Suzuki 2005 GSF1200 Manuals

Manuals and User Guides for Suzuki 2005 GSF1200. We have 1 Suzuki 2005 GSF1200 manual available for free PDF download: Service Manual

Suzuki 2005 GSF1200 Service Manual (447 pages)

Brand: Suzuki | Category: Motorcycle | Size: 44 MB

Section 1 Engine

55
- General Information
  13
- Cylinder Identification
  18
- Special Tools
  24
- Maintenance and Lubrication
  27
- Scheduled Maintenance
  28
- Lubrication Points
  29
- Compression Pressure Check
  44
- Oil Pressure Check
  44
- Table of Contents
  55
- Engine General Information and Diagnosis
  59
- Crankcase Emission Control System Description
  62
- Exhaust Emission Control System Description
  63
- Noise Emission Control System Description
  63
- Schematic and Routing Diagram
  
  64
  - PAIR System Hose Routing Diagram
    64
- Repair Instructions
  
  65
- Special Tools and Equipment
  
  68
  - Engine Mechanical
    69
- Repair Instructions
  
  71
  - Valve Clearance Inspection and Adjustment
    93
    
    Camshaft Sprocket Inspection
    95
    
    Camshaft Sprocket Removal and Installation
    95
    
    Cam Chain Guide Removal and Installation
    96
    
    Cam Chain Guide Inspection
    97
    
    Cam Chain Tensioner Inspection
    97
    
    Cylinder Head Disassembly and Assembly
    98
    
    Cylinder Head Related Parts Inspection
    101
    
    Valve Guide Replacement
    104
    
    Valve Seat Repair
    106
    
    Cylinder Inspection
    106
    
    Piston Ring Components
    107
    
    Piston Ring Removal and Installation
    107
    
    Engine Bottom Side Disassembly
    110
    
    Engine Bottom Side Assembly
    116
    
    Conrod Removal and Installation
    128
    
    Conrod and Crankshaft Inspection
    129
    
    Conrod Crank Pin Bearing Inspection and Selection
    130
    
    Crankshaft Journal Bearing Inspection and Selection
    132
    
    Crankshaft Thrust Clearance Inspection and Selection
    134
- Specifications
  
  136
  - Service Data
    136
  - Tightening Torque Specifications
    138
- Special Tools and Equipment
  
  138
  - Recommended Service Material
    138
- Engine Lubrication System
  
  141
- Precautions
  
  141
  - Engine Lubrication System Chart Diagram
    142
  - Engine Lubrication Symptom Diagnosis
    143
- Repair Instructions
  
  144
- Specifications
  
  149
  - Service Data
    149
- Precautions
  
  150
  - Engine Cooling System Warning
    150
- General Description
  
  151
- Repair Instructions
  
  154
- Specifications
  
  162
  - Service Data
    162
  - Tightening Torque Specifications
    162
- Special Tools and Equipment
  
  162
  - Recommended Service Material
    162
- Fuel System
  
  163
- Precautions
  
  163
  - Precautions for Fuel System
    163
- General Description
  
  164
  - I.D. No. Location
    164
  - Fuel System Description
    164
- Schematic and Routing Diagram
  
  171
- Diagnostic Information and Procedures
  
  174
  - Carburetor Symptom Diagnosis
    174
- Repair Instructions
  
  175
  - Fuel Tank Construction
    175
  - Fuel Tank Removal and Installation
    176
  - Fuel Valve Removal and Installation
    176
  - Fuel Filter Inspection and Cleaning
    177
  - Fuel Level Gauge Removal and Installation
    177
  - Fuel Level Gauge Inspection
    178
  - Throttle Cable Removal and Installation
    178
  - Throttle Cable Inspection
    178
  - Throttle Cable Play Inspection and Adjustment
    178
  - Starter Cable Removal and Installation
    178
  - Starter Cable Inspection
    178
  - Carburetor Components
    179
  - Carburetor Assembly Removal and Installation
    181
  - Carburetor Disassembly
    182
  - Carburetor Assembly
    185
  - Float Height Inspection and Adjustment
    186
  - Carburetor Inspection and Cleaning
    187
  - Carburetor Heater Inspection (for
    188
  - TP Sensor Inspection
    188
  - TP Sensor Replacement
    189
  - Carburetor Synchronization
    190
  - Engine Idle Speed Inspection
    191
  - Fuel Line Inspection
    191
  - Air Cleaner Element Removal and Installation
    191
  - Air Cleaner Element Inspection and Cleaning
    191
- Specifications
  
