Suzuki GSF650 Manuals

Manuals and User Guides for Suzuki GSF650. We have 2 Suzuki GSF650 manuals available for free PDF download: Service Manual

Suzuki GSF650 Service Manual

Suzuki GSF650 Service Manual (697 pages)

Brand: Suzuki | Category: Motorcycle | Size: 60.73 MB
Table of contents
General Information13................................................................................................................................................................
Fuel And Oil Recommendation16................................................................................................................................................................
Vehicle Identification Number16................................................................................................................................................................
Cylinder Identification17................................................................................................................................................................
Maintenance And Lubrication34................................................................................................................................................................
Scheduled Maintenance34................................................................................................................................................................
Fuel Line Inspection45................................................................................................................................................................
Table Of Contents71................................................................................................................................................................
Precautions75................................................................................................................................................................
Precautions For Engine75................................................................................................................................................................
Section75................................................................................................................................................................
Engine General Information And Diagnosis76................................................................................................................................................................
General Description76................................................................................................................................................................
Injection Timing Description76................................................................................................................................................................
Self-diagnosis Function (gsf650/s/a/sak7)77................................................................................................................................................................
Self-diagnosis Function (gsx650fk8)79................................................................................................................................................................
Schematic And Routing Diagram81................................................................................................................................................................
Fi System Wiring Diagram81................................................................................................................................................................
Terminal Alignment Of Ecm Coupler82................................................................................................................................................................
Fi System Parts Location83................................................................................................................................................................
Diagnostic Information And Procedures84................................................................................................................................................................
Engine Symptom Diagnosis84................................................................................................................................................................
Self-diagnostic Procedures (gsf650/s/a/sak7)88................................................................................................................................................................
Use Of Sds Diagnosis Reset Procedures90................................................................................................................................................................
Show Data When Trouble (dtc)90................................................................................................................................................................
Sds Check92................................................................................................................................................................
Dtc Table96................................................................................................................................................................
Fail-safe Function Table97................................................................................................................................................................
Fi System Troubleshooting98................................................................................................................................................................
Malfunction Code And Defective Condition Table99................................................................................................................................................................
Dtc "c12" (p0335): Ckp Sensor Circuit Malfunction102................................................................................................................................................................
Dtc "c13" (p0105-h/l): Iap Sensor (#1) Circuit Malfunction105................................................................................................................................................................
Dtc "c14" (p0120-h/l): Tp Sensor Circuit Malfunction114................................................................................................................................................................
Dtc "c15" (p0115-h/l): Ect Sensor Circuit Malfunction122................................................................................................................................................................
Dtc "c17" (p1750-h/l): Iap Sensor (#2) Circuit Malfunction129................................................................................................................................................................
Dtc "c21" (p0110-h/l): Iat Sensor Circuit Malfunction137................................................................................................................................................................
Dtc "c23" (p1651-h/l): To Sensor Circuit Malfunction144................................................................................................................................................................
Dtc "c24" (p0351), "c25" (p0352), "c26" (p0353) Or "c27" (p0354): Ignition System Malfunction150................................................................................................................................................................
Dtc "c28" (p1655): Secondary Throttle Valve Actuator (stva) Malfunction150................................................................................................................................................................
Dtc "c29" (p1654-h/l): Secondary Throttle Position Sensor (stps) Circuit Malfunction154................................................................................................................................................................
Dtc "c31" (p0705): Gp Switch Circuit Malfunction162................................................................................................................................................................
Dtc "c32" (p0201), "c33" (p0202), "c34" (p0203) Or "c35" (p0204): Fuel Injector Circuit Malfunction164................................................................................................................................................................
Dtc "c40" (p0505, P0506 Or P0507): Isc Valve Circuit Malfunction168................................................................................................................................................................
Dtc "c41" (p0230-h/l): Fp Relay Circuit Malfunction174................................................................................................................................................................
Dtc "c41" (p2505): Ecm Power Input Signal Malfunction177................................................................................................................................................................
Dtc "c42" (p1650): Ig Switch Circuit Malfunction179................................................................................................................................................................
Dtc "c44" (p0130/p0135): Ho2 Sensor (ho2s) Circuit Malfunction179................................................................................................................................................................
Dtc "c49" (p1656): Pair Solenoid Valve Circuit Malfunction185................................................................................................................................................................
Dtc "c60" (p0480): Cooling Fan Relay Circuit Malfunction189................................................................................................................................................................
Self-diagnostic Procedures (gsx650fk8)192................................................................................................................................................................
Specifications193................................................................................................................................................................
Service Data193................................................................................................................................................................
Special Tools And Equipment194................................................................................................................................................................
Special Tool194................................................................................................................................................................
Emission Control Devices195................................................................................................................................................................
Precautions For Emission Control Devices195................................................................................................................................................................
Fuel Injection System Description195................................................................................................................................................................
Crankcase Emission Control System Description196................................................................................................................................................................
Exhaust Emission Control System Description197................................................................................................................................................................
Noise Emission Control System Description197................................................................................................................................................................
Pair System Hose Routing Diagram198................................................................................................................................................................
Repair Instructions199................................................................................................................................................................
Heated Oxygen Sensor (ho2s) Removal And Installation199................................................................................................................................................................
Heated Oxygen Sensor (ho2s) Inspection200................................................................................................................................................................
Pair Reed Valve Removal And Installation200................................................................................................................................................................
Pair Control Solenoid Valve Removal And Installation200................................................................................................................................................................
Pair System Inspection201................................................................................................................................................................
Crankcase Breather (pcv) Hose Inspection202................................................................................................................................................................
Crankcase Breather (pcv) Hose / Cover Removal And Installation202................................................................................................................................................................
Crankcase Breather (pcv) Cover Inspection203................................................................................................................................................................
Tightening Torque Specifications204................................................................................................................................................................
Recommended Service Material204................................................................................................................................................................
Engine Electrical Devices205................................................................................................................................................................
