Suzuki 2006 GSF1200AK6 Supplementary Service Manual
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Suzuki 2006 GSF1200AK6 Supplementary Service Manual

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GSF1200A /SA
USE THIS MANUAL WITH:
GSF1200/S SERVICE MANUAL (99500-39280-01E)
9 9 5 0 1 - 3 9 5 7 0 - 0 1 E

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Summary of Contents for Suzuki 2006 GSF1200AK6

  • Page 1 GSF1200A /SA USE THIS MANUAL WITH: GSF1200/S SERVICE MANUAL (99500-39280-01E) 9 9 5 0 1 - 3 9 5 7 0 - 0 1 E...

  • Page 2: Table Of Contents

    GSF1200AK6/SAK6 (’06-MODEL) GSF1200AK6/SAK6 (’06-MODEL) This manual describes ABS service data, ABS specifications and ABS servicing procedures which differ from those of the GSF1200K6/SK6 (’06-model). NOTE: • Any differences between the GSF1200K6/SK6 (’06-model) and GSF1200AK6/SAK6 (’06-model) in specifications and service data are indicated with an asterisk mark (*). •...
  • Page 3 GSF1200AK6/SAK6 (’06-MODEL) GSF1200AK6/SAK6 (’06-MODEL) CONTENTS DTC DELETING AND ABS OPERATION CHECK ........34 SDS CHECK ..................... 36 USE OF SDS DIAGNOSTIC PROCEDURES........... 37 USE OF SDS DIAGNOSIS RESET PROCEDURE ........38 ACTIVE CONTROL INSPECTION ............40 DTC TROUBLESHOOTING ..............45 ABS COMPONENT REMOVAL, INSPECTION AND INSTALLATION ...

  • Page 4: Specifications

    GSF1200AK6/SAK6 (’06-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 130 mm (83.9 in) Overall width ............790 mm (31.1 in) Overall height ............1 095 mm (43.1 in) ........GSF1200A 1 235 mm (48.6 in) ........GSF1200SA Wheelbase ............1 480 mm (58.3 in) Ground clearance..........
  • Page 5 GSF1200AK6/SAK6 (’06-MODEL) CHASSIS 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 ..........136 mm (5.4 in) Caster ..............25° 20’ Trail ..............104 mm (4.10 in) Steering angle............

  • Page 6: Introduction

    GSF1200AK6/SAK6 (’06-MODEL) INTRODUCTION ABS (Anti-lock Brake System) This system not only prevents the wheels from locking while braking, but also provides more stable braking by controlling the wheel speed so as to maximize the friction between the tires and road surface. If the wheels lock up, the motorcycle cannot be steered and may fall over.
  • Page 7 GSF1200AK6/SAK6 (’06-MODEL) RELATIONSHIP BETWEEN THE SLIP RATIO, SIDE FORCE AND THE FRICTION BETWEEN THE TIRE AND ROAD SURFACE The relationship between the slip ratio, side force and the friction between the tire and road surface are shown in the following graph. * “Side force”...
  • Page 8 GSF1200AK6/SAK6 (’06-MODEL) ABS CONTROL CYCLE In order to understand the ABS control cycle, it is necessary to understand the normal control cycle on a well-gripped road. The ABS control flows at various wheel speeds and brake fluid pressure changes as shown in the following graph.

  • Page 9: Front And Rear Wheel Speed Sensors

    GSF1200AK6/SAK6 (’06-MODEL) FRONT AND REAR WHEEL SPEED SENSORS Wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2. ABS CONTROL UNIT ABS control unit calculates signals input from each one of front ABS control unit and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to Hydraulic Unit (HU).
  • Page 10 GSF1200AK6/SAK6 (’06-MODEL) 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 sec- onds.