  192
  - Service Data
    192
  - Tightening Torque Specifications
    192
- Special Tools and Equipment
  
  193
  - Recommended Service Material
    193
  - Special Tool
    193
- Ignition System
  
  194
- Schematic and Routing Diagram
  
  194
  - Ignition System Diagram
    194
- Diagnostic Information and Procedures
  
  195
  - Ignition System Symptom Diagnosis
    195
  - No Spark or Poor Spark
    196
- Repair Instructions
  
  197
  - Ignition Coil and Spark Plug Cap Components
    197
  - Spark Plug Removal and Installation
    197
  - Spark Plug Inspection and Cleaning
    197
  - Ignition Coil Inspection
    197
  - Ignition Coil Assembly Removal and Installation
    199
  - Spark Plug Removal and Installation
    199
  - Spark Plug Inspection
    199
  - CKP Sensor Inspection
    199
  - CKP Sensor Removal and Installation
    201
  - Engine Stop Switch Inspection
    203
  - Ignition Switch Inspection
    203
  - Ignition Switch Removal and Installation
    203
- Specifications
  
  204
  - Service Data
    204
  - Tightening Torque Specifications
    204
- Special Tools and Equipment
  
  204
  - Recommended Service Material
    204
  - Special Tool
    204
- Starting System
  
  205
- General Description
  
  205
  - Starting System Diagram
    205
  - Side-Stand / Ignition Interlock System Description
    205
- Schematic and Routing Diagram
  
  207
  - Starting System Diagram
    207
- Component Location
  
  207
  - Starting System Components Location
    207
- Diagnostic Information and Procedures
  
  207
- Repair Instructions
  
  209
- Specifications
  
  220
  - Service Data
    220
  - Tightening Torque Specifications
    220
- Special Tools and Equipment
  
  221
  - Recommended Service Material
    221
  - Special Tool
    221
- Charging System
  
  222
- General Description
  
  222
  - Charging System Description (Generator with IC Regulator)
    222
- Component Location
  
  223
  - Charging System Components Location
    223
- Diagnostic Information and Procedures
  
  223
  - Charging System Symptom Diagnosis
    223
  - Battery Runs down Quickly
    224
- Repair Instructions
  
  225
  - Battery Current Leakage Inspection
    225
  - Regulated Voltage Inspection
    225
  - Generator Components
    226
  - Generator Removal and Installation
    227
  - Generator Disassembly and Assembly
    228
  - Generator Parts Inspection
    231
  - Battery Components
    233
  - Battery Charging
    233
  - Battery Removal and Installation
    236
  - Battery Visual Inspection
    236
- Specifications
  
  237
  - Service Data
    237
  - Tightening Torque Specifications
    237
- Special Tools and Equipment
  
  238
  - Recommended Service Material
    238
  - Special Tool
    238
- Exhaust System
  
  239
  - Precautions for Exhaust System
    239
- Repair Instructions
  
  239
- Specifications
  
  242
  - Tightening Torque Specifications
    242
- Special Tools and Equipment
  
  242
  - Recommended Service Material
    242
Section 2 Suspension

243
- Precautions
  
  244
  - Precautions for Suspension
    244
- Suspension General Diagnosis
  
  245
- Diagnostic Information and Procedures
  
  245
  - Suspension and Wheel Symptom Diagnosis
    245
- Front Suspension
  
  246
- Repair Instructions
  
  246
  - Front Fork Components
    246
  - Front Fork Removal and Installation
    247
  - Front Fork Disassembly and Assembly
    248
  - Front Fork Inspection
    253
  - Front Fork Parts Inspection
    253
- Specifications
  
  254
  - Service Data
    254
  - Tightening Torque Specifications
    254
- Special Tools and Equipment
  
