Suzuki 1200 bandit Service Manual Download | Manualshive

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1H-3 Ignition System:

No Spark or Poor Spark

B649G11804001

Troubleshooting

NOTE
Check that the transmission is in neutral and the engine stop switch is in the “RUN” position. Grasp
the clutch lever. Check that the fuse is not blown and the battery is fully-charged before diagnosing.

Step

Action

Yes

No

1

Check the ignition system couplers for poor connections.

Is there connection in the ignition system couplers?

Go to step 2.

Poor connection of
couplers.

2

Measure the battery voltage between input lead wires (G/B
and B/W) at the ignitor with the ignition switch in the “ON”
position.

Is the voltage OK?

Go to Step 3.

• Faulty ignition switch.
• Faulty turn signal/

side-stand relay.

• Faulty engine stop

switch.

• Broken wire harness

or poor connection of
related circuit
couplers.

3

Measure the ignition coil primary peak voltage. Refer to
“Ignition Coil Inspection: ”.

NOTE
This ignition coil primary peak voltage
inspection method is applicable only with the
multi-circuit tester and the peak volt adaptor.

Is the peak voltage OK?

Go to step 4.

Go to step 5.

4

Inspect the spark plugs. Refer to “Spark Plug Inspection and
Cleaning: in Section 0B”.

Is the spark plug OK?

Go to Step 5.

Faulty spark plug(-s).

5

Inspect the ignition coil. Refer to “Ignition Coil Inspection: ”.

Is the ignition coil(-s) OK?

Go to step 6.

Faulty ignition coil(-s).

6

Measure the CKP sensor peak voltage and its resistance.
Refer to “CKP Sensor Inspection: ”.

NOTE
The CKP sensor peak voltage inspection is
applicable only with the multi-circuit tester and
peak volt adaptor.

Is the peak voltage and resistance OK?

• Faulty ignitor.
• Poor connection of

ignition couplers.

• Faulty CKP sensor.
• Metal particles or

foreign material being
stuck on the CKP
sensor and rotor tip.

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Summary of Contents for 1200 bandit

Page 1: ...9 9 5 0 0 3 9 2 8 0 0 1 E GSF1200 GSF1200S ...

Page 2: ...ecifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills an...

Page 3: ...sion 2 i Precautions 2 1 Suspension General Diagnosis 2A 1 Front Suspension 2B 1 Rear Suspension 2C 1 Wheels and Tires 2D 1 Driveline Axle 3 i Precautions 3 1 Drive Chain Drive Train Drive Shaft 3A 1 Brake 4 i Precautions 4 1 Brake Control System and Diagnosis 4A 1 Front Brakes 4B 1 Rear Brakes 4C 1 Transmission Transaxle 5 i Precautions 5 1 Manual Transmission 5B 1 Clutch 5C 1 Steering 6 i Precau...

Page 4: ......

Page 5: ...Table of Contents 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 Warning Caution Note 00 1 General Precautions 00 1 Precautions for Electrical Circuit Service 00 2 ...

Page 6: ... do not touch the engine engine oil oil cooler and exhaust system until they have cooled After servicing the fuel oil exhaust or brake systems check all lines and fittings related to the system for leaks CAUTION If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that ...

Page 7: ...disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly...

Page 8: ...art great care should be taken not to apply any sharp impacts during removal and installation Be careful not to touch the electrical terminals of the Ignitor unit and ABS control unit HU The static electricity from your body may damage this part When disconnecting and connecting the Ignitor unit and ABS control unit HU couplers make sure to turn OFF the ignition switch or electronic parts may get ...

Page 9: ...mmeter to the Ignitor and ABS control unit HU with its coupler connected If attempted damage to Ignitor and ABS control unit HU or sensors may result Be sure to use a specified voltmeter ohmmeter Otherwise accurate measurements may not be obtained and personal injury may result Electrical Circuit Inspection Procedure While there are various methods for electrical circuit inspection described here ...

Page 10: ...icated infinity or over limit the circuit is open between terminals A and C 2 Disconnect the coupler B and measure resistance between couplers A and B 1 If no continuity is indicated the circuit is open between couplers A and B 1 If continuity is indicated there is an open circuit between couplers B 2 and C or an abnormality in coupler B 2 or coupler C Voltage check If voltage is supplied to the c...

Page 11: ... checked branches to other parts as shown disconnect all connectors couplers of those parts Otherwise diagnosis will be misled 3 Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A and C 4 Disconnect the connector coupler included in circuit coupler B and measure resistance ...

Page 12: ...tance with the multi circuit tester 1 will be shown as 10 00 MΩ and 1 flashes in the display Check that no voltage is applied before making the measurement If voltage is applied the tester may be damaged After using the tester turn the power off Special tool 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead ...

Page 13: ...6 Exhaust Pipe Bolt and Muffler Mounting Bolt Inspection 0B 6 Valve Clearance Inspection and Adjustment 0B 7 Fuel Line Inspection 0B 8 Engine Oil and Filter Replacement 0B 9 Throttle Cable Play Inspection and Adjustment 0B 10 Engine Idle Speed Inspection and Adjustment 0B 11 Throttle Valve Synchronization 0B 11 PAIR System Inspection 0B 11 Clutch System Inspection 0B 11 Clutch Hose Replacement 0B ...

Page 14: ...ly SUZUKI MOLY PASTE or equivalent 99000 25140 Apply SUZUKI SILICONE GREASE or equivalent 99000 25100 Apply THERMO GREASE or equivalent 99000 59029 Apply SUZUKI BOND 1207B or equivalent 99000 31140 Apply SUZUKI BOND 1215 or equivalent 99000 31110 Apply THREAD LOCK SUPER 1303 or equivalent 99000 32030 Apply THREAD LOCK SUPER 1322 or equivalent 99000 32110 Apply THREAD LOCK 1342 or equivalent 99000 ...

Page 15: ... Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light F FTPC Valve Fuel Tank Pressure Control Valve G GEN Generator GND Ground GP Switch Gear Position Switch H HC Hydrocarbons I IG Ignition J JASO Japanese Automobile Standards Organization L LCD Liquid Crystal Display LED Light Emitting Diode Malfunction Indicator Lamp LH Left Hand M Max Maximum...

Page 16: ...03 NOTE Difference between photographs and actual motorcycles may exist depending on the markets SUZUKI GSF1200 2006 model Right Side Left Side SUZUKI GSF1200S 2006 model Right Side Left Side I649G1010008 01 I649G1010009 01 I649G1010005 06 I649G1010006 05 ...

Page 17: ... Specification and classification DOT4 WARNING Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never reuse brake flui...

Page 18: ...300100001 GSF1200S K6 E 28 Canada JS1GV79A 62100001 Symbol Wire Color Symbol Wire Color B Black Bl B Blue with Black tracer Bl Blue Br B Brown with Black tracer Br Brown G B Green with Black tracer Dbr Dark brown G Bl Green with Blue tracer Dg Dark green G Y Green with Yellow tracer G Green O G Orange with Green tracer Lg Light green O R Orange with Red tracer W White O W Orange with White tracer ...

Page 19: ...8 3 Fuel caution label For E 02 For E 02 24 4 Screen label For E 02 19 24 28 5 Warning steering label For E 02 19 24 28 6 Tire information label For E 02 19 For E 02 19 24 28 7 General warning label For E 02 19 For E 02 19 24 28 8 ICES Canada label For E 28 9 I D plate For E 02 19 For E 02 19 24 10 Safety plate For E 28 A Frame head Left side B Cowling body C Chain cover D Frame side tube Right si...

Page 20: ...lectrical Components Location B649G10103001 3 4 2 7 8 5 1 6 I649G1010003 05 1 Ignition coil 3 Handlebar switch RH 5 Rear brake light switch 7 CKP sensor 2 Ignition switch 4 Front brake light switch 6 Throttle position sensor 8 Oil pressure switch ...

Page 21: ...04 9 Clutch lever position switch 14 Main fuse 19 Generator 10 Handlebar switch LH 15 Battery 20 Carburetor heater For E 02 19 11 Fuse box 16 Ignitor 21 Speed sensor 12 Turn signal Side stand relay 17 Horn 22 Gear position switch 13 Starter relay 18 Starter motor 23 Side stand switch ...

Page 22: ...s GSF1200S Item Specification Remark Type 4 stroke air cooled DOHC Number of cylinders 4 Bore 79 0 mm 3 110 in Stroke 59 0 mm 2 323 in Displacement 1 157 cm3 70 6 cu in Compression ratio 9 5 1 Carburetor MIKUNI BSR36 Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet sump Idle speed 1 300 100 r min E 28 1 200 100 r min Others Item Specification Remark Clutch Wet mu...

Page 23: ...min E 28 7 B T D C at 1 200 r min Others Spark plug NGK JR9B Battery 12 V 36 kC 10 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 10 15 15 10 A Headlight 12 V 60 55 W H4 GSF1200 12 V 55 W H7 12 V 55 W H7 GSF1200S Position light 12 V 5 W GSF1200 12 V 5W x 2 GSF1200S Turn signal light 12 V 21 W x 4 Brake light Taillight 12 V 21 5 W License plate light 12 V 5 W Speedometer light ...

Page 24: ...pers 1 100 mm 10 34 mm Dial gauge 1 100 mm Magnetic stand 09900 20803 09900 20805 09900 21304 09900 22301 09900 22302 Thickness gauge Tire depth gauge V block set 100 mm Plastigauge 09900 22403 09900 25008 09900 25009 09910 60611 Small bore gauge 18 35 mm Multi circuit tester set Needle pointed probe set Universal clamp wrench TT09900 06106 01 TT09900 06107 02 TT09900 06108 02 TT09900 20102 01 TT0...

Page 25: ...spring compressor 09916 14910 09916 34542 09916 34570 09916 34580 Valve lifter attachment Reamer handle Valve guide reamer 4 95 mm Valve guide reamer 10 8 mm 09916 44310 09916 74521 09916 74550 09916 84511 Valve guide remover installer Holder body Band 73 85 mm Tweezers TT09913 50121 01 TT09913 60910 01 TT09913 61510 01 TT09913 70210 01 TT09915 40610 01 TT09915 63210 01 TT09915 64510 01 TT09915 74...

Page 26: ... holder Sliding shaft Rotor remover Steering stem nut wrench 09940 52841 09940 52861 09940 92720 09941 34513 Inner rod holder Front fork oil seal installer Spring scale Steering race installer 09941 54911 09941 74911 09943 74111 Bearing outer race remover Steering bearing installer Fork oil level gauge TT09917 14920 01 TT09917 47010 01 TT09920 34820 01 TT09920 34840 01 TT09920 53740 02 TT09921 202...

Page 27: ...periodic service work necessary to keep the motorcycle operating at peak performance and economy Maintenance intervals are expressed in terms of kilometers miles and months for your convenience NOTE More frequent servicing may be required on motorcycles that are used under severe conditions General Description Recommended Fluids and Lubricants B649G10201001 Refer to Fuel and Oil Recommendation in ...

Page 28: ...alve clearance I I I Spark plugs I R I R Fuel line I I I I Engine oil R R R R R Engine oil filter R R Throttle cable play I I I I I Engine idle speed I I I I I Throttle valve synchronization I I PAIR air supply system I I Clutch hose I I I I Replace every 4 years Clutch fluid I I I I Replace every 2 years Drive chain I I I I I Clean and lubricate every 1 000 km 600 mile Brakes I I I I I Brake hose...

Page 29: ...rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions 2 1 3 4 6 5 7 I649G1020001 03 1 Brake lever holder and throttle cables 5 Gearshift pivot and left footrest pivot 2 Brake pedal pivot and right footrest pivot 6 Center stand pivot and spring hoo...

Page 30: ... sure that the mark points A up After cleaning or installing the air cleaner element drain water from the air cleaner by removing the drain plug Air Cleaner Element Inspection and Cleaning B649G10206002 Refer to Air Cleaner Element Removal and Installation Inspect air cleaner element Every 6 000 km 4 000 miles 12 months Replace air cleaner element Every 18 000 km 11 000 miles 36 months Inspection ...

Page 31: ... is too short carbon will be deposited on the screw portion of the plug hole and engine damage may result 1 Remove the spark plug caps 2 Remove the spark plugs with the spark plug wrench Special tool A 09930 10121 Spark plug wrench set Installation Install the spark plugs in the reverse order of removal Pay attention to the following points CAUTION Before tightening the spark plug to the specified...

Page 32: ...ssary Spark plug gap 0 6 0 7 mm 0 024 0 028 in Special tool A 09900 20803 Thickness gauge Electrodes Condition Check to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread Exhaust Pipe Bolt and Muffler Mounting Bolt Inspection B649G10206021 Tighten exhaust pipe bolt and muffler mou...

Page 33: ...n 1D NOTE The valve clearance specification is different for both intake and exhaust valves Valve clearance When cold IN 0 10 0 15 mm 0 004 0 006 in EX 0 18 0 23 mm 0 007 0 009 in NOTE The camshafts must be at positions A or B in order to check or adjust the valve clearance Clearance readings should not be taken with the camshafts in any other position than the ones shown The valve clearance shoul...

Page 34: ...all the following items a CKP sensor cover Refer to CKP Sensor Removal and Installation in Section 1H b Cylinder head cover Refer to Engine Top Side Assembly in Section 1D c Breather cover d Spark plugs and plug caps Refer to Spark Plug Removal and Installation e PAIR valve Refer to PAIR System Removal and Installation in Section 1B f Frame head covers for GSF1200 Refer to Exterior Parts Removal a...

Page 35: ...orque and pour new oil through the oil filler When performing an oil change without oil filter replacement the engine will hold about 3 3 L of oil Use of SF SG or SH SJ in API with MA in JASO Tightening torque Oil drain plug a 23 N m 2 3 kgf m 16 5 lb ft 4 Start up the engine and allow it to run for several minutes at idling speed 5 Turn off the engine and wait about three minutes then check the o...

Page 36: ... m 2 0 kgf m 14 5 lb ft 5 Add new engine oil and check the oil level is as described in the engine oil replacement procedure Necessary amount of engine oil Oil change 3 3 L 3 4 2 9 US lmp qt Oil and filter change 3 5 L 3 6 3 0 US lmp qt Engine overhaul 4 6 L 4 9 4 0 US lmp qt Throttle Cable Play Inspection and Adjustment B649G10206012 Inspect throttle cable play Initially at 1 000 km 6 000 miles 2...

Page 37: ... years WARNING The clutch system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long period of mine Check the clutch hose and hose joints for cracks and flui...

Page 38: ...cts are found the drive chain must be replaced Refer to Drive Chain Replacement in Section 3A Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear Improper chain adjustment Missing O ring seals NOTE When replacing the drive chain replace the drive chain and sprockets as a set Drive Chain Length Inspection 1 Remove the cotter pin For E 28 2 Loosen the axle nut 1 3 L...

Page 39: ...d Lubricating B649G10206029 Clean and lubricate drive chain Every 1 000 km 600 miles Clean and lubricate the drive chain in the following procedures 1 Clean the drive chain with kerosine If the drive chain tends to rust quickly the intervals must be shortened CAUTION Do not use trichloroethylene gasoline or any similar solvent These fluids have too great a dissolving power for this chain and they ...

Page 40: ... fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs When the brake fluid level is below the lower limit line replenish with brake fluid that meets the following specification BF Brake fluid DOT 4 Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line A on the pad When the wear exceeds the grooved limit line replace ...

Page 41: ...rom Brake Fluid Circuit B649G10206034 Refer to Air Bleeding from Brake Fluid Circuit in Section 4A Brake Fluid Replacement B649G10206035 Refer to Brake Fluid Replacement in Section 4A Tire Inspection B649G10206017 Inspect tire Every 6 000 km 4 000 miles 12 months Tire Tread Condition Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dange...

Page 42: ...f the ground with the wheel facing straight ahead grasp the lower fork tubes near the axle and pull forward If play is found readjust the steering Refer to Steering Tension Adjustment in Section 6B Front Fork Inspection B649G10206019 Inspect front fork Every 12 000 km 7 500 miles 24 months Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace ...

Page 43: ... ft 5 Air bleeder valve Clutch 6 Front brake Clutch master cylinder mounting bolt 23 N m 2 3 kgf m 16 5 lb ft 7 Brake hose union bolt Front brake 10 N m 1 0 kgf m 7 0 lb ft 8 Clutch hose union bolt b 3 b 3 a 1 b 2 b 2 I649G1020055 04 b 2 b 4 c 5 I649G1020056 05 d 6 d 6 b 8 b 7 I649G1020057 03 9 Rear shock absorber mounting nut Upper 50 N m 5 0 kgf m 36 0 lb ft 10 Cushion rod mounting nut 78 N m 7 ...

Page 44: ... 5 5 lb ft 21 Air bleeder valve Brake 23 N m 2 3 kgf m 16 5 lb ft 22 Brake disc bolt Rear 6 N m 0 6 kgf m 4 5 lb ft 23 Rear brake caliper mounting bolt 22 N m 2 2 kgf m 16 0 lb ft 24 Brake hose union bolt Rear 25 Front footrest bolt 29 Front footrest bracket mounting bolt 26 Brake hose union bolt Rear 23 N m 2 3 kgf m 16 5 lb ft 27 Rear brake master cylinder mounting bolt 35 N m 3 5 kgf m 25 5 lb ...

Page 45: ...e Material B649G10208001 Special Tool B649G10208002 Fastening part Tightening torque Note N m kgf m lb ft Spark plug 11 1 1 8 0 Exhaust pipe bolt 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Muffler connecting bolt 23 2 3 16 5 Oil drain plug 23 2 3 16 5 Oil filter 20 2 0 14 5 Rear axle nut 100 10 0 72 5 Rear master cylinder rod lock nut 18 1 8 13 0 Material SUZUKI recommended product or Specifica...

Page 46: ...0 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX INNER 35 0 1 38 OUTER 37 8 1 49 Valve spring tension IN EX INNER 53 65 N 5 3 6 5 kgf 11 7 14 3 lbs at length 28 mm 1 10 in OUTER 131 151 N 13 1 15 1 kgf 28 9 33 3 lbs at length 31 5 mm 1 24 in Item Standard Limit Cam height IN 33 58 33 62 1 3220 1 3236 33 28 1 3102 EX 32 65 32 69 1...

Page 47: ...n ring groove width 1st 1 01 1 03 0 040 0 041 2nd 1 01 1 03 0 040 0 041 Oil 2 01 2 03 0 079 0 080 Piston ring thickness 1st 0 975 0 990 0 0384 0 0390 2nd 0 970 0 990 0 038 0 039 Piston pin bore 20 002 20 008 0 7875 0 7877 20 030 0 7886 Piston pin O D 19 992 20 000 0 7871 0 7874 19 980 0 7866 Item Standard Limit Conrod small end I D 20 010 20 018 0 7878 0 7881 20 040 0 7890 Conrod big end side clea...

