSX1300BKAK8) B823H34504018 Possible Cause Valve relay circuit open or short, broken fuse for valve relay, faulty valve relay, interruption of valve, failure output from ABS control unit, etc. Troubleshooting NOTE After repairing the trouble, clear the DTC using SDS tool. Refer to “DTC (Diagnostic Trouble Code) Deleting (GSX1300BKAK8) (Page 4E-25)”.

  • Page 94: Specifications

    4E-59 ABS: Step Action 2) Measure the voltage between “3” (R) and “4” (B/W) at Replace the ABS Inspect the wire the coupler. control unit/HU. Refer to harness. (Faulty “ABS Control Unit/HU solenoid or ground wire) Special tool Removal and (A): 09900–25008 (Multi-circuit tester set) Installation Tester knob indication...
  • Page 95 ABS: 4E-60 09900–25008 09900–25009 Multi-circuit tester set Needle pointed probe set (Page 4E-17) / (Page 4E-20) / (Page 4E-18) / (Page 4E-22) / (Page 4E-20) / (Page 4E-22) / (Page 4E-21) / (Page 4E-42) / (Page 4E-22) / (Page 4E-42) / (Page 4E-22) / (Page 4E-43) / (Page 4E-39) /...
  • Page 96 4E-61 ABS:...
  • Page 97 Table of Contents 9- i Section 9 Body and Accessories CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........9-* Turn Signal / Side-Stand Relay Removal and Installation ............
  • Page 98 9-ii Table of Contents Seat Lock Cable Routing Diagram...... 9D-* Rear Fender Heat Shield / Cushion Attachment ............9D-* Repair Instructions ..........9D-* Wiring Harness Protector Attachment ....9D-* Frame Cover Construction ........9D-* Fastener Removal and Installation...... 9D-* Frame Side Cover Cushion Attachment....9D-* Exterior Parts Removal and Installation ....

  • Page 99: Wiring Systems

    Wiring Systems: 9A-1 Wiring Systems Body and Accessories Schematic and Routing Diagram Wiring Diagram (GSX1300BKAK8) B823H39102003 Refer to “Wire Color Symbols in Section 0A in related manual”.
  • Page 100 9A-2 Wiring Systems: For E-02, 19, 24 I823H3910903-04...
  • Page 101 Wiring Systems: 9A-3 For E-03, 28 I823H3910904-04...
  • Page 102 9A-4 Wiring Systems: For E-33 I823H3910905-03...
  • Page 103 Wiring Systems: 9A-5 Wiring Harness Routing Diagram (GSX1300BKAK8) B823H39102004 “A” “B” “C” I823H3910901-08 1. Wiring harness protector 11. Speed sensor lead : Stick the wiring harness protector onto the seat rail bolt. 2. Clamp 12. Oil pressure switch lead : Bind the front brake pipe, speed sensor lead wire, oil pressure switch lead wire and HO2 sensor lead wire with the clamp.
  • Page 104 9A-6 Wiring Systems: VIEW OF RIGHT “E” “A” “C” “A” “B” “D” I823H3910902-02...
  • Page 105 Wiring Systems: 9A-7 1. Clamp 15. Spacer : Pass the radiator breather hose above the horn bracket. Be careful not to contact the lead wires with the horn bracket. 2. Clamp 16. Cushion : Bind the handlebar switch wiring harnesses. Cut off the excess end of the clamp.
  • Page 106 9A-8 Wiring Systems: “ a ” “C” “D” “A” “B” I823H3910906-03 1. Clutch hose 9. Clamp : Bind the clutch hose and left handlebar switch lead wires. Cut off the excess end of the clamp. 2. Left handlebar switch lead wire 10.
  • Page 107 Prepared by February, 2008 Part No. 99501-39580-01E Printed in Japan...
  • Page 108 Printed in Japan...

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