  • Page 11: Hydraulic Unit (Hu)

    GSF1200AK6/SAK6 (’06-MODEL) HYDRAULIC UNIT (HU) 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 12: Hydraulic Unit Solenoid Valves (Inlet/Outlet)

    GSF1200AK6/SAK6 (’06-MODEL) HYDRAULIC UNIT SOLENOID VALVES (INLET/OUTLET) The solenoid valves switch the brake fluid circuit to one of three positions (increasing, decreasing and main- taining pressure) according to the signal that is output from the ABS control unit. As the ABS control unit energize the coil, the valve compresses its spring and open/close the circuit.
  • Page 13 GSF1200AK6/SAK6 (’06-MODEL) WHEN OPERATING THE ABS Brake fluid pressure-decreasing mode If the slip ratio exceeds the set value, or if a decrease of brake fluid pressure does not accelerate the wheel to the set speed, high enough for the brake fluid pressure to be maintained constant, the ABS will lower the brake fluid pressure to prevent the wheels from locking.
  • Page 14 GSF1200AK6/SAK6 (’06-MODEL) Brake fluid pressure-increasing mode If the accelerating wheel speed exceeds the set value, the ABS increases the pressure. At this time, the ABS control unit outputs the signal to stop the solenoid valve coils from being energized, opening the inlet valve and closing the outlet valve, and sending the pressurized brake fluid from the master cylinder to the brake caliper.

  • Page 15: Fail-Safe Function

    GSF1200AK6/SAK6 (’06-MODEL) FAIL-SAFE FUNCTION If malfunction occurs in the ABS electric system, this sets fail-safe relay OFF. Consequently, motor relay will be set OFF and the indicator light ON, and no current will be applied to motor solenoid valve inactivating ABS and turning ABS indicator light ON.

  • Page 16: Cautions In Servicing

    GSF1200AK6/SAK6 (’06-MODEL) CAUTIONS IN SERVICING ABS WIRING • The ABS parts are connected to various lead wires. The cou- pler and lead wire connections, as well as the lead wire and Click wire harness routings must be done correctly. Make sure that the proper clamps are used and positioned correctly.

  • Page 17: Abs Control Unit/Hu

    GSF1200AK6/SAK6 (’06-MODEL) ABS CONTROL UNIT/HU Incorrect • Never allow dust or water to contact the ABS control unit/HU. • Never subject the ABS control unit/HU to strong impacts or Incorrect allow them to be dropped. • The ABS control unit/HU cannot be disassembled. Replace Incorrect the whole unit with a new one.

  • Page 18: Tester

    GSF1200AK6/SAK6 (’06-MODEL) TESTER MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. • Since the resistance may differ depending on the tester used and the temperature, the resistance should be set to the spec- ification.

  • Page 19: Abs Components

    GSF1200AK6/SAK6 (’06-MODEL) ABS COMPONENTS ABS COMPONENTS LOCATION 1 ABS control unit/HU 5 Front wheel speed sensor rotor 2 Mode selection coupler 6 Rear wheel speed sensor 3 SDS coupler 7 Rear wheel speed sensor rotor 4 Front wheel speed sensor...

  • Page 20: Abs Wiring Diagram

    GSF1200AK6/SAK6 (’06-MODEL) ABS WIRING DIAGRAM...

  • Page 21: Abs Unit System Diagram

    GSF1200AK6/SAK6 (’06-MODEL) ABS UNIT SYSTEM DIAGRAM...

  • Page 22: Abs Troubleshooting

    GSF1200AK6/SAK6 (’06-MODEL) ABS TROUBLESHOOTING ABS TROUBLESHOOTING DESCRIPTION Many of the ABS malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the ABS. Before beginning any repairs, thoroughly read and understand this Supplementary Service Manual. The ABS is equipped with a self-diagnosis function.

  • Page 23: Troubleshooting Procedure

    GSF1200AK6/SAK6 (’06-MODEL) TROUBLESHOOTING PROCEDURE Troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. (!Page 24) 2. Perform the pre-diagnosis inspection. (!Page 25) 3.

  • Page 24: Basic Troubleshooting Diagram

    GSF1200AK6/SAK6 (’06-MODEL) BASIC TROUBLESHOOTING DIAGRAM 1. Gather information from the customer. (!Page 24) 2. Perform the pre-diagnosis inspection. (!Page 25) 3. Inspect the ABS indicator light. (!Page 28) 4. Output the DTCs stored in the ABS control unit. (!Page 32) 5.