Precautions For Engine Electrical Device205................................................................................................................................................................
Engine Electrical Components Location205................................................................................................................................................................
Ecm Removal And Installation205................................................................................................................................................................
Ckp Sensor Inspection205................................................................................................................................................................
Ckp Sensor Removal And Installation205................................................................................................................................................................
Iap Sensor (#1) Inspection205................................................................................................................................................................
Iap Sensor (#1) Removal And Installation206................................................................................................................................................................
Iap / Tp / Iat Sensor Inspection206................................................................................................................................................................
Iap / Tp / Iat Sensor Removal And Installation206................................................................................................................................................................
Ect Sensor Removal And Installation206................................................................................................................................................................
Ect Sensor Inspection207................................................................................................................................................................
To Sensor Removal And Installation207................................................................................................................................................................
To Sensor Inspection207................................................................................................................................................................
Stp Sensor Inspection207................................................................................................................................................................
Stp Sensor Adjustment208................................................................................................................................................................
Stp Sensor Removal And Installation208................................................................................................................................................................
Stv Actuator Inspection209................................................................................................................................................................
Stv Actuator Removal And Installation209................................................................................................................................................................
Isc Valve Inspection209................................................................................................................................................................
Isc Valve Removal And Installation209................................................................................................................................................................
Isc Valve Preset And Opening Initialization209................................................................................................................................................................
Ho2 Sensor Inspection210................................................................................................................................................................
Ho2 Sensor Removal And Installation210................................................................................................................................................................
Gp Switch Inspection210................................................................................................................................................................
Gp Switch Removal And Installation210................................................................................................................................................................
Engine Mechanical213................................................................................................................................................................
Camshaft And Sprocket Assembly Diagram213................................................................................................................................................................
Throttle Cable Routing Diagram (gsf650/s/a/sak7)214................................................................................................................................................................
Throttle Cable Routing Diagram (gsx650fk8)215................................................................................................................................................................
Engine Mechanical Symptom Diagnosis216................................................................................................................................................................
Compression Pressure Check216................................................................................................................................................................
Engine Components Removable With The Engine In Place217................................................................................................................................................................
Air Cleaner Element Removal And Installation219................................................................................................................................................................
Air Cleaner Element Inspection And Cleaning219................................................................................................................................................................
Air Cleaner Box Removal And Installation219................................................................................................................................................................
Throttle Cable Removal And Installation219................................................................................................................................................................
Throttle Cable Inspection220................................................................................................................................................................
Adjustment220................................................................................................................................................................
Throttle Body Components220................................................................................................................................................................
Throttle Body Construction221................................................................................................................................................................
Throttle Body Removal And Installation222................................................................................................................................................................
Throttle Body Disassembly And Assembly223................................................................................................................................................................
Throttle Body Inspection And Cleaning227................................................................................................................................................................
Throttle Valve Synchronization228................................................................................................................................................................
Engine Assembly Removal230................................................................................................................................................................
Engine Assembly Installation233................................................................................................................................................................
Engine Top Side Disassembly236................................................................................................................................................................
Engine Top Side Assembly238................................................................................................................................................................
Valve Clearance Inspection And Adjustment245................................................................................................................................................................
Cylinder Head Cover Inspection246................................................................................................................................................................
Camshaft Inspection246................................................................................................................................................................
Camshaft Sprocket Inspection248................................................................................................................................................................
Camshaft Sprocket Removal And Installation248................................................................................................................................................................
Cam Chain Tension Adjuster Inspection248................................................................................................................................................................
Cam Chain Guide Removal And Installation249................................................................................................................................................................
Cam Chain Guide Inspection249................................................................................................................................................................
Cam Chain Tensioner Inspection249................................................................................................................................................................
Cylinder Head Disassembly And Assembly250................................................................................................................................................................
Cylinder Head Related Parts Inspection253................................................................................................................................................................
Valve Guide Replacement256................................................................................................................................................................
Valve Seat Repair257................................................................................................................................................................
Cylinder Disassembly And Assembly258................................................................................................................................................................
Cylinder Inspection259................................................................................................................................................................
Piston Ring Removal And Installation260................................................................................................................................................................
Piston And Piston Ring Inspection261................................................................................................................................................................
Engine Bottom Side Disassembly263................................................................................................................................................................
Engine Bottom Side Assembly270................................................................................................................................................................
Conrod Removal And Installation279................................................................................................................................................................
Conrod And Crankshaft Inspection281................................................................................................................................................................
Conrod Crank Pin Bearing Inspection And Selection282................................................................................................................................................................
Crankshaft Journal Bearing Inspection And Selection283................................................................................................................................................................
Crankshaft Thrust Clearance Inspection And Selection285................................................................................................................................................................
Engine Lubrication System294................................................................................................................................................................
Precautions For Engine Oil294................................................................................................................................................................
Engine Lubrication System Chart Diagram295................................................................................................................................................................
Oil Pan295................................................................................................................................................................
Engine Lubrication Symptom Diagnosis296................................................................................................................................................................
Oil Pressure Check296................................................................................................................................................................
Engine Oil And Filter Replacement297................................................................................................................................................................
Engine Oil Level Inspection297................................................................................................................................................................
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal And Installation297................................................................................................................................................................
Oil Pressure Regulator / Oil Strainer Inspection299................................................................................................................................................................
Oil Pressure Switch Removal And Installation300................................................................................................................................................................
Oil Pressure Switch Inspection300................................................................................................................................................................
Oil Jet Removal And Installation301................................................................................................................................................................
Oil Gallery Jet Removal And Installation302................................................................................................................................................................
Oil Jet / Oil Gallery Jet Inspection303................................................................................................................................................................
Oil Pump Removal And Installation303................................................................................................................................................................
Oil Pump Inspection305................................................................................................................................................................
Engine Cooling System307................................................................................................................................................................
Engine Cooling System Warning307................................................................................................................................................................
Precautions For Engine Coolant307................................................................................................................................................................
Engine Coolant Description307................................................................................................................................................................
