Suzuki GSF650 Manuals

Manuals and User Guides for Suzuki GSF650. We have 3 Suzuki GSF650 manuals available for free PDF download: Service Manual

Suzuki GSF650 Service Manual (697 pages)

Brand: Suzuki | Category: Motorcycle | Size: 60.73 MB

Section 1 Engine

71
- General Information
  13
- Vehicle Identification Number
  16
- Fuel and Oil Recommendation
  16
- Cylinder Identification
  17
- Maintenance and Lubrication
  34
- Scheduled Maintenance
  34
- Fuel Line Inspection
  45
- Table of Contents
  71
- Table of Contents
  72
- Precautions
  
  75
  - Precautions for Engine
    75
  - Section
    75
- Engine General Information and Diagnosis
  
  76
- General Description
  
  76
- Schematic and Routing Diagram
  
  81
- Diagnostic Information and Procedures
  
  84
- Specifications
  
  193
  - Service Data
    193
- Special Tools and Equipment
  
  194
  - Special Tool
    194
- Emission Control Devices
  
  195
- Precautions
  
  195
  - Precautions for Emission Control Devices
    195
- General Description
  
  195
- Schematic and Routing Diagram
  
  198
  - PAIR System Hose Routing Diagram
    198
- Repair Instructions
  
  199
- Special Tools and Equipment
  
  204
  - Recommended Service Material
    204
  - Special Tool
    204
- Engine Electrical Devices
  
  205
- Precautions
  
  205
  - Precautions for Engine Electrical Device
    205
  - Engine Electrical Components Location
    205
- Diagnostic Information and Procedures
  
  205
  - Engine Symptom Diagnosis
    205
- Repair Instructions
  
  205
  - ECM Removal and Installation
    205
  - CKP Sensor Inspection
    205
  - CKP Sensor Removal and Installation
    205
  - IAP Sensor (#1) Removal and Installation
    206
  - IAP / TP / IAT Sensor Inspection
    206
  - IAP / TP / IAT Sensor Removal and Installation
    206
  - ECT Sensor Removal and Installation
    206
  - ECT Sensor Inspection
    207
  - TO Sensor Removal and Installation
    207
  - TO Sensor Inspection
    207
  - STP Sensor Inspection
    207
  - STP Sensor Adjustment
    208
  - STP Sensor Removal and Installation
    208
  - STV Actuator Inspection
    209
  - STV Actuator Removal and Installation
    209
  - ISC Valve Inspection
    209
  - ISC Valve Removal and Installation
    209
  - ISC Valve Preset and Opening Initialization
    209
  - HO2 Sensor Inspection
    210
  - HO2 Sensor Removal and Installation
    210
  - GP Switch Inspection
    210
  - GP Switch Removal and Installation
    210
  - Service Data
    211
  - Tightening Torque Specifications
    211
- Special Tools and Equipment
  
  212
  - Recommended Service Material
    212
  - Special Tool
    212
- Engine Mechanical
  
  213
- Schematic and Routing Diagram
  
  213
- Diagnostic Information and Procedures
  
  216
  - Engine Mechanical Symptom Diagnosis
    216
  - Compression Pressure Check
    216
- Repair Instructions
  