  • Page 25: Information Gathering

    GSF1200AK6/SAK6 (’06-MODEL) 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 26: Pre-Diagnosis Inspection

    70ZR17M/C (58W) for front and 180/55ZR17M/C (73W) for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a SUZUKI Genuine Tire. * Replace the tire as a set, otherwise the DTC “25” may be stored.
  • Page 27 GSF1200AK6/SAK6 (’06-MODEL) ABS COMPONENT Wheel speed sensor – sensor rotor clearance • Inspect the clearance between the wheel speed sensor and sensor rotor for each wheel using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) "...
  • Page 28 GSF1200AK6/SAK6 (’06-MODEL) • Check for continuity between N (B/W) at the coupler and the battery - terminal, also O (B/W) at the coupler and the bat- ABS control unit coupler (Harness end) tery - terminal. " 09900-25008: Multi-circuit tester set ( Tester knob indication: Continuity ()) If there are no continuity, repair the coupler or wire harness.

  • Page 29: Abs Indicator Light Inspection

    GSF1200AK6/SAK6 (’06-MODEL) ABS INDICATOR LIGHT INSPECTION Step 1 1) Check if the ABS indicator light lights up when turning the ignition switch to ON. Does the ABS indicator light up? Go to step 2. Go to step 3. The ABS indicator light lights up Step 2 1) Ride the motorcycle at more than 10 km/h (6.2 mile/h).
  • Page 30 GSF1200AK6/SAK6 (’06-MODEL) Step 4 1) Turn the ignition switch to OFF. ABS control unit coupler (Harness end) 2) Disconnect the ABS control unit coupler. (!Page 26) 3) Turn the ignition switch to ON with the ABS control unit cou- pler disconnected, measure the voltage between F (O/Y) and N (B/W) at the coupler.
  • Page 31 GSF1200AK6/SAK6 (’06-MODEL) Step 7 The ABS indicator light does not go off 1) Turn the ignition switch to OFF. 2) Remove the left frame cover. (!GSF1200K6/SK6 9D-5) 3) Remove the fuse box mounting bolt. (!Page 28) 4) Open the fuse box and inspect the ignition fuse 1. Ignition fuse: 15 A Is the ignition fuse OK? Go to step 8.
  • Page 32 GSF1200AK6/SAK6 (’06-MODEL) Step 10 1) Turn the ignition switch to OFF. 2) Remove the right frame cover. (!GSF1200K6/SK6 9D-5) 3) Short the mode select coupler terminals (Orange – B/W) using the special tool. " 09930-82710: Mode select switch 4) Check for continuity between C (Orange) and N (B/W) at the coupler.

  • Page 33: Dtc (Diagnostic Trouble Code) Output

    GSF1200AK6/SAK6 (’06-MODEL) DTC (Diagnostic Trouble Code) OUTPUT Connect the special tool to the mode select coupler to output the memorized DTCs on the ABS indicator light. • Turn the ignition switch to OFF. • Remove the right frame cover. (!GSF1200K6/SK6 9D-5) •...

  • Page 34: Gsf1200Ak6/Sak6 ('06-Model)

    GSF1200AK6/SAK6 (’06-MODEL) 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 35: Dtc Deleting And Abs Operation Check

    GSF1200AK6/SAK6 (’06-MODEL) DTC DELETING AND ABS OPERATION CHECK DTC DELETING • Connect the special tool to the mode select coupler (O – B/W) and output the DTCs. " 09930-82710: Mode select switch • While the DTCs are being output, set the special tool to OFF. The DTC deletion mode starts 12.5 seconds after the switch is set to OFF.
  • Page 36 GSF1200AK6/SAK6 (’06-MODEL) Permitted range of Cleaning complete DTC indication erasing DTC ABS indicator light 1 sec. 0.4 sec. 0.4 sec. each 0.4 sec. each each Cleaning start Indicate signal “Cleaning complete” Mode select switch 1 sec. 1 sec. 1 sec. 1 sec.

  • Page 37: Sds Check

    GSF1200AK6/SAK6 (’06-MODEL) SDS CHECK Using SDS, take the sample of data from the new motorcycle and at the time of periodic maintenance at your dealership. 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 38: Use Of Sds Diagnostic Procedures

    GSF1200AK6/SAK6 (’06-MODEL) USE OF SDS DIAGNOSTIC PROCEDURES * 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 discon- nection will erase the memorized information in ABS HU mem- ory.