Page 48: ... 1 565 72 46 Final reduction ratio 3 000 45 15 Gear ratios 1st Low 2 384 31 13 2nd 1 631 31 19 3rd 1 250 25 20 4th 1 045 23 22 5th Top 0 913 21 23 Gearshift fork to gearshift fork groove clearance No 1 No 2 No 3 0 1 0 3 0 004 0 012 0 50 0 020 Gearshift fork groove width No 1 No 2 No 3 5 0 5 1 0 197 0 201 Gearshift fork thickness No 1 No 2 No 3 4 8 4 9 0 189 0 193 Drive chain Type RK GB50GSVZ3 Link...

Page 49: ... Limit 14 0 0 55 DENSO Brush length Limit 4 5 0 18 Generator maximum output More than 550 W at 5 000 r min Regulated voltage 13 5 15 V at 5 000 r min Starter motor brush length Standard 12 5 0 49 Limit 6 0 0 24 Starter relay resistance 3 6 Ω Battery Type designation FT12A BS Capacity 12 V 36 0 kC 10 Ah 10 HR Standard electrolyte S G 1 320 at 20 C 68 F Fuse size Headlight HI 10 A LO 10 A Ignition 1...

Page 50: ...rake caliper piston diameter Front Leading 30 150 30 200 1 1870 1 1890 Trailing 33 884 33 934 1 3340 1 3360 Rear 38 098 38 148 1 4999 1 5019 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Wheel rim size Front 17 M C x MT3 50 Rear 17 M C x MT5 50 Item Standard Limit Front fork stroke 130 5 1 Front fork inner tube O D 43 1 69 Front fork spring free...

Page 51: ...ne containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible E 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recommended The others countries Fuel tank capacity Including reserve 20 L 5 3 4 4 US lmp gal Reserve only 4 4 L 1 2 1 0 US lmp gal Engine oil type SAE 10W ...

Page 52: ... M6 Initial 6 0 6 4 5 Final 11 1 1 8 0 M8 Initial 13 1 3 9 5 Final 22 2 2 16 0 Main oil galley plug 40 4 0 29 0 Oil pump mounting bolt 10 1 0 7 0 Oil drain plug 23 2 3 16 5 Oil pan bolt 14 1 4 10 0 Speed sensor rotor bolt 20 2 0 14 5 Clutch sleeve hub nut 150 15 0 108 5 Exhaust pipe bolt 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Muffler connecting bolt 23 2 3 16 5 Engine sprocket nut 115 11 5 ...

Page 53: ... valve Rear brake 6 0 0 6 4 5 Air bleeder valve Clutch 8 0 8 6 0 Side stand nut 40 4 0 29 0 Rear combination light mounting bolt 2 0 0 2 1 5 Brake disc bolt front rear 23 2 3 16 5 Front footrest bolt 35 3 5 25 5 Front footrest bracket mounting bolt 23 2 3 16 5 Front brake pad mounting pin 16 1 6 11 5 Swingarm pivot nut 100 10 0 72 5 Rear shock absorber mounting nut upper lower 50 5 0 36 0 Cushion ...

Page 54: ... 7 marked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 0 2 1 5 5 3 0 3 2 0 5 0 5 3 5 6 6 0 6 4 5 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5 85 8 5 61 5 14 65 6 5 47 0 135 13 5 97 5 16 105 10 5 76 0 210 21 0 152 0 18 160 16 0 115 5 240 24 0 173 5 3 2 1 a a a I649G1030001 03 1 Conventional bolt 2 4 marked bolt 3 7 marked bolt ...

Page 55: ...haft Inspection 1D 25 Camshaft Sprocket Inspection 1D 27 Camshaft Sprocket Removal and Installation 1D 27 Cam Chain Tension Adjuster Inspection 1D 28 Cam Chain Guide Removal and Installation 1D 28 Cam Chain Guide Inspection 1D 29 Cam Chain Tensioner Inspection 1D 29 Cylinder Head Disassembly and Assembly 1D 30 Cylinder Head Related Parts Inspection 1D 33 Valve Guide Replacement 1D 36 Valve Seat Re...

Page 56: ...tion 1G 2 Schematic and Routing Diagram 1G 9 Carburetor Hose Routing Diagram 1G 9 Fuel Tank Drain Hose and Breather Hose Routing Diagram 1G 10 Throttle Cable Starter Cable Routing Diagram 1G 11 Diagnostic Information and Procedures 1G 12 Carburetor Symptom Diagnosis 1G 12 Repair Instructions 1G 13 Fuel Tank Construction 1G 13 Fuel Tank Removal and Installation 1G 14 Fuel Valve Removal and Installa...

Page 57: ...nd Installation 1I 12 Starter Clutch Inspection 1I 14 Starter Button Inspection 1I 15 Specifications 1I 16 Service Data 1I 16 Tightening Torque Specifications 1I 16 Special Tools and Equipment 1I 17 Recommended Service Material 1I 17 Special Tool 1I 17 Charging System 1J 1 General Description 1J 1 Charging System Description Generator with IC Regulator 1J 1 Component Location 1J 2 Charging System ...

Page 58: ...1 1 Precautions Precautions Precautions Precautions for Engine B649G11000001 Refer to General Precautions in Section 00 and Precautions for Electrical Circuit Service in Section 00 ...

Page 59: ...r replace Clogged fuel filter Clean or replace Engine stalls often Fouled spark plug Clean or replace Defective CKP sensor Replace Defective ignitor Replace Clogged fuel hose Clean Clogged carburetor jet Clean Valve clearance out of adjustment Adjust Engine noisy Excessive valve chatter Excessive valve clearance Adjust Weak or broken valve spring Replace Worn rocker arm or rocker arm shaft Replace...

Page 60: ...t Clean or replace Clogged fuel hose resulting in inadequate fuel supply to carburetor Clean and prime Engine lacks power Insufficient valve clearance Adjust Weak valve spring Replace Mistimed valves Adjust Worn cylinder Rebore or replace Worn piston ring Replace Improper valve seating Repair or replace Fouled spark plug Clean or replace Incorrect spark plug Replace Clogged carburetor jet Clean In...

Page 61: ...uch closer tolerances than standard machined jets If replacement of the jets is needed be sure to replace them only with the same type of jets A jet needle with only one clip position is also used If jet needle replacement is necessary only replace it with a jet needle of the same type Suzuki recommends that Genuine Suzuki Parts be utilized whenever possible for the best possible performance and d...

Page 62: ...g crankcase emissions into the atmosphere Blow by gas in the engine is constantly drawn into the crankcase which is returned to the combustion chamber through the PCV hose air cleaner box and carburetors 1 2 A B C D E F I649G1120006 02 1 To PAIR control valve A Blow by gas C Fuel Air mixture E Vacuum 2 PCV hose B Fresh air D Fuel emulsion F Exhaust gas ...

Page 63: ...vice or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among Those Acts Presumed to Constitute Tampering are the Acts Listed Below Removing or puncturing the muffler b...

Page 64: ...ful not to contact the PAIR hoses with the throttle cables G Marking White must face rear side 3 PAIR hose No 3 B Pass the PAIR hose 5 in front of the oil pipe H Marking White must face top side 4 PAIR hose No 4 C Pass the PAIR hose 5 through inside of the oil pipe I Connect the vacuum hose to No 4 carburetor 5 PAIR hose Fresh air D Install the PAIR control valve along with its bracket 6 Vacuum ho...

Page 65: ...pipes hoses from each cylinder Installation Install the PAIR valve in the reverse order of removal Pay attention to the following points CAUTION Use a new gasket 1 to prevent exhaust gas leakage Tighten the PAIR pipe mounting nuts to the specified torque Tightening torque PAIR pipe mounting nut a 10 N m 1 0 kgf m 7 0 lb ft Tighten the PAIR valve mounting bolt to the specified torque Tightening tor...

Page 66: ...AIR System Removal and Installation 2 Remove the PAIR valve covers 1 3 Remove the reed valves 4 Inspect the reed valves for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR valve with a new one 5 Install the read valve and PAIR valve covers 6 Install the PAIR valve Refer to PAIR System Removal and Installation PAIR Valve 1 Remove the PAIR valve Refer to PAIR Sys...

Page 67: ...the PAIR valve Refer to PAIR System Removal and Installation PCV Hose Inspection B649G11206006 Inspect the PCV hose in the following procedures 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 2 Inspect the PCV hose 1 for wear and damage If it is worn or damaged replace the PCV hose with a new one 3 Check that the hose 1 is securely connected 4 Install the fuel tank...

Page 68: ...ning torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Special Tools and Equipment Special Tool B649G11208001 Fastening part Tightening torque Note N m kgf m lb ft PAIR pipe mounting nut 10 1 0 7 0 PAIR valve mounting bolt 10 1 0 7 0 09917 47010 Vacuum pump gauge ...

Page 69: ...Engine Mechanical 1D 1 Engine Mechanical Schematic and Routing Diagram Camshaft and Sprocket Assembly Diagram B649G11402001 24th pin 1st pin I649G1140075 03 ...

Page 70: ...ection is tight Special tool A 09915 64510 Compression gauge set B 09915 63210 Compression gauge adaptor 6 Keep the throttle grip in the fully opened position 7 Press the starter button and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression 8 Repeat this procedure with the other cylinders Compression pressure specification Low compression pressure can i...

Page 71: ... Oil Sump Filter Oil Pressure Regulator Removal and Installation in Section 1E Oil sump filter Refer to Oil Pan Oil Sump Filter Oil Pressure Regulator Removal and Installation in Section 1E Refer to Oil Pan Oil Sump Filter Cleaning in Section 1E Refer to Oil Pan Oil Sump Filter Oil Pressure Regulator Removal and Installation in Section 1E Carburetors Refer to Carburetor Assembly Removal and Instal...

Page 72: ...m Removal Inspection Installation Clutch cover Refer to Clutch Removal in Section 5C Refer to Clutch Installation in Section 5C Clutch plates Refer to Clutch Removal in Section 5C Refer to Clutch Parts Inspection in Section 5C Refer to Clutch Installation in Section 5C Clutch sleeve hub Refer to Clutch Removal in Section 5C Refer to Clutch Installation in Section 5C Generator Oil pump drive gears ...

Page 73: ...n in Section 9D 4 Remove the cowling GSF1200 Refer to Exterior Parts Removal and Installation in Section 9D 5 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 6 Remove the air cleaner box mounting bolts 1 7 Disconnect the battery lead wire 8 Disconnect the engine ground wire coupler 2 9 Disconnect all of the spark plug caps 3 10 Disconnect the breather PCV hose 4 11 D...

Page 74: ...enerator lead wire 11 and coupler 12 19 Disengage the gearshift lever link by removing the bolt 20 Remove the engine sprocket cover by removing the bolts 21 Remove the speed sensor rotor 13 while depressing the rear brake pedal 22 Flatten the lock washer 14 23 Remove the engine sprocket nut 15 while depressing the rear brake pedal 24 Remove the lock washer 14 7 8 I649G1140007 03 9 I649G1140303 02 ...

Page 75: ...on in Section 1K 28 Remove the oil cooler and oil cooler hoses Refer to Oil Cooler Oil Cooler Hose Removal and Installation in Section 1F 29 Support the engine with a proper jack 30 Remove the frame down tube mounting bolts 19 and nuts 31 Remove the engine mounting brackets 20 by removing their bolts and nuts 32 Remove the engine mounting bolts 21 nuts and spacer 22 16 17 I649G1140011 03 18 I649G1...

Page 76: ...o drop the engine accidentally when the engine mounting bolts and nuts are removed 20 20 21 22 19 19 19 20 A A 20 I649G1140018 04 19 Frame down tube mounting bolt 22 Spacer 20 Engine mounting bracket A Only for E 28 model The engine mounting brackets and its bolts are not equipped at the frame down tubes 21 Engine mounting bolt ...

Page 77: ...s are self locking Once the nuts have been removed they are no longer of any use Be sure to use new nuts and tighten them to the specified torque c 4 d 2 b b c 4 d 5 e d h f g f 5 e d 5 e d 6 f e 7 i a 1 a 3 c 3 c c c A I649G1140300 04 1 Engine mounting bolt Upper b 140 mm 5 5 in A Only for E 28 model The engine mounting bracket and its bolts are not equipped at the frame down tubes 2 Engine mount...

Page 78: ...1303 or equivalent Tighten the speed sensor rotor bolt 10 to the specified torque Tightening torque Speed sensor rotor bolt h 20 N m 2 0 kgf m 14 5 lb ft Before installing the engine sprocket cover apply a small quantity of SUZUKI SUPER GREASE A to the push rod Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the spark plug caps onto the spark plugs Make sure that each spark plug cap...

Page 79: ...uting Diagram in Section 9A and Throttle Cable Starter Cable Routing Diagram in Section 1G Install the gearshift lever to the gearshift shaft in the correct position Gearshift lever height J 55 mm 2 2 in Tighten the oil drain plug to the specified torque Tightening torque Oil drain plug i 23 N m 2 3 kgf m 16 5 lb ft I649G1170033 01 J I649G1140029 02 i I649G1140030 03 ...

Page 80: ...l and Installation B649G11406065 Refer to Air Cleaner Element Removal and Installation in Section 0B Air Cleaner Element Inspection and Cleaning B649G11406066 Refer to Air Cleaner Element Inspection and Cleaning in Section 0B Engine Top Side Disassembly B649G11406004 It is unnecessary to remove the engine assembly from the frame when servicing the engine top side NOTE Before servicing the engine t...

Page 81: ...mark on the CKP rotor with the center of the CKP sensor Also position the notches A on the right end of each camshaft as shown 4 After removing the spring holder bolt 2 and spring 3 remove the cam chain tension adjuster 4 5 Remove the camshaft journal holders NOTE Be sure to loosen the camshaft journal holder bolts evenly and in a crisscross pattern 6 Remove the intake 5 and exhaust camshafts 6 Cy...

Page 82: ... using a plastic mallet CAUTION Be careful not to damage the fins when removing or handling the cylinder head Cylinder 1 Remove the cylinder head gasket 1 O rings 2 and dowel pins 3 2 Remove the left and right oil return pipes 4 3 Remove the cylinder base nut 5 4 Firmly grip the cylinder at both ends and lift it straight up If the cylinder does not come off lightly tap on the finless portions of i...

Page 83: ...p Side Assembly B649G11406046 Assemble the engine top side in the reverse order of disassembly Pay attention to the following points Cylinder Stud Bolt Install each cylinder stud bolt as shown NOTE Before installing the cylinder stud bolt 4 apply a light coat of the recommended bond to its threads Sealant 99000 31140 SUZUKI Bond 1207B or equivalent Tightening torque Cylinder stud bolt 15 N m 1 5 k...

Page 84: ...wel pins and the new cylinder gasket Before installing the cylinder oil the big and small ends of each conrod and also the sliding surface of each piston CAUTION Use a new gasket to prevent oil leakage NOTE Install the gasket with the UP mark facing up as shown Position the piston ring gaps as shown Before inserting each piston into its cylinder check that the gaps are properly positioned Install ...

Page 85: ...o prevent oil leakage Install the new O rings 2 onto the oil return pipes and apply SUZUKI SUPER GREASE A to the O rings CAUTION Replace the O rings 2 with new ones to prevent oil leakage Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the right and left oil return pipes Cylinder Head Place the cylinder head onto the cylinder Place the cylinder head plate 1 onto the cylinder head Cy...

Page 86: ...ecified torque Tightening torque Cylinder head bolt a 10 N m 1 0 kgf m 7 0 lb ft Install the cam chain guide 2 as shown While holding down the cam chain rotate the crankshaft clockwise and align the T mark on the CKP sensor rotor with the center of the CKP sensor CAUTION Turn the crankshaft using a 19 mm wrench Never rotate the crankshaft using a 6 mm T type wrench 6 2 4 8 9 5 1 3 7 12 11 10 I649G...

Page 87: ... journals and do not leave any dry spots Also apply engine oil onto the camshaft journal holders M O Molybdenum oil Molybdenum oil solution The exhaust camshaft has the embossed letters EX and the intake camshaft has the embossed letters IN Also the right end of each camshaft has a notch A I649G1140069 02 IN EX EX IN A I649G1140070 02 ...

Page 88: ...e the cam chain with the exhaust camshaft sprocket The other arrow marked 2 should now be pointing straight up Starting from the roller pin B that is directly above the arrow marked 2 count out 24 roller pins from the exhaust camshaft side going towards the intake camshaft side Engage the 24th roller pin C on the cam chain with the arrow marked 3 on the intake sprocket Refer to the following illus...

Page 89: ...Engine Mechanical 1D 21 B I649G1140073 02 C I649G1140074 02 24th pin 1st pin I649G1140075 03 ...

Page 90: ...ade of a special material and much superior in strength compared with other types of high strength bolts Take special care not to use other types of bolts NOTE Damage to the cylinder head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not tightened evenly Tighten the camshaft journal holder bolts to the specified torque Tightening torque Camshaft journal ...

Page 91: ...o the cam chain tension adjuster and tighten the spring holder bolt 4 to the specified torque Tightening torque Cam chain tension spring holder bolt b 38 N m 3 8 kgf m 27 5 lb ft CAUTION After installing the cam chain tension adjuster check the cam chain slack to make sure that the cam chain tension adjuster is working properly After installing the cam chain tension adjuster rotate the crankshaft ...

Page 92: ...as shown Sealant 99000 31140 SUZUKI Bond 1207B or equivalent Place the cylinder head cover onto the cylinder head Install the four gaskets onto each cylinder head cover union bolt 3 and apply oil to thread and gasket before tighten them to the specified torque CAUTION Replace the gaskets with new ones to prevent oil leakage Tightening torque Cylinder head cover union bolt a 20 N m 2 0 kgf m 14 5 l...

Page 93: ... Inspection and Adjustment B649G11406067 Refer to Valve Clearance Inspection and Adjustment in Section 0B Camshaft Inspection B649G11406048 Refer to Engine Top Side Disassembly Refer to Engine Top Side Assembly Camshaft Identification The exhaust camshaft has the embossed letters EX and the intake camshaft has the embossed letters IN Cam Wear Check the camshaft for wear or damage Measure the cam h...

Page 94: ...ion Refer to Engine Top Side Assembly 4 Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque NOTE Do not rotate the camshafts with the plastigauge in place Tightening torque Camshaft journal holder bolt a 10 N m 1 0 kgf m 7 0 lb ft 5 Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale 6 This measurement...

Page 95: ... damage If they are worn or damaged replace the sprockets and cam chain as a set 3 Install the camshafts Refer to Engine Top Side Assembly Camshaft Sprocket Removal and Installation B649G11406050 Removal 1 Remove the camshafts Refer to Engine Top Side Disassembly 2 Remove the camshaft sprockets 1 Installation NOTE The fixed position of each camshaft sprocket is determined by arrow mark 3 for the i...

Page 96: ...t mechanism 1 and move the push rod 2 in place to see if it slides smoothly If it does not slide smoothly or the ratchet mechanism is worn or damaged replace the cam chain tension adjuster with a new one 3 Install the cam chain tension adjuster Refer to Engine Top Side Assembly Cam Chain Guide Removal and Installation B649G11406068 Removal 1 Remove the cylinder head cover Refer to Engine Top Side ...