  255
  - Recommended Service Material
    255
  - Special Tool
    255
- Rear Suspension
  
  256
- Repair Instructions
  
  256
- Specifications
  
  267
  - Service Data
    267
  - Tightening Torque Specifications
    267
- Special Tools and Equipment
  
  268
  - Recommended Service Material
    268
  - Special Tool
    268
- Wheels and Tires
  
  269
- Precautions
  
  269
  - Precautions for Wheel and Tire
    269
- Repair Instructions
  
  270
- Specifications
  
  286
  - Service Data
    286
  - Tightening Torque Specifications
    286
- Special Tools and Equipment
  
  287
  - Recommended Service Material
    287
  - Special Tool
    287
Section 3 Driveline / Axle

289
- Precautions
  
  290
  - Precautions for Driveline / Axle
    290
- Diagnostic Information and Procedures
  
  291
  - Drive Chain and Sprocket Symptom Diagnosis
    291
- Repair Instructions
  
  291
- Drive Chain / Drive Train / Drive Shaft
  
  291
- Specifications
  
  299
  - Service Data
    299
  - Tightening Torque Specifications
    299
- Special Tools and Equipment
  
  300
  - Recommended Service Material
    300
  - Special Tool
    300
Section 4 Brake

301
- Precautions
  
  302
  - Precautions for Brake System
    302
  - Brake Fluid Information
    302
- Schematic and Routing Diagram
  
  303
  - Front Brake Hose Routing Diagram
    303
  - Rear Brake Hose Routing Diagram
    305
- Brake Control System and Diagnosis
  
  303
- Diagnostic Information and Procedures
  
  306
  - Brake Symptom Diagnosis
    306
- Repair Instructions
  
  306
- Specifications
  
  317
  - Service Data
    317
  - Tightening Torque Specifications
    317
- Special Tools and Equipment
  
  318
  - Recommended Service Material
    318
  - Special Tool
    318
- Front Brakes
  
  319
- Repair Instructions
  
  319
- Specifications
  
  325
  - Service Data
    325
  - Tightening Torque Specifications
    325
- Special Tools and Equipment
  
  326
  - Recommended Service Material
    326
  - Special Tool
    326
- Repair Instructions
  
  327
  - Rear Brake Components
    327
  - Rear Brake Pad Inspection
    328
  - Rear Brake Pad Replacement
    328
  - Rear Brake Caliper Removal and Installation
    329
  - Rear Brake Caliper Disassembly and Assembly
    330
  - Rear Brake Caliper Parts Inspection
    332
  - Rear Brake Disc Removal and Installation
    333
  - Rear Brake Disc Inspection
    333
- Rear Brakes
  
  327
- Specifications
  
  335
  - Service Data
    335
  - Tightening Torque Specifications
    335
- Special Tools and Equipment
  
  336
  - Recommended Service Material
    336
  - Special Tool
    336
Section 5 Transmission / Transaxle

337
- Precautions
  
  338
  - Precautions for Transmission / Transaxle
    338
- Manual Transmission
  
  339
- Diagnostic Information and Procedures
  
  339
  - Manual Transmission Symptom Diagnosis
    339
- Repair Instructions
  
  340
- Specifications
  
  361
  - Service Data
    361
  - Tightening Torque Specifications
    361
- Special Tools and Equipment
  
  362
  - Recommended Service Material
    362
  - Special Tool
    362
- Clutch
  
  363
- Precautions
  
  363
  - Precautions for Clutch System
    363
  - Clutch Fluid (Brake Fluid) Information
    363
- Schematic and Routing Diagram
  
  364
  - Clutch Hose Routing Diagram
    364
- Repair Instructions
  
  366
- Diagnostic Information and Procedures
  
  366
  - Clutch System Symptom Diagnosis
    366
- Specifications
  
  383
  - Service Data
    383
  - Tightening Torque Specifications
    383
- Special Tools and Equipment
  
  384
  - Recommended Service Material
    384
  - Special Tool
    384
Section 6 Steering

