User Manuals: Suzuki GSX1200 1999 Motorcycle

User Manuals: Suzuki GSX1200 1999 Motorcycle

Manuals and User Guides for Suzuki GSX1200 1999 Motorcycle. We have 1 Suzuki GSX1200 1999 Motorcycle manual available for free PDF download: Service Manual

Suzuki GSX1200 1999 Service Manual

Suzuki GSX1200 1999 Service Manual (274 pages)

Brand: Suzuki | Category: Motorcycle | Size: 16 MB

Table of Contents

General Information 1

5
- Table of Contents
  5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Gsx1200X ('99-Model)
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  8
- Fuel
  8
- Engine Oil
  9
- Brake Fluid
  9
- Front Fork Oil
  9
- Break-In Procedures
  9
- Cylinder Identification
  9
- Information Labels
  10
- Specifications
  11
- Country or Area Codes
  13
Periodic Maintenance 2

14
- Periodic Maintenance Chart
  15
- Periodic Maintenance Schedule
  15
- Lubrication Points
  16
- Maintenance and Tune-Up Procedures
  17
- Valve Clearance
  17
- Spark Plug
  18
- Exhaust Pipe Bolt and Muffler Bolt
  19
- Air Cleaner Element
  20
- Engine Oil and Oil Filter
  21
- Fuel Hose
  22
- Carburetor Synchronization
  23
- Engine Idle Speed
  23
- Throttle Cable Play
  23
- Clutch
  24
- Drive Chain
  25
- Brake
  27
- Tire
  30
- Front Fork
  31
- Rear Suspension
  31
- Steering
  31
- Chassis Bolt and Nut
  32
- Compression Pressure Check
  34
- Oil Pressure Check
  35
Engine

36
- Engine Components Removable with Engine in Place
  37
- Engine Removal
  38
- Engine Removal and Reinstallation
  38
- Engine Reinstallation
  43
- Engine Disassembly
  46
- Engine Components Inspection and Service
  58
- Cylinder Head
  60
- Valve
  60
- Camshaft
  68
- Cam Chain Tension Adjuster
  70
- Piston
  72
- Piston Ring
  73
- Piston Pin
  74
- Conrod
  76
- Crankshaft
  79
- Clutch
  81
- Oil Pump
  82
- Transmission
  83
- Engine Reassembly
  88
Fuel and Lubrication System

110
- Fuel System
  111
- Fuel Pump
  112
- Fuel Pump Mechanism
  112
- Fuel Tank
  112
- Remounting
  112
- Removal
  112
- Inspection
  113
- Removal
  113
- Fuel Valve
  115
- Removal
  115
- Fuel Level Gauge Removal
  116
- Inspection and Cleaning
  116
- Remounting
  116
- Carburetor
  117
- Construction
  117
- I.D. No. Location
  118
- Specification
  118
- Diaphragm and Piston Operation
  119
- Slow System
  120
- Main System
  121
- Float System
  122
- Starter (Enricher) System
  122
- Removal
  123
- Disassembly
  124
- Carburetor Cleaning
  127
- Carburetor Inspection
  128
- Reassembly and Installation
  129
- Carburetor Synchronization
  131
- Lubrication System
  133
- Oil Filter
  133
- Oil Pressure
  133
- Oil Sump Filter
  133
- Engine Lubrication System Chart
  134
- Engine Lubrication System
  135
- Cylinder Head Cooling System Chart
  136
- Cylinder Head Cooling System
  137
- Engine Oil Cooling System
  138
Chassis