  • Page 39: Use Of Sds Diagnosis Reset Procedure

    GSF1200AK6/SAK6 (’06-MODEL) USE OF SDS DIAGNOSIS RESET PROCE- DURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the ABS button 1. • Click the “DTC inspection” button 2. • Check the DTC. •...
  • Page 40 GSF1200AK6/SAK6 (’06-MODEL) • Follow the displayed instructions. • Check that both “Current DTC” 4 and “Past DTC” 5 are deleted (NIL).

  • Page 41: Active Control Inspection

    GSF1200AK6/SAK6 (’06-MODEL) 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 “ABS” 1. 4) Click “Active control” 2. 5) Click “ABS HU operating” 3.
  • Page 42 GSF1200AK6/SAK6 (’06-MODEL) 6) It progresses to the next according to the following indication of screens. Return Next Cancel Help Return Next Cancel Help...
  • Page 43 GSF1200AK6/SAK6 (’06-MODEL) Return Next Cancel Help 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 44 GSF1200AK6/SAK6 (’06-MODEL) Return Next Cancel Help 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 45 GSF1200AK6/SAK6 (’06-MODEL) DTC TABLE Indicator (Diagnostic Malfunction cause status Page Trouble Code) None Normal ON *1 — !Page 45 13/C1613 Wheel speed sensor rotor malfunction (F) !Page 47 14/C1614 Wheel speed sensor rotor malfunction (R) !Page 49 22/C1622 ABS actuator circuit malfunction (F) !Page 50 23/C1623 ABS actuator circuit malfunction (R)