  217
  - Engine Components Removable with the Engine in Place
    217
  - Air Cleaner Element Removal and Installation
    219
  - Air Cleaner Element Inspection and Cleaning
    219
  - Air Cleaner Box Removal and Installation
    219
  - Throttle Cable Removal and Installation
    219
  - Throttle Cable Inspection
    220
  - Adjustment
    220
  - Throttle Body Components
    220
  - Throttle Body Construction
    221
  - Throttle Body Removal and Installation
    222
  - Throttle Body Disassembly and Assembly
    223
  - Throttle Body Inspection and Cleaning
    227
  - Throttle Valve Synchronization
    228
  - Engine Assembly Removal
    230
  - Engine Assembly Installation
    233
  - Engine Top Side Disassembly
    236
  - Engine Top Side Assembly
    238
  - Valve Clearance Inspection and Adjustment
    245
  - Cylinder Head Cover Inspection
    246
  - Camshaft Inspection
    246
  - Camshaft Sprocket Inspection
    248
  - Camshaft Sprocket Removal and Installation
    248
  - Cam Chain Tension Adjuster Inspection
    248
  - Cam Chain Guide Removal and Installation
    249
  - Cam Chain Guide Inspection
    249
  - Cam Chain Tensioner Inspection
    249
  - Cylinder Head Disassembly and Assembly
    250
  - Cylinder Head Related Parts Inspection
    253
  - Valve Guide Replacement
    256
  - Valve Seat Repair
    257
  - Cylinder Disassembly and Assembly
    258
  - Cylinder Inspection
    259
  - Piston Ring Removal and Installation
    260
  - Piston and Piston Ring Inspection
    261
  - Engine Bottom Side Disassembly
    263
  - Engine Bottom Side Assembly
    270
  - Conrod Removal and Installation
    279
  - Conrod and Crankshaft Inspection
    281
  - Conrod Crank Pin Bearing Inspection and Selection
    282
  - Crankshaft Journal Bearing Inspection and Selection
    283
  - Crankshaft Thrust Clearance Inspection and Selection
    285
  - Service Data
    288
  - Tightening Torque Specifications
    290
- Special Tools and Equipment
  
  291
  - Recommended Service Material
    291
  - Special Tool
    291
- Engine Lubrication System
  
  294
- Precautions
  
  294
  - Precautions for Engine Oil
    294
- Schematic and Routing Diagram
  
  295
  - Engine Lubrication System Chart Diagram
    295
  - Oil Pan
    295
- Diagnostic Information and Procedures
  
  296
  - Engine Lubrication Symptom Diagnosis
    296
  - Oil Pressure Check
    296
- Repair Instructions
  
  297
- Specifications
  
  305
  - Service Data
    305
  - Tightening Torque Specifications
    305
- Special Tools and Equipment
  
  306
  - Recommended Service Material
    306
  - Special Tool
    306
- Engine Cooling System
  
  307
- Precautions
  
  307
  - Engine Cooling System Warning
    307
  - Precautions for Engine Coolant
    307
- General Description
  
  307
  - Engine Coolant Description
    307
- Schematic and Routing Diagram
  
  308
  - Cooling Circuit Diagram
    308
  - Water Hose Routing Diagram
    309
- Diagnostic Information and Procedures
  
  310
  - Engine Cooling Symptom Diagnosis
    310
- Repair Instructions
  
  310
  - Cooling Circuit Inspection
    310
  - Radiator Cap Inspection
    311
  - Radiator / Cooling Fan Motor Removal and Installation
    311
  - Radiator Inspection and Cleaning
    312
  - Radiator Hose Removal and Installation
    312
  - Radiator Reservoir Tank Inspection
    313
  - Water Hose Inspection
    313
  - Radiator Reservoir Tank Removal and Installation
    313
  - Cooling Fan Inspection
    314
  - Cooling Fan Relay Inspection
    314
  - ECT Sensor Removal and Installation
    315
  - ECT Sensor Inspection
    315
  - Thermostat Connector / Thermostat Removal and Installation
    315
  - Thermostat Inspection
    316
  - Water Pump Components
    317
  - Water Pump Construction
    318
  - Water Pump Removal and Installation
    318
  - Water Pump Disassembly and Assembly
    319
  - Water Pump Related Parts Inspection
    322
- Specifications
  
  323
  - Service Data
    323
  - Tightening Torque Specifications
    324
- Special Tools and Equipment
  
  324
  - Recommended Service Material
    324
  - Special Tool
    324
- Fuel System
  
  325
- Precautions
  
  325
  - Precautions for Fuel System
    325
- General Description
  
  326
  - Fuel System Description
    326
- Schematic and Routing Diagram
  
  327
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram
    327
- Diagnostic Information and Procedures
  
