Suzuki 2005 GSF1200S Manuals

Manuals and User Guides for Suzuki 2005 GSF1200S. We have 1 Suzuki 2005 GSF1200S manual available for free PDF download: Service Manual

Suzuki 2005 GSF1200S Service Manual (447 pages)

Brand: Suzuki | Category: Motorcycle | Size: 44.31 MB

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

PAIR System Removal And Installation 65

PCV Hose Removal And Installation 67

Tightening Torque Specifications 68

Special Tools And Equipment 68

Engine Mechanical 69

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

Oil Cooler / Oil Cooler Hose Removal And Installation 144

Oil Cooler / Oil Cooler Hose Inspection 144

Oil Cooler Cleaning 144

Oil Pressure Regulator Inspection 145

Oil Pan / Oil Sump Filter Cleaning 146

Oil Pressure Switch Removal And Installation 146

Oil Pressure Switch Inspection 147

Oil Jet (For The Cylinder Head) Removal And Installation 147

Oil Jet (For The Piston Cooling And Transmission) Removal And Installation 147

Oil Pump Removal And Installation 148

Oil Pump Inspection 148

Specifications 149

Service Data 149

Engine Cooling System Warning 150

General Description 151

Engine Cooling System Description 151

Cylinder Head Cooling System Chart Diagram 152

Engine Cooling Symptom Diagnosis 153

Engine Cooling System Components 154

Oil Cooler And Oil Cooler Hose Components 155

Oil Cooler And Oil Cooler Hose Construction 156

Oil Cooler / Oil Cooler Hose Removal And Installation 157

Engine Cooling Hose Removal And Installation 158

Oil Pump / Oil Pressure Regulator Removal And Installation 159

Oil Nozzle Removal And Installation 159

Oil Return Pipe (Cylinder Side) Removal And Installation 160

Oil Return Pipe (Crankcase Side) Removal And Installation 160

Engine Cooling System Inspection 160

Oil Cooler Cleaning 161

Specifications 162

Service Data 162

Tightening Torque Specifications 162

Special Tools And Equipment 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

Carburetor Hose Routing Diagram 171

Fuel Tank Drain Hose And Breather Hose Routing Diagram 172

Throttle Cable / Starter Cable Routing Diagram 173

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

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 Assembly 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