Page 97: ...lace it with a new one Refer to Engine Top Side Disassembly Engine Top Side Assembly and Cam Chain Guide Removal and Installation 3 Install the cam chain guides Refer to Cam Chain Guide Removal and Installation Cam Chain Tensioner Inspection B649G11406053 Inspect the cam chain tensioner in the following procedures 1 Separate the crankcases upper and lower Refer to Engine Bottom Side Disassembly 2 ...

Page 98: ...en pull out the shaft 4 Using the special tools compress the valve spring and remove the valve cotters 6 from the valve stem Special tool A 09916 14510 Valve spring compressor B 09916 14910 Valve lifter attachment C 09916 84511 Tweezers 5 Remove the valve spring retainer 7 and the inner and outer valve springs 8 6 Remove the valve spring seat 7 Remove the valve from the combustion chamber side 8 R...

Page 99: ...sert the valves with their stems coated with molybdenum oil solution Coat the entire stem making sure that there are no gaps CAUTION When inserting each valve take care not to damage the lip of the oil seal M O Molybdenum oil Molybdenum oil solution 5 Install the valve springs with the smaller pitch A facing the cylinder head 1 I649G1140218 02 2 3 I649G1140219 02 2 4 I649G1140220 02 3 4 I649G11402...

Page 100: ...r B 09916 14910 Valve lifter attachment C 09916 84511 Tweezers 7 Apply engine oil to the rocker arm shaft sufficiently 8 Install the rocker arms 6 springs 7 and rocker arm shaft 9 Tighten the rocker arm shaft set bolt 8 and cylinder head plug 9 to the specified torque Tightening torque Rocker arm shaft set bolt a 9 N m 0 9 kgf m 6 5 lb ft Cylinder head plug b 28 N m 2 8 kgf m 20 0 lb ft 10 Apply S...

Page 101: ... places If readings exceed the service limit replace the cylinder head Special tool 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 2 mm 0 008 in Valve Stem Runout Support the valve using V blocks as shown and check its runout using the dial gauge If the runout exceeds the service limit replace the valve Special tool A 09900 20606 Dial gauge 1 100 mm B 09900 20701 Magnetic sta...

Page 102: ...recheck the deflection Special tool A 09900 20205 Micrometer 0 25mm Valve stem O D Standard IN 4 965 4 980 mm 0 1955 0 1961 in Standard EX 4 945 4 960 mm 0 1947 0 1953 in NOTE If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in valve guide replacement Refer to Valve Guide Replacement Valve Stem End Condition Inspect the valve stem end face...

Page 103: ...5mm Rocker Arm Inside Diameter Measure the rocker arm inside diameter in two directions at right angle to each other If the inside diameter measured exceeds the standard value replace the rocker arm Rocker arm I D Standard 12 000 12 018 mm 0 4724 0 4731 in Special tool A 09900 20605 Dial calipers 1 100 mm 10 34 mm Valve Seat Width 1 Visually check for valve seat width on each valve face If the val...

Page 104: ... prevent the valve from sealing Refer to Valve Seat Repair WARNING Always use extreme caution when handling gasoline NOTE After servicing the valve seats be sure to check the valve clearance after the cylinder head has been reinstalled Refer to Valve Clearance Inspection and Adjustment in Section 0B Valve Guide Replacement B649G11406056 1 Remove the cylinder head Refer to Engine Top Side Disassemb...

Page 105: ...uide into the guide hole using the valve guide installer CAUTION Failure to oil the valve guide hole before driving the new guide into place may result in a damaged guide or head Special tool A 09916 44310 Valve guide remover installer 9 After installing the valve guides refinish their guiding bores using the reamer Be sure to clean and oil the guides after reaming Special tool C 09916 34542 Reame...

Page 106: ...sket surface of the cylinder for distortion Use a straightedge and thickness gauge Take clearance readings at several places If any reading exceeds the service limit replace the cylinder Special tool 09900 20803 Thickness gauge Cylinder distortion Service limit 0 2 mm 0 008 in Cylinder Bore Measure the cylinder bore diameter at six places If any one of the measurements exceed the limit overhaul th...

Page 107: ...n push up the opposite side of the 1st ring 2 to remove it NOTE Do not expand the piston ring excessively since it is apt to be broken down 3 Remove the 2nd ring and oil ring in the same procedure 2 A 2 B 50 2 N 2N N N 1 A 1 B 50 3 C 4 4 I649G1140362 02 1 1st ring A Standard piston ring 2 2nd ring B Oversize piston ring 3 Oil ring spacer C Color Red is standard Blue is 0 5 mm oversize 4 Side rail ...

Page 108: ...ing 3 differ in shape NOTE Face the side with the stamped mark A upward when assembling 2 After installing all the position ring check that each ring rotates smoothly 3 Install the piston and piston pin Refer to Engine Top Side Assembly Piston and Piston Ring Inspection B649G11406059 Refer to Piston Ring Removal and Installation Piston Diameter Measure the piston diameter using the micrometer at 1...

Page 109: ...tandard 1st 1 01 1 03 mm 0 040 0 041 in Standard 2nd 1 01 1 03 mm 0 040 0 041 in Standard Oil 2 01 2 03 mm 0 079 0 080 in Piston ring thickness Standard 1st 0 975 0 990 mm 0 0384 0 0390 in Standard 2nd 0 970 0 990 mm 0 038 0 039 in Piston Ring Free End Gap and Piston Ring End Gap Measure the piston ring free end gap using vernier calipers Next fit the piston ring squarely into the cylinder and mea...

Page 110: ...he measurements are out of specification replace the piston pin Special tool C 09900 20205 Micrometer 0 25mm Piston pin O D Service limit 19 980 mm 0 7866 in Engine Bottom Side Disassembly B649G11406005 NOTE The crankcase must be separated to service the crankshaft and conrod 1 Remove the engine assembly Refer to Engine Assembly Removal 2 Disassemble the engine top side Refer to Engine Top Side Di...

Page 111: ...tch Removal in Section 5C 2 Draw out the clutch push rod 2 Gearshift 1 Remove the snap ring and washer from the gearshift shaft Special tool 09900 06107 Snap ring pliers 2 Draw out the gearshift shaft 1 and then remove the gearshift cam driven gear 2 NOTE When removing the gearshift cam driven gear do not lose the gearshifting pawl 3 pin 4 and spring 5 Oil Pump Driven Gear 1 Remove the snap ring 1...

Page 112: ...allation in Section 1I Gear Position Switch 1 Flatten the tabs on the oil seal retainer and remove the bolts 2 Remove the oil seal retainer 1 3 Remove the gear position switch 2 4 Remove the O ring 3 switch contact 4 and spring 5 NOTE Do not lose the O ring switch contact and spring Crankcase 1 Remove the countershaft bearing retainer 1 2 4 3 2 I649G1140112 02 1 I649G1140113 03 1 I649G1140116 01 2...

Page 113: ...ower crankcase bolts and nut 9 Remove the main oil gallery plug 7 and O ring 10 Loosen the crankcase bolts in descending numerical order and then remove them NOTE Two allen bolts are located at position A to tighten the crankshaft 11 Remove the oil return pipe 8 2 I649G1140120 02 3 I649G1140121 03 4 5 6 7 I649G1140122 03 I649G1140123 01 I649G1140124 01 7 7 I649G1140125 02 A 10 12 11 6 2 4 8 7 3 1 ...

Page 114: ...s difficult to separate the crankcase halves set the proper bolt and nut to the crankcase by separating the upper and lower crankcase halves as shown in the illustration Crankshaft 1 Remove the crankshaft assembly 1 from the upper crankcase 2 Remove the thrust bearings 2 NOTE The crankshaft thrust bearings 2 are located between the crankshaft assembly and upper crankcase Cam Chain Tensioner 1 Remo...

Page 115: ...rnal bearings unless absolutely necessary Make a note of where the crankshaft journal bearings are removed from so that they can be reinstalled in their original positions 2 Remove the oil jets 1 for the piston cooling Transmission 1 Remove the countershaft assembly 1 and driveshaft assembly 2 2 Remove the C rings 3 and bearing pins 4 NOTE Do not lose the C rings and bearing pins 3 Hold the gearsh...

Page 116: ...ooth rotation Replace the bearing if there is anything unusual Special tool 09900 06106 Snap ring pliers 7 Remove the gearshift cam stopper bolt 13 Oil Pump Oil Jet For The Transmission 1 Remove the oil pump 1 2 Remove the oil jets for the transmission 2 3 Remove the O rings and dowel pins Engine Bottom Side Assembly B649G11406047 Assembly the engine bottom side in the reverse of disassembly Pay a...

Page 117: ...ue Tightening torque Oil pump mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the oil jets for the transmission 5 NOTE Apply engine oil to the O rings Make sure that the oil jets in the lower crankcase are not clogged Transmission Install the gearshift cam stopper bolt 1 NOTE Before installing the gearshift cam stopper bolt 1 apply a small quantity of THREAD LOCK 1342 to it Thread lock cement 990...

Page 118: ...ft forks and transmission gears to be installed easily Install the gearshift forks into the crankcase in the correct position and direction For the 6th Top driven gear 8 For the 3rd 4th drive gear 9 For the 5th driven gear 10 Hold the gearshift forks 11 by hand when installing the gearshift fork shaft 12 Install the bearing pins 13 and C rings 14 into the upper crankcase 3 4 5 6 I649G1140145 01 7 ...

Page 119: ...ake sure that the oil jets 1 in the upper crankcase are not clogged Crankshaft Journal Bearing When installing the crankshaft journal bearings into the upper and lower crankcases be sure to install the tab A first and then press in the opposite side of the bearing CAUTION Do not touch the bearing surfaces with your hands Grasp the bearings by their edges NOTE Inspect and select the crankshaft jour...

Page 120: ...nkshaft journal bearing M O Molybdenum oil Molybdenum oil solution Install the crankshaft assembly along with the cam chain into the upper crankcase Insert the right and left thrust bearings with the oil grooves facing towards the crankshaft web NOTE Inspect and select the crankshaft thrust clearance if necessary Refer to Crankshaft Thrust Clearance Inspection and Selection 1 2 I649G1140155 02 I64...

Page 121: ...nkcase as follows Sealant 99000 31140 SUZUKI Bond 1207B or equivalent NOTE Make sure that the mating surfaces are free from moisture oil dust and other foreign materials Apply a bond thinly and evenly and assemble the crankcases within a few minutes of application Take extreme care not to apply any bond to the bearing surfaces I649G1140157 01 The line of BOND I649G1140158 02 ...

Page 122: ... m 16 0 lb ft Tighten the main oil gallery plug 2 to the specified torque CAUTION Replace the O ring with a new one Tightening torque Main oil gallery plug a 40 N m 4 0 kgf m 29 0 lb ft Install the engine ground wire 3 to the correct position as shown Tighten the lower and upper crankcase bolts M6 and nuts to the specified torque Tightening torque Crankcase bolt and nut M6 Initial 6 N m 0 6 kgf m ...

Page 123: ...Engine Mechanical 1D 55 CAUTION Use a new gasket washer to prevent oil leakage 4 I649G1140349 01 3 5 B I649G1140363 01 C I649G1140364 01 I649G1140358 01 ...

Page 124: ...l leakage Install a new gasket and the oil pan CAUTION Replace the oil pan gasket with a new one to prevent oil leakage Install a new gasket washer 10 to the oil pan bolt 11 as shown CAUTION Use a new gasket washer to prevent oil leakage Tighten the oil pan bolts to the specified torque Tightening torque Oil pan bolt 14 N m 1 4 kgf m 10 lb ft 6 7 8 9 I649G1140165 02 10 11 I649G1140359 01 I649G1140...

Page 125: ...itch be sure to install the spring 1 switch contact 2 and O ring 3 properly CAUTION Replace the O ring with a new one Install the oil seal retainer 4 with the four bolts and then bend up the tabs on the retainer NOTE Route the gear position switch lead wire to the inside of the oil seal retainer s tab A as shown Starter Clutch Install the starter clutch component parts Refer to Starter Clutch Remo...

Page 126: ...rshift cam driven gear Install the washer and fix the gearshift shaft with the snap ring CAUTION Replace the snap ring with a new one Special tool 09900 06107 Snap ring pliers Clutch Install the clutch component parts Refer to Clutch Installation in Section 5C CKP Sensor Oil Pressure Switch Install the CKP sensor component parts Refer to CKP Sensor Removal and Installation in Section 1H Install th...

Page 127: ...ne Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the generator 1 Tightening torque Generator mounting bolt a 25 N m 2 5 kgf m 18 0 lb ft Starter Motor Apply a grease to the starter motor O ring CAUTION Replace the O ring with a new one Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the starter motor with the bolts and tighten them to the specified torque Tightening...

Page 128: ...ing the bearings into the bearing cap and conrod be sure to install the tab A first and then press in the opposite side of the bearing NOTE Inspect and select the conrod crank pin bearing if necessary Refer to Conrod Crank Pin Bearing Inspection and Selection 2 Apply molybdenum oil solution to the crank pin and bearing surface M O Molybdenum oil Molybdenum oil solution 3 When mounting the conrod o...

Page 129: ...nrod and measure the conrod big end width and crank pin width Refer to Conrod Removal and Installation If any of the measurements are out of specification replace the conrod or crankshaft Special tool B 09900 20205 Micrometer 0 25mm C 09900 20605 Dial calipers 1 100 mm 10 34 mm Conrod big end width Standard 20 95 21 00 mm 0 825 0 827 in Crank pin width Standard 21 10 21 15 mm 0 831 0 833 in Cranks...

Page 130: ... of plastigauge is installed Tightening torque Conrod cap nut Initial 25 N m 2 5 kgf m 18 0 lb ft Conrod cap nut Final 51 N m 5 1 kgf m 37 0 lb ft 4 Remove the bearing caps and measure the width of the compressed plastigauge using the envelope scale This measurement should be taken at the widest part of the compressed plastigauge If the oil clearance exceeds the service limit select the specified ...

Page 131: ...laced as a set Bearing selection table Bearing thickness specification Code B O D specification 1 37 992 38 000 mm 1 4957 1 4961 in 2 37 984 37 992 mm 1 4954 1 4957 in 3 37 976 37 984 mm 1 4951 1 4954 in B I649G1140283 01 A I649G1140335 02 Crank pin O D B Code 1 2 3 Conrod I D A 1 Green Black Brown 2 Black Brown Yellow Color C Part No Thickness Green 12164 46E01 0A0 1 480 1 484 mm 0 0583 0 0584 in...

Page 132: ...Initial 13 N m 1 3 kgf m 9 5 lb ft Crankcase bolt M8 Final 22 N m 2 2 kgf m 16 0 lb ft 4 Remove the lower crankcase and measure the width of compressed plastigauge using the envelope scale This measurement should be taken at the widest part of the compressed plastigauge If the oil clearance exceeds the service limit select the specified bearings from the bearing selection table Crankshaft journal ...

Page 133: ...0 mm 1 4170 1 4173 in B 35 984 35 992 mm 1 4167 1 4170 in C 35 976 35 984 mm 1 4164 1 4167 in B I649G1140339 01 A I649G1140340 02 Crankshaft O D B Code A B C Crankcase I D A A Green Black Brown B Black Brown Yellow Color Part No Thickness Green 12229 06B00 0A0 1 12229 06B10 0A0 2 1 486 1 490 mm 0 0585 0 0587 in Black 12229 06B00 0B0 1 12229 06B10 0B0 2 1 490 1 494 mm 0 0587 0 0588 in Brown 12229 0...

Page 134: ...0 08 mm 0 0016 0 0031 in Selection 1 Remove the right side thrust bearing and measure its thickness using the micrometer If the thickness of the right side thrust bearing is below standard replace it with a new bearing and measure the thrust clearance again as described above Special tool A 09900 20205 Micrometer 0 25mm Right side thrust bearing thickness Standard 2 420 2 440 mm 0 0953 0 0961 in 2...

Page 135: ...8B00 0H0 2 36 2 38 mm 0 0929 0 0937 in 0 04 0 08 mm 0 0016 0 0031 in 2 44 2 46 mm 0 0961 0 0969 in Orange 12228 48B00 0G0 2 38 2 40 mm 0 0937 0 0945 in 2 46 2 48 mm 0 0969 0 0976 in Blue 12228 48B00 0F0 2 40 2 42 mm 0 0945 0 0953 in 2 48 2 50 mm 0 0976 0 0984 in Green 12228 48B00 0E0 2 42 2 44 mm 0 0953 0 0961 in 2 50 2 52 mm 0 0984 0 0992 in Yellow 12228 48B00 0D0 2 44 2 46 mm 0 0961 0 0969 in 2 ...

Page 136: ...alve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free length IN EX INNER 35 0 1 38 OUTER 37 8 1 49 Valve spring tension IN EX INNER 53 65 N 5 3 6 5 kgf 11 7 14 3 lbs at length 28 mm 1 10 in OUTER 131 151 N 13 1 15 1 kgf 28 9 33 3 lbs at length 31 5 mm 1 24 in Item Standard Limit Cam height IN 33 58 33 62 1 3220 1 3236 33 28 1 3102 EX 32 65 32 69 1 28...

Page 137: ...ston ring groove width 1st 1 01 1 03 0 040 0 041 2nd 1 01 1 03 0 040 0 041 Oil 2 01 2 03 0 079 0 080 Piston ring thickness 1st 0 975 0 990 0 0384 0 0390 2nd 0 970 0 990 0 038 0 039 Piston pin bore 20 002 20 008 0 7875 0 7877 20 030 0 7886 Piston pin O D 19 992 20 000 0 7871 0 7874 19 980 0 7866 Item Standard Limit Conrod small end I D 20 010 20 018 0 7878 0 7881 20 040 0 7890 Conrod big end side c...

Page 138: ... 20 2 0 14 5 Cylinder head cover bolt 14 1 4 10 0 Cooling hose mounting bolt 10 1 0 7 0 PAIR pipe mounting nut 10 1 0 7 0 Camshaft sprocket bolt 25 2 5 18 0 Cam chain guide bolt 6 0 6 4 5 Rocker arm shaft set bolt 9 0 9 6 5 Cylinder head plug 28 2 8 20 0 Oil pump mounting bolt 10 1 0 7 0 Crankcase bolt M8 Initial 13 1 3 9 5 Crankcase bolt M8 Final 22 2 2 16 0 Main oil gallery plug 40 4 0 29 0 Cran...

Page 139: ...9900 20102 09900 20202 Vernier calipers 1 20 mm 200 mm Micrometer 1 100 mm 25 50mm 09900 20204 09900 20205 Micrometer 75 100mm Micrometer 0 25mm 09900 20508 09900 20602 Cylinder gauge set Dial gauge 1 1000mm 1mm 09900 20605 09900 20606 Dial calipers 1 100 mm 10 34 mm Dial gauge 1 100 mm 09900 20701 09900 20803 Magnetic stand Thickness gauge 09900 21304 09900 22301 V block 100mm Plastigauge 0 025 0...