  328
  - Fuel System Diagnosis
    328
- Repair Instructions
  
  329
- Specifications
  
  339
  - Service Data
    339
  - Tightening Torque Specifications
    339
- Special Tools and Equipment
  
  340
  - Recommended Service Material
    340
  - Special Tool
    340
- Ignition System
  
  341
- Schematic and Routing Diagram
  
  341
  - Ignition System Diagram
    341
  - Ignition System Components Location
    341
- Diagnostic Information and Procedures
  
  341
  - Ignition System Symptom Diagnosis
    341
  - No Spark or Poor Spark
    342
- Repair Instructions
  
  343
- Specifications
  
  349
  - Service Data
    349
  - Tightening Torque Specifications
    349
- Special Tools and Equipment
  
  349
  - Special Tool
    349
- Starting System
  
  350
- Schematic and Routing Diagram
  
  350
  - Starting System Diagram
    350
- Component Location
  
  350
  - Starting System Components Location
    350
- Diagnostic Information and Procedures
  
  350
- Repair Instructions
  
  352
- Specifications
  
  361
  - Service Data
    361
  - Tightening Torque Specifications
    361
- Special Tools and Equipment
  
  362
  - Recommended Service Material
    362
  - Special Tool
    362
- Charging System
  
  363
- Schematic and Routing Diagram
  
  363
  - Charging System Diagram
    363
- Component Location
  
  363
  - Charging System Components Location
    363
- Diagnostic Information and Procedures
  
  363
  - Charging System Symptom Diagnosis
    363
  - Battery Runs down Quickly
    364
- Repair Instructions
  
  365
  - Battery Current Leakage Inspection
    365
  - Regulated Voltage Inspection
    365
  - Generator Inspection
    365
  - Generator Removal and Installation
    366
  - Regulator / Rectifier Construction
    370
  - Regulator / Rectifier Inspection
    370
  - Battery Components
    371
  - Battery Charging
    371
  - Battery Removal and Installation
    374
  - Battery Visual Inspection
    374
- Specifications
  
  375
  - Service Data
    375
  - Tightening Torque Specifications
    375
- Special Tools and Equipment
  
  375
  - Recommended Service Material
    375
  - Special Tool
    376
- Exhaust System
  
  377
- Precautions
  
  377
  - Precautions for Exhaust System
    377
- Repair Instructions
  
  378
- Specifications
  
  382
  - Tightening Torque Specifications
    382
- Special Tools and Equipment
  
  382
  - Recommended Service Material
    382
Section 2 Suspension

383
- Precautions
  
  385
  - Precautions for Suspension
    385
- 2A-1 Suspension General Diagnosis
  
  386
- Diagnostic Information and Procedures
  
  386
  - Suspension and Wheel Symptom Diagnosis
    386
- Repair Instructions
  
  387
  - Front Fork Components
    387
  - Front Fork Removal and Installation
    388
  - Front Fork Disassembly and Assembly
    389
  - Front Fork Inspection
    395
  - Front Fork Parts Inspection
    395
- Front Suspension
  
  387
- Special Tools and Equipment
  
  396
  - Recommended Service Material
    396
  - Special Tool
    397
- Specifications
  
  396
  - Service Data
    396
  - Tightening Torque Specifications
    396
- Rear Suspension
  
  398
- Repair Instructions
  
  398
- Specifications
  
  410
  - Service Data
    410
  - Tightening Torque Specifications
    410
- Special Tools and Equipment
  
  410
  - Recommended Service Material
    410
  - Special Tool
    411
- Wheels and Tires
  
  412
- Precautions
  
  412
  - Precautions for Wheel and Tire
    412
- Repair Instructions
  
  413
- Specifications
  
  437
  - Service Data
    437
  - Tightening Torque Specifications
    437
Section 3 Driveline / Axle

439
- Precautions
  
  440
  - Precautions for Driveline / Axle
    440
- Diagnostic Information and Procedures
  