  • Page 46: Dtc Troubleshooting

    GSF1200AK6/SAK6 (’06-MODEL) DTC TROUBLESHOOTING DTC “13” (C1613): Wheel speed sensor rotor malfunction (F) POSSIBLE CAUSE • Front wheel speed sensor rotor distortion • Faulty front wheel speed sensor or wiring discontinuity, etc. Step 1 1) Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge.
  • Page 47 GSF1200AK6/SAK6 (’06-MODEL) Step 4 1) Inspect the front tire and wheel. % Type: DUNLOP D218F N 120/70ZR17M/C (58W) Tire pressure Solo riding: 250 kPa (2.50 kgf/cm , 36 psi) Dual riding: 250 kPa (2.50 kgf/cm , 36 psi) Wheel runout Service limit (axial and radial): 2.0 mm (0.08 in) Are the front tire type, tire pressure and wheel runout OK? Replace the ABS control unit/HU.
  • Page 48 GSF1200AK6/SAK6 (’06-MODEL) DTC “14” (C1614): Wheel speed sensor rotor malfunction (R) POSSIBLE CAUSE • Rear wheel speed sensor rotor distortion • Faulty rear wheel speed sensor or wiring discontinuity, etc. Step 1 1) Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge.
  • Page 49 GSF1200AK6/SAK6 (’06-MODEL) Step 4 1) Inspect the rear tire and wheel. % Type: DUNLOP D218N 180/55ZR17M/C (73W) Tire pressure Solo riding: 250 kPa (2.50 kgf/cm , 36 psi) Dual riding: 250 kPa (2.50 kgf/cm , 36 psi) Wheel runout Service limit (axial and radial): 2.0 mm (0.08 in) Are the rear tire type, tire pressure and wheel runout OK? Replace the ABS control unit/HU.
  • Page 50 GSF1200AK6/SAK6 (’06-MODEL) DTC “22” (C1622): ABS actuator circuit malfunction (F) POSSIBLE CAUSE • Wire harness discontinuity • Front wheel locking, etc. Step 1 1) Raise the front wheel off the ground and support the motorcy- cle with a jack or wooden block. 2) Inspect the dragging of the front brake.
  • Page 51 GSF1200AK6/SAK6 (’06-MODEL) DTC “23” (C1623): ABS actuator circuit malfunction (R) POSSIBLE CAUSE • Wire harness discontinuity • Rear wheel locking, etc. Step 1 1) Support the motorcycle with its center stand. 2) Inspect the dragging of the rear brake. Is there any dragging in the rear brake? Inspect the rear brake master cylinder and the caliper.
  • Page 52 GSF1200AK6/SAK6 (’06-MODEL) DTC “25” (C1625): Wheel speed sensor related mulfunction POSSIBLE CAUSE • Incorrect tire size, poor tire pressure • Deformed wheel, etc. Step 1 1) Check that the specified tires are installed. TIRE TYPE: Front: DUNLOP D218F N 120/70ZR17M/C (58W) Rear: DUNLOP D218N 180/55ZR17M/C (73W) Are the tires OK? Go to step 2.
  • Page 53 GSF1200AK6/SAK6 (’06-MODEL) Step 4 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) "...
  • Page 54 GSF1200AK6/SAK6 (’06-MODEL) DTC “35” (C1635): ABS motor malfunction POSSIBLE CAUSE • Faulty HU motor • Faulty wiring, etc. Step 1 1) Inspect if the pump motor makes turning noise by setting the ignition switch to ON from OFF when the vehicle stands still. Does the pump motor make any turning noise? Faulty HU motor Replace the ABS control unit/HU.
  • Page 55 GSF1200AK6/SAK6 (’06-MODEL) DTC “41” (C1641): Wheel speed sensor signal malfunction (F) POSSIBLE CAUSE • Poor contact on the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Step 1 1) Inspect the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge.
  • Page 56 GSF1200AK6/SAK6 (’06-MODEL) DTC “42” (C1642): Wheel speed sensor circuit open (F) POSSIBLE CAUSE • Poor contact on the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the right frame head cover. (GSF1200A) (!GSF1200K6/SK6 9D-6) 3) Remove the left frame cover.
  • Page 57 GSF1200AK6/SAK6 (’06-MODEL) Step 4 Sensor side 1) Measure the resistance between B (White) and ground at the front wheel speed sensor coupler. % Normal value: ∞ Ω (Infinity) * Tester knob indication: Resistance (Ω) Is the resistance between B and ground OK? Inspect the wire harness.
  • Page 58 GSF1200AK6/SAK6 (’06-MODEL) DTC “43” (C1643): Wheel speed sensor circuit short (F) POSSIBLE CAUSE • Poor contact on the front wheel speed sensor coupler • Faulty front wheel speed sensor, etc. Step 1 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the left frame cover.
  • Page 59 GSF1200AK6/SAK6 (’06-MODEL) DTC “44” (C1644): Wheel speed sensor signal malfunction (R) POSSIBLE CAUSE • Poor contact on the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Step 1 1) Inspect the clearance between the rear wheel speed sensor and sensor rotor using the thickness gauge.
  • Page 60 GSF1200AK6/SAK6 (’06-MODEL) DTC “45” (C1645): Wheel speed sensor circuit open (R) POSSIBLE CAUSE • Poor contact on the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the frame covers, left and right. (!GSF1200K6/SK6 9D-5) 3) Remove the fuse box mounting bolt.
  • Page 61 GSF1200AK6/SAK6 (’06-MODEL) Step 4 Sensor side 1) Measure the resistance between B (White) and ground at the rear wheel speed sensor coupler. % Normal value: ∞ Ω (Infinity) Is the resistance between B and ground OK? Inspect the wire harness. (Faulty W/Y wire) Replace the rear wheel speed sensor.
  • Page 62 GSF1200AK6/SAK6 (’06-MODEL) DTC “46” (C1646): Wheel speed sensor circuit short (R) POSSIBLE CAUSE • Poor contact on the rear wheel speed sensor coupler • Faulty rear wheel speed sensor, etc. Step 1 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the left frame cover.
  • Page 63 GSF1200AK6/SAK6 (’06-MODEL) DTC “47” (C1647): Supply voltage (Increased) POSSIBLE CAUSE • Faulty alternator • Faulty ABS control unit • Faulty wire harness, etc. Step 1 1) Remove the seat. (!GSF1200K6/SK6 9D-5) 2) Measure the voltage between the + and - battery terminals using the multi-circuit tester.
  • Page 64 GSF1200AK6/SAK6 (’06-MODEL) Step 3 1) Turn the ignition switch to OFF. ABS control unit coupler (Harness end) 2) Remove the left frame cover. (!GSF1200K6/SK6 9D-5) 3) Remove the fuse box mounting bolt. (!Page 28) 4) Check the ABS control unit coupler for loose or poor con- tacts.
  • Page 65 GSF1200AK6/SAK6 (’06-MODEL) DTC “48” (C1648): Supply voltage (Decreased) POSSIBLE CAUSE • Faulty alternator • Faulty battery • Faulty wire harness, etc. Step 1 1) Remove the seat. (!GSF1200K6/SK6 9D-5) 2) Measure the voltage between the + and - battery terminals using the multi-circuit tester.
  • Page 66 GSF1200AK6/SAK6 (’06-MODEL) DTC “55” (C1655): ABS control unit malfunction POSSIBLE CAUSE Faulty ABS control unit Step 1 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 –...
  • Page 67 GSF1200AK6/SAK6 (’06-MODEL) DTC “61” (C1661): ABS solenoid malfunction POSSIBLE CAUSE Faulty solenoid valve or relay Step 1 1) Turn the ignition switch to OFF. 2) Remove the fuse box mounting bolt. (!Page 28) 3) Open the fuse box and inspect the ABS fuse 1. ABS fuse: 15 A Is the ABS fuse OK? Go to step 2.