Page 140: ...0 09916 10911 Compression gauge set Valve lapper set 09916 14510 09916 14910 Valve spring compressor Valve lifter attachment 09916 34542 09916 34570 Reamer handle Valve guide reamer 4 95 mm 09916 34580 09916 44310 Valve guide reamer 10 8 mm Valve guide remover installer 09916 74521 09916 74550 Holder body Band bore 73 85 mm 09916 84511 09930 10121 Tweezers Spark plug wrench set ...

Page 141: ...E 1 Engine Lubrication System Precautions Precautions for Engine Oil B649G11500001 Refer to Fuel and Oil Recommendation in Section 0A Schematic and Routing Diagram Engine Lubrication Circuit Diagram B649G11502002 I649G1150002 01 ...

Page 142: ...L JET OIL JET OIL JET OIL JET OIL PRESSURE SWITCH CRANKSHAFT JOURNALS COUNTERSHAFT LEFT SIDE BEARING NO 1 PISTON AND PISTON PIN STUD BOLTS EXHAUST SIDE PISTON CYLINDER WALL CONROD BIG END EXHAUST ROCKER ARM SHAFTS EXHAUST ROCKER ARMS EXHAUST CAM FACES EXHAUST CAMSHAFT JOURNALS INTAKE ROCKER ARMS INTAKE ROCKER ARM SHAFTS INTAKE CAMSHAFT JOURNALS INTAKE CAM FACES STARTER CLUTCH BUSHING STUD BOLTS IN...

Page 143: ... as follows Summer 10 min at 2 000 r min Winter 20 min at 2 000 r min 5 After warm up increase the engine speed to 3 000 r min Observe the tachometer and read the oil pressure gauge If the oil pressure is lower or higher than the specification the following causes may be considered Oil pressure specification Above 300 kPa 3 0 kgf cm2 43 psi at 3 000 r min oil temp at 60 C 140 F Below 600 kPa 6 0 k...

Page 144: ...oval and Installation in Section 1F Oil Cooler Oil Cooler Hose Inspection B649G11506003 Refer to Engine Cooling System Inspection in Section 1F Oil Cooler Cleaning B649G11506022 Refer to Oil Cooler Cleaning in Section 1F Oil Pan Oil Sump Filter Oil Pressure Regulator Removal and Installation B649G11506023 Removal 1 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B 2 Remove ...

Page 145: ...4 to the oil pan bolt as shown Tightening torque Oil pan bolt b 14 N m 1 4 kgf m 10 0 lb ft 5 Install the oil cooler hose Refer to Oil Cooler Oil Cooler Hose Removal and Installation in Section 1F 6 Install the exhaust pipe and muffler Refer to Exhaust Pipe Muffler Removal and Installation in Section 1K 7 Pour engine oil Refer to Engine Oil and Filter Replacement in Section 0B Oil Pressure Regulat...

Page 146: ...6026 Refer to Electrical Components Location in Section 0A Removal 1 Drain engine oil Refer to Engine Oil and Filter Replacement in Section 0B 2 Remove the CKP sensor cover Refer to CKP Sensor Removal and Installation in Section 1H 3 Disconnect the oil pressure switch lead wire 4 Remove the oil pressure switch Installation 1 Install the oil pressure switch apply the SUZUKI BOND to its thread and t...

Page 147: ... the cylinder head Installation Installation is in the reverse order of removal Refer to Engine Top Side Assembly in Section 1D Pay attention to the following points NOTE Before installing the oil jets apply a light coat of engine oil to the O rings Oil Jet For the Piston Cooling and Transmission Removal and Installation B649G11506028 1 Remove the engine assembly Refer to Engine Assembly Removal i...

Page 148: ...ts Refer to Oil Jet For the Cylinder Head Removal and Installation and Oil Jet For the Piston Cooling and Transmission Removal and Installation Oil Pump Removal and Installation B649G11506030 Refer to Oil Pump Oil Pressure Regulator Removal and Installation in Section 1F Oil Pump Inspection B649G11506031 Inspect the oil pump in the following procedures 1 Remove the oil pump Refer to Oil Pump Oil P...

Page 149: ...cm2 43 psi Below 600 kPa 6 0 kgf cm2 85 psi at 3 000 r min Item Specification Note Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 3 300 ml 3 4 2 9 US lmp qt Filter change 3 500 ml 3 6 3 0 US lmp qt Overhaul 4 600 ml 4 9 4 0 US lmp qt Fastening part Tightening torque Note N m kgf m lb ft Main oil gallery plug 40 4 0 29 0 Oil pressure regulator 28 2 8 20 0 Oil ...

Page 150: ... B649G11600001 WARNING To avoid the danger of being burned do not touch the oil cooling system when the system is hot Any service on the oil cooling system should be performed when the system is cool Precautions for Engine Oil B649G11600002 Refer to Fuel and Oil Recommendation in Section 0A ...

Page 151: ...he cylinder head cover through the cooling hoses located in the center area of upper crankcase and enters the drilled passage in the cylinder head cover Oil is then jet sprayed from the jet nozzle into the oil chamber on the upper area of combustion chamber With oil splash guarded by the oil chamber plate jetted oil is guided to the cylinder head return port and returns to the oil pan through the ...

Page 152: ...1F 3 Engine Cooling System Schematic and Routing Diagram Cylinder Head Cooling System Chart Diagram B649G11602003 I649G1160002 02 ...

Page 153: ...e cause Correction Reference Item Engine overheats Carbon build up on piston crown Clean Insufficient amount of engine oil Check level and add Defective oil pump Replace Clogged oil circuit Clean Clogged oil cooler Clean or replace Dirty or bent oil cooler fins Clean or repair Loose oil nozzle Replace Incorrect engine oil Change ...

Page 154: ... pipe LH 2 O ring 10 Gasket 18 Upper oil return pipe RH 3 Cooling oil hoses 11 Oil sump filter protector 19 O ring 4 O ring 12 Oil sump filter A For cylinder head cooling 5 Oil pump mounting bolt 13 Oil sump filter mounting bolt 10 N m 1 0 kgf m 7 0 lb ft 6 Oil pump 14 Oil sump filter protector mounting bolt Apply THREAD LOCK 1342 to thread part 7 Oil pump driven gear 15 Lower oil return pipe LH D...

Page 155: ...b 8 a 7 4 5 a 7 I649G1160028 01 1 Oil cooler mounting bolt 5 Oil cooler hose RH 10 N m 1 0 kgf m 7 0 lb ft 2 Oil cooler 6 Gasket washer 28 N m 2 8 kgf m 20 0 lb ft 3 O ring 7 Oil cooler bracket bolt Apply THREAD LOCK 1322 to thread part 4 Oil cooler hose LH 8 Oil cooler hose union bolt Do not reuse ...

Page 156: ...gine Cooling System Oil Cooler and Oil Cooler Hose Construction B649G11606028 a b a a a I649G1160003 04 10 N m 1 0 kgf m 7 0 lb ft Apply THREAD LOCK 1322 to thread part 23 N m 2 3 kgf m 16 5 lb ft Do not reuse ...

Page 157: ... O rings from the oil cooler Installation Installation is in the reverse order of removal Pay attention to the following points CAUTION Replace the O rings and gasket washers with new ones to prevent oil leakage Tighten the oil cooler hose connecting bolts to the specified torque Tightening torque Oil cooler hose connecting bolt a 10 N m 1 0 kgf m 7 0 lb ft Tighten the oil cooler mounting bolts to...

Page 158: ...l Refer to Engine Oil and Filter Replacement in Section 0B Engine Cooling Hose Removal and Installation B649G11606029 Removal 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 2 Remove the cooling hoses 1 Installation CAUTION Replace the O rings 1 and 2 with new ones to prevent oil leakage 1 Install the left and right cooling hoses and tighten their mounting bolts to...

Page 159: ...s with new ones to prevent oil leakage Install the O rings 1 and 2 and dowel pins 3 in the correct position as shown Apply a small quantity of THREAD LOCK 1342 to the bolts Thread lock cement 99000 32050 Thread Lock Cement 1342 or equivalent Install the oil pump 4 into the lower crankcase and tighten the bolts to the specified torque Tightening torque Oil pump mounting bolt a 10 N m 1 0 kgf m 7 0 ...

Page 160: ...g hose assembly with a new one Inspect the cooling hoses are connected securely If any leakage from the connecting section should be corrected by proper tightening or replace the O ring with a new one Oil Cooler Hose Inspect the oil cooler hoses for damage and oil leaks If any defects are found replace the oil cooler hose s with a new one Oil Cooler Inspect the oil cooler for oil leaks If any defe...

Page 161: ...e Disassembly in Section 1D 2 Inspect the oil nozzles 1 are installed properly They press fitted in the cylinder head If it is loosened replace the oil nozzle with a new one and its gasket with a new one Refer to Oil Nozzle Removal and Installation 3 Install the cylinder head cover Refer to Engine Top Side Assembly in Section 1D Oil Cooler Cleaning B649G11606036 Blow out any foreign matter that is...

Page 162: ...ion Item Standard Limit Oil pump reduction ratio 1 703 72 46 x 37 34 Oil pressure at 60 C 140 F Above 300 kPa 3 0 kgf cm2 43 psi Below 600 kPa 6 0 kgf cm2 85 psi at 3 000 r min Item Specification Note Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 3 300 ml 3 4 2 9 US lmp qt Filter change 3 500 ml 3 6 3 0 US lmp qt Overhaul 4 600 ml 4 9 4 0 US lmp qt Fastening...

Page 163: ...l System 1G 1 Fuel System Precautions Precautions for Fuel System B649G11700001 WARNING Gasoline is highly flammable and explosive Extreme care must be taken Keep heat sparks and flames away from gasoline ...

Page 164: ...G11701002 Fuel System The fuel system consists of a fuel tank fuel filter fuel valve vacuum hose fuel hose and carburetor assembly When there is negative pressure vacuum in the combustion chamber the fuel is able to flow from the fuel tank through the fuel valve and then to the carburetor assembly A I649G1170001 01 A B I649G1170002 02 A Vacuum B Fuel ...

Page 165: ...e pressure vacuum A is generated in the combustion chamber and reaches the diaphragm through a passage in the carburetor s main bore and the vacuum hose This negative pressure vacuum A is higher than the spring pressure which causes the diaphragm to force open the fuel valve 1 and allow fuel B to flow to the carburetor assembly A B 1 2 A B I649G1170003 02 1 Fuel valve A Vacuum A Fuel stop conditio...

Page 166: ...ragm chamber 2 through an orifice C provided in the piston valve 1 Rising negative pressure overcomes the spring 3 force causing the piston valve 1 to rise into the diaphragm chamber and prevent the air velocity from increasing Thus air velocity in the venturi passage is kept relatively constant for improved fuel atomization and the precise air fuel mixture 2 3 1 A C B A B I649G1170004 03 1 Piston...

Page 167: ... jet 4 This mixture rich with fuel then goes up through the pilot passage to the pilot screw 5 Part of the mixture is discharged into the main bore through bypass ports 6 The mixture is metered by the pilot screw 5 and sprayed into the main bore through the pilot outlet port 7 2 1 3 4 5 6 7 A B C I649G1170005 01 1 Throttle valve 3 Pilot jet 5 Pilot screw 7 Pilot outlet port B Fuel Air mixture 2 Fl...

Page 168: ...s an emulsion The emulsified fuel then passes through the clearance between the needle jet 5 and jet needle 7 and is discharged into the venturi A where it meets the main air stream being drawn by the engine Mixture proportioning is accomplished in the needle jet 5 The clearance through which the emulsified fuel must flow ultimately depends on throttle position 1 2 3 4 5 6 7 A B C D I649G1170006 0...

Page 169: ...tarter plunger 4 and mixes again with the air coming through a passage extending from behind the diaphragm The two successive mixtures of the fuel with the air provide the proper air fuel mixture for starting This occurs when the mixture is sprayed through the starter outlet port 5 into the main bore NOTE A starter enricher system is operated almost the same way as a choke 1 2 3 4 5 A B C 3 I649G1...

Page 170: ...ses and the needle valve 2 pushes up against the valve seat When this occurs no fuel enters the float chamber 3 As the fuel level falls the float 1 lowers and the needle valve 2 unseats itself admitting fuel into the float chamber 3 In this manner the needle valve 2 admits and shuts off fuel to maintain the appropriate fuel level inside the float chamber 3 1 Float 3 Float chamber 2 Needle valve A ...

Page 171: ...side RH LH RH LH 6 I649G1170009 02 1 Fuel hose Connected to the carburetor and fuel valve 5 Air vent hose RH 9 Air cleaner box drain hose 2 Vacuum hose To fuel valve 6 Air vent hose LH 10 Fuel tank breather hose 3 Vacuum hose To 4 carburetor 7 PCV hose 11 Wiring harness 4 Vacuum hose To PAIR valve 8 Fuel tank drain hose 12 Inside wall of the right frame ...

Page 172: ...ank drain hose 5 Air cleaner drain hose 2 Fuel tank breather hose No 1 6 Hoses Be careful not to bind the fuel tank drain hose and fuel tank breather hose with the other hoses and wire harness 3 Fuel tank breather hose No 2 7 Clamp Clamp end should face down side Tip of clamp should face outside 4 Fuel tank breather hose No 3 ...

Page 173: ...ting the No 1 throttle cable set the No 1 throttle thread length to 3 5 mm 0 12 0 20 in by the cable adjuster A then adjust the throttle cable play by the cable adjuster B to the specified cable play at the throttle grip 6 PAIR valve 2 No 2 throttle cable 7 PCV hose 3 Cable guide C Only for GSF1200S 4 Starter Enricher cable a Pass the starter Enricher cable through between the PAIR hoses 5 Clutch ...

Page 174: ...r tighten Clogged or loose pilot air jet Clean or tighten Air leaking from carburetor joint vacuum pipe joint or starter Tighten or replace defective part Clogged pilot outlet port Clean Clogged bypass port Clean Starter enricher plunger not fully closed Adjust Medium or high speed trouble Clogged main jet Clean Clogged main air jet Clean Clogged needle jet Clean Improperly working throttle valve ...

Page 175: ... 03 1 Fuel valve 5 Rear bracket cushion Be careful not to mistake the assembling position and direction 2 Gasket washer A Apply adhesive agent to the cushion rubber 3 Gasket 4 4 N m 0 44 kg f 3 2 lb ft 4 Fuel tank rear cushion Be careful not to mistake the assembling position and direction Do not reuse ...

Page 176: ...emove the fuel tank Installation Install the fuel tank in the reverse order of removal Pay attention to the following point CAUTION Be careful not to bend the hoses Fuel Valve Removal and Installation B649G11706020 Removal WARNING Gasoline is very explosive Extreme care must be taken 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation 2 Remove the fuel valve 1 Installation Install t...

Page 177: ...loss in engine power may result Clean the fuel filter with compressed air 4 Reinstall the fuel valve Refer to Fuel Valve Removal and Installation 5 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation Fuel Level Gauge Removal and Installation B649G11706022 Removal WARNING Gasoline is very explosive Extreme care must be taken 1 Remove the fuel tank Refer to Fuel Tank Removal and Inst...

Page 178: ...on Throttle Cable Inspection B649G11706025 Check that the throttle grip moves smoothly from full open to full close If it does not smoothly lubricate the throttle cables Throttle Cable Play Inspection and Adjustment B649G11706012 Refer to Throttle Cable Play Inspection and Adjustment in Section 0B Starter Cable Removal and Installation B649G11706026 Removal 1 Remove the fuel tank Refer to Fuel Tan...

Page 179: ...ottle position sensor 5 0 N m 0 5 kgf m 3 5 lb ft 2 Fuel joint pipe No 1 9 Carburetor set shaft 2 0 N m 0 2 kgf m 1 5 lb ft 3 Seal 10 Starter Enricher plate Apply grease 4 Fuel joint pipe No 2 11 Throttle stop screw Apply thermo grease 5 O ring 12 Carburetor heater Do not reuse 6 Air vent joint pipe 13 Thermo switch 7 Throttle valve synchronizing screw A For E 02 19 ...

Page 180: ...ssembly 22 Starter jet 2 Spring 9 Jet needle 16 Float 23 Gasket O ring 3 Jet needle stopper 10 Diaphragm 17 Needle jet 24 Float chamber 4 O ring 11 O ring 18 O ring 25 Pilot screw 5 Spring 12 Piston valve 19 Main jet holder 26 Vacuum inlet cap 6 Washer 13 Pilot air jet 20 Main jet Apply grease 7 E ring 14 Starter Enricher plunger 21 Pilot jet Do not reuse ...

Page 181: ...ve carburetor clamp screws 6 Move the air cleaner box backward 7 Disconnect the carburetor heater lead wire coupler 2 For E 02 19 8 Remove the thermo switch 3 For E 02 19 9 Disconnect the starter cable 4 and throttle cables 5 10 Disconnect the vacuum hose 6 11 Remove the carburetor assembly Installation Install the carburetor assembly in the reverse order of removal Pay attention to the following ...

Page 182: ...lost Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor CAUTION Avoid removing the throttle position sensor from the carburetor body unless absolutely necessary The TP sensor is preset at the factory Prior to disassembly mark the throttle position sensor s original position with pain...

Page 183: ...emove the jet needle stopper 9 spring 10 washer 11 spacer 12 and jet needle 13 11 Remove the starter enricher plunger assembly 14 CAUTION Never remove the throttle valve 15 12 Remove the pilot air jet 16 CAUTION Do not remove the main air jet 17 It is press fitted at the factory and attempting to remove it will cause damage 5 I649G1170038 01 6 7 8 I649G1170039 01 9 11 12 13 10 I649G1170040 01 14 I...

Page 184: ...se and count the number of turns until it is lightly seated Make a note of how many turns were made When reassembling the pilot screw you will want to set it to its original position Pilot Screw Removal For with Tampering Plug Type Because harsh cleaning solvents can damage the O ring seals in the pilot system the pilot system components should be removed before cleaning 1 Use a 1 8 size drill bit...

Page 185: ...with new ones Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent After cleaning reinstall the pilot screw to the original setting by turning the screw 1 in until it lightly seats and then backing it out the same number of turns counted during disassembly Install a new plug by tapping it into place with a punch For with tampering plug type Check the float height Refer to Float Height Inspection...

Page 186: ... plate engine side downward and tighten the upper and lower carburetor set shafts to the specified torque Tightening torque Carburetor set shaft a 5 0 N m 0 5 kgf m 3 5 lb ft Float Height Inspection and Adjustment B649G11706004 Inspect and adjust the float height in the following procedures 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation 2 Remove the carburetor assembly Refer to...

Page 187: ...nd by pass ports Needle Valve Check the needle valve for damage or worn If foreign matter is caught between the valve seat and the needle valve the gasoline will continue flowing and overflow If the valve seat and needle valve are worn beyond the permissible limits similar trouble will occur Conversely if the needle valve sticks the gasoline will not flow into the float chamber Clean the float cha...