  441
  - Drive Chain and Sprocket Symptom Diagnosis
    441
- Repair Instructions
  
  441
- Drive Chain / Drive Train / Drive Shaft
  
  441
- Specifications
  
  450
  - Service Data
    450
  - Tightening Torque Specifications
    451
- Special Tools and Equipment
  
  451
  - Recommended Service Material
    451
  - Special Tool
    451
Section 4 Brake

453
- Precautions
  
  455
  - Precautions for Brake System
    455
  - Brake Fluid Information
    455
- Schematic and Routing Diagram
  
  456
- Brake Control System and Diagnosis
  
  456
- Repair Instructions
  
  459
- Diagnostic Information and Procedures
  
  459
  - Brake Symptom Diagnosis
    459
- Specifications
  
  470
  - Service Data
    470
  - Tightening Torque Specifications
    471
- Special Tools and Equipment
  
  471
  - Recommended Service Material
    471
  - Special Tool
    471
- Front Brakes
  
  472
- Repair Instructions
  
  472
- Specifications
  
  478
  - Service Data
    478
  - Tightening Torque Specifications
    478
- Special Tools and Equipment
  
  478
  - Recommended Service Material
    478
  - Special Tool
    479
- Rear Brakes
  
  480
- Repair Instructions
  
  480
  - Rear Brake Components
    480
  - Rear Brake Pad Inspection
    481
  - Rear Brake Pad Replacement
    481
  - Rear Brake Caliper Removal and Installation
    482
  - Rear Brake Caliper Disassembly and Assembly
    483
  - Rear Brake Caliper Parts Inspection
    485
  - Rear Brake Disc Removal and Installation
    485
  - Rear Brake Disc Inspection
    486
- Specifications
  
  486
  - Service Data
    486
  - Tightening Torque Specifications
    487
- Special Tools and Equipment
  
  487
  - Recommended Service Material
    487
  - Special Tool
    487
- Precautions
  
  488
  - Precautions for ABS
    488
  - ABS Information
    488
- General Description
  
  488
- Abs
  
  488
- Schematic and Routing Diagram
  
  494
  - ABS Wiring Diagram
    494
  - ABS Unit Diagram
    495
  - Front Wheel Speed Sensor Routing Diagram
    496
  - Rear Wheel Speed Sensor Routing Diagram
    498
- Component Location
  
  499
  - ABS Components Location
    499
- Diagnostic Information and Procedures
  
  500
- Repair Instructions
  
  556
- Specifications
  
  562
  - Tightening Torque Specifications
    562
- Special Tools and Equipment
  
  562
  - Special Tool
    562
Section 5 Transmission / Transaxle

565
- Precautions
  
  566
  - Precautions for Transmission / Transaxle
    566
- Diagnostic Information and Procedures
  
  567
  - Manual Transmission Symptom Diagnosis
    567
- Manual Transmission
  
  567
- Repair Instructions
  
  568
- Specifications
  
  585
  - Service Data
    585
  - Tightening Torque Specifications
    586
- Special Tools and Equipment
  
  586
  - Recommended Service Material
    586
  - Special Tool
    587
- Precautions
  
  588
  - Precautions for Clutch System
    588
  - Clutch Fluid (Brake Fluid) Information
    588
- Clutch
  
  588
- Schematic and Routing Diagram
  
  589
  - Clutch Hose Routing Diagram
    589
- Repair Instructions
  
  590
- Diagnostic Information and Procedures
  
  590
  - Clutch System Symptom Diagnosis
    590
- Specifications
  
  606
  - Service Data
    606
  - Tightening Torque Specifications
    606
- Special Tools and Equipment
  
  607
  - Recommended Service Material
    607
  - Special Tool
    607

Suzuki GSF650 Service Manual (333 pages)