139
- Construction
  140
- Removal
  140
- Seat, Frame Cover and Seat Tail Cover
  140
- Remounting
  141
- Construction
  142
- Front Wheel
  142
- Removal
  144
- Inspection and Disassembly
  145
- Reassembly and Remounting
  146
- Construction
  148
- Front Fork
  148
- Removal and Disassembly
  149
- Inspection
  150
- Reassembly and Remounting
  151
- Construction
  154
- Removal and Disassembly
  154
- Steering
  154
- Inspection and Disassembly
  158
- Reassembly and Remounting
  159
- Steering Tension Adjustment
  162
- Construction
  163
- Rear Wheel
  163
- Removal
  165
- Inspection and Disassembly
  166
- Reassembly and Remounting
  167
- Construction
  169
- Rear Suspension
  169
- Removal
  171
- Inspection and Disassembly
  172
- Reassembly and Remounting
  173
- Final Inspection and Adjustment
  174
- Suspension Setting
  175
- Construction
  176
- Front Brake
  176
- Brake Fluid Replacement
  177
- Brake Pad Replacement
  177
- Brake Caliper Removal and Disassembly
  178
- Brake Caliper Inspection
  179
- Brake Caliper Reassembly and Remounting
  179
- Brake Disc Inspection
  180
- Master Cylinder Removal and Disassembly
  181
- Master Cylinder Inspection
  182
- Master Cylinder Reassembly and Remounting
  183
- Construction
  185
- Rear Brake
  185
- Brake Fluid Replacement
  186
- Brake Pad Replacement
  186
- Brake Caliper Removal and Disassembly
  187
- Brake Caliper Inspection
  188
- Brake Caliper Reassembly and Remounting
  188
- Master Cylinder Removal and Disassembly
  189
- Master Cylinder Inspection
  190
- Master Cylinder Reassembly and Remounting
  190
- Clutch Master Cylinder
  191
- Inspection
  192
- Tire Removal
  192
- Tire Installation
  193
Electrical System

195
- Cautions in Servicing
  196
- Location of Electrical Components
  198
- Charging System
  200
- Description (Generator with IC Regulator)
  200
- Troubleshooting
  201
- Inspection
  202
- Generator Removal and Disassembly
  203
- Generator Inspection
  205
- Generator Reassembly and Remounting
  208
- Generator Reassembly Information
  210
- Side-Stand/Ignition Interlock System Description
  211
- Starter System and Side-Stand/Ignition Interlock System
  211
- Starter System Description
  211
- Troubleshooting
  213
- Starter Motor Inspection
  214
- Starter Motor Removal and Disassembly
  214
- Starter Motor Reassembly
  215
- Starter Relay Inspection
  216
- Side-Stand/Ignition Interlock System Part Inspection
  217
- Description
  220
- Ignition System (Digital Ignitor)
  220
- Troubleshooting
  221
- Inspection
  222
- Combination Meter
  226
- Inspection
  226
- Removal and Disassembly
  226
- Headlight
  230
- Lamps
  230
- Brake Light/Taillight
  231
- Turn Signal Lights
  231
- Relays
  232
- Starter Relay
  232
- Turn Signal/Side-Stand Relay
  232
- Switches
  233
- Battery
  234
- Initial Charging
  234
- Specifications
  234
- Servicing
  235
- Recharging Operation
  236
Servicing Information

237
- Engine
  238
- Troubleshooting
  238
- Carburetor
  241
- Chassis
  242
- Brakes
  243
- Electrical
  244
- Battery
  245
- Wiring Diagram
  246
- Wire Harness Routing
  247
- Wire Harness, Cable and Hose Routing
  247
- Cable Routing
  250
- Fuel Hose Routing
  251
- Front Brake Hose Routing
  252
- Rear Brake Hose Routing
  253
- Clutch Hose Routing
  254
- Brake Pedal
  255
- Center Stand Spring
  256
- Side-Stand Spring
  256
- Fuel Level Gauge Wire Routing/Fuel Tank Protection Sheet
  257
- Fuel Tank Water Drain Hose/Fuel Tank Air Breather Hose Routing
  258
- Fuel Tank under Cover
  259
- Speedometer Cable Routing
  259
- Engine Mounting Bolt Installation
  260
- Seat Tail Cover Installation
  261
- Special Tools
  262
- Engine
  265
- Tightening Torque
  265
- Chassis
  266
- Tightening Torque Chart
  267
- Service Data
  268

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