Page 188: ...y negative terminal to the terminal B 4 Check that the heater section C is heated in 5 minutes after the battery has been connected If the carburetor heater is not heated up replace the carburetor heater with a new one WARNING Do not touch the carburetor heater directly to prevent burn 5 Reinstall the carburetor assembly Refer to Carburetor Assembly Removal and Installation Thermo switch For E 02 ...

Page 189: ...ect the TP sensor coupler 1 and remove the TP sensor 2 2 Temporary install the TP sensor 3 Measure the resistance between the TP sensor terminals A to C as shown Special tool A 09900 25008 Multi circuit tester set Tester knob indication Resistance Ω Throttle position sensor resistance A to C 3 5 6 5 kΩ 4 Fully open the throttle valve with the throttle lever 5 Measure the resistance between the TP ...

Page 190: ... bottle to the fuel hose 3 Remove the vacuum hose 1 for fuel valve and install a proper cap to the three way joint 4 Start up the engine and run it in idling condition for warming up 5 Stop the warmed up engine 6 Remove a proper cap and connect the digital vacuum tester hose to the three way joint 7 Remove the vacuum inlet caps from the carburetors for cylinders 1 2 and 3 8 Connect the vacuum test...

Page 191: ...tal vacuum tester tachometer and fuel bottle 15 Reinstall the vacuum hose for fuel valve and vacuum inlet caps 16 Reinstall the fuel tank Refer to Fuel Tank Removal and Installation Engine Idle Speed Inspection B649G11706013 Refer to Engine Idle Speed Inspection and Adjustment in Section 0B Fuel Line Inspection B649G11706014 Refer to Fuel Line Inspection in Section 0B Air Cleaner Element Removal a...

Page 192: ...s back Throttle cable play Pulling cable 2 0 4 0 mm 0 08 0 16 in Starter enricher plunger cable play 0 5 1 0 mm 0 02 0 04 in Item Specification Note Fuel type Use only unleaded gasoline of at least 87 pump octane or 91 octane R 2 M 2 or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents a...

Page 193: ...also described in the following Carburetor Components Special Tool B649G11708002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 THERMO GREASE or equivalent P No 99000 59029 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circuit tester set ...

Page 194: ...nsistor of the ignition coil output circuit which is connected to the primary windings of the ignition coils which is turned off and on accordingly Thus it induces the secondary current in the ignition coil s secondary windings and produces the spark between the spark plug gaps The ignition cutoff circuit is incorporated in the ignitor to prevent the engine from overreving If the engine speed reac...

Page 195: ...lace Defective ignitor Replace Spark plug is wet or quickly becomes fouled with carbon Excessively rich air fuel mixture Adjust carburetor Excessively high idling speed Adjust carburetor Incorrect gasoline Change Dirty air cleaner element Clean or replace Incorrect spark plug Cold type Change to hot type spark plug Spark plug quickly becomes fouled with oil or carbon Worn piston ring Replace Worn ...

Page 196: ... circuit couplers 3 Measure the ignition coil primary peak voltage Refer to Ignition Coil Inspection NOTE This ignition coil primary peak voltage inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Go to step 4 Go to step 5 4 Inspect the spark plugs Refer to Spark Plug Inspection and Cleaning in Section 0B Is the spark plug OK Go to S...

Page 197: ...l Inspection B649G11806008 Refer to Electrical Components Location in Section 0A Ignition Coil Primary Peak Voltage 1 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 2 Disconnect all the spark plug caps 3 Connect new spark plugs 1 to each spark plug cap and ground them on the cylinder NOTE Be sure that all the spark plugs are connected properly and the battery used i...

Page 198: ...ter probes and spark plugs to prevent an electric shock while testing 6 Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage If the voltages are lower than standard values inspect the ignition coil and the CKP sensor Ignition coil primary peak voltage 140 V and more 7 After measuring the ignition coil primary peak voltage reinstall the removed parts Ign...

Page 199: ...isconnect all of the spark plug caps 3 Remove the ignition coil assembly as shown in the ignition coil and spark plug cap components Refer to Ignition Coil and Spark Plug Cap Components Installation Install the ignition coil assembly in the reverse order of removal Pay attention to the following point Connect all of the spark plug caps securely Spark Plug Removal and Installation B649G11806016 Ref...

Page 200: ...nd measure the highest CKP sensor peak voltage CKP sensor peak voltage 1 0 V and more B BI Y W 6 If the peak voltage measured on the ignitor coupler is lower than the standard value measure the peak voltage on the CKP sensor coupler as follows a Remove the left frame cover Refer to Exterior Parts Removal and Installation in Section 9D b Disconnect the CKP sensor coupler 7 c Connect the multi circu...

Page 201: ... 2 Disconnect the CKP sensor coupler 1 3 Measure the resistance between the lead wires and ground If the resistance is not within the specified value the CKP sensor must be replaced Refer to CKP Sensor Removal and Installation Tester knob indication Resistance Ω CKP sensor resistance Approx 130 200 Ω Blue Yellow Ω Blue Ground 4 After measuring the CKP sensor resistance reinstall the removed parts ...

Page 202: ... 31140 SUZUKI Bond 1207B or equivalent Hold the nut and tighten the CKP sensor rotor bolt to the specified torque Tightening torque CKP sensor rotor bolt 25 N m 2 5 kgf m 18 0 lb ft Connect the oil pressure switch lead wire Route the CKP sensor lead wire Refer to Wiring Harness Routing Diagram in Section 9A Apply a bond lightly to the CKP sensor cover gasket mating surface as shown Sealant 99000 3...

Page 203: ...stop switch for continuity with a tester If any abnormality is found replace the right handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the engine stop switch inspection reinstall the removed parts Ignition Switch Inspection B649G11806014 Refer to...

Page 204: ...k plug Type NGK JR9B Gap 0 6 0 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance Approx 130 200 Ω Tester range x 100 Ω CKP sensor peak voltage 1 0 V and more Ignition coil resistance Primary tap tap Approx 2 4 Ω Tester range x 1 Ω Secondary Spark plug cap Spark plug cap Approx 30 40 kΩ Tester range x 1 kΩ Ignition coil primary peak voltage 140 V and more Fastening part Tigh...

Page 205: ...rt the engine Side stand Ignition Interlock System Description B649G11901002 Refer to Wire Color Symbols in Section 0A This side stand ignition interlock system prevents the motorcycle from being started with the side stand down The system is operated by an electric circuit provided between the battery and ignition coil B Bl Bl B Bl G B O B R Starter motor Ignition switch Fuse 30 A Side stand swit...

Page 206: ... The current flow A switches on the side stand relay and the ignition coils send voltage to the spark plugs even when the side stand is kept down Side stand Up ON The current flow B switches on the side stand relay and the ignition coils send voltage to the spark plugs The engine can be started in any gear Battery Ignition switch ON Turn signal side stand relay Gear position switch ON Side stand s...

Page 207: ... Fuse 30 A Side stand switch Starter relay Engine stop switch Starter button Turn signal side stand relay Fuse 15 A Gear position switch Battery Clutch lever position switch B W B Y I649G1190001 01 Condition Possible cause Correction Reference Item Engine does not turn though the starter motor runs Faulty starter clutch Replace Starter button is not effective Run down battery Repair or replace Def...

Page 208: ...arge amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Faulty starter motor 3 Measure the starter relay voltage at the starter relay connectors between B Bl and B Y when the starter button is pushed Is a voltage OK Go to Step 4 Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty gear positio...

Page 209: ...d wire nut 6 5 N m 0 65 kgf m 4 7 lb ft 2 Housing end Inside 7 Washer set 12 Starter motor mounting bolt Apply grease to sliding surface 3 Washer set 8 Brush holder 13 O ring Apply moly past to sliding surface 4 O ring 9 Brush spring 5 N m 0 5 kgf m 3 5 lb ft Apply thread lock to thread part 5 Starter motor case 10 Housing end Outside 6 N m 0 6 kgf m 4 5 lb ft Do not reuse ...

Page 210: ...val Pay attention to the following points Apply SUZUKI SUPER GREASE A to the starter motor O ring Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent CAUTION Replace the O ring with a new one Apply a small quantity of THREAD LOCK 1342 to the starter motor mounting bolts and tighten them to the specified torque Thread lock cement 99000 32050 Thread Lock Cement 1342 or equivalent Tightening torqu...

Page 211: ...eplace the O rings with new ones to prevent oil leakage and moisture Apply SUZUKI SUPER GREASE A to the lip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Fit the washer to the housing end correctly as shown Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft Moly paste 99000 25140 SUZUKI Moly paste or equivalent Align the match mark on the starter motor case ...

Page 212: ... abnormal wear or undercut A If the commutator is abnormally worn replace the armature If the commutator surface is discolored polish it with 400 sandpaper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator 1 with a saw blade Armature Coil Measure for continuity between each segment Measure for continuity between each segment and the armature shaft If there is no ...

Page 213: ...al Starter Relay Inspection B649G11906015 Inspect the starter relay in the following procedures 1 Remove the starter relay Refer to Starter Relay Removal and Installation 2 Apply 12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the relay is ok CAUTION Do not apply batter...

Page 214: ...l Side stand Ignition Interlock System Parts Inspection B649G11906017 Refer to Electrical Components Location in Section 0A Check the interlock system for proper operation If the interlock system does not operate properly check each component for damage or abnormalities If any abnormality is found replace the component with a new one Side stand Switch 1 Remove the left frame cover Refer to Exterio...

Page 215: ...stall the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation Diode inspection 1 Remove the turn signal side stand relay Refer to Turn Signal Side stand Relay Removal and Installation 2 Measure the voltage between the terminals using the multi circuit tester Special tool 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the multi...

Page 216: ...oupler to the wiring harness 5 Install the seat Refer to Exterior Parts Removal and Installation in Section 9D Starter Clutch Components B649G11906018 Starter Clutch Removal and Installation B649G11906019 Removal 1 Remove the starter motor Refer to Starter Motor Removal and Installation 2 Drain engine oil 3 Remove the starter clutch cover Bl G Bl R B B W I649G1190048 01 ON Neutral OFF Except neutr...

Page 217: ...er clutch assembly in the reverse order of removal Pay attention to the following points Remove the grease from the tapered portion of the starter clutch and crankshaft Use a nonflammable cleaning solvent to wipe off any oil or grease and make sure that the surfaces are completely dry Apply a small quantity of THREAD LOCK SUPER 1303 to the threads of the starter clutch mounting bolt Thread lock ce...

Page 218: ...0 Refer to Starter Clutch Removal and Installation Starter Clutch Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand The gear turns in only one direction The starter driven gear should turn smoothly If excessive resistance is felt while turning the starter driven gear inspect the starter clutch Also inspect the surface of the starter driven gear which ...

Page 219: ...ect the right handlebar switch coupler 1 3 Inspect the starter button for continuity with a tester If any abnormality is found replace the right handle switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the starter button inspection reinstall the removed part...

Page 220: ...g torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Item Specification Note Starter motor brush length Standard 12 5 0 49 Limit 6 0 0 24 Starter relay resistance 3 6 Ω Fastening part Tightening torque Note N m kgf m lb ft Starter motor mounting bolt 6 0 6 4 5 Starter motor lead wire nut 5 0 5 3 5 Cooling hose mounting bolt 10 1 0 7 0 Starter m...

Page 221: ...or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Moly paste SUZUKI Moly paste or equivalent P No 99000 25140 Sealant SUZUKI Bond 1207B or equivalent P No 99000 31140 Thread lock cement Thread Lock Cement Super 1303 or equivalent P No 99000 32030 Thread Lock Cement 1342 or equivalent P No 99000 32050 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circ...

Page 222: ...coil which is mounted on the rotor The stator windings are assembled on the inside of a laminated core that forms part of the generator housing A rectifier bridge which is connected to the stator windings contains eight diodes and electrically changes the stator A C voltage to D C voltage which appears at the generator output terminal IG B B P F IG IG E E Stator coil Rotor coil Ignition switch IC ...

Page 223: ...n and tighten ground connection Poor contact of generator lead wire coupler Repair or connect properly Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent short circuitting Repair or replace Internally short circuited generator Replace Defective IC regulator or rectifier Replace Sulfation acidic white powdery substance or spots on surfaces of cell plates Cracke...

Page 224: ...nspection Is the charging voltage OK Faulty battery Abnormal driving condition Go to Step 4 4 Measure the continuity of the stator coil and rotor coil Refer to Generator Parts Inspection Is the continuity of the stator coil and rotor coil OK Go to Step 5 Faulty stator coil Disconnected lead wires 5 Inspect the slip rings and brushes Refer to Generator Parts Inspection Is the slip rings and brushes...

Page 225: ...plers and connectors one by one so as to locate the position of trouble 5 Install the seat Refer to Exterior Parts Removal and Installation in Section 9D Regulated Voltage Inspection B649G11A06002 NOTE When making this test be sure that the battery is in fully charged condition Inspect the regulated voltage in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installat...

Page 226: ... 3 25 lb ft 3 Damper housing 11 Rotor 19 Generator end cover 2 5 N m 0 25 kgf m 1 80 lb ft 4 Oil seal 12 Bearing cover 2 20 Generator driven gear nut Apply oil 5 O ring 13 Slip ring side bearing 21 Generator mounting bolt Apply grease to oil seal lip 6 Spacer 14 Bearing cover 1 22 Generator housing nut Apply moly paste 7 Generator end housing 15 Generator housing 23 Bearing retainer screw Apply th...

Page 227: ...ay attention to the following points Tighten the generator mounting bolts to the specified torque Tightening torque Generator mounting bolt a 25 N m 2 5 kgf m 18 0 lb ft Route the wire harness properly Refer to Wiring Harness Routing Diagram in Section 9A Before installing the engine sprocket cover apply a small quantity of SUZUKI SUPER GREASE A to the clutch push rod Grease 99000 25010 SUZUKI SUP...

Page 228: ...using 1 using the special tool Special tool A 09913 61510 Bearing puller 3 Remove the generator end cover 2 4 Remove the brush holder 3 and IC regulator 4 5 Remove the stator coil lead wires mounting screws 5 6 Remove the rectifier 6 NOTE Straighten the stator coil lead wires using long nose pliers then remove the rectifier 7 Remove the generator housing nuts 8 Separate the generator housing 7 fro...

Page 229: ...ring retainer 12 13 Remove the bearing 13 washer 14 and spacer 15 14 Remove the oil seal 16 Assembly Reassembly is in the reverse order of disassembly Pay attention to the following points CAUTION The removed bearing s and oil seal should be replaced with new one s Replace the O ring with a new one Apply SUZUKI SUPER GREASE A to the lip of the oil seal Grease 99000 25010 SUZUKI SUPER GREASE A or e...

Page 230: ...ring side bearing onto the generator end housing turn the expander ring and align the expander ring lug C with the center of the chamfered edge D of the bearing outer race Tighten the generator housing nuts 7 to the specified torque Tightening torque Generator housing nut b 4 5 N m 0 45 kgf m 3 25 lb ft A Hand press B Jig A Hand press 1 Bearing B jig 2 Rotor a a I649G11A0023 02 B A I649G11A0024 02...

Page 231: ... Generator Driven Gear Damper Inspect the generator driven gear dampers for wear and damage If any defects are found replace the generator driven gear dampers as a set NOTE When installing the generator driven gear dampers apply SUZUKI MOLY PASTE to the damper surface Moly paste 99000 25140 SUZUKI Moly paste or equivalent Stater Coil Continuity Check Measure the continuity between the lead wires o...

Page 232: ...ice limit replace the carbon brushes with new ones Brush length a Service limit 4 5 mm 0 18 mm Special tool A 09900 20102 Vernire calipers Rectifier Measure the voltage among the terminal 1 and the other terminals P1 P2 P3 and P4 Put the tester lead on the terminal 1 and the other lead to P1 P2 P3 and P4 terminals Observe the reading and then switch the leads Perform other side tests among the ter...

Page 233: ...ttery must be removed from the vehicle and must be put on the level ground 1 Remove the aluminum tape 1 which seals the battery filler holes A 2 Remove the caps 2 from the electrolyte container NOTE Do not remove or pierce the sealed areas B of the electrolyte container After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Terminal Terminal Voltage ...

Page 234: ...e bottom of the electrolyte container two or three times Never remove the container from the battery 6 After confirming that the electrolyte has entered the battery completely remove the electrolyte containers from the battery 7 Wait for about 20 minutes 8 Insert the caps 4 into the filler holes pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s...

Page 235: ... battery from the motorcycle Refer to Battery Removal and Installation 2 Measure the battery voltage using the multi circuit tester If the voltage reading is less than the 12 V DC recharge the battery with a battery charger Recharging time 1 2 A for 5 to 10 hours or 5 A for 1 hour CAUTION Be careful not to permit the charging current to exceed 5 A at any time 3 After recharging wait at least 30 mi...

Page 236: ...ion to following points CAUTION Never use anything except the specified battery Tighten the battery lead wire mounting bolts securely Battery Visual Inspection B649G11A06017 Inspect the battery in the following procedures 1 Remove the seat Refer to Exterior Parts Removal and Installation in Section 9D 2 Visually inspect the surface of the battery container If any signs of cracking or electrolyte l...

Page 237: ...ightening Torque Specifications in Section 0C Item Specification Note Type designation FT12A BS Capacity 12V 36 0 kC 10 Ah 10HR Standard electrolyte S G 1 320 at 20 C 68 F Item Specification Note Generator maximum output More than 550 W at 5 000 r min Regulated voltage 13 5 15 V at 5 000 r min Generator Slip ring O D Limit 14 0 0 55 DENSO Brush length Limit 4 5 0 18 Fastening part Tightening torqu...

Page 238: ...9G11A08002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Moly paste SUZUKI Moly paste or equivalent P No 99000 25140 Thread lock cement Thread Lock Cement 1342 or equivalent P No 99000 32050 09900 20102 09900 25008 Vernier calipers 1 20 mm 200 mm Multi circuit tester set 09913 60910 09913 61510 Bearing remover Bearing puller ...

Page 239: ...en the system is cool CAUTION Make sure that the exhaust pipe and muffler have enough clearance from the rubber parts and plastic parts to avoid melting Repair Instructions Exhaust System Construction B649G11B06004 1 3 2 a 4 a 5 a 6 a 6 A B I649G11B0001 05 1 Exhaust pipe 4 Exhaust pipe bolt A Chamfer Do not reuse 2 Muffler 5 Muffler connecting bolt B Apply exhaust gas sealer 3 Muffler connector 6 ...

Page 240: ...n to the following points CAUTION Replace the gaskets with new ones Install the exhaust pipe gaskets 1 CAUTION Be sure to face the tabs A on the exhaust pipe gaskets 1 to the engine side when installing them NOTE When installing new exhaust pipe muffler assembly connectors remove all of the old sealer from the exhaust pipes and from inside the muffler Apply the exhaust gas sealer B to both the ins...