Brand: Suzuki | Category: Motorcycle | Size: 22.6 MB

General Information 1

5
- How to Use this Manual
  3
- Table of Contents
  5
- General Information
  5
- General Precautions
  6
- Warning/Caution/Note
  6
- Serial Number Location
  8
- Suzuki Gsf650 (2005-Model)
  8
- Suzuki Gsf650S (2005-Model)
  8
- Fuel and Oil Recommendation
  9
  - FUEL (for Canada)
    9
  - FUEL (for Other Countries)
    9
  - Engine Oil
    9
  - Brake Fluid
    9
  - Front Fork Oil
    9
- BREAK-Ln PROCEDURES
  10
- Cylinder Identification
  10
- Information Labels
  11
- Specifications
  12
  - Dimensions and Dry Mass
    12
  - Drive Train
    12
Periodic Maintenance

14
- Periodic Maintenance Schedule
  15
  - Periodic Maintenance Chart
    15
  - Lubrication Points
    16
- Maintenance and Tune-Up Procedures
  17
  - Valve Clearance
    17
  - Spark Plugs
    19
  - Exhaust Pipe Bolts and Muffler Bolts
    20
  - Air Cleaner
    21
  - Engine Oil and Oil Filter
    22
  - Fuel Line
    24
  - Engine Idle Speed
    24
  - Throttle Cable Play
    24
  - Carburetor Synchronization
    25
  - Pair (Air Supply) System
    25
  - Fuel Filter
    25
  - Clutch Cable Play
    25
  - Drive Chain
    26
  - Brakes
    28
  - Tires
    31
  - Steering
    31
  - Tire Tread Depth
    31
  - Front Forks
    32
  - Rear Suspension
    32
  - Chassis Bolts and Nuts
    33
- Compression Pressure Check
  35
  - Compression Test Procedure
    35
- Oil Pressure Check
  36
  - Oil Pressure Test Procedure
    36
Engine

37
- Engine Components Removable with Engine in Place
  38
- Engine Removal and Installation
  39
  - Removal
    39
  - Installation
    43
- Engine Disassembly
  48
- Engine Components Inspection and Service
  62
- Engine Reassembly
  99
- Engine Lubrication System
  122
  - Oil Pump
    122
  - Oil Sump Filter/Oil Pressure Regulator
    122
  - Oil Pressure Switch
    125
  - Oil Cooler
    126
  - Oil Filter
    126
  - Oil Pressure
    126
  - Oil Jet
    127
  - Engine Lubrication System Chart
    129
  - Engine Lubrication System
    130
  - Cylinder Head Cover
    131
  - Cylinder Head Cooling System Chart
    131
  - Cylinder Head Cooling System
    132
- Pair (Air Supply) System
  133
  - Removal
    133
  - Inspection
    133
  - Installation
    134
Fuel System

136
- Fuel System
  137
- Fuel Tank
  138
  - Removal
    138
  - Remounting
    138
- Fuel Valve
  139
  - Removal
    140
  - Inspection and Cleaning
    140
  - Installation
    140
- Fuel Filter
  141
  - Removal
    141
  - Inspection
    141
  - Installation
    141
- Fuel Level Gauge
  142
  - Removal and Installation
    142
- Carburetor
  143
  - Construction
    143
  - Specifications
    144
  - I.D. No. Location
    145
  - Diaphragm and Piston Operation
    146
  - Slow System
    147
  - Main System
    148
  - Starter (Enricher) System
    149
  - Float System
    149
  - Removal
    150
  - Disassembly
    151
  - Cleaning
    154
  - Inspection
    155
  - Reassembly
    156
  - Remounting
    159
  - Carburetor Synchronization
    160
Chassis