Starting System 205

General Description 205

Starting System Diagram 205

Side-stand / Ignition Interlock System Description 205

Schematic And Routing Diagram 207

Component Location 207

Starting System Components Location 207

Diagnostic Information And Procedures 207

Starter Motor Will Not Run 208

Starter Motor Runs But Does Not Crank The Engine 208

Repair Instructions 209

Starter Motor Components 209

Starter Motor Removal And Installation 210

Starter Motor Disassembly And Assembly 211

Starter Motor Inspection 212

Starter Relay Removal And Installation 213

Starter Relay Inspection 213

Turn Signal / Side-stand Relay Removal And Installation 214

Side-stand / Ignition Interlock System Parts Inspection 214

Starter Clutch Components 216

Starter Clutch Removal And Installation 216

Starter Clutch Inspection 218

Starter Button Inspection 219

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

Exhaust System Construction 239

Exhaust Pipe / Muffler Removal And Installation 240

Exhaust System Inspection 241

Precautions 244

Precautions For Suspension 244

Suspension General Diagnosis 245

Diagnostic Information And Procedures 245

Suspension And Wheel Symptom Diagnosis 245

Front Suspension 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

Rear Suspension Components 256

Rear Suspension Assembly Construction 257

Rear Shock Absorber Removal And Installation 258

Rear Suspension Inspection 258

Rear Shock Absorber Inspection 258

Rear Suspension Adjustment 259

Rear Shock Absorber Disposal 259

Cushion Lever Removal And Installation 260

Cushion Lever Inspection 260

Cushion Lever Bearing Removal And Installation 261

Swingarm / Cushion Rod Removal And Installation 262

Swingarm Related Parts Inspection 264

Swingarm Bearing Removal And Installation 265

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

Front Wheel Components 270

Front Wheel Assembly Construction 271

Front Wheel Assembly Removal And Installation 272

Front Wheel Related Parts Inspection 274

Front Wheel Dust Seal / Bearing Removal And Installation 274

Rear Wheel Components 277

Rear Wheel Assembly Construction 278

Rear Wheel Assembly Removal And Installation 279

Rear Wheel Related Parts Inspection 280

Rear Wheel Dust Seal / Bearing / Removal And Installation 281

Tire Removal And Installation 282

Wheel / Tire / Air Valve Inspection And Cleaning 284

Air Valve Removal And Installation 284

Wheel Balance Check And Adjustment 285

Specifications 286

Service Data 286

Tightening Torque Specifications 286

Special Tools And Equipment 287

Recommended Service Material 287

Special Tool 287

Precautions 290

Precautions For Driveline / Axle 290

Drive Chain / Drive Train / Drive Shaft 291

Diagnostic Information And Procedures 291

Drive Chain And Sprocket Symptom Diagnosis 291

Repair Instructions 291

Engine Sprocket Removal And Installation 292

Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation 293

Drive Chain Related Parts Inspection 294

Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation 295

Drive Chain Replacement 296

Specifications 299

Service Data 299

Tightening Torque Specifications 299

Special Tools And Equipment 300

Recommended Service Material 300

Special Tool 300

Precautions 302

Precautions For Brake System 302

Brake Fluid Information 302

Brake Control System And Diagnosis 303

Schematic And Routing Diagram 303

Front Brake Hose Routing Diagram 303

Rear Brake Hose Routing Diagram 305

Diagnostic Information And Procedures 306

Brake Symptom Diagnosis 306

Repair Instructions 306

Brake Pedal Height Inspection And Adjustment 306

Rear Brake Light Switch Inspection 307

Rear Brake Light Switch Inspection And Adjustment 307

Brake Fluid Level Check 307

Brake Hose Inspection 307

Brake Fluid Replacement 308

Front Brake Hose Removal And Installation 310

Rear Brake Hose Removal And Installation 310

Front Brake Master Cylinder Components 310

Front Brake Master Cylinder Assembly Removal And Installation 311

Front Master Cylinder / Brake Lever Disassembly And Assembly 312

Front Master Cylinder Parts Inspection 313

Rear Brake Master Cylinder Components 314

Rear Brake Master Cylinder Assembly Removal And Installation 314

Rear Brake Master Cylinder Disassembly And Assembly 315

Rear Brake Master Cylinder Parts Inspection 316

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

Front Brake Components 319

Front Brake Pad Inspection 320

Front Brake Pad Replacement 320

Front Brake Caliper Removal And Installation 321

Front Brake Caliper Disassembly And Assembly 321

Front Brake Caliper Parts Inspection 323

Front Brake Disc Removal And Installation 324

Front Brake Disc Inspection 324

Rear Brakes 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

Specifications 335

Service Data 335

Tightening Torque Specifications 335

Special Tools And Equipment 336

Recommended Service Material 336

Special Tool 336

Precautions 338

Precautions For Transmission / Transaxle 338

Manual Transmission 339

Diagnostic Information And Procedures 339

Manual Transmission Symptom Diagnosis 339

Repair Instructions 340

Transmission Components 340

Transmission Removal 340

Transmission Installation 343

Transmission Construction 351

Countershaft Gear And Driveshaft Gear Disassembly 351

Countershaft Gear And Driveshaft Gear Assembly 353

Transmission Related Parts Inspection 354

Gear Position Switch Inspection 355

Gear Position Switch Removal And Installation 355

Gearshift Shaft / Gearshift Cam Driven Gear Components 356

Gearshift Shaft / Gearshift Cam Driven Gear Removal And Installation 357

Gearshift Linkage Inspection 359

Gearshift Shaft Oil Seal Removal And Installation 359

Gearshift Lever Height Inspection And Adjustment 360

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

Diagnostic Information And Procedures 366

Clutch System Symptom Diagnosis 366

Repair Instructions 366

Clutch Lever Position Switch Inspection 366

Clutch Fluid Replacement 367

Clutch Hose Removal And Installation 368

Clutch Control System Components 369

Clutch Master Cylinder Assembly Removal And Installation 370

Clutch Master Cylinder / Clutch Lever Disassembly And Assembly 371

Clutch Master Cylinder Parts Inspection 372

Clutch Release Cylinder / Push Rod Removal And Installation 372

Clutch Release Cylinder Disassembly And Assembly 373

Clutch Release Cylinder Inspection 374

Clutch Components 375

Clutch Assembly Diagram 376

Clutch Removal 376

Clutch Installation 378

Clutch Parts Inspection 381

Specifications 383

Service Data 383

Tightening Torque Specifications 383

Special Tools And Equipment 384

Recommended Service Material 384

Special Tool 384

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

Precautions 403

Precautions For Electrical System 403

Component Location 403

Electrical Components Location 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

Lighting Systems 411

Repair Instructions 411

Headlight Components 411

Headlight Removal And Installation 412

Headlight Bulb Replacement 412

Headlight Beam Adjustment 414

Rear Combination Light Components 415

Rear Combination Light Construction 415

Rear Combination Light Removal And Installation 416

Brake Light Bulb / Taillight Bulb Replacement 416

License Plate Light Components 417

License Plate Light Removal And Installation 417

License Plate Light Bulb Replacement 417

Turn Signal Light Components 418

Front Turn Signal Light Removal And Installation 418

Rear Turn Signal Light Removal And Installation 419

Turn Signal Light Bulb Replacement 419

Reflex Refrector Construction 420

Turn Signal / Side-stand Relay Inspection 420

Turn Signal / Side-stand Relay Removal And Installation 420

Hazard Switch Inspection 421

Turn Signal Switch Inspection 421

Passing Light Switch Inspection 421

Dimmer Switch Inspection 422

Specifications 423

Service Data 423

Tightening Torque Specifications 423

Special Tools And Equipment 423

Combination Meter / Fuel Meter / Horn 424

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

Recommended Service Material 432

Exterior Parts 433

Schematic And Routing Diagram 433

Seat Lock Cable Routing Diagram 433

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

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 GSF1200S Manuals

Manuals and User Guides for Suzuki 2005 GSF1200S. We have 1 Suzuki 2005 GSF1200S manual available for free PDF download: Service Manual

Suzuki 2005 GSF1200S Service Manual (447 pages)

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Suzuki 2005 GSF1200S Manuals

Manuals and User Guides for Suzuki 2005 GSF1200S. We have 1 Suzuki 2005 GSF1200S manual available for free PDF download: Service Manual

Suzuki 2005 GSF1200S Service Manual (447 pages)

Table of contents

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Related Products

Suzuki Categories