Page 241: ...exhaust pipe connection and muffler connection for exhaust gas leakage and mounting condition If any defect is found replace the exhaust pipe or muffler with a new one Check the exhaust pipe bolts muffler connecting bolt and muffler mounting bolts are tightened to their specified torque Tightening torque Exhaust pipe bolt a 23 N m 2 3 kgf m 16 5 lb ft Muffler connecting bolt b 23 N m 2 3 kgf m 16 ...

Page 242: ...ener not specified in this section refer to Tightening Torque Specifications in Section 0C Special Tools and Equipment Recommended Service Material B649G11B08001 Fastening part Tightening torque Note N m kgf m lb ft Exhaust pipe bolt 23 2 3 16 5 Muffler connecting bolt 23 2 3 16 5 Muffler mounting bolt 23 2 3 16 5 Material SUZUKI recommended product or Specification Note Exhaust gas sealer PERMATE...

Page 243: ...aring Removal and Installation 2C 6 Swingarm Cushion Rod Removal and Installation 2C 7 Swingarm Related Parts Inspection 2C 9 Swingarm Bearing Removal and Installation 2C 10 Specifications 2C 12 Service Data 2C 12 Tightening Torque Specifications 2C 12 Special Tools and Equipment 2C 13 Recommended Service Material 2C 13 Special Tool 2C 13 Wheels and Tires 2D 1 Precautions 2D 1 Precautions for Whee...

Page 244: ...ns bolts and nuts are an important part in that it could affect the performance of vital parts They must be tightened to the specified torque periodically and if the suspension effect is lost replace it with a new one CAUTION Never attempt to heat quench or straighten any suspension part Replace it with a new one or damage to the part may result ...

Page 245: ...level and drain Front suspension too noisy Insufficient fork oil Check level and add Loose front suspension fastener Tighten Wobbly rear wheel Distorted wheel rim Replace Worn rear wheel bearing Replace Defective or incorrect tire Replace Worn swingarm bearing Replace Worn Rear suspension bushing Replace Loose rear suspension fastener Tighten Rear suspension too soft Weak rear shock absorber sprin...

Page 246: ... 2 Dust seal 9 Damper rod bolt 16 Front fork cap bolt 20 N m 2 0 kgf m 14 5 lb ft 3 Oil seal stopper ring 10 Front axle pinch bolt 17 O ring 23 N m 2 3 kgf m 16 5 lb ft 4 Oil seal 11 Inner tube 18 Inner rod lock nut Apply thread lock to thread part 5 Oil seal retainer 12 Inner tube slide metal 19 Spring seat Apply fork oil 6 Outer tube slide metal 13 Damper rod Inner rod cylinder 20 Spacer Do not ...

Page 247: ...OTE Slightly loosen the front fork cap bolt 5 to facilitate later disassembly 6 Loosen the front fork lower clamp bolts 6 and remove the front fork NOTE Hold the front fork by the hand to prevent sliding out of the steering stem Installation 1 Set the front fork to the front fork lower bracket temporarily by tightening the lower clamp bolts 2 Tighten the front fork cap bolt 1 to the specified torq...

Page 248: ...he front fender along with the fender plate nut 8 Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation in Section 2D NOTE Before tightening the front axle and front axle pinch bolts move the front fork up and down four or five times WARNING After remounting the brake caliper pump the brake lever until the pistons push the pads correctly Front Fork Disassembly and...

Page 249: ...oke it several times to drain out fork oil 6 Hold the fork inverted for a few minutes to drain oil 7 Remove the dust seal 8 8 Remove the oil seal stopper ring 9 9 Remove the damper rod bolt 10 10 Remove the inner rod cylinder 11 11 Remove the oil lock piece 12 2 4 3 I649G1220040 01 5 6 7 I649G1220041 01 I649G1220012 01 8 I649G1220013 02 9 I649G1220014 02 10 I649G1220015 02 11 I649G1220016 02 12 I6...

Page 250: ...er tube slide metal 3 CAUTION When installing the oil seal to inner tube be careful not to damage the oil seal lip Apply fork oil to the outer slide metal and oil seal lip Oil 99000 99001 SS8 SUZUKI FORK OIL SS 08 or equivalent Hold the inner tube vertically clean the metal groove and install the inner tube slide metal by hand CAUTION Do not damage the Teflon coated surface of the inner tube s sli...

Page 251: ...d Lock Cement 1342 or equivalent Tightening torque Front fork damper rod bolt 20 N m 2 0 kgf m 14 5 lb ft Fork oil Place the front fork vertically without spring Compress it fully Pour specified front fork oil up to the top level of the inner tube Oil 99000 99001 SS8 SUZUKI FORK OIL SS 08 or equivalent Capacity each leg 516 ml 17 4 18 2 US lmp oz Move the inner rod slowly with the special tool mor...

Page 252: ...vel with the special tool NOTE When adjusting the fork oil level remove the fork spring and compress the inner tube fully Special tool A 09943 74111 Fork oil level gauge Fork oil level a 107 mm 4 2 in Fork spring Install the fork spring as shown NOTE The smaller pitch a should face to the bottom side of the front fork Inner rod and lock nut Install the special tool and pull up the inner rod Specia...

Page 253: ...t Fork Inspection B649G12206005 Refer to Front Fork Inspection in Section 0B Front Fork Parts Inspection B649G12206004 Refer to Front Fork Disassembly and Assembly Inner and Outer Tubes Inspect the inner tube sliding surface and outer tube sliding surface for scuffing Fork Spring Measure the fork spring free length If it is shorter than the service limit replace it with a new one Front fork spring...

Page 254: ...dard Limit Front fork stroke 130 5 1 Front fork inner tube O D 43 1 69 Front fork spring free length 392 8 15 46 384 15 1 Front fork oil level 107 4 2 Front fork spring adjuster 3rd groove from top Item Specification Note Front fork oil type Fork oil SS 08 or equivalent fork oil Front fork oil capacity each leg 516 ml 17 4 18 2 US lmp oz Fastening part Tightening torque Note N m kgf m lb ft Front ...

Page 255: ...llowing Front Fork Components Special Tool B649G12208002 Material SUZUKI recommended product or Specification Note Oil SUZUKI FORK OIL SS 08 or equivalent P No 99000 99001 SS8 Thread lock cement Thread Lock Cement 1342 or equivalent P No 99000 32050 09940 52841 09940 52861 Inner rod holder Front fork oil seal installer 09943 74111 Fork oil level gauge ...

Page 256: ... 01 1 Rear shock absorber 6 Cushion rod mounting nut 11 Chain buffer Apply grease to bearing 2 Rear shock absorber mounting nut 7 Chain case 12 Swingarm pivot nut Do not reuse 3 Cushion rod 8 Swingarm 50N m 5 0 kgf m 36 0 lb ft 4 Cushion lever 9 Plate 78N m 7 8 kgf m 56 5 lb ft 5 Cushion lever mounting nut 10 Chain adjuster 100N m 10 0 kgf m 72 5 lb ft ...

Page 257: ...b 5 b 3 c 6 I649G1230040 04 1 Rear shock absorber mounting nut Upper 4 Cushion rod Lower 50 N m 5 0 kgf m 36 0 lb ft Apply grease to bearing 2 Rear shock absorber mounting nut Lower 5 Cushion lever mounting nut 78 N m 7 8 kgf m 56 5 lb ft 3 Cushion rod Upper 6 Swingarm pivot nut 100 N m 10 0 kgf m 72 5 lb ft ...

Page 258: ...nd nuts Tightening torque Rear shock absorber mounting nut a 50 N m 5 0 kgf m 36 0 lb ft Tighten the cushion lever mounting bolt and nut Tightening torque Cushion lever mounting nut b 78 N m 7 8 kgf m 56 5 lb ft Rear Suspension Inspection B649G12306021 Refer to Rear Suspension Inspection in Section 0B Rear Shock Absorber Inspection B649G12306003 Inspect the rear shock absorber in the following pro...

Page 259: ... 1 1 4 turns out from stiffest position GSF1200S Rear Shock Absorber Disposal B649G12306013 Refer to Rear Shock Absorber Removal and Installation The rear shock absorber unit contains high pressure nitrogen gas WARNING Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause an explosion Release gas pressure before disposing Gas Pressure Release Make ...

Page 260: ...enter stand and support the motorcycle with a jack to be no load for the cushion lever 2 Remove the cushion lever by removing its related bolts and nuts Installation Install the cushion lever in the reverse order of removal Pay attention to the following point Tighten each nut to the specified torque Tightening torque Cushion lever mounting nut a 78 N m 7 8 kgf m 56 5 lb ft Cushion rod mounting nu...

Page 261: ...t is found replace the cushion lever with a new one Cushion Rod Refer to Swingarm Related Parts Inspection Cushion Lever Bearing Removal and Installation B649G12306015 Removal 1 Remove the cushion lever Refer to Rear Shock Absorber Removal and Installation 2 Remove the cushion lever bearings using the special tools Special tool A 09923 73210 Bearing remover B 09930 30102 Sliding shaft C 09913 7021...

Page 262: ...E A or equivalent 3 Install the cushion lever Refer to Rear Shock Absorber Removal and Installation Swingarm Cushion Rod Removal and Installation B649G12306016 Removal 1 Remove the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D 2 Remove the drive chain cover 1 3 Remove the brake hose clamps 4 Remove the cushion lever 2 and rear shock absorber 3 Refer to Rea...

Page 263: ...ay attention to the following points Tighten the cushion rod mounting nut and to the specified torque NOTE The stamped marks A on the cushion rod should be face out side Tightening torque Cushion rod mounting nut a 78 N m 7 8 kgf m 56 5 lb ft Tighten the swingarm pivot nut to the specified torque Tightening torque Swingarm pivot nut b 100 N m 10 0 kgf m 72 5 lb ft 4 5 I649G1230021 01 6 I649G123002...

Page 264: ... Related Parts Inspection B649G12306017 Refer to Swingarm Cushion Rod Removal and Installation Spacers 1 Remove the spacers from the swingarm 2 Inspect the spacers for wear and damage If any defects are found replace the spacers with new ones Chain Buffer Inspect the chain buffer for wear and damage If any defect is found replace the chain buffer with a new one Swingarm Bearing and Cushion Rod Bea...

Page 265: ... Swingarm pivot shaft runout Service limit 0 3 mm 0 01 in Swingarm Bearing Removal and Installation B649G12306018 Removal 1 Remove the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation in Section 2D 2 Remove the swingarm Refer to Swingarm Cushion Rod Removal and Installation 3 Draw out the swingarm pivot bearings 1 using the special tool Special tool A 09921 20240 Bearing r...

Page 266: ...s the bearings into the swingarm pivot with the special tool NOTE When installing the bearing stamped mark on the bearing must face outside Special tool B 09941 34513 Steering race installer 4 Apply SUZUKI SUPER GREASE A to the bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the swingarm Refer to Swingarm Cushion Rod Removal and Installation 6 Install the rear wheel assem...

Page 267: ...efer to Tightening Torque Specifications in Section 0C Item Standard Limit Rear shock absorber spring adjuster 4th position Rear shock absorber damping force adjuster Rebound GSF1200 1 1 8 turns out from stiffest position GSF1200S 1 1 4 turns out from stiffest position Rear wheel travel 136 5 4 Swingarm pivot shaft runout 0 3 0 01 Fastening part Tightening torque Note N m kgf m lb ft Rear shock ab...

Page 268: ...on Special Tool B649G12308002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 09900 20606 09900 20701 Dial gauge 1 100 mm Magnetic stand 09900 21304 09913 70210 V block 100mm Bearing installer set 09921 20240 09923 73210 Bearing remover set Bearing remover 09924 84521 09930 30102 Bearing installer set Sliding shaft 09941 34513 S...

Page 269: ...aller amount of tire in contact with the load which can contribute to skidding and loss of control Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion crack nick or scratch When tire replacement is necessary the original equipment type tire should be used Do not mix different types of tires on the same vehicle such as radial and bias belted tires excep...

Page 270: ...6 5 4 12 1 3 a 2 I649G1240052 02 1 Front axle 6 Spacer 11 Wheel balancer Apply thread lock to thread part 2 Brake disc bolt 7 Front wheel 12 Air valve Do not reuse 3 Brake disc 8 Collar 23 N m 2 3 kgf m 16 5 lb ft 4 Dust seal 9 Front axle bolt 100 N m 10 0 kgf m 72 5 lb ft 5 Bearing 10 Tire Apply grease ...

Page 271: ...ht b 2 a 1 b 2 a 1 c 3 a 4 a 4 a I649G1240050 04 1 Brake disc bolt a Clearance Apply grease 2 Brake caliper mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Apply thread lock to thread part 3 Front axle bolt 26 N m 2 6 kgf m 19 lb ft 4 Front axle pinch bolt 100 N m 10 0 kgf m 72 5 lb ft ...

Page 272: ...ground and support the motorcycle with a jack or a wooden block CAUTION Do not carry out the work with the motorcycle resting on the side stand Do not support the motorcycle with the exhaust pipe Make sure that the motorcycle is supported securely 6 Loosen two axle pinch bolts 3 on the left front fork leg 7 Draw out the front axle and remove the front wheel NOTE After removing the front wheel fit ...

Page 273: ...tly 4 Hold the front axle with the special tool and tighten the front axle bolt 1 to the specified torque Special tool A 09900 18740 Hexagon socket 24 mm Tightening torque Front axle bolt a 100 N m 10 0 kgf m 72 5 lb ft 5 Tighten two axle pinch bolts 2 on the right fork leg to the specified torque Tightening torque Front axle pinch bolt b 23 N m 2 3 kgf m 16 5 lb ft 6 Move the front fork up and do...

Page 274: ...ked as shown does not exceed the service limit An excessive runout is usually due to worn or loosened wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel runout Service limit Axial and Radial 2 0 mm 0 08 in Wheel Bearing Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner rac...

Page 275: ... SUZUKI SUPER GREASE A to the wheel bearings Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 First install the right wheel bearing then install the spacer 1 and left wheel bearing Special tool A 09924 84510 Bearing installer set CAUTION The sealed cover of the bearing must face outside 2 B I649G1240017 02 3 I649G1240018 01 I649G1240019 01 1 Spacer a Clearance A I649G1240020 02 Left Right ...

Page 276: ...l tool B 09913 70210 Bearing installer set 4 Apply SUZUKI SUPER GREASE A to the lip of dust seals Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 5 Install the front wheel assembly Refer to Front Wheel Assembly Removal and Installation B I649G1240022 02 I649G1240023 02 ...

Page 277: ...0 kgf m 43 5 lb ft 2 Rear sprocket 9 Spacer 16 Air valve 23 N m 2 3 kgf m 16 5 lb ft 3 Dust seal 10 Bearing 17 Tire Apply grease 4 Bearing 11 Dust seal 18 Wheel balancer Apply thread lock to thread part 5 Sprocket mounting drum 12 Collar A Only for E 28 Do not reuse 6 Retainer 13 Rear brake disc B Except for E 28 7 Wheel damper 14 Rear axle 100 N m 10 0 kgf m 72 5 lb ft ...

Page 278: ...Right A I649G1240051 04 1 Rear sprocket nut 4 Brake disc bolt 60 N m 6 0 kgf m 43 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 2 Rear axle nut a Clearance 100 N m 10 0 kgf m 72 5 lb ft Apply grease 3 Brake caliper mounting bolt A Only for E 28 22 N m 2 2 kgf m 16 0 lb ft Apply thread lock to thread part ...

Page 279: ... and collar 3 Installation 1 Install the spacer 1 and collar 2 2 Install the rear wheel with the rear axle and tighten the rear axle nut temporarily 3 Adjust the drive chain slack after installing the rear wheel Refer to Drive Chain Inspection and Adjustment in Section 0B 4 Tighten the rear axle nut 3 to the specified torque Tightening torque Rear axle nut a 100 N m 10 0 kgf m 72 5 lb ft WARNING A...

Page 280: ...Installation Axle Shaft Using a dial gauge check the rear axle for runout If the runout exceeds the limit replace the axle shaft Axle shaft runout Service limit 0 25 mm 0 010 in Special tool A 09900 20607 Dial gauge 1 100mm 10mm B 09900 20701 Magnetic stand C 09900 21304 V block 100mm Wheel Make sure that the wheel runout checked as shown does not exceed the service limit An excessive runout is us...

Page 281: ...and Installation 2 Remove the rear sprocket mounting drum assembly from the rear wheel Refer to Rear Sprocket Rear Sprocket Mounting Drum Removal and Installation in Section 3A 3 Remove the dust seal 1 Special tool A 09913 50121 Oil seal remover 4 Remove the bearings 2 using the special tool Special tool B 09921 20240 Bearing remover set 5 Remove the spacer 3 Installation CAUTION The removed dust ...

Page 282: ...tion in Section 3A 6 Install the rear wheel assembly Refer to Rear Wheel Assembly Removal and Installation Tire Removal and Installation B649G12406023 Removal The most critical factor of a tubeless tire is the seal between the wheel rim and the tire bead For this reason it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as...

Page 283: ...alling the tire the arrow A on the side wall should point to the direction of wheel rotation Align the chalk mark put on the tire at the time of removal with the valve position 3 Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facilitating air inflation 4 Inflate the tire WARNING Do not inflate the tire to more than 400 kPa 4 0 kgf ...

Page 284: ...oval and Installation Tire Tire must be checked for the following points Nick and rupture on side wall Tire tread depth Refer to Tire Inspection in Section 0B Tread separation Abnormal uneven wear on tread Surface damage on bead Localized tread wear due to skidding Flat spot Abnormal condition of inner liner Air Valve Inspect the air valve for peeling and damage If any defect is found replace the ...

Page 285: ...n and Rear Wheel Assembly Removal and Installation 2 Remove the mounting drum from the rear wheel For rear wheel Refer to Rear Wheel Assembly Removal and Installation 3 Check the wheel balance using the balancer and adjust the wheel balance if necessary CAUTION For operating procedures refer to the instructions supplied by the wheel balancer manufacturer 4 When installing the balancer weights 1 to...

Page 286: ...mit Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Wheel rim size Front 17 M C x MT3 50 Rear 17 M C x MT5 50 Item Standard Limit Cold inflation tire pressure Solo Dual riding Front 250 kPa 2 50 kgf cm2 36 psi Rear 250 kPa 2 50 kgf cm2 36 psi Tire size Front 120 70 ZR17M C 58 W Rear 180 55 ZR17M C 73 W Tire type Front DUNLOP D218FN Rear DUNLOP D21...

Page 287: ...ssembly Construction Special Tool B649G12408002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 09900 18740 09900 20607 Hexagon socket 24 mm Dial gauge 1 100mm 10mm 09900 20701 09900 21304 Magnetic stand V block 100mm 09913 50121 09913 70210 Oil seal remover Bearing installer set 09921 20240 09924 84510 Bearing remover set Beari...

Page 288: ...2D 20 Wheels and Tires ...