Cooling Circuit Diagram308................................................................................................................................................................
Water Hose Routing Diagram309................................................................................................................................................................
Engine Cooling Symptom Diagnosis310................................................................................................................................................................
Cooling Circuit Inspection310................................................................................................................................................................
Radiator Cap Inspection311................................................................................................................................................................
Radiator / Cooling Fan Motor Removal And Installation311................................................................................................................................................................
Radiator Inspection And Cleaning312................................................................................................................................................................
Radiator Hose Removal And Installation312................................................................................................................................................................
Radiator Reservoir Tank Inspection313................................................................................................................................................................
Water Hose Inspection313................................................................................................................................................................
Radiator Reservoir Tank Removal And Installation313................................................................................................................................................................
Cooling Fan Inspection314................................................................................................................................................................
Cooling Fan Relay Inspection314................................................................................................................................................................
Thermostat Connector / Thermostat Removal And Installation315................................................................................................................................................................
Thermostat Inspection316................................................................................................................................................................
Water Pump Components317................................................................................................................................................................
Water Pump Construction318................................................................................................................................................................
Water Pump Removal And Installation318................................................................................................................................................................
Water Pump Disassembly And Assembly319................................................................................................................................................................
Water Pump Related Parts Inspection322................................................................................................................................................................
Fuel System325................................................................................................................................................................
Precautions For Fuel System325................................................................................................................................................................
Fuel System Description326................................................................................................................................................................
Fuel Tank Drain Hose And Breather Hose Routing Diagram327................................................................................................................................................................
Fuel System Diagnosis328................................................................................................................................................................
Fuel Pressure Inspection329................................................................................................................................................................
Fuel Pump Inspection329................................................................................................................................................................
Fuel Discharge Amount Inspection330................................................................................................................................................................
Fuel Pump Relay Inspection330................................................................................................................................................................
Fuel Hose Leakage Inspection331................................................................................................................................................................
Fuel Level Gauge Inspection331................................................................................................................................................................
Fuel Level Indicator Inspection331................................................................................................................................................................
Fuel Level Indicator Switch (thermistor) Inspection331................................................................................................................................................................
Fuel Tank Construction332................................................................................................................................................................
Fuel Tank Removal And Installation333................................................................................................................................................................
Fuel Pump Components334................................................................................................................................................................
Fuel Pump Assembly / Fuel Level Gauge Removal And Installation335................................................................................................................................................................
Fuel Level Gauge And Fuel Level Indicator Switch Inspection336................................................................................................................................................................
Fuel Pump Disassembly And Assembly336................................................................................................................................................................
Fuel Mesh Filter Inspection And Cleaning338................................................................................................................................................................
Fuel Hose Inspection338................................................................................................................................................................
Fuel Injector / Fuel Delivery Pipe / T-joint Removal And Installation338................................................................................................................................................................
Fuel Injector Inspection And Cleaning339................................................................................................................................................................
Ignition System341................................................................................................................................................................
Ignition System Diagram341................................................................................................................................................................
Ignition System Components Location341................................................................................................................................................................
Ignition System Symptom Diagnosis341................................................................................................................................................................
No Spark Or Poor Spark342................................................................................................................................................................
Ignition Coil / Plug Cap And Spark Plug Removal And Installation343................................................................................................................................................................
Spark Plug Inspection And Cleaning344................................................................................................................................................................
Ignition Coil / Plug Cap Inspection344................................................................................................................................................................
Engine Stop Switch Inspection347................................................................................................................................................................
Ignition Switch Inspection347................................................................................................................................................................
Ignition Switch Removal And Installation347................................................................................................................................................................
Starting System350................................................................................................................................................................
Starting System Diagram350................................................................................................................................................................
Component Location350................................................................................................................................................................
Starting System Components Location350................................................................................................................................................................
Starting System Symptom Diagnosis350................................................................................................................................................................
Starter Motor Will Not Run351................................................................................................................................................................
Starter Motor Runs But Does Not Crank The Engine351................................................................................................................................................................
Starter Motor Components352................................................................................................................................................................
Starter Motor Removal And Installation353................................................................................................................................................................
Starter Motor Disassembly And Assembly353................................................................................................................................................................
Starter Motor Inspection354................................................................................................................................................................
Starter Relay Removal And Installation355................................................................................................................................................................
Starter Relay Inspection356................................................................................................................................................................
Turn Signal / Side-stand Relay Removal And Installation356................................................................................................................................................................
Side-stand / Ignition Interlock System Parts Inspection357................................................................................................................................................................
Starter Clutch Removal And Installation359................................................................................................................................................................
Starter Clutch Inspection360................................................................................................................................................................
Starter Button Inspection361................................................................................................................................................................
Charging System363................................................................................................................................................................
Charging System Diagram363................................................................................................................................................................
Charging System Components Location363................................................................................................................................................................
Charging System Symptom Diagnosis363................................................................................................................................................................
Battery Runs Down Quickly364................................................................................................................................................................
Battery Current Leakage Inspection365................................................................................................................................................................
Regulated Voltage Inspection365................................................................................................................................................................
Generator Inspection365................................................................................................................................................................
Generator Removal And Installation366................................................................................................................................................................
Regulator / Rectifier Construction370................................................................................................................................................................
Regulator / Rectifier Inspection370................................................................................................................................................................
Battery Components371................................................................................................................................................................
Battery Charging371................................................................................................................................................................
Battery Removal And Installation374................................................................................................................................................................
Battery Visual Inspection374................................................................................................................................................................
Exhaust System377................................................................................................................................................................
Precautions For Exhaust System377................................................................................................................................................................
Exhaust System Construction378................................................................................................................................................................
Exhaust Pipe / Muffler Removal And Installation379................................................................................................................................................................
Exhaust System Inspection381................................................................................................................................................................
Precautions For Suspension385................................................................................................................................................................
2a-1 Suspension General Diagnosis386................................................................................................................................................................