385
- Precautions
  
  386
  - Precautions for Steering
    386
- Steering General Diagnosis
  
  387
- Diagnostic Information and Procedures
  
  387
  - Steering Symptom Diagnosis
    387
- Steering / Handlebar
  
  388
- Repair Instructions
  
  388
  - Handlebars Components
    388
  - Handlebars Removal and Installation
    389
  - Handlebars Inspection
    390
  - Steering Components
    391
  - Steering Removal and Installation
    392
  - Steering Related Parts Inspection
    396
  - Steering System Inspection
    396
  - Steering Stem Bearing Removal and Installation
    396
  - Steering Tension Adjustment
    397
- Specifications
  
  399
  - Tightening Torque Specifications
    399
- Special Tools and Equipment
  
  400
  - Recommended Service Material
    400
  - Special Tool
    400
Section 9 Body and Accessories

401
- Component Location
  
  403
  - Electrical Components Location
    403
- Precautions
  
  403
  - Precautions for Electrical System
    403
- Wiring Systems
  
  404
- Schematic and Routing Diagram
  
  404
  - Wiring Diagram
    404
  - GSF1200 (for E02, 19)
    405
  - Wiring Harness Routing Diagram
    408
- Specifications
  
  410
  - Service Data
    410
  - Tightening Torque Specifications
    410
- Repair Instructions
  
  411
- Lighting Systems
  
  411
- Specifications
  
  423
  - Service Data
    423
  - Tightening Torque Specifications
    423
- Special Tools and Equipment
  
  423
  - Special Tool
    423
- Repair Instructions
  
  424
  - Combination Meter Components
    424
  - Combination Meter Removal and Installation
    426
  - Combination Meter Disassembly and Assembly
    426
  - Combination Meter LED Check
    427
  - Fuel Level Indicator Inspection
    427
  - Fuel Level Gauge Inspection
    428
  - Speedometer Inspection
    428
  - Speed Sensor Removal and Installation
    428
  - Speed Sensor Inspection
    429
  - Oil Pressure Indicator Inspection
    429
  - Oil Pressure Switch Removal and Installation
    430
  - Ignition Switch Inspection
    430
  - Ignition Switch Removal and Installation
    430
  - Horn Inspection
    430
  - Horn Removal and Installation
    431
- Combination Meter / Fuel Meter / Horn
  
  424
- Specifications
  
  432
  - Service Data
    432
- Special Tools and Equipment
  
  432
  - Recommended Service Material
    432
  - Special Tool
    432
- Exterior Parts
  
  433
- Schematic and Routing Diagram
  
  433
  - Seat Lock Cable Routing Diagram
    433
- Repair Instructions
  
  434
  - Exterior Parts Construction
    434
  - Frame Cover Cushion Construction
    436
  - Fastener Removal and Installation
    437
  - Exterior Parts Removal and Installation
    437
  - Seat Height Adjustment
    440
- Body Structure
  
  441
- Repair Instructions
  
  441
  - Body Frame Construction
    441
  - Engine Mounting Bracket Bushing Replacement
    441
  - Engine Mount Bushing Replacement
    441
  - Battery Protector Construction
    442
  - Front Footrest Bracket Construction
    443
  - Side-Stand Construction
    443
  - Side-Stand Removal and Installation
    444

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Suzuki 2005 GSF1200 Manuals

Suzuki 2005 GSF1200 Service Manual (447 pages)

Table of Contents

Section 1 Engine

Schematic and Routing Diagram

Repair Instructions

Special Tools and Equipment

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Repair Instructions

Specifications

Precautions

General Description

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

General Description

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Repair Instructions

Specifications

Special Tools and Equipment

Section 2 Suspension

Precautions

Suspension General Diagnosis

Diagnostic Information and Procedures

Front Suspension

Repair Instructions

Specifications

Special Tools and Equipment

Rear Suspension

Repair Instructions

Specifications

Special Tools and Equipment

Wheels and Tires

Precautions

Repair Instructions

Specifications

Special Tools and Equipment

Section 3 Driveline / Axle

Precautions

Diagnostic Information and Procedures

Repair Instructions

Drive Chain / Drive Train / Drive Shaft

Specifications

Special Tools and Equipment

Section 4 Brake

Precautions

Schematic and Routing Diagram

Brake Control System and Diagnosis