  • Page 68: Abs Component Removal, Inspection And Installation

    GSF1200AK6/SAK6 (’06-MODEL) IRREPARABLE MALFUNCTIONS Even though the ABS is operating correctly, a DTC is memo- rized in any of the following conditions. Conditions • If the motorcycle is put on its centerstand, the engine is started and only the rear wheel is rotated. •...
  • Page 69 GSF1200AK6/SAK6 (’06-MODEL) • Remove the front wheel speed sensor rotor 2. When replacing the tire, make sure not to damage the sensor rotor. • Remove the right frame head cover. (GSF1200) (!GSF1200K6/SK6 9D-6) • Disconnect the coupler clamp and remove the front wheel speed sensor.
  • Page 70 GSF1200AK6/SAK6 (’06-MODEL) • Align the recess A on the speed sensor bracket with the stop- per B on the right front fork. • Check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge. % Wheel speed sensor – sensor rotor clearance: 0.3 –...
  • Page 71 GSF1200AK6/SAK6 (’06-MODEL) Right Left 26 N . m 26 N . m (2.6 kgf-m, 19.0 lb-ft) (2.6 kgf-m, 19.0 lb-ft) 100 N . m (10.0 kgf-m, 72.5 lb-ft) Clearance 23 N . m 23 N . m (2.3 kgf-m, 16.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft) Front wheel speed sensor...
  • Page 72 GSF1200AK6/SAK6 (’06-MODEL) REAR WHEEL SPEED SENSOR/SENSOR ROTOR REMOVAL * The ABS is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. * Do not hit the sensor rotor when dismounting the wheel.
  • Page 73 GSF1200AK6/SAK6 (’06-MODEL) INSPECTION • Inspect the wheel speed sensor for damage. • Clean the sensor if any metal particle or foreign material stuck on it. • Check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. INSTALLATION Installation is in the reverse order of removal.
  • Page 74 GSF1200AK6/SAK6 (’06-MODEL) Right Left 60 N . m 23 N . m (6.0 kgf-m, 43.5 lb-ft) (2.3 kgf-m, 16.5 lb-ft) Rear wheel speed sensor Clearance 100 N . m (10.0 kgf-m, 72.5 lb-ft) 22 N . m (2.2 kgf-m, 16.0 lb-ft) Only for E-28...
  • Page 75 GSF1200AK6/SAK6 (’06-MODEL) ABS CONTROL UNIT/HU REMOVAL When storing the brake fluid, seal the container completely and keep away from children. * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not mix differ- ent types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers.

  • Page 76: Combination Meter

    GSF1200AK6/SAK6 (’06-MODEL) • Remove the reservoir mounting bolt. (!GSF1200K6/SK6 4A-12) • Remove the ABS control unit/HU by removing the mounting bolts. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points. • Tighten the brake pipe flare nuts to the specified torque. , Brake pipe flare nut: 16 N·m (1.6 kgf-m, 11.5 lb-ft) * Route the brake hoses and pipes correctly.