Suspension And Wheel Symptom Diagnosis386................................................................................................................................................................
Front Suspension387................................................................................................................................................................
Front Fork Components387................................................................................................................................................................
Front Fork Removal And Installation388................................................................................................................................................................
Front Fork Disassembly And Assembly389................................................................................................................................................................
Front Fork Inspection395................................................................................................................................................................
Front Fork Parts Inspection395................................................................................................................................................................
Rear Suspension398................................................................................................................................................................
Rear Suspension Components398................................................................................................................................................................
Rear Suspension Assembly Construction399................................................................................................................................................................
Rear Shock Absorber Removal And Installation400................................................................................................................................................................
Rear Suspension Inspection401................................................................................................................................................................
Rear Shock Absorber Inspection401................................................................................................................................................................
Rear Suspension Adjustment401................................................................................................................................................................
Rear Shock Absorber Disposal402................................................................................................................................................................
Cushion Lever Removal And Installation403................................................................................................................................................................
Cushion Lever Inspection404................................................................................................................................................................
Cushion Lever Bearing Removal And Installation404................................................................................................................................................................
Swingarm / Cushion Rod Removal And Installation405................................................................................................................................................................
Swingarm Related Parts Inspection407................................................................................................................................................................
Swingarm Bearing Removal And Installation408................................................................................................................................................................
Wheels And Tires412................................................................................................................................................................
Precautions For Wheel And Tire412................................................................................................................................................................
Front Wheel Components (gsf650/s/u/suk7)413................................................................................................................................................................
Front Wheel Assembly Construction (gsf650/s/u/suk7)414................................................................................................................................................................
Front Wheel Assembly Removal And Installation (gsf650/s/u/suk7)415................................................................................................................................................................
Front Wheel Related Parts Inspection417................................................................................................................................................................
Front Wheel Dust Seal / Bearing Removal And Installation418................................................................................................................................................................
Rear Wheel Components (gsf650/s/u/suk7)420................................................................................................................................................................
Rear Wheel Assembly Construction (gsf650/s/u/suk7)421................................................................................................................................................................
Rear Wheel Assembly Removal And Installation (gsf650/s/u/suk7)422................................................................................................................................................................
Rear Wheel Related Parts Inspection423................................................................................................................................................................
Rear Wheel Dust Seal / Bearing Removal And Installation424................................................................................................................................................................
Tire Removal And Installation426................................................................................................................................................................
Wheel / Tire / Air Valve Inspection And Cleaning427................................................................................................................................................................
Air Valve Removal And Installation428................................................................................................................................................................
Wheel Balance Check And Adjustment428................................................................................................................................................................
Front Wheel Components (gsf650a/ua/sa/asuk7)429................................................................................................................................................................
Front Wheel Assembly Construction (gsf650a/ua/sa/asuk7)430................................................................................................................................................................
Front Wheel Assembly Removal And Installation (gsf650a/ua/sa/asuk7)431................................................................................................................................................................
Rear Wheel Components (gsf650a/ua/sa/asuk7)434................................................................................................................................................................
Rear Wheel Assembly Construction (gsf650a/ua/sa/asuk7)435................................................................................................................................................................
Rear Wheel Assembly Removal And Installation (gsf650a/ua/sa/asuk7)435................................................................................................................................................................
Precautions For Driveline / Axle440................................................................................................................................................................
Drive Chain / Drive Train / Drive Shaft441................................................................................................................................................................
Drive Chain And Sprocket Symptom Diagnosis441................................................................................................................................................................
Drive Chain Related Components441................................................................................................................................................................
Engine Sprocket Removal And Installation442................................................................................................................................................................
Rear Sprocket / Rear Sprocket Mounting Drum Removal And Installation444................................................................................................................................................................
Drive Chain Related Parts Inspection445................................................................................................................................................................
Sprocket Mounting Drum Dust Seal / Bearing Removal And Installation446................................................................................................................................................................
Drive Chain Replacement447................................................................................................................................................................
Precautions For Brake System455................................................................................................................................................................
Brake Fluid Information455................................................................................................................................................................
Brake Control System And Diagnosis456................................................................................................................................................................
Front Brake Hose Routing Diagram (gsf650)456................................................................................................................................................................
Front Brake Hose Routing Diagram (gsf650s)457................................................................................................................................................................
Rear Brake Hose Routing Diagram458................................................................................................................................................................
Brake Symptom Diagnosis459................................................................................................................................................................
Brake Pedal Height Inspection And Adjustment459................................................................................................................................................................
Front Brake Light Switch Inspection459................................................................................................................................................................
Rear Brake Light Switch Inspection460................................................................................................................................................................
Rear Brake Light Switch Inspection And Adjustment460................................................................................................................................................................
Brake Fluid Level Check460................................................................................................................................................................
Brake Hose Inspection460................................................................................................................................................................
Air Bleeding From Brake Fluid Circuit460................................................................................................................................................................
Brake Fluid Replacement462................................................................................................................................................................
Brake Hose Removal And Installation463................................................................................................................................................................
Front Brake Master Cylinder Components464................................................................................................................................................................
Front Brake Master Cylinder Assembly Removal And Installation464................................................................................................................................................................
Front Brake Master Cylinder / Brake Lever Disassembly And Assembly465................................................................................................................................................................
Front Brake Master Cylinder Parts Inspection467................................................................................................................................................................
Rear Brake Master Cylinder Components467................................................................................................................................................................
Rear Brake Master Cylinder Assembly Removal And Installation468................................................................................................................................................................
Rear Brake Master Cylinder Disassembly And Assembly469................................................................................................................................................................
Rear Brake Master Cylinder Parts Inspection470................................................................................................................................................................
Front Brakes472................................................................................................................................................................
Front Brake Components472................................................................................................................................................................
Front Brake Pad Inspection472................................................................................................................................................................
Front Brake Pad Replacement473................................................................................................................................................................
Front Brake Caliper Removal And Installation473................................................................................................................................................................
