Suzuki GSF1200 2001 Manuals

Manuals and User Guides for Suzuki GSF1200 2001. We have 1 Suzuki GSF1200 2001 manual available for free PDF download: Service Manual

Suzuki GSF1200 2001 Service Manual

Suzuki GSF1200 2001 Service Manual (368 pages)

Brand: Suzuki | Category: Motorcycle | Size: 19.5 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- How to Use this Manual
  3
- General Information
  6
  - Suzuki Gsf1200Sk1 (2001-Model)
    8
  - Serial Number Location
    8
  - Fuel and Oil Recommendation
    8
    
    Fuel
    8
    
    Engine Oil
    9
    
    Brake Fluid
    9
    
    Front Fork Oil
    9
  - Break-In Procedures
    9
  - Cylinder Identification
    9
  - Information Labels
    10
  - Specifications
    11
  - Country or Area Codes
    13
- General Precautions
  6
- Warning/Caution/Note
  6
Periodic Maintenance

14
- Periodic Maintenance Schedule
  15
  - Periodic Maintenance Chart
    15
  - Lubrication Points
    16
- Maintenance and Tune-Up Procedures
  17
  - Valve Clearance
    17
  - Engine
    17
  - Spark Plugs
    18
  - Exhaust Pipe Bolts and Muffler Bolts
    20
  - Air Cleaner
    20
  - Engine Oil and Oil Filter
    22
  - Fuel Hose
    23
  - Engine Idle Speed
    24
  - Throttle Cable Play
    24
  - Carburetor Synchronization
    25
  - Evaporative Emission Control System (E-33 Only)
    25
  - Clutch
    26
  - Drive Chain
    27
  - Brakes
    29
  - Tires
    32
  - Steering
    33
  - Front Fork
    34
  - Rear Suspension
    34
  - Chassis Bolts and Nuts
    35
- Compression Pressure Check
  37
- Oil Pressure Check
  38
Engine

39
- Engine Components Removable with Engine in Place
  40
- Engine Removal and Installation
  41
  - Engine Removal
    41
  - Engine Reinstallation
    46
- Engine Disassembly and Reassembly
  50
  - Engine Disassembly
    50
  - Engine Reassembly
    64
- Engine Components Inspection and Service
  88
  - Camshaft/Cylinder Head
    88
  - Cam Chain Tensioner
    90
  - Valve
    92
  - Valve Guide
    94
  - Valve Seat
    95
  - Valve Spring
    99
  - Cylinder
    103
  - Piston Ring Groove Width
    104
  - Piston Ring Thickness
    104
  - Piston Ring End Gap
    104
  - Piston Pin
    105
  - Clutch Inspection
    107
  - Starter Clutch Inspection
    108
  - Gearshift Linkage Inspection
    109
  - Transmission Inspection and Service
    111
  - Conrod
    119
  - Crankshaft
    121
    
    Crankshaft Thrust Clearance Adjustment
    123
    
    Crankshaft Runout
    124
- Engine Lubrication System
  125
  - Oil Filter
    130
  - Oil Pressure
    130
  - Oil Jet
    130
- Pair (Air Supply) System
  136
Fuel System

139
- Fuel System
  140
- Fuel Tank
  141
  - Removal
    141
  - Remounting
    141
- Fuel Valve
  142
  - Removal
    143
  - Inspection and Cleaning
    143
  - Remounting
    143
- Fuel Level Gauge
  144
  - Removal
    144
  - Inspection
    144
  - Installation
    144
- Carburetor
  145
  - Construction
    145
  - Specifications
    146
  - I.D. No. Location
    147
  - Diaphragm and Piston Operation
    148
  - Slow System
    149
  - Main System
    150
  - Starter (Enricher) System
    151
  - Float System
    151
  - Removal
    152
  - Disassembly
    153
  - Carburetor Cleaning
    157
  - Carburetor Heater Inspection
    157
  - Thermo-Switch Inspection
    157
  - Carburetor Inspection
    158
  - Reassembly
    159
  - Remounting
    161
  - Carburetor Synchronization
    162
Chassis

165
- Exterior Parts
  166
  - Construction
    166
  - Removal
    167
  - Remounting
    170
- Front Wheel
  171
  - Construction
    171
  - Removal
    173
  - Inspection and Disassembly
    173
  - Reassembly
    174
  - Remounting
    175
- Front Fork
  176
  - Construction
    176
  - Removal and Disassembly
    177
  - Inspection
    180
  - Reassembly and Remounting
    180
- Steering
  186
  - Construction
    186
  - Removal and Disassembly
    186
  - Inspection and Disassembly
    188
  - Reassembly and Remounting
    188
  - Steering Tension Adjustment
    191
- Rear Wheel
  192
  - Construction
    192
  - Removal
    194
  - Inspection and Disassembly
    195
  - Reassembly
    196
  - Remounting
    197
- Rear Suspension
  198
  - Construction
    198
  - Removal
    200
  - Inspection and Disassembly
    201
  - Reassembly
    203
  - Rear Shock Absorber Disposal
    204
  - Remounting
    205
  - Final Inspection and Adjustment
    206
  - Suspension Setting
    206
- Front Brake
  207
  - Construction
    207
  - Brake Pad Replacement
    208
  - Brake Fluid Replacement
    208
    
    Caliper Removal and Disassembly
    209
    
    Caliper Inspection
    210
    
    Brake Disc Inspection
    212
    
    Rear Brake
    217
  - Brake Caliper Removal and Disassembly
    219
  - Brake Caliper Inspection
    220
  - Brake Caliper Reassembly and Remounting
    220
  - Master Cylinder Inspection
    222
  - Master Cylinder Reassembly and Remounting
    223
- Clutch Master Cylinder
  224
  - Construction
    224
  - Removal
    224
  - Disassembly and Reassembly
    224
  - Tire and Wheel
    225
  - Tire Removal
    225
  - Inspection
    225
  - Tire Tread Depth
    225
  - Tire Installation
    226
Electrical System

228
- Cautions in Servicing
  229
  - Connecting the Battery
    230
  - Using the Multi Circuit Tester
    231
  - Location of Electrical Components
    232
- Charging System
  234
  - Description (Generator with IC Regulator)
    234
  - Troubleshooting
    235
  - Inspection
    236
- Generator
  237
  - Removal and Disassembly
    238
  - Inspection
    240
  - Generator Reassembly and Remounting
    243
- Starter System and Side-Stand Ignition Interlock System
  245
- Ignition System (Digital Ignitor)
  254
  - Description
    254
  - Troubleshooting
    255
  - Inspection
    256
- Combination Meter
  260
  - Removal
    260
  - Disassembly
    260
  - Inspection
    260
- Lamps
  264
  - Headlight
    264
  - Brake Light/Taillight and License Plate Light
    265
  - Turn Signal Lights
    265
- Relays
  266
  - Starter Relay
    266
  - Turn Signal/Side-Stand Relay
    266
- Switches
  267
- Battery
  268
  - Specifications
    268
  - Removal
    268
  - Remounting
    268
  - Initial Charging
    269
  - Servicing
    270
  - Recharging Operation
    271
Servicing Information

272
- Troubleshooting
  273
  - Engine
    273
  - Carburetor
    277
  - Chassis
    277
  - Brakes
    278
  - Electrical
    279
  - Battery
    280
- Wiring Diagram
  281
- Wire Harness, Cable and Hose Routing
  283
  - Wire Harness Routing
    283
  - Cable Routing
    286
  - Pair (Air Supply) System Hose Routing
    287
  - Fuel Hose Routing
    288
  - Clutch Hose Routing
    289
  - Oil Hose Routing
    290
  - Front Brake Hose Routing
    291
  - Rear Brake Hose Routing
    292
  - Front Footrest Bracket Set-Up
    293
  - Fuel Tank Set-Up
    294
  - High-Tension Cord Routing
    295
  - Muffler Mounting
    295
  - Center Stand Springs
    296
  - Cowling and Cowling Brace Set-Up
    297
  - Cowling Cushion and Tape
    299
  - Front Fender Cushion
    300
  - Seat Lock Cable Routing
    300
  - Fuel Tank Air Breather Hose/Fuel Tank Drain Hose
    301
- Special Tools
  303
- Tightening Torque
  306
  - Engine
    306
  - Chassis
    307
  - Tightening Torque Chart
    308
- Service Data
  309
Gsf1200K1 (2001-Model)

318
- Specifications
  319
  - Dimensions and Dry Mass
    319
- Headlight/Headlight Housing/Combination Meter
  321
  - Bulb Replacement
    323
  - Headlight Beam Adjustment
    324
- Wiring Diagram
  325
- Wire Harness Routing
  326
- Front Brake Hose Routing
  328
- Service Data
  329
- Gsf1200K2/Sk2 ('02-Model)
  338
  - Service Data (Gsf1200S)
    341
  - Service Data (Gsf1200)
    350
  - Wiring Diagram Gsf1200S
    359
  - Wiring Diagram Gsf1200
    362
  - Wire Harness Routing (Gsf1200S)
    364
  - Wire Harness Routing (Gsf1200)
    365

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