163
- Exterior Parts
  165
  - Construction
    165
  - Removal
    166
  - Installation
    168
- Front Wheel
  169
  - Construction
    169
  - Removal
    170
  - Inspection and Disassembly
    170
  - Reassembly and Installation
    172
- Front Fork
  175
  - Construction
    175
  - Removal and Disassembly
    176
  - Inspection
    178
  - Reassembly and Installation
    179
- Handlebars and Steering
  183
  - Construction
    183
  - Handlebars
    184
  - Steering
    186
  - Steering Tension Adjustment
    190
- Rear Wheel
  191
  - Construction
    191
  - Removal
    192
  - Inspection and Disassembly
    193
  - Reassembly and Installation
    195
- Rear Suspension
  198
  - Construction
    198
  - Removal
    199
  - Inspection and Disassembly
    200
  - Reassembly
    202
  - Rear Shock Absorber Disposal
    203
  - Installation
    204
  - Final Inspection and Adjustment
    207
  - Suspension Setting
    207
- Front Brake
  208
  - Construction
    208
  - Brake Pad Replacement
    209
  - Brake Fluid Replacement
    210
  - Brake Caliper Removal and Disassembly
    211
  - Brake Caliper Inspection
    212
  - Brake Caliper Reassembly and Installation
    213
  - Brake Disc Inspection
    214
  - Master Cylinder Removal and Disassembly
    215
  - Master Cylinder Inspection
    216
  - Master Cylinder Reassembly and Installation
    217
- Rear Brake
  219
  - Construction
    219
  - Brake Pad Replacement
    220
  - Brake Fluid Replacement
    221
  - Brake Caliper Removal and Disassembly
    222
  - Brake Caliper Inspection
    223
  - Brake Caliper Reassembly and Installation
    223
  - Master Cylinder Removal and Disassembly
    225
  - Master Cylinder Inspection
    226
  - Master Cylinder Reassembly and Installation
    226
- Tire and Wheel
  228
  - Tire Removal
    228
  - Inspection
    228
  - Installation
    229
- Drive Chain
  232
  - Cutting
    232
  - Connecting
    233
- Riding Position Adjustment
  236
  - Seat Height Adjustment
    236
  - Handlebar Height Adjustment
    237
Electrical System

238
- Cautions in Servicing
  240
  - Connector
    240
  - Coupler
    240
  - Clamp
    240
  - Fuse
    240
  - Semi-Conductor Equipped Part
    241
  - Battery
    241
  - Connecting the Battery
    241
  - Wiring Procedure
    241
  - Using the Multi-Circuit Tester
    242
- Location of Electrical Components
  243
- Charging System
  245
  - Description (Generator with IC Regulator)
    245
  - Troubleshooting
    246
  - Inspection
    248
- Generator
  249
  - Removal and Disassembly
    250
  - Inspection
    252
  - Generator Reassembly and Remounting
    255
- Starter System and Side-Stand Ignition Interlock System
  257
- Ignition System (Digital Ignitor)
  266
  - Description
    266
  - Troubleshooting
    267
  - Inspection
    269
- Combination Meter
  273
  - Removal
    273
  - Disassembly
    273
  - Inspection
    275
- Lamps
  278
  - Headlight
    278
  - Brake Light/Taillight and License Plate Light
    282
  - Turn Signal Lights
    282
- Relays
  283
  - Turn Signal/Side-Stand Relay
    283
  - Starter Relay
    283
- Switches
  284
  - Ignition Switch Removal and Installation
    284
  - Inspection
    285
- Battery
  286
  - Specifications
    286
  - Initial Charging
    286
  - Servicing
    288
  - Recharging Operation
    288

Suzuki GSF650 Service Manual (66 pages)

Brand: Suzuki | Category: Motorcycle | Size: 2.93 MB

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Suzuki GSF650 Manuals

Suzuki GSF650 Service Manual (697 pages)

Table of Contents

Section 1 Engine

Precautions

Engine General Information and Diagnosis

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Specifications

Special Tools and Equipment

Emission Control Devices

Precautions

General Description

Schematic and Routing Diagram

Repair Instructions

Special Tools and Equipment

Engine Electrical Devices

Precautions

Diagnostic Information and Procedures

Repair Instructions

Special Tools and Equipment

Engine Mechanical

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

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

Section 2 Suspension

Precautions

2A-1 Suspension General Diagnosis

Diagnostic Information and Procedures

Repair Instructions