Front Brake Caliper Disassembly And Assembly474................................................................................................................................................................
Front Brake Caliper Parts Inspection476................................................................................................................................................................
Front Brake Disc Removal And Installation477................................................................................................................................................................
Front Brake Disc Inspection477................................................................................................................................................................
Rear Brakes480................................................................................................................................................................
Rear Brake Components480................................................................................................................................................................
Rear Brake Pad Inspection481................................................................................................................................................................
Rear Brake Pad Replacement481................................................................................................................................................................
Rear Brake Caliper Removal And Installation482................................................................................................................................................................
Rear Brake Caliper Disassembly And Assembly483................................................................................................................................................................
Rear Brake Caliper Parts Inspection485................................................................................................................................................................
Rear Brake Disc Removal And Installation485................................................................................................................................................................
Rear Brake Disc Inspection486................................................................................................................................................................
Abs488................................................................................................................................................................
Precautions For Abs488................................................................................................................................................................
Abs Information488................................................................................................................................................................
Wheel Speed Sensor Description488................................................................................................................................................................
Abs Control Unit Description489................................................................................................................................................................
Hydraulic Unit (hu) Description491................................................................................................................................................................
Self-diagnosis Function And Abs Indicator Light Description492................................................................................................................................................................
Fail-safe Function Description493................................................................................................................................................................
Abs Wiring Diagram494................................................................................................................................................................
Abs Unit Diagram495................................................................................................................................................................
Front Wheel Speed Sensor Routing Diagram496................................................................................................................................................................
Rear Wheel Speed Sensor Routing Diagram498................................................................................................................................................................
Abs Components Location499................................................................................................................................................................
Abs Troubleshooting500................................................................................................................................................................
Pre-diagnosis Inspection502................................................................................................................................................................
Abs Indicator Light Inspection504................................................................................................................................................................
Dtc (diagnostic Trouble Code) Output510................................................................................................................................................................
Dtc (diagnostic Trouble Code) Deleting513................................................................................................................................................................
Active Control Inspection517................................................................................................................................................................
Dtc "13" (c1613): Wheel Speed Sensor Rotor Malfunction522................................................................................................................................................................
Dtc "14" (c1614): Wheel Speed Sensor Rotor Malfunction524................................................................................................................................................................
Dtc "22" (c1622): Abs Actuator Circuit Malfunction526................................................................................................................................................................
Dtc "23" (c1623): Abs Actuator Circuit Malfunction527................................................................................................................................................................
Dtc "25" (c1625): Wheel Speed Sensor Related Malfunction529................................................................................................................................................................
Dtc "35" (c1635): Abs Motor Malfunction531................................................................................................................................................................
Dtc "41" (c1641): Wheel Speed Sensor Signal Malfunction533................................................................................................................................................................
Dtc "42" (c1642): Wheel Speed Sensor Circuit Open534................................................................................................................................................................
Dtc "43" (c1643): Wheel Speed Sensor Circuit Short539................................................................................................................................................................
Dtc "44" (c1644): Wheel Speed Sensor Signal Malfunction541................................................................................................................................................................
Dtc "45" (c1645): Wheel Speed Sensor Circuit Open543................................................................................................................................................................
Dtc "46" (c1646): Wheel Speed Sensor Circuit Short547................................................................................................................................................................
Dtc "47" (c1647): Supply Voltage (increased)549................................................................................................................................................................
Dtc "48" (c1648): Supply Voltage (decreased)551................................................................................................................................................................
Dtc "55" (c1655): Abs Control Unit Malfunction553................................................................................................................................................................
Dtc "61" (c1661): Abs Solenoid Malfunction555................................................................................................................................................................
Abs Control Unit Coupler Disconnect And Connect556................................................................................................................................................................
Front Wheel Speed Sensor Removal And Installation557................................................................................................................................................................
Rear Wheel Speed Sensor Removal And Installation557................................................................................................................................................................
Front Wheel Speed Sensor Rotor Removal And Installation558................................................................................................................................................................
Rear Wheel Speed Sensor Rotor Removal And Installation559................................................................................................................................................................
Wheel Speed Sensor And Sensor Rotor Inspection560................................................................................................................................................................
Abs Control Unit/hu Removal And Installation560................................................................................................................................................................
Precautions For Transmission / Transaxle566................................................................................................................................................................
Manual Transmission567................................................................................................................................................................
Manual Transmission Symptom Diagnosis567................................................................................................................................................................
Transmission Components568................................................................................................................................................................
Transmission Removal568................................................................................................................................................................
Transmission Installation571................................................................................................................................................................
Transmission Construction574................................................................................................................................................................
Countershaft Gear / Driveshaft Gear Disassembly And Assembly575................................................................................................................................................................
Transmission Related Parts Inspection577................................................................................................................................................................
Gear Position Switch Inspection578................................................................................................................................................................
Gear Position Switch Removal And Installation578................................................................................................................................................................
Gearshift Lever Construction579................................................................................................................................................................
Gearshift Lever Removal And Installation580................................................................................................................................................................
Gearshift Lever Height Inspection And Adjustment580................................................................................................................................................................
Gearshift Shaft / Gearshift Cam Plate Components580................................................................................................................................................................
Gearshift Construction580................................................................................................................................................................
Gearshift Shaft / Gearshift Cam Plate Removal And Installation581................................................................................................................................................................
Gearshift Linkage Inspection584................................................................................................................................................................
Gearshift Shaft Oil Seal / Bearing Removal And Installation584................................................................................................................................................................
Clutch588................................................................................................................................................................
Precautions For Clutch System588................................................................................................................................................................
Clutch Fluid (brake Fluid) Information588................................................................................................................................................................
Clutch Hose Routing Diagram589................................................................................................................................................................
Clutch System Symptom Diagnosis590................................................................................................................................................................
Clutch Lever Position Switch Inspection590................................................................................................................................................................
Clutch Fluid Level Check590................................................................................................................................................................
Clutch Hose Inspection590................................................................................................................................................................