Page 289: ...ctions 3A 1 Drive Chain Related Components 3A 1 Engine Sprocket Removal and Installation 3A 2 Rear Sprocket Rear Sprocket Mounting Drum Removal and Installation 3A 3 Drive Chain Related Parts Inspection 3A 4 Sprocket Mounting Drum Dust Seal Bearing Removal and Installation 3A 5 Drive Chain Replacement 3A 6 Specifications 3A 9 Service Data 3A 9 Tightening Torque Specifications 3A 9 Special Tools an...

Page 290: ...in with a spray type chain cleaner and blow dry with compressed air If the drive chain cannot be cleaned with a spray cleaner it may be necessary to use a kerosine Always follow the chemical manufacturer s instructions on proper use handling and storage Lubricate the drive chain with a heavy weight motor oil Wipe off any excess oil or chain lubricant Do not use any oil sold commercially as drive c...

Page 291: ...orrection Reference Item Noisy Drive Chain Worn sprocket Replace Worn drive chain Replace Stretched drive chain Replace Too large drive chain slack Adjust Drive chain out of adjustment Adjust b 8 7 3 6 5 4 1 2 a I649G1310001 02 1 Engine sprocket 6 Sprocket mounting drum Apply grease 2 Drive chain 7 Retainer Apply thread lock to thread part 3 Rear sprocket 8 Wheel damper Do not reuse 4 Dust seal 11...

Page 292: ...ock washer 2 7 Loosen the rear axle nut 4 and chain adjusters 5 to provide additional chain slack 8 Remove the engine sprocket 6 Installation Install the engine sprocket in the reverse order of removal Pay attention to the following points Install a new lock washer 1 and apply THREAD LOCK SUPER 1303 to the driveshaft Thread lock cement 99000 32030 Thread Lock Cement Super 1303 or equivalent Tighte...

Page 293: ...r to the gearshift shaft in the correct position Gearshift lever height a Standard 55 mm 2 2 in Adjust the drive chain slack Refer to Drive Chain Inspection and Adjustment in Section 0B Rear Sprocket Rear Sprocket Mounting Drum Removal and Installation B649G13106009 Removal 1 Remove the rear wheel assembly by disengaging the drive chain Refer to Rear Wheel Assembly Removal and Installation in Sect...

Page 294: ...emoval and Installation Dust Seal Inspect the sprocket mounting drum dust seal for wear or damage If any damage is found replace the dust seal with a new one Bearing Inspect the play of the sprocket mounting drum bearings by hand while they are in the wheel and drum Rotate the inner race by hand to inspect for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Engi...

Page 295: ... 70210 Bearing installer set Installation CAUTION The removed dust seal and bearing must be replaced with new ones 1 Apply grease to the bearing before installing Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent 2 Install the bearing and dust seal to the sprocket mounting drum using the special tool Special tool A 09913 70210 Bearing installer set 3 Apply grease to the dust seal lip Grease 9...

Page 296: ...ng disjointed on the holder part 8 of the tool 3 Turn in both the adjuster bolt 6 and pressure bolt A 3 so that each of their end hole fits over the chain joint pin properly 4 Tighten the pressure bolt A 3 with the bar 5 Turn in the pressure bolt B 4 with the bar 5 and force out the drive chain joint pin 9 CAUTION Continue turning in the pressure bolt B 4 until the joint pin has been completely pu...

Page 297: ...art number RK 27620 24F00 4 Apply grease on the recessed portion of the joint plate holder 3 and set the joint plate 10 NOTE When positioning the joint plate 10 on the tool its stamp mark must face the joint plate holder 3 side 5 Set the drive chain on the tool as illustrated and turn in the adjuster bolt 5 to secure the wedge holder wedge pin 4 6 Turn in the pressure bolt A 6 and align two joint ...

Page 298: ...n by turning approximately 7 8 turn the pressure bolt A 3 with the bar until the pin end diameter becomes the specified dimension CAUTION After joining of the chain has been completed check to make sure that the link is smooth and no abnormal condition is found Should any abnormal condition be found reassemble the chain link using the new joint parts Pin end diameter specification a RK 5 45 5 85 m...

Page 299: ...ents Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Item Standard Limit Final reduction ratio 3 000 45 15 Drive chain Type RK GB50GSVZ3 Links 116 links 20 pitch length 319 4 12 57 Drive chain slack 20 30 0 8 1 2 Fastening part Tightening torque Note N m kgf m lb ft Engine sprocket nut 115 11 5 83 0 Speed sensor ...

Page 300: ...omponents Special Tool B649G13108002 Material SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Thread lock cement Thread Lock Cement Super 1303 or equivalent P No 99000 32030 Thread Lock Cement 1342 or equivalent P No 99000 32050 09913 50121 09913 70210 Oil seal remover Bearing installer set 09922 22711 Drive chain cutting and joining too...

Page 301: ...ation 4A 12 Rear Brake Master Cylinder Disassembly and Assembly 4A 13 Rear Brake Master Cylinder Parts Inspection 4A 14 Specifications 4A 15 Service Data 4A 15 Tightening Torque Specifications 4A 15 Special Tools and Equipment 4A 16 Recommended Service Material 4A 16 Special Tool 4A 16 Front Brakes 4B 1 Repair Instructions 4B 1 Front Brake Components 4B 1 Front Brake Pad Inspection 4B 2 Front Brak...

Page 302: ...ing or which has been stored for long periods of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc ...

Page 303: ...49G1410001 04 1 Front brake hose No 1 6 Clamp Insert the clamp to the hole of the front fender fully 2 Front brake hose No 2 23 N m 2 3 kgf m 16 5 lb ft 3 Stopper After the brake hose union has contacted the stopper tighten the union bolt 7 5 N m 0 75 kgf m 5 5 lb ft 4 Clamp After positioning the clamp with the stopper tighten the clamp bolt 26 N m 2 6 kgf m 19 0 lb ft 5 Brake hose Clamp the brake...

Page 304: ...ully 2 Front brake hose No 2 7 Front brake hose No 1 Pass the front brake hose No 1 to the brake hose guide 3 Stopper After the brake hose union has contacted the stopper tighten the union bolt 23 N m 2 3 kgf m 16 5 lb ft 4 Clamp After positioning the clamp with the stopper tighten the clamp bolt 7 5 N m 0 75 kgf m 5 5 lb ft 5 Brake hose Clamp the brake hose firmly 26 N m 2 6 kgf m 19 0 lb ft ...

Page 305: ...0003 05 1 Brake hose clamp Brake hose clamp ends should face forward 6 N m 0 6 kgf m 4 5 lb ft 2 Brake hose clamp Brake hose clamp ends should face backward 22 N m 2 2 kgf m 16 0 lb ft 3 Stopper After the brake hose union has contacted the stopper tighten the union bolt 27 N m 2 7 kgf m 19 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft ...

Page 306: ...n pads Replace Oil adhesion on friction surface of pads Clean disc and pads Worn disc Replace Air in hydraulic system Bleed air Not enough brake fluid in the reservoir Replenish Brake squeaking Carbon adhesion on pad surface Repair surface with sandpaper Tilted pad Correct pad fitting or replace Damaged wheel bearing Replace Loose front wheel axle or rear wheel axle Tighten to specified torque Wor...

Page 307: ... from Brake Fluid Circuit B649G14106023 Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air...

Page 308: ...bleeder valve Front brake 7 5 N m 0 75 kgf m 5 5 lb ft 9 Install the reservoir cap Rear Brake Bleed air from the rear brake system as the same manner of front brake NOTE The only difference of bleeding operation from the front brake is that the rear master cylinder is actuated by a pedal Tightening torque Air bleeder valve Rear brake 6 0 N m 0 6 kgf m 4 5 lb ft Brake Fluid Replacement B649G1410602...

Page 309: ...ection 9D 3 Remove the brake fluid reservoir cap and diaphragm 4 Suck up the old brake fluid as much as possible 5 Fill the reservoir with new brake fluid BF Brake fluid DOT 4 6 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle 7 Loosen the air bleeder valve and pump the brake pedal until the old brake fluid flows out of the brake system 8 Close t...

Page 310: ...e right frame cover Refer to Exterior Parts Removal and Installation in Section 9D 2 Drain bracket fluid Refer to Brake Fluid Replacement 3 Remove the rear brake hose as shown in the rear brake hose routing diagram Refer to Rear Brake Hose Routing Diagram Installation CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage 1 Install the rear brake hose as shown in th...

Page 311: ...ttention to the following points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holder bolt first Tightening torque Master cylinder holder bolt Upper and Lower a 10 N m 1 0 kgf m 7 0 lb ft After setting the brake hose union to the stopper tighten the union bolt to the sp...

Page 312: ... cup 9 Primary cup 10 Spring 11 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent...

Page 313: ...Tightening torque Brake lever pivot bolt 1 0 N m 0 1 kgf m 0 72 lb ft Brake lever pivot bolt lock nut 6 0 N m 0 6 kgf m 4 5 lb ft Front Master Cylinder Parts Inspection B649G14106030 Refer to Front Master Cylinder Brake Lever Disassembly and Assembly Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston Inspect the piston surface for any scratches or other damag...

Page 314: ...ake hose union bolt 2 on the master cylinder to catch any spilt brake fluid 5 Remove the brake hose union bolt 2 and disconnect the brake hose 6 Loosen the lock nut 3 7 Remove the master cylinder mounting bolts 4 8 Remove the master cylinder along with the reservoir by turning the push rod 5 1 3 a 2 4 6 a b 5 FWD FWD I649G1410029 05 1 Reservoir tank 4 Master cylinder 23 N m 2 3 kgf m 16 5 lb ft Ap...

Page 315: ...ck nut b 18 N m 1 8 kgf m 13 0 lb ft Brake hose union bolt c 23 N m 2 3 kgf m 16 5 lb ft Bleed air from the system after reassembling the master cylinder Refer to Brake System Inspection in Section 0B Adjust the brake pedal height Refer to Brake System Inspection in Section 0B Rear Brake Master Cylinder Disassembly and Assembly B649G14106033 Refer to Rear Brake Master Cylinder Assembly Removal and...

Page 316: ...all of the master cylinder component to be inserted into the bore BF Brake fluid DOT 4 Apply SUZUKI SILICONE GREASE to the push rod end Grease 99000 25100 SUZUKI Silicone Grease or equivalent Install the O ring 1 CAUTION Replace the O ring 1 with a new one Rear Brake Master Cylinder Parts Inspection B649G14106034 Refer to Rear Brake Master Cylinder Disassembly and Assembly Master Cylinder Inspect ...

Page 317: ...tion 0C Item Standard Limit Rear brake pedal height 60 2 4 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Rear 14 000 14 043 0 5512 0 5529 Master cylinder piston diameter Front 15 827 15 854 0 6231 0 6242 Rear 13 957 13 984 0 5495 0 5506 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lb ft Air bleeder valve Front brake 7 5 0 75 5 5 Air bleede...

Page 318: ...l is also described in the following Front Brake Master Cylinder Components Rear Brake Master Cylinder Components Special Tool B649G14108002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 09900 06108 09900 25008 Snap ring pliers Multi circuit tester set ...

Page 319: ... e 4 I649G1420001 04 1 O ring 6 Front brake disc 23 N m 2 3 kgf m 16 5 lb ft 2 Piston seal 7 5 N m 0 75 kgf m 5 5 lb ft Apply thread lock to thread part 3 Dust seal 16 N m 1 6 kgf m 11 5 lb ft Apply brake fluid 4 Piston 21 N m 2 1 kgf m 15 0 lb ft Do not reuse 5 Front brake pad set 26 N m 2 6 kgf m 19 0 lb ft ...

Page 320: ...by removing the pad mounting pin 2 CAUTION Do not operate the brake lever while dismounting the pads 3 Clean up the caliper especially around the caliper piston 4 Install the new brake pads CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected 5 Tighten the pad mounting pin to the specified torque Tightening torque Front brake pad mounting pin a 16 N m 1 ...

Page 321: ...ghten each bolt to the specified torque Tightening torque Front brake caliper mounting bolt a 26 N m 2 6 kgf m 19 0 lb ft Front brake caliper housing bolt b 21 N m 2 1 kgf m 15 0 lb ft After setting the brake hose union to the stopper tighten the union bolt to the specified torque CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tightening torque Front brake h...

Page 322: ...e order of disassembly Pay attention to the following points Wash the caliper bores and pistons with specified brake fluid Particularly wash the dust seal grooves and piston seal grooves BF Brake fluid DOT 4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off after washing the components Wh...

Page 323: ...on Special tool A 09930 11920 Torx bit JT 40H B 09930 11940 Bit holder Tightening torque Front brake caliper housing bolt a 21 N m 2 1 kgf m 15 0 lb ft Install the brake pads Refer to Front Brake Pad Replacement Front Brake Caliper Parts Inspection B649G14206016 Refer to Front Brake Caliper Disassembly and Assembly Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks scratches ...

Page 324: ... Brake Disc Inspection B649G14206018 Brake Disc Thickness Check the brake disc for damage or cracks and measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if defect is found Special tool A 09900 20205 Micrometer 0 25mm Brake disc thickness Service limit Front 4 5 mm 0 18 in Brake Disc Runout 1 Remove the front brake caliper Refer to...

Page 325: ...thickness Front 4 8 5 2 0 189 0 205 4 5 0 18 Brake disc runout 0 30 0 012 Brake caliper cylinder bore Front Leading 30 230 30 306 1 1902 1 1931 Trailing 33 960 34 036 1 3370 1 3400 Brake caliper piston diameter Front Leading 30 150 30 200 1 1870 1 1890 Trailing 33 884 33 934 1 3340 1 3360 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lb ft Front bra...

Page 326: ...ing Front Brake Components Special Tool B649G14208002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Thread lock cement Thread Lock Cement Super 1360 or equivalent P No 99000 32130 09900 20205 09900 20607 Micrometer 0 25mm Dial gauge 1 100mm 10mm 09900 20701 09930 11920 Magnetic stand Torx bit JT 40H 09930 11940 Bit holder ...

Page 327: ... 0 N m 0 6 kgf m 4 5 lb ft Apply silicone grease to sliding surface 2 Piston 27 N m 2 7 kgf m 19 5 lb ft Apply thread lock to thread part 3 Piston seal 18 N m 1 8 kgf m 13 0 lb ft Apply brake fluid 4 Dust seal 2 5 N m 0 25 kgf m 1 8 lb ft Do not reuse 5 Rear brake pad Shim set 22 N m 2 2 kgf m 16 0 lb ft 6 Rear brake disc 23 N m 2 3 kgf m 16 5 lb ft ...

Page 328: ...Pad Replacement B649G14306013 1 Remove the plug 1 2 Loosen the pad mounting pin 2 3 Remove the caliper mounting bolt 3 CAUTION Do not operate the brake pedal while dismounting the pads 4 Remove the pad mounting pin 2 and brake pads with the rear caliper pivoted up 5 Clean up the caliper especially around the caliper piston 6 Assemble the new brake pad 4 insulator 5 and shim 6 CAUTION Replace the b...

Page 329: ... the brake pads pump the brake pedal few times to check for proper brake operation and then check the brake fluid level Rear Brake Caliper Removal and Installation B649G14306014 Removal 1 Drain brake fluid Refer to Brake Fluid Replacement in Section 4A 2 Remove the brake hose from the caliper by removing the union bolt 1 and catch the brake fluid in a suitable receptacle NOTE Place a rag underneat...

Page 330: ... the specified torque CAUTION The seal washers should be replaced with the new ones to prevent fluid leakage Tightening torque Brake hose union bolt b 23 N m 2 3 kgf m 16 5 lb ft Bleed air from the brake system after installing the caliper Refer to Brake System Inspection in Section 0B Check the brake fluid leakage and brake operation WARNING Brake fluid if it leaks will interfere with safe runnin...

Page 331: ... attention to the following points Wash the caliper bore and piston with specified brake fluid Particularly wash the dust seal groove and piston seal groove BF Brake fluid DOT 4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off after washing the components When washing the components use ...

Page 332: ...emoval and Installation Tightening torque Rear brake caliper sliding pin a 27 N m 2 7 kgf m 19 5 lb ft Rear Brake Caliper Parts Inspection B649G14306016 Refer to Rear Brake Caliper Disassembly and Assembly Brake Caliper Cylinder Inspect the brake caliper cylinder wall for nicks scratches or other damage If any damage is found replace the caliper with a new one Brake Caliper Piston Inspect the brak...

Page 333: ...the following points Make sure that the brake discs are clean and free of any grease Apply THREAD LOCK SUPER 1360 to the brake disc bolts and tighten them to the specified torque Thread lock cement 99000 32130 Thread Lock Cement Super 1360 or equivalent Tightening torque Brake disc bolt a 23 N m 2 3 kgf m 16 5 lb ft Rear Brake Disc Inspection B649G14306018 Brake Disc Thickness Check the brake disc...

Page 334: ...easure the runout using the dial gauge Replace the disc if the runout exceeds the service limit Special tool A 09900 20606 Dial gauge 1 100 mm B 09900 20701 Magnetic stand Brake disc runout Service limit 0 30 mm 0 012 in 3 Install the rear brake caliper Refer to Rear Brake Caliper Removal and Installation A I649G1430028 02 ...

Page 335: ...on 0C Item Standard Limit Brake disc thickness Rear 4 8 5 2 0 189 0 205 4 5 0 18 Brake disc runout 0 30 0 012 Brake caliper cylinder bore Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diameter Rear 38 098 38 148 1 4999 1 5019 Item Specification Note Brake fluid type DOT 4 Fastening part Tightening torque Note N m kgf m lb ft Rear brake caliper mounting bolt 22 2 2 16 0 Rear brake pad mount...

Page 336: ... Rear Brake Components Special Tool B649G14308002 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Grease SUZUKI Silicone Grease or equivalent P No 99000 25100 Thread lock cement Thread Lock Cement Super 1360 or equivalent P No 99000 32130 09900 20205 09900 20606 Micrometer 0 25mm Dial gauge 1 100 mm 09900 20701 Magnetic stand ...

Page 337: ...B 24 Recommended Service Material 5B 24 Special Tool 5B 24 Clutch 5C 1 Precautions 5C 1 Precautions for Clutch System 5C 1 Clutch Fluid Brake Fluid Information 5C 1 Schematic and Routing Diagram 5C 2 Clutch Hose Routing Diagram 5C 2 Diagnostic Information and Procedures 5C 4 Clutch System Symptom Diagnosis 5C 4 Repair Instructions 5C 4 Clutch Lever Position Switch Inspection 5C 4 Clutch Fluid Leve...

Page 338: ...5 1 Precautions Precautions Precautions Precautions for Transmission Transaxle B649G15000001 Refer to General Precautions in Section 00 ...

Page 339: ...ft spline Replace driveshaft Worn or rubbing primary gear Replace Worn bearing Replace Transmission will not shift Broken gearshift cam Replace Distorted gearshift fork Replace Worn gearshift pawl Replace Transmission will not shift back Broken gearshift shaft return spring Replace Rubbing or stuck gearshift shaft Repair or replace Worn or distorted gearshift fork Replace Transmission jumps out of...