  • Page 77: Wire Harness, Hose Routing And Sensor Installation

    GSF1200AK6/SAK6 (’06-MODEL) WIRE HARNESS, HOSE ROUTING AND SENSOR INSTALLATION WIRE HARNESS ROUTING Handle switch harness Starter cable Handlebar switch (LH and RH) PAIR hose Ignition switch Front ABS sensor Clamp Clamp Starter Carburetor heater (E-02, 19) cable Starter Throttle cable cables Thermo switch (E-02, 19)
  • Page 78 GSF1200AK6/SAK6 (’06-MODEL) Check the adhesive lead wire protection seat *1 Cut the tip of wire clamp after clamping. when servicing. Don’t contact the ABS unit wire harness with the ABS bracket.

  • Page 79: Front Brake Hose Routing

    GSF1200AK6/SAK6 (’06-MODEL) FRONT BRAKE HOSE ROUTING GSF1200A Brake pipe A Brake pipe B Rubber cushion ABS control 14˚ unit/HU 28˚ Rubber cushion Yellow paint 42˚ Brake pipe A Brake pipe A Brake pipe B Frame 14˚ Brake pipe B 14˚ 14˚...
  • Page 80 GSF1200AK6/SAK6 (’06-MODEL) GSF1200SA Brake pipe A Brake pipe B Brake hose Throttle cable Rubber cushion ABS control 49˚ unit/HU 42˚ Rubber cushion 42˚ Brake pipe A Brake pipe A Brake pipe B Frame Brake pipe B 14˚ 14˚ 14˚ 49˚ 42˚...

  • Page 81: Rear Brake Hose Routing

    GSF1200AK6/SAK6 (’06-MODEL) REAR BRAKE HOSE ROUTING Brake pipe A Brake pipe B Face the clamp end forward. White paint Insert the brake hose firmly. Brake hose C Brake hose D 28˚ 14˚ Face the clamp end backward. Pass through the brake pipe A under the brake Pass through the brake hose C outside of the pipe B.

  • Page 82: Front Wheel Speed Sensor Installation

    GSF1200AK6/SAK6 (’06-MODEL) FRONT WHEEL SPEED SENSOR INSTALLATION GSF1200A Clamp Guide Clamp Front brake hose No.2 (L) Front wheel speed sensor Outside mark Clamp Set the clamp Set the clamp Set the clamp as sho as shown. as shown. Pass through the sensor lead wire between Clamp the sensor lead wire sleeve with the brake hose No.2 and brake hose No.2 (L).
  • Page 83 GSF1200AK6/SAK6 (’06-MODEL) GSF1200SA Clamp Guide Clamp Front brake hose No.2 (L) Clamp Outside mark Pass through the sensor lead wire between Clamp the sensor lead wire sleeve with the brake hose No.2 and brake hose No.2 (L). brake hose. Pass through the sensor lead wire in front of Pass through the sensor lead wire inside of the the brake hose.

  • Page 84: Rear Wheel Speed Sensor Installation

    GSF1200AK6/SAK6 (’06-MODEL) REAR WHEEL SPEED SENSOR INSTALLATION ABS sensor harness Brake hose Brake hose guide 35 mm (1.4 in) Brake hose Outside mark Brake hose guide After the clamp has contacted to the stopper, Pass through the sensor lead wire on the brake tighten the bolt.

  • Page 85: Special Tools

    GSF1200AK6/SAK6 (’06-MODEL) SPECIAL TOOLS 09900-20803 09900-25008 09900-20602 09900-20701 09900-20806 09900-20805 Multi-circuit tester Dial gauge Magnetic stand Thickness gauge Tire depth gauge 09900-25009 Needle pointed 09904-41010 09930-82710 99565-01010-008 probe set SDS set tool Mode select switch CD-ROM Ver. 8 NOTE: When order the special tool, please confirm whether it is available or not. TIGHTENING TORQUE ITEM N·m...

  • Page 86: Service Data

    GSF1200AK6/SAK6 (’06-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diameter 28.5 — (1.12) — (1.0) Valve clearance (when cold) 0.10 – 0.15 — (0.004 – 0.006) 0.18 – 0.23 — (0.007 – 0.009) Valve-guide to valve-stem 0.020 –...
  • Page 87 GSF1200AK6/SAK6 (’06-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.58 – 33.62 33.28 (1.3220 – 1.3236) (1.3102) 32.65 – 32.69 32.35 (1.2854 – 1.2870) (1.2736) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 88 GSF1200AK6/SAK6 (’06-MODEL) ITEM STANDARD LIMIT Piston-ring to piston-ring-groove 0.180 — clearance (0.007) 0.150 — (0.006) Piston ring groove width 1.01 – 1.03 — (0.040 – 0.041) 1.01 – 1.03 — (0.040 – 0.041) 2.01 – 2.03 — (0.079 – 0.080) Piston ring thickness 0.975 –...

  • Page 89: Oil Pump

    GSF1200AK6/SAK6 (’06-MODEL) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.703 (72/46 × 37/34) — Oil pressure (at 60 °C, 140 °F) Above 300 kPa (3.0 kgf/cm , 43 psi) Below 600 kPa (6.0 kgf/cm , 85 psi) — at 3 000 r/min CLUTCH Unit: mm (in)
  • Page 90 GSF1200AK6/SAK6 (’06-MODEL) CARBURETOR SPECIFICATION ITEM E-02, 19, 24 E-28 ← Carburetor type MIKUNI BSR36 ← Bore size 36 mm (1.42 in) I.D. No. 49G0 49G1 Idle r/min 1 200 ± 100 r/min 1 300 ± 100 r/min Float height 13.0 ± 1.0 mm ←...
  • Page 91 GSF1200AK6/SAK6 (’06-MODEL) ITEM SPECIFICATION NOTE Battery Type designation FT12A-BS Capacity 12 V 36.0 kC (10 Ah)/10 HR Standard 1.320 at 20 °C (68 °F) electrolyte S.G. Fuse size 10 A Headlight 10 A Ignition 15 A Signal 15 A Meter 10 A Main 30 A...
  • Page 92 GSF1200AK6/SAK6 (’06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.4) Brake disc thickness 4.8 – 5.2 Front (0.189 – 0.205) (0.18) 4.8 – 5.2 Rear (0.189 – 0.205) (0.18) Brake disc runout 0.30 —...
  • Page 93 GSF1200AK6/SAK6 (’06-MODEL) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke 130 (5.1) — Front fork inner tube O.D. 43 (1.69) — Front fork spring free length 391.5 (15.41) 383 (15.08) Front fork oil level 110 (4.2) — Front fork spring adjuster 3rd groove from top —...
  • Page 94 GSF1200AK6/SAK6 (’06-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane (R/2 + M/2) or higher rated by the Research Method. Gasoline containing MTBE (MethyI Tertiary ButyI E-28 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro- sion inhibitor is permissible.

  • Page 95: Wiring Diagram

    WIRING DIAGRAM GSF1200A SPEEDOMETER TURN-R : TURN SIGNAL INDICATOR LIGHT (R) TURN-L : TURN SIGNAL INDICATOR LIGHT (L) TURN-R NEUTRAL : NEUTRAL INDICATOR LIGHT TURN-L HANDLE SWITCH (R) HI-BEAM : HIGH BEAM INDICATOR LIGHT NEUTRAL : ABS INDICATOR LIGHT FRONT BRAKE ENGINE : OIL INDICAOTR LIGHT...
  • Page 96 GSF1200SA (E-02, 19) TURN-R : TURN SIGNAL INDICATOR LIGHT (R) TURN-L : TURN SIGNAL INDICATOR LIGHT (L) SPEEDOMETER NEUTRAL : NEUTRAL INDICATOR LIGHT TURN-R HI-BEAM : HIGH BEAM INDICATOR LIGHT HANDLE SWITCH (R) : ABS INDICATOR LIGHT TURN-L FRONT : OIL INDICATOR LIGHT SIDE-STAND NEUTRAL ENGINE...
  • Page 97 GSF1200SA (E-24, 28) TURN-R : TURN SIGNAL INDICATOR LIGHT (R) TURN-L : TURN SIGNAL INDICATOR LIGHT (L) SPEEDOMETER NEUTRAL : NEUTRAL INDICATOR LIGHT TURN-R HI-BEAM : HIGH BEAM INDICATOR LIGHT HANDLE SWITCH (R) : ABS INDICATOR LIGHT TURN-L FRONT : OIL INDICATOR LIGHT SIDE-STAND NEUTRAL ENGINE...
  • Page 98 Prepared by February, 2006 Part No. 99501-39570-01E Printed in Japan...
  • Page 99 Printed in Japan...

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2006 gsf1200sak6

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