Air Bleeding From Clutch Fluid Circuit590................................................................................................................................................................
Clutch Fluid Replacement591................................................................................................................................................................
Clutch Hose Removal And Installation592................................................................................................................................................................
Clutch Control System Components593................................................................................................................................................................
Clutch Master Cylinder Assembly Removal And Installation593................................................................................................................................................................
Clutch Master Cylinder / Clutch Lever Disassembly And Assembly595................................................................................................................................................................
Clutch Master Cylinder Parts Inspection596................................................................................................................................................................
Clutch Release Cylinder / Push Rod Removal And Installation596................................................................................................................................................................
Clutch Push Rod (left) Inspection597................................................................................................................................................................
Clutch Release Cylinder Disassembly And Assembly597................................................................................................................................................................
Clutch Release Cylinder Inspection598................................................................................................................................................................
Clutch Components599................................................................................................................................................................
Clutch Removal599................................................................................................................................................................
Clutch Installation601................................................................................................................................................................
Clutch Parts Inspection604................................................................................................................................................................
Precautions For Steering610................................................................................................................................................................
Steering General Diagnosis611................................................................................................................................................................
Steering Symptom Diagnosis611................................................................................................................................................................
Steering / Handlebar612................................................................................................................................................................
Handlebars Components612................................................................................................................................................................
Handlebar Construction (gsf650/s/a/sak7)613................................................................................................................................................................
Handlebars Removal And Installation614................................................................................................................................................................
Handlebars Inspection615................................................................................................................................................................
Handlebar Height Adjustment615................................................................................................................................................................
Steering Components616................................................................................................................................................................
Steering Removal And Installation617................................................................................................................................................................
Steering Related Parts Inspection619................................................................................................................................................................
Steering System Inspection620................................................................................................................................................................
Steering Stem Bearing Removal And Installation620................................................................................................................................................................
Steering Tension Adjustment621................................................................................................................................................................
Handlebar Construction (gsx650fk8)622................................................................................................................................................................
Precautions For Electrical System627................................................................................................................................................................
Electrical Components Location627................................................................................................................................................................
Wiring Systems628................................................................................................................................................................
Wiring Diagram (gsf650k7)628................................................................................................................................................................
Wiring Diagram (gsf650sk7)630................................................................................................................................................................
Wiring Diagram (gsf650a/uak7)632................................................................................................................................................................
Wiring Diagram (gsf650sa/asuk7)633................................................................................................................................................................
Wiring Harness Routing Diagram (gsf650/s/a/sak7)635................................................................................................................................................................
Wiring Diagram (gsx650fk8)638................................................................................................................................................................
Wiring Harness Routing Diagram (gsx650fk8)640................................................................................................................................................................
Service Data (gsf650/s/u/suk7)641................................................................................................................................................................
Service Data (gsf650a/ua/sa/asuk7)641................................................................................................................................................................
Lighting Systems642................................................................................................................................................................
Headlight Components (gsf650/ak7)642................................................................................................................................................................
Headlight Components (gsf650s/sak7)642................................................................................................................................................................
Headlight Removal And Installation (gsf650/ S/a/sak7)643................................................................................................................................................................
Headlight Bulb Replacement (gsf650/s/a/ Sak7)643................................................................................................................................................................
Headlight Beam Adjustment (gsf650/s/a/ Sak7)645................................................................................................................................................................
Rear Combination Light Components646................................................................................................................................................................
Rear Combination Light Construction646................................................................................................................................................................
Rear Combination Light Removal And Installation647................................................................................................................................................................
Brake Light Bulb / Taillight Bulb Replacement647................................................................................................................................................................
License Plate Light Components648................................................................................................................................................................
License Plate Light Removal And Installation648................................................................................................................................................................
License Plate Light Bulb Replacement648................................................................................................................................................................
Turn Signal Light Components649................................................................................................................................................................
Front Turn Signal Light Removal And Installation649................................................................................................................................................................
Rear Turn Signal Light Removal And Installation649................................................................................................................................................................
Turn Signal Light Bulb Replacement650................................................................................................................................................................
Reflex Refractor Construction (gsf650/s/a/sak7)650................................................................................................................................................................
Turn Signal / Side-stand Relay Inspection651................................................................................................................................................................
Hazard Switch Inspection651................................................................................................................................................................
Turn Signal Switch Inspection651................................................................................................................................................................
Passing Light Switch Inspection652................................................................................................................................................................
Dimmer Switch Inspection652................................................................................................................................................................
Headlight Components (gsx650fk8)653................................................................................................................................................................
Headlight Removal And Installation (gsx650fk8)654................................................................................................................................................................
Headlight Bulb Replacement (gsx650fk8)654................................................................................................................................................................
Headlight Beam Adjustment (gsx650fk8)655................................................................................................................................................................
Reflex Refractor Construction (gsx650fk8)656................................................................................................................................................................
Service Data (gsf650/s/a/sak7)656................................................................................................................................................................
Service Data (gsx650fk8)656................................................................................................................................................................
Combination Meter / Fuel Meter / Horn658................................................................................................................................................................
Combination Meter System Description (gsf650/s/a/sak7)658................................................................................................................................................................
Combination Meter System Description (gsx650fk8)659................................................................................................................................................................
Combination Meter Components (gsf650/s/a/sak7)660................................................................................................................................................................
Combination Meter Removal And Installation (gsf650/s/a/sak7)662................................................................................................................................................................
Combination Meter Disassembly And Assembly (gsf650/s/a/sak7)662................................................................................................................................................................
Combination Meter Inspection (gsf650/s/a/ Sak7)663................................................................................................................................................................
Engine Coolant Temperature Indicator Light Inspection (gsf650/s/a/sak7)664................................................................................................................................................................
Engine Coolant Temperature Removal And Installation664................................................................................................................................................................
Speedometer Inspection666................................................................................................................................................................
Speed Sensor Removal And Installation666................................................................................................................................................................