Page 340: ...l and Installation in Section 1H 7 Remove the clutch component parts Refer to Clutch Removal in Section 5C 8 Remove the gearshift shaft and gearshift driven gear Refer to Gearshift Shaft Gearshift Cam Driven Gear Removal and Installation 9 Remove the starter clutch component parts Refer to Starter Clutch Removal and Installation in Section 1I 8 9 10 11 7 6 4 1 2 3 5 12 13 13 13 17 16 14 15 I649G15...

Page 341: ...g 4 13 Remove the upper crankcase bolts and nut 14 Remove the oil pan 5 15 Remove the shim 6 and O ring 7 16 Remove the oil sump filter 8 17 Remove the oil return pipe 9 18 Remove the lower crankcase bolts and nut 19 Remove the main oil gallery plug 10 and O ring 1 2 I649G1520001 01 3 I649G1520002 01 4 I649G1520003 01 5 I649G1520004 01 8 6 7 9 I649G1520005 02 I649G1520006 01 I649G1520007 01 10 10 ...

Page 342: ...ower crankcase NOTE If it is difficult to separate the crankcase halves set the proper bolt and nut to the crankcase by separating the upper and lower crankcase halves as shown in the illustration 23 Remove the countershaft assembly 12 and driveshaft assembly 13 24 Remove the C rings 14 and bearing pins 15 NOTE Do not lose the C rings and bearing pins 25 Hold the gearshift forks 16 and draw out th...

Page 343: ...earshift cam stopper bolt 23 Transmission Installation B649G15206028 Install the transmission in the reverse order of removal Pay attention to the following points Gearshift Cam Apply a small quantity of THREAD LOCK 1342 to the gearshift cam stopper bolt and tighten it Thread lock cement 99000 32050 Thread Lock Cement 1342 or equivalent NOTE When installing the gearshift cam stopper plate 1 align ...

Page 344: ...ansmission gears to be installed easily Gearshift Fork Install the gearshift forks into the crankcase in the correct position and direction Hold the gearshift forks by hand when installing the gearshift fork shaft 4 2 Gearshift cam 5 Spring 3 Gearshift cam stopper 6 Snap ring 4 Snap ring 2 3 4 5 I649G1520021 01 6 A I649G1520022 02 I649G1520023 01 1 For the 4th driven gear 2 For the 3rd drive gear ...

Page 345: ... 4 into the upper crankcase Install the countershaft end cap in the proper position A NOTE Be sure to install the bearing dowel pins 5 in their respective positions Make sure that the countershaft assembly turns freely while holding the driveshaft assembly If it does not turn freely turn the gearshift cam to the neutral position 1 1 2 2 I649G1520026 01 3 4 5 A 5 I649G1520027 02 ...

Page 346: ...0 31140 SUZUKI Bond 1207B or equivalent NOTE Make sure that the mating surfaces are free from moisture oil dust and other foreign materials Apply the bond thinly and evenly and assemble the crankcases within a few minutes of application Take extreme care not to apply any bond to the bearing surfaces I649G1520028 01 ...

Page 347: ...Tighten the main oil gallery plug 1 to the specified torque CAUTION Replace the O ring with a new one Tightening torque Main oil gallery plug a 40 N m 4 0 kgf m 29 0 lb ft Tighten the lower and upper crankcase bolts M6 and nuts to the specified torque Tightening torque Crankcase bolt and nut M6 Initial 6 N m 0 6 kgf m 4 5 lb ft Crankcase bolt and nut M6 Final 11 N m 1 1 kgf m 8 0 lb ft NOTE Instal...

Page 348: ...5B 10 Manual Transmission CAUTION Use a new gasket washer to prevent oil leakage 2 I649G1520033 02 B 3 4 I649G1520032 02 C I649G1520034 01 I649G1520031 01 ...

Page 349: ...new one to prevent oil leakage NOTE Install a new gasket washer 1 to the oil pan bolt as shown CAUTION Use a new gasket washer 1 to prevent oil leakage Bearing Retainer Apply a small quantity of THREAD LOCK 1342 to the two screws Thread lock cement 99000 32050 Thread Lock Cement 1342 or equivalent Install the countershaft bearing retainer 1 Gear Position Switch Install the gear position switch NOT...

Page 350: ... Clutch Installation in Section 5C Install the CKP sensor component parts and connect the oil pressure switch lead wire Refer to CKP Sensor Removal and Installation in Section 1H and Oil Pressure Switch Removal and Installation in Section 1E Install the cam chain tensioner Refer to Engine Bottom Side Assembly in Section 1D CAUTION Be sure to check the camshaft position Install a new oil filter Ref...

Page 351: ...Transmission Removal and Transmission Installation Countershaft Gear Disassembly CAUTION Identify the position of each removed part Organize the parts in their respective groups i e drive or driven so that they can be reinstalled in their original positions 1 Remove the left end bearing 1 and oil seal 2 I649G1520042 02 1 2 I649G1520043 01 ...

Page 352: ... 3rd drive gear 4 5th Top drive gear 6 and 2nd drive gear 8 6 Remove the snap ring 11 and 4th drive gear 10 Special tool 09900 06107 Snap ring pliers Driveshaft Gear Disassembly CAUTION Identify the position of each removed part Organize the parts in their respective groups i e drive or driven so that they can be reinstalled in their original positions Disassemble the driveshaft gear as shown in t...

Page 353: ...ated in its groove and securely fitted NOTE Before installing the gears rotate the bearing by hand to inspect for abnormal noises and smooth rotation Replace the bearing if there is anything unusual Before installing the gears lightly coat the driveshaft countershaft and bushings with molybdenum oil solution Before installing the oil seal apply SUZUKI SUPER GREASE A to the oil seal lip Moly paste ...

Page 354: ...nd positiveness of the shifting action Using a thickness gauge check the gearshift fork clearance in the groove of its gear If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Special tool A 09900 20803 Thickness gauge Gearshift fork to gearshift fork groove clearance Standard 0 10 0 30 mm 0 004 0 012 in Service limit 0 50 mm 0 020 in Gearshift Fork...

Page 355: ...sition switch coupler make sure to turn off the ignition switch or electronic parts may get damaged Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity test 4 Connect the gear position switch coupler to the wiring harness 5 Install the seat Refer to Exterior Parts Removal and Installation in Section 9D Gear Position Switch Removal and Installation B649G15206034 Refe...

Page 356: ...e following points CAUTION Replace the O ring 1 with a new one Install the gear position switch NOTE When installing the gear position switch be sure to install the spring 2 switch contact 3 and O ring 1 properly Route the gear position switch lead wire Refer to Wiring Harness Routing Diagram in Section 9A Gearshift Shaft Gearshift Cam Driven Gear Components B649G15206038 1 I649G1520080 01 I649G15...

Page 357: ...out the gearshift shaft 1 and then remove the gearshift cam driven gear 2 NOTE When removing the gearshift cam driven gear 2 do not lose the gearshifting pawl 3 pin 4 and spring 5 5 Remove the gearshifting pawls 3 pins 4 and springs 5 from the gearshift cam driven gear 2 6 Remove the return spring 6 from the gearshift shaft 1 Installation Install the gearshift shaft and gearshift cam driven gear i...

Page 358: ...ws Thread lock cement 99000 32050 Thread Lock Cement 1342 or equivalent Install the gearshift shaft 7 NOTE Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear Install the washer and fix the gearshift shaft with the snap ring CAUTION Never reuse a snap ring Special tool 09900 06107 Snap ring pliers 1 2 3 1 2 3 4 I649G1520069 01 A 3 I649G1520070 01 5 ...

Page 359: ...the gearshift shaft hole for damage or wear Gearshift Shaft Oil Seal Removal and Installation B649G15206037 Removal 1 Remove the gearshift shaft Refer to Gearshift Shaft Gearshift Cam Driven Gear Removal and Installation 2 Remove the gearshift shaft oil seal from the lower crankcase Installation Install the oil seal in the reverse order of removal Pay attention to the following points CAUTION The ...

Page 360: ...pect the gearshift lever height a between the pedal top face and footrest Adjust the gearshift lever height if necessary Gearshift lever height a Standard 55 mm 2 2 in 2 Loosen the lock nuts 1 3 Turn the gearshift link rod 2 until the gearshift lever is 55 mm 2 2 in below the top of the footrest 4 Tighten the lock nuts securely a I649G1520082 01 1 1 2 I649G1520083 01 ...

Page 361: ... 1 565 72 46 Final reduction ratio 3 000 45 15 Gear ratios 1st Low 2 384 31 13 2nd 1 631 31 19 3rd 1 250 25 20 4th 1 045 23 22 5th Top 0 913 21 23 Gearshift fork to gearshift fork groove clearance No 1 No 2 No 3 0 1 0 3 0 004 0 012 0 50 0 020 Gearshift fork groove width No 1 No 2 No 3 5 0 5 1 0 197 0 201 Gearshift fork thickness No 1 No 2 No 3 4 8 4 9 0 189 0 193 Gearshift lever height 55 2 2 Fast...

Page 362: ...al SUZUKI recommended product or Specification Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Moly paste SUZUKI Moly paste or equivalent P No 99000 25140 Sealant SUZUKI Bond 1207B or equivalent P No 99000 31140 Thread lock cement Thread Lock Cement 1342 or equivalent P No 99000 32050 09900 06107 09900 20102 Snap ring pliers Vernier calipers 1 20 mm 200 mm 09900 20803 09900 25008 ...

Page 363: ...d taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing clutch components use fresh brake fluid Never use cleaning solvent CAUTION Immediately and completely wipe ...

Page 364: ...on has contacted the stopper tighten the union bolt 7 Clutch hose Pass the clutch hose through outside of the wire harness 3 Grommet Install the grommet of the clutch hose to the clutch hose guide properly 23 N m 2 3 kgf m 16 5 lb ft 4 Clutch hose clamp Insert the clutch hose clamp end to the hole of the frame fully 8 N m 0 8 kgf m 6 0 lb ft 5 Clutch hose Pass through the clutch hose between the f...

Page 365: ...rail Be careful not to contact the clutch hose and frame cover bracket 3 Starter cable 9 Fixed clamp Align the white paint mark on the clutch hose to the fixed clamp 4 Clutch hose guide 10 Clutch hose Pass the clutch hose through outside of the wire harness 5 Stopper After the clutch hose union has contacted the stopper tighten the union bolt 23 N m 2 3 kgf m 16 5 lb ft 6 Grommet Install the gromm...

Page 366: ...ber materials etc The clutch fluid circuit may be purged of air in the following manner 1 Keep the motorcycle upright and place the handlebars straight 2 Fill up the master cylinder reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of dirt Condition Possible cause Correction Reference Item Engine is noisy Noise seems to come from the clutch Worn counter...

Page 367: ...rque Air bleeder valve Clutch 8 N m 0 8 kgf m 6 0 lb ft 9 Fill the reservoir with brake fluid to the upper end of the inspection window 10 Install the reservoir cap Clutch Fluid Replacement B649G15306011 CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastic rubber materials etc 1 Place the motorcycle on a level surface and keep the handlebars straight 2 Remove the clu...

Page 368: ...efer to Clutch Fluid Replacement 2 Remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 3 Remove the clutch hose as shown in the clutch hose routing diagram Refer to Clutch Hose Routing Diagram Installation 1 Install the clutch hose as shown in the clutch hose routing diagram Refer to Clutch Hose Routing Diagram 2 Install the fuel tank Refer to Fuel Tank Removal and Insta...

Page 369: ... Push rod 7 Push rod 8 N m 0 8 kgf m 6 0 lb ft 2 Piston Cup set 8 Clutch release cylinder set 10 N m 1 0 kgf m 7 0 lb ft 3 Clutch hose 9 Air bleeder Apply brake fluid 4 Reservoir cap A For GSF1200 Apply grease 5 Plate B For GSF1200S Apply silicone grease 6 Diaphragm 23 N m 2 3 kgf m 16 5 lb ft Do not reuse ...

Page 370: ...ing points When installing the master cylinder 1 onto the handlebars 2 align the master cylinder holder s mating surface A with the punch mark B on the handlebars 2 and tighten the upper holder bolt first Tightening torque Clutch master cylinder holder bolt a 10 N m 1 0 kgf m 7 0 lb ft After setting the clutch hose union to the stopper tighten the union bolt to the specified torque CAUTION The sea...

Page 371: ...imary cup 12 Spring 13 Assembly Assemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new clutch fluid before reassembly Do not wipe the clutch fluid off after washing the components When washing the components use the specified clutch fluid Brake fluid Never use different types of fluid or cleaning s...

Page 372: ...r Cylinder Parts Inspection B649G15306017 Refer to Clutch Master Cylinder Clutch Lever Disassembly and Assembly Master Cylinder Inspect the master cylinder bore for any scratches or other damage Piston Inspect the piston surface for any scratches or other damage Rubber Parts Inspect the primary cup secondary cup and dust boot for wear or damage Clutch Release Cylinder Push Rod Removal and Installa...

Page 373: ...ER GREASE A to the push rod Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Install the clutch hose as shown in the clutch hose routing diagram Refer to Clutch Hose Routing Diagram Bleed air from the clutch system Refer to Air Bleeding from Clutch Fluid Circuit Clutch Release Cylinder Disassembly and Assembly B649G15306019 Refer to Clutch Release Cylinder Push Rod Removal and Installation D...

Page 374: ... brake fluid off after washing the components When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvent such as gasoline kerosine or the others Bleed air from the clutch system Refer to Air Bleeding from Clutch Fluid Circuit Clutch Release Cylinder Inspection B649G15306020 Refer to Clutch Release Cylinder Disassembly and Assembly Inspect the c...

Page 375: ...he No 1 and No 2 driven plats are 9 in total 16 Primary driven gear assembly 3 Bearing 10 No 1 drive plate 17 Generator Oil pump drive gears 4 Clutch push piece 11 No 1 driven plate 5 8 pcs The No 1 and No 2 driven plats are 9 in total 150 N m 15 0 kgf m 108 5 lb ft 5 Clutch sleeve hub nut 12 No 3 drive plate Apply oil 6 Clutch diaphragm spring holder 13 Spring washer Do not reuse 7 Clutch diaphra...

Page 376: ...er Replacement in Section 0B 2 Remove the clutch cover 1 3 Remove the clutch pressure plate lifter 2 by removing the snap ring Special tool 09900 06108 Snap ring pliers 1 2 a 3 I649G1530029 01 1 Diaphragm springs 3 Clutch sleeve hub nut 2 Diaphragm spring holder 150 N m 15 0 kgf m 108 5 lb ft 1 I649G1530030 01 2 I649G1530031 01 ...

Page 377: ...920 34820 Clutch pressure plate holder 6 After removing the clutch sleeve hub nut remove the lock washer 7 7 Remove the clutch diaphragm spring holder 8 by removing the screws 8 Remove the clutch diaphragm springs 9 clutch diaphragm spring seat 10 and clutch pressure plate 11 9 Remove the clutch drive and driven plates along with the clutch sleeve hub 10 Remove the thrust washer 12 3 4 5 I649G1530...

Page 378: ...n gear assembly as shown 3 Install the primary driven gear assembly onto the countershaft and apply engine oil onto the needle bearing and spacer NOTE If it is difficult to install the primary driven gear rotate the crankshaft Be sure to engage the oil pump driven gear generator driven gear and primary driven gear with their respective drive gears 4 Install the thrust washer 3 onto the countershaf...

Page 379: ...iven plate No 2 should be used within 4 pcs The driven plate No 2 should be installed between third to seventh position from the pressure plate A B 7 6 8 10 9 I649G1530044 02 6 No 3 drive plate 10 No 2 driven plate 1 4 pcs The No 1 and No 2 driven plats are 9 in total 7 No 1 drive plate A Direction of inside 8 No 2 drive plate B Pressure plate side 9 No 1 driven plate 5 8 pcs The No 1 and No 2 dri...

Page 380: ... sleeve hub nut to the specified torque by using the torque wrench and clutch pressure plate holder Special tool A 09920 34820 Clutch pressure plate holder Tightening torque Clutch sleeve hub nut 150 N m 15 0 kgf m 108 5 lb ft 13 Lock the clutch sleeve hub nut with a center punch 14 Insert the clutch push rod 15 into the countershaft 15 Install the clutch push piece 16 bearing 17 and thrust washer...

Page 381: ...wo gasket washers onto the clutch cover bolts 19 as shown CAUTION Use only new gasket washers to prevent oil leakage 20 Tighten the clutch cover bolts securely 21 Pour Engine oil Refer to Engine Oil and Filter Replacement in Section 0B Clutch Parts Inspection B649G15306025 Refer to Clutch Removal and Clutch Installation Clutch Diaphragm Spring Measure the free height a of each diaphragm spring wit...

Page 382: ...Clutch drive plate claw width Service limit No 1 No 2 and No 3 drive plates 13 0 mm 0 51 in Measure each driven plate for distortion with a thickness gauge and surface plate Replace driven plates which exceed the limit Special tool B 09900 20803 Thickness gauge Clutch driven plate distortion Service limit 0 10 mm 0 004 in Clutch Release Bearing Inspect the clutch release bearing for any abnormalit...

Page 383: ... 121 2 62 0 103 Clutch drive plate claw width 13 0 0 51 Clutch driven plate distortion 0 10 0 004 Clutch spring free height 3 1 0 12 Clutch master cylinder bore 14 000 14 043 0 5511 0 5529 Clutch master cylinder piston diam 13 957 13 984 0 5495 0 5506 Clutch release cylinder bore 38 18 38 23 1 503 1 505 Clutch release cylinder piston diam 38 08 38 13 1 500 1 501 Item Specification Note Brake fluid...

Page 384: ...2 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 SUZUKI Silicone Grease or equivalent P No 99000 25100 Sealant SUZUKI Bond 1207B or equivalent P No 99000 31140 09900 06108 09900 20102 Snap ring pliers Vernier calipers 1 20 mm 200 mm 09900 20803 09900 25008 Thickness gauge Multi circuit tester set 09920 34820 C...

Page 385: ...B 1 Handlebars Components 6B 1 Handlebars Removal and Installation 6B 2 Handlebars Inspection 6B 3 Steering Components 6B 4 Steering Removal and Installation 6B 5 Steering Related Parts Inspection 6B 9 Steering System Inspection 6B 9 Steering Stem Bearing Removal and Installation 6B 9 Steering Tension Adjustment 6B 10 Specifications 6B 12 Tightening Torque Specifications 6B 12 Special Tools and Eq...

Page 386: ...6 1 Precautions Precautions Precautions Precautions for Steering B649G16000001 Refer to General Precautions in Section 00 ...

Page 387: ...en bearing in steering stem Replace Distorted steering stem Replace Not enough pressure in tires Adjust Wobbly Handlebars Loss of balance between right and left front forks Replace fork or adjust fork oil level or replace spring Distorted front fork Repair or replace Distorted front axle or crooked tire Replace Loose steering stem nut Adjust Worn or incorrect tire or wrong tire pressure Adjust or ...

Page 388: ