Suzuki GSF1250SA Manuals

Manuals and User Guides for Suzuki GSF1250SA. We have 1 Suzuki GSF1250SA manual available for free PDF download: Service Manual

Suzuki GSF1250SA Service Manual (685 pages)

Brand: Suzuki | Category: Motorcycle | Size: 55.77 MB

Section 1 Engine

65
- General Information
  16
- Fuel and Oil Recommendation
  19
- Vehicle Identification Number
  19
- Cylinder Identification
  20
- Maintenance and Lubrication
  32
- Scheduled Maintenance
  32
- Lubrication Points
  33
- Table of Contents
  65
- Precautions
  
  69
  - Precautions for Engine
    69
- Engine General Information and Diagnosis
  
  70
- General Description
  
  70
  - Injection Timing Description
    70
  - Self-Diagnosis Function
    71
- Schematic and Routing Diagram
  
  73
  - FI System Wiring Diagram
    73
  - Terminal Alignment of ECM Coupler
    74
- Component Location
  
  75
  - FI System Parts Location
    75
- Diagnostic Information and Procedures
  
  76
- Specifications
  
  183
  - Service Data
    183
- Special Tools and Equipment
  
  184
  - Special Tool
    184
- Emission Control Devices
  
  185
- Precautions
  
  185
  - Precautions for Emission Control Devices
    185
- General Description
  
  185
- Schematic and Routing Diagram
  
  188
  - PAIR System Hose Routing Diagram
    188
- Repair Instructions
  
  189
- Specifications
  
  194
  - Service Data
    194
  - Tightening Torque Specifications
    194
- Special Tools and Equipment
  
  194
  - Recommended Service Material
    194
  - Special Tool
    194
- Engine Electrical Devices
  
  195
- Precautions
  
  195
  - Precautions for Engine Electrical Device
    195
- Component Location
  
  195
  - Engine Electrical Components Location
    195
- Diagnostic Information and Procedures
  
  195
  - Engine Symptom Diagnosis
    195
- Repair Instructions
  
  195
  - ECM Removal and Installation
    195
  - CKP Sensor Inspection
    195
  - IAP Sensor (No.1) Removal and Installation
    196
  - IAP / TP / IAT Sensor Inspection
    196
  - IAP / TP / IAT Sensor Removal and Installation
    196
  - ECT Sensor Removal and Installation
    196
  - ECT Sensor Inspection
    197
  - TO Sensor Removal and Installation
    197
  - TO Sensor Inspection
    197
  - STP Sensor Inspection
    197
  - STP Sensor Adjustment
    198
  - STP Sensor Removal and Installation
    198
  - STV Actuator Inspection
    199
  - STV Actuator Removal and Installation
    199
  - ISC Valve Inspection
    199
  - ISC Valve Removal and Installation
    199
  - ISC Valve Preset and Opening Initialization
    200
  - HO2 Sensor Inspection
    200
  - HO2 Sensor Removal and Installation
    200
  - GP Switch Inspection
    200
  - GP Switch Removal and Installation
    200
- Specifications
  
  201
  - Service Data
    201
  - Tightening Torque Specifications
    202
- Special Tools and Equipment
  
  202
  - Recommended Service Material
    202
  - Special Tool
    202
- Engine Mechanical
  
  203
- Schematic and Routing Diagram
  
  203
  - Camshaft and Sprocket Assembly Diagram
    203
  - Throttle Cable Routing Diagram
    204
- Diagnostic Information and Procedures
  
  205
  - Engine Mechanical Symptom Diagnosis
    205
  - Compression Pressure Check
    205
- Repair Instructions
  
  206
  - Engine Components Removable with the Engine in Place
    206
  - Air Cleaner Element Removal and Installation
    208
  - Air Cleaner Element Inspection and Cleaning
    208
  - Air Cleaner Box Removal and Installation
    208
  - Throttle Cable Removal and Installation
    208
  - Throttle Cable Inspection
    209
  - Throttle Cable Play Inspection and Adjustment
    209
  - Throttle Body Components
    209
  - Throttle Body Construction
    210
  - Throttle Body Removal and Installation
    211
  - Throttle Body Disassembly and Assembly
    212
  - Throttle Body Inspection and Cleaning
    217
  - Throttle Valve Synchronization
    217
  - Engine Assembly Removal
    219
  - Engine Assembly Installation
    223
  - Tightening Torque
    224
  - Engine Top Side Disassembly
    226
  - Engine Top Side Assembly
    230
  - Valve Clearance Inspection and Adjustment
    238
  - Camshaft Inspection
    238
  - Camshaft Sprocket Inspection
    240
  - Camshaft Sprocket Removal and Installation
    240
  - Cam Chain Tension Adjuster Inspection
    241
  - Cam Chain Guide Removal and Installation
    241
  - Cam Chain Guide Inspection
    241
  - Cam Chain Tensioner Inspection
    242
  - Cylinder Head Disassembly and Assembly
    242
  - Cylinder Head Related Parts Inspection
    246
  - Valve Guide Replacement
    249
  - Valve Seat Repair
    250
  - Cylinder Disassembly and Assembly
    250
  - Cylinder Inspection
    252
  - Piston Ring Removal and Installation
    253
  - Piston and Piston Ring Inspection
    254
  - Engine Bottom Side Disassembly
    255
  - Engine Bottom Side Assembly
    263
  - Crank Balancer Disassembly and Assembly
    274
  - Crank Balancer Inspection
    275
  - Conrod Removal and Installation
    276
  - Conrod and Crankshaft Inspection
    277
  - Conrod Crank Pin Bearing Inspection and Selection
    278
  - Crankshaft Journal Bearing Inspection and Selection
    280
  - Crankshaft Thrust Clearance Inspection and Selection
    282
- Specifications
  
  285
  - Service Data
    285
  - Tightening Torque Specifications
    286
- Special Tools and Equipment
  
  287
  - Recommended Service Material
    287
  - Special Tool
    288
- Engine Lubrication System
  
  291
- Precautions
  
  291
  - Precautions for Engine Oil
    291
- Schematic and Routing Diagram
  
  292
  - Engine Lubrication System Chart Diagram
    292
  - Oil Pan
    292
- Diagnostic Information and Procedures
  
  293
  - Engine Lubrication Symptom Diagnosis
    293
  - Oil Pressure Check
    293
- Repair Instructions
  
  294
- Specifications
  
  303
  - Service Data
    303
  - Tightening Torque Specifications
    303
- Special Tools and Equipment
  
  304
  - Recommended Service Material
    304
  - Special Tool
    304
- Engine Cooling System
  
  305
- Precautions
  
  305
  - Precautions for Engine Cooling System
    305
  - Precautions for Engine Coolant
    305
- General Description
  
  305
  - Engine Coolant Description
    305
- Schematic and Routing Diagram
  
  306
  - Cooling Circuit Diagram
    306
  - Water Hose Routing Diagram
    307
- Diagnostic Information and Procedures
  
  308
  - Engine Cooling Symptom Diagnosis
    308
- Repair Instructions
  
  308
  - Cooling Circuit Inspection
    308
  - Radiator Cap Inspection
    309
  - Radiator Inspection and Cleaning
    309
  - Radiator / Cooling Fan Motor Removal and Installation
    309
  - Water Hose Inspection
    310
  - Water Hose Removal and Installation
    311
  - Radiator Reservoir Tank Inspection
    311
  - Radiator Reservoir Tank Removal and Installation
    312
  - Cooling Fan Inspection
    312
  - Cooling Fan Relay Inspection
    313
  - ECT Sensor Removal and Installation
    313
  - ECT Sensor Inspection
    313
  - Thermostat Connector / Thermostat Removal and Installation
    313
  - Thermostat Inspection
    315
  - Water Pump Components
    316
  - Water Pump Construction
    316
  - Water Pump Removal and Installation
    317
  - Water Pump Disassembly and Assembly
    318
  - Water Pump Related Parts Inspection
    321
- Specifications
  
  322
  - Service Data
    322
  - Tightening Torque Specifications
    322
- Special Tools and Equipment
  
  323
  - Recommended Service Material
    323
  - Special Tool
    323
- Fuel System
  
  324
- Precautions
  
  324
  - Precautions for Fuel System
    324
- General Description
  
  325
  - Fuel System Description
    325
- Schematic and Routing Diagram
  
  326
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram
    326
- Diagnostic Information and Procedures
  
  327
  - Fuel System Diagnosis
    327
- Repair Instructions
  
  328
- Specifications
  
  338
  - Service Data
    338
  - Tightening Torque Specifications
    338
- Special Tools and Equipment
  
  339
  - Recommended Service Material
    339
  - Special Tool
    339
- Ignition System
  
  340
- Schematic and Routing Diagram
  
  340
  - Ignition System Diagram
    340
  - Ignition System Components Location
    340
- Diagnostic Information and Procedures
  
  341
  - Ignition System Symptom Diagnosis
    341
  - No Spark or Poor Spark
    342
- Repair Instructions
  
  343
- Specifications
  
  350
  - Service Data
    350
  - Tightening Torque Specifications
    350
- Special Tools and Equipment
  
  350
  - Special Tool
    350
- Starting System
  
  351
- Schematic and Routing Diagram
  
  351
  - Starting System Diagram
    351
- Component Location
  
  351
  - Starting System Components Location
    351
- Diagnostic Information and Procedures
  
  351
- Repair Instructions
  
  353
- Specifications
  
  363
  - Service Data
    363
  - Tightening Torque Specifications
    363
- Special Tools and Equipment
  
  364
  - Recommended Service Material
    364
  - Special Tool
    364
- Charging System
  
  365
- Schematic and Routing Diagram
  
  365
  - Charging System Diagram
    365
- Component Location
  
  365
  - Charging System Components Location
    365
- Diagnostic Information and Procedures
  
  365
  - Charging System Symptom Diagnosis
    365
  - Battery Runs down Quickly
    366
- Repair Instructions
  
  367
  - Battery Current Leakage Inspection
    367
  - Regulated Voltage Inspection
    367
  - Generator Inspection
    367
  - Generator Removal and Installation
    368
  - Regulator / Rectifier Construction
    372
  - Regulator / Rectifier Inspection
    372
  - Battery Components
    373
  - Battery Charging
    373
  - Battery Removal and Installation
    376
  - Battery Visual Inspection
    376
- Specifications
  
  377
  - Service Data
    377
  - Tightening Torque Specifications
    377
- Special Tools and Equipment
  
  378
  - Recommended Service Material
    378
  - Special Tool
    378
- Exhaust System
  
  379
- Precautions
  
  379
  - Precautions for Exhaust System
    379
- Repair Instructions
  
  380
- Specifications
  
  384
  - Tightening Torque Specifications
    384
- Special Tools and Equipment
  
  384
  - Recommended Service Material
    384
Section 2 Suspension

385
- Precautions
  
  386
  - Precautions for Suspension
    386
- Suspension General Diagnosis
  
  387
- Diagnostic Information and Procedures
  
  387
  - Suspension and Wheel Symptom Diagnosis
    387
- Repair Instructions
  
  388
  - Front Fork Components
    388
  - Front Fork Removal and Installation
    389
  - Front Fork Inspection
    390
  - Front Fork Adjustment
    391
  - Front Fork Disassembly and Assembly
    391
  - Front Fork Parts Inspection
    396
- Front Suspension
  
  388
- Specifications
  
  397
  - Service Data
    397
  - Tightening Torque Specifications
    397
- Special Tools and Equipment
  
  398
  - Recommended Service Material
    398
  - Special Tool
    398
- Rear Suspension
  
  399
- Repair Instructions
  
  399
- Specifications
  
  410
  - Service Data
    410
  - Tightening Torque Specifications
    410
- Special Tools and Equipment
  
  411
  - Recommended Service Material
    411
  - Special Tool
    411
- Wheels and Tires
  
  412
- Precautions
  
  412
  - Precautions for Wheel and Tire
    412
- Repair Instructions
  
  413
- Specifications
  
  434
  - Service Data
    434
  - Tightening Torque Specifications
    435
- Special Tools and Equipment
  
  435
  - Recommended Service Material
    435
  - Special Tool
    435
Section 3 Driveline / Axle

437
- Precautions
  
  438
  - Precautions for Driveline / Axle
    438
- Diagnostic Information and Procedures
  
  439
  - Drive Chain and Sprocket Symptom Diagnosis
    439
- Repair Instructions
  
  439
- Drive Chain / Drive Train / Drive Shaft
  
  439
- Specifications
  
  448
  - Service Data
    448
  - Tightening Torque Specifications
    448
- Special Tools and Equipment
  
  449
  - Recommended Service Material
    449
  - Special Tool
    449
Section 4 Brake

451
- Precautions
  
  453
  - Precautions for Brake System
    453
  - Brake Fluid Information
    453
- Brake Control System and Diagnosis
  
  454
- Schematic and Routing Diagram
  
  454
  - Front Brake Hose Routing Diagram
    454
  - Rear Brake Hose Routing Diagram
    458
- Repair Instructions
  
  460
- Diagnostic Information and Procedures
  
  460
  - Brake Symptom Diagnosis
    460
- Specifications
  
  474
  - Service Data
    474
  - Tightening Torque Specifications
    474
- Special Tools and Equipment
  
  475
  - Recommended Service Material
    475
  - Special Tool
    475
- Front Brakes
  
  476
- Repair Instructions
  
  476
- Specifications
  
  483
  - Service Data
    483
  - Tightening Torque Specifications
    483
- Special Tools and Equipment
  
  484
  - Recommended Service Material
    484
  - Special Tool
    484
- Repair Instructions
  
  485
  - Rear Brake Components
    485
  - Rear Brake Pad Inspection
    486
  - Rear Brake Pad Replacement
    486
  - Rear Brake Caliper Removal and Installation
    488
  - Rear Brake Caliper Disassembly and Assembly
    488
  - Rear Brake Caliper Parts Inspection
    490
  - Rear Brake Disc Removal and Installation
    491
  - Rear Brake Disc Inspection
    491
- Rear Brakes
  
  485
- Specifications
  
  492
  - Service Data
    492
  - Tightening Torque Specifications
    492
- Special Tools and Equipment
  
  493
  - Recommended Service Material
    493
  - Special Tool
    493
- Precautions
  
  494
  - Precautions for ABS
    494
  - ABS Information
    494
- General Description
  
  494
- Abs
  
  494
- Schematic and Routing Diagram
  
  500
  - ABS Wiring Diagram
    500
  - ABS Unit Diagram
    501
  - Front Wheel Speed Sensor Routing Diagram
    502
  - Rear Wheel Speed Sensor Routing Diagram
    504
- Component Location
  
  505
  - ABS Components Location
    505
- Diagnostic Information and Procedures
  
  506
- Repair Instructions
  
  563
- Specifications
  
  569
  - Tightening Torque Specifications
    569
- Special Tools and Equipment
  
  569
  - Special Tool
    569
Section 5 Transmission / Transaxle

571
- Precautions
  
  572
  - Precautions for Transmission / Transaxle
    572
- Diagnostic Information and Procedures
  
  573
  - Manual Transmission Symptom Diagnosis
    573
- Manual Transmission
  
  573
- Repair Instructions
  
  574
- Specifications
  
  592
  - Service Data
    592
  - Tightening Torque Specifications
    592
- Special Tools and Equipment
  
  593
  - Recommended Service Material
    593
  - Special Tool
    593
- Precautions
  
  594
  - Precautions for Clutch System
    594
  - Clutch Fluid (Brake Fluid) Information
    594
- Clutch
  
  594
- Schematic and Routing Diagram
  
  595
  - Clutch Hose Routing Diagram
    595
- Repair Instructions
  
  596
- Diagnostic Information and Procedures
  
  596
  - Clutch System Symptom Diagnosis
    596
- Specifications
  
  612
  - Service Data
    612
  - Tightening Torque Specifications
    612
- Special Tools and Equipment
  
  613
  - Recommended Service Material
    613
  - Special Tool
    613
Section 6 Steering

615
- Precautions
  
  616
  - Precautions for Steering
    616
- Steering General Diagnosis
  
  617
- Diagnostic Information and Procedures
  
  617
  - Steering Symptom Diagnosis
    617
- Repair Instructions
  
  618
  - Handlebar Components
    618
  - Handlebar Construction
    619
  - Handlebar Removal and Installation
    620
  - Handlebars Inspection
    621
  - Steering Components
    622
  - Steering Removal and Installation
    623
  - Steering Related Parts Inspection
    626
  - Steering System Inspection
    626
  - Steering Stem Bearing Removal and Installation
    626
  - Steering Tension Adjustment
    627
- Steering / Handlebar
  
  618
- Specifications
  
  628
  - Tightening Torque Specifications
    628
- Special Tools and Equipment
  
  629
  - Recommended Service Material
    629
  - Special Tool
    629
Section 9 Body and Accessories

631
- Precautions
  
  633
  - Precautions for Electrical System
    633
- Component Location
  
  633
  - Electrical Components Location
    633
- Schematic and Routing Diagram
  
  634
  - Wiring Diagram (GSF1250)
    634
  - Wiring Diagram (GSF1250S)
    636
  - Wiring Diagram (GSF1250A)
    638
  - Wiring Diagram (GSF1250SA)
    639
  - Wiring Harness Routing Diagram
    641
- Wiring Systems
  
  634
- Specifications
  
  644
  - Service Data
    644
  - Tightening Torque Specifications
    644
- Repair Instructions
  
  645
- Lighting Systems
  
  645
- Special Tools and Equipment
  
  657
  - Special Tool
    657
- Specifications
  
  657
  - Service Data
    657
  - Tightening Torque Specifications
    657
- Combination Meter / Fuel Meter / Horn
  
  658
- General Description
  
  658
  - Combination Meter System Description
    658
- Repair Instructions
  
  659
- Special Tools and Equipment
  
  669
  - Special Tool
    669
- Specifications
  
  669
  - Service Data
    669
  - Tightening Torque Specifications
    669
- Exterior Parts
  
  670
- Schematic and Routing Diagram
  
  670
  - Seat Lock Cable Routing Diagram
    670
- Repair Instructions
  
  671
  - Exterior Parts Construction
    671
  - Front Fender Construction
    673
  - Frame Cover Cushion Construction
    673
  - Engine Sprocket Outer Cover Cushion Construction
    674
  - Fastener Removal and Installation
    674
  - Exterior Parts Removal and Installation
    675
  - Seat Height Adjustment
    678
- Body Structure
  
  679
- Repair Instructions
  
  679
  - Body Frame Construction
    679
  - Engine Mounting Bracket Bushing Replacement
    679
    
    Engine Mount Bushing Replacement
    680
    
    Front Footrest Bracket Construction
    680
    
    Side-Stand Construction
    681
    
    Side-Stand Removal and Installation
    682
    
    Center Stand Construction
    682
    
    Center Stand Removal and Installation
    682
- Specifications
  
  683
  - Tightening Torque Specifications
    683
- Special Tools and Equipment
  
  683
  - Recommended Service Material
    683

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Suzuki GSF1250SA Manuals

Suzuki GSF1250SA Service Manual (685 pages)

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Specifications

Special Tools and Equipment

Engine Electrical Devices

Precautions

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

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

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Repair Instructions

Specifications

Special Tools and Equipment