Speed Sensor Inspection667................................................................................................................................................................
Oil Pressure Indicator Inspection (gsf650/s/ A/sak7)667................................................................................................................................................................
Horn Inspection (gsf650/s/a/sak7)668................................................................................................................................................................
Horn Removal And Installation (gsf650/s/a/ Sak7)669................................................................................................................................................................
Combination Meter Components (gsx650fk8)670................................................................................................................................................................
Combination Meter Removal And Installation (gsx650fk8)670................................................................................................................................................................
Combination Meter Disassembly And Assembly (gsx650fk8)671................................................................................................................................................................
Combination Meter Inspection (gsx650fk8)671................................................................................................................................................................
Engine Coolant Temperature Indicator Light Inspection (gsx650fk8)672................................................................................................................................................................
Oil Pressure Indicator Inspection (gsx650fk8)673................................................................................................................................................................
Horn Inspection (gsx650fk8)673................................................................................................................................................................
Horn Removal And Installation (gsx650fk8)673................................................................................................................................................................
Exterior Parts675................................................................................................................................................................
Seat Lock Cable Routing Diagram675................................................................................................................................................................
Exterior Parts Construction (gsf650s/sak7)676................................................................................................................................................................
Frame Head Cover Construction (gsf650/ak7)677................................................................................................................................................................
Front Fender Construction678................................................................................................................................................................
Frame Cover Cushion Construction678................................................................................................................................................................
Engine Sprocket Outer Cover Cushion679................................................................................................................................................................
Fastener Removal And Installation679................................................................................................................................................................
Exterior Parts Removal And Installation (gsf650/s/a/sak7)680................................................................................................................................................................
Seat Height Adjustment682................................................................................................................................................................
Cowling Construction (gsx650fk8)684................................................................................................................................................................
Under Cowl Construction (gsx650fk8)685................................................................................................................................................................
Under Cowl Bracket Cushion Attachment (gsx650fk8)686................................................................................................................................................................
Under Cowl Protector Cushion Attachment (gsx650fk8)686................................................................................................................................................................
Upper Panel Cushion Attachment (gsx650fk8)687................................................................................................................................................................
Windscreen Cushion Attachment (gsx650fk8)687................................................................................................................................................................
Intake Net Cover Construction Attachment (gsx650fk8)688................................................................................................................................................................
Exterior Parts Removal And Installation (gsx650fk8)688................................................................................................................................................................
Body Structure691................................................................................................................................................................
Body Frame Construction691................................................................................................................................................................
Engine Mounting Bracket Bushing Replacement692................................................................................................................................................................
Engine Mount Bushing Replacement692................................................................................................................................................................
Front Footrest Bracket Construction692................................................................................................................................................................
Side-stand Construction693................................................................................................................................................................
Side-stand Removal And Installation693................................................................................................................................................................
Center Stand Construction694................................................................................................................................................................
Center Stand Removal And Installation694................................................................................................................................................................

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Suzuki GSF650 Service Manual

Suzuki GSF650 Service Manual (333 pages)

Brand: Suzuki | Category: Motorcycle | Size: 22.6 MB
Table of contents
Table Of Contents2................................................................................................................................................................
How To Use This Manual3................................................................................................................................................................
General Information5................................................................................................................................................................
General Precautions6................................................................................................................................................................
Serial Number Location8................................................................................................................................................................
Suzuki Gsf650 (2005-model)8................................................................................................................................................................
Suzuki Gsf650s (2005-model)8................................................................................................................................................................
Fuel And Oil Recommendation9................................................................................................................................................................
Engine Oil9................................................................................................................................................................
Brake Fluid9................................................................................................................................................................
Front Fork Oil9................................................................................................................................................................
Fuel (for Canada)9................................................................................................................................................................
Fuel (for Other Countries)9................................................................................................................................................................
Break-ln Procedures10................................................................................................................................................................
Cylinder Identification10................................................................................................................................................................
Information Labels11................................................................................................................................................................
Specifications12................................................................................................................................................................
Dimensions And Dry Mass12................................................................................................................................................................
Drive Train12................................................................................................................................................................
Periodic Maintenance14................................................................................................................................................................
Periodic Maintenance Schedule15................................................................................................................................................................
Periodic Maintenance Chart15................................................................................................................................................................
Lubrication Points16................................................................................................................................................................
Valve Clearance17................................................................................................................................................................
Maintenance And Tune-up Procedures17................................................................................................................................................................
Spark Plugs19................................................................................................................................................................
Exhaust Pipe Bolts And Muffler Bolts20................................................................................................................................................................
Air Cleaner21................................................................................................................................................................
Engine Oil And Oil Filter22................................................................................................................................................................
Fuel Line24................................................................................................................................................................
Engine Idle Speed24................................................................................................................................................................
Throttle Cable Play24................................................................................................................................................................
Carburetor Synchronization25................................................................................................................................................................
Fuel Filter25................................................................................................................................................................
Clutch Cable Play25................................................................................................................................................................
Drive Chain26................................................................................................................................................................
Tire Tread Depth31................................................................................................................................................................
Front Forks32................................................................................................................................................................
Chassis Bolts And Nuts33................................................................................................................................................................
Compression Pressure Check35................................................................................................................................................................
Compression Test Procedure35................................................................................................................................................................
Oil Pressure Check36................................................................................................................................................................
Oil Pressure Test Procedure36................................................................................................................................................................
Engine Components Removable With Engine In Place38................................................................................................................................................................
Engine Removal And Installation39................................................................................................................................................................
Engine Disassembly48................................................................................................................................................................
Engine Components Inspection And Service62................................................................................................................................................................
Camshaft/cylinder Head Inspection And Service62................................................................................................................................................................
Cylinder Block/piston Inspection75................................................................................................................................................................
Piston Ring Thickness77................................................................................................................................................................
Clutch/clutch Release Assembly Inspection79................................................................................................................................................................
Starter Clutch Inspection81................................................................................................................................................................
Gearshift Linkage Inspection81................................................................................................................................................................
Transmission Inspection And Service83................................................................................................................................................................
Conrod/crankshaft Inspection91................................................................................................................................................................
Crankshaft Thrust Clearance Adjustment96................................................................................................................................................................
Crankshaft Runout98................................................................................................................................................................
Engine Reassembly99................................................................................................................................................................
Engine Lubrication System122................................................................................................................................................................
Oil Pressure Switch125................................................................................................................................................................
Oil Cooler126................................................................................................................................................................
Oil Pressure126................................................................................................................................................................
Oil Filter126................................................................................................................................................................
Oil Jet127................................................................................................................................................................
Engine Lubrication System Chart129................................................................................................................................................................
Cylinder Head Cover131................................................................................................................................................................
Cylinder Head Cooling System Chart131................................................................................................................................................................
Cylinder Head Cooling System132................................................................................................................................................................
Fuel System136................................................................................................................................................................
Fuel Tank138................................................................................................................................................................
Fuel Valve139................................................................................................................................................................
Inspection And Cleaning140................................................................................................................................................................
Fuel Level Gauge142................................................................................................................................................................
Removal And Installation142................................................................................................................................................................
I.d. No. Location145................................................................................................................................................................
Diaphragm And Piston Operation146................................................................................................................................................................
Slow System147................................................................................................................................................................
Main System148................................................................................................................................................................
Starter (enricher) System149................................................................................................................................................................
Float System149................................................................................................................................................................
Chassis163................................................................................................................................................................
Exterior Parts165................................................................................................................................................................
Front Wheel169................................................................................................................................................................
Reassembly And Installation172................................................................................................................................................................
Front Fork175................................................................................................................................................................
Removal And Disassembly176................................................................................................................................................................
Handlebars And Steering183................................................................................................................................................................
Steering Tension Adjustment190................................................................................................................................................................
Rear Wheel191................................................................................................................................................................
Rear Suspension198................................................................................................................................................................
Rear Shock Absorber Disposal203................................................................................................................................................................
Suspension Setting207................................................................................................................................................................
Final Inspection And Adjustment207................................................................................................................................................................
Front Brake208................................................................................................................................................................
Brake Pad Replacement209................................................................................................................................................................
Brake Fluid Replacement210................................................................................................................................................................
Brake Caliper Inspection212................................................................................................................................................................
Brake Disc Inspection214................................................................................................................................................................
Master Cylinder Removal And Disassembly215................................................................................................................................................................
Master Cylinder Inspection216................................................................................................................................................................
Rear Brake219................................................................................................................................................................
Tire And Wheel228................................................................................................................................................................
Tire Removal228................................................................................................................................................................
Seat Height Adjustment236................................................................................................................................................................
Riding Position Adjustment236................................................................................................................................................................
Handlebar Height Adjustment237................................................................................................................................................................
Electrical System238................................................................................................................................................................
Cautions In Servicing240................................................................................................................................................................
Connecting The Battery241................................................................................................................................................................
Wiring Procedure241................................................................................................................................................................
Using The Multi-circuit Tester242................................................................................................................................................................
Location Of Electrical Components243................................................................................................................................................................
Charging System245................................................................................................................................................................
Description (generator With Ic Regulator)245................................................................................................................................................................
Troubleshooting246................................................................................................................................................................
Generator Reassembly And Remounting255................................................................................................................................................................
Starter System And Side-stand Ignition Interlock System257................................................................................................................................................................
Starter System Description257................................................................................................................................................................
Side-stand/ignition Interlock System Description257................................................................................................................................................................
Starter Motor Removal And Disassembly260................................................................................................................................................................
Starter Motor Inspection261................................................................................................................................................................
Starter Motor Reassembly And Remounting261................................................................................................................................................................
Starter Relay Inspection263................................................................................................................................................................
Side-stand/ignition Interlock System Part Inspection264................................................................................................................................................................
Ignition System (digital Ignitor)266................................................................................................................................................................
Combination Meter273................................................................................................................................................................
Turn Signal Lights282................................................................................................................................................................
Starter Relay283................................................................................................................................................................
Initial Charging286................................................................................................................................................................
Recharging Operation288................................................................................................................................................................
Servicing Information289................................................................................................................................................................
Front Axle294................................................................................................................................................................
Battery (mf Battery)297................................................................................................................................................................
Wiring Diagram298................................................................................................................................................................
Wire Harness, Cable And Hose Routing300................................................................................................................................................................
Wire Harness Routing300................................................................................................................................................................
Cable Routing (gsf)303................................................................................................................................................................
Cable Routing (gsf650s)304................................................................................................................................................................
Carburetor Hose Routing305................................................................................................................................................................
Fuel Tank Drain Hose Routing306................................................................................................................................................................
Pair (air Supply) System Hose Routing307................................................................................................................................................................
Front Brake Hose Routing308................................................................................................................................................................
Rear Brake Hose Routing309................................................................................................................................................................
Ignition Coil Installation310................................................................................................................................................................
Spark Plug Cap Installation310................................................................................................................................................................
Fuel Tank Set Up311................................................................................................................................................................
Front Footrest Bracket Set-up312................................................................................................................................................................
Muffler Mounting312................................................................................................................................................................
Side-stand Springs313................................................................................................................................................................
Center Stand Springs313................................................................................................................................................................
Exterior Parts Construction314................................................................................................................................................................
Frame Cover Cushion315................................................................................................................................................................
Seat Lock Cable Routing315................................................................................................................................................................
Taillight Installaion316................................................................................................................................................................
Reflex Refrector Installation316................................................................................................................................................................
Battery Protector Installation317................................................................................................................................................................
Special Tools318................................................................................................................................................................
Tightening Torque321................................................................................................................................................................
Air Bleeder Valve322................................................................................................................................................................
Tightening Torque Chart323................................................................................................................................................................
Service Data324................................................................................................................................................................
Oil Pump326................................................................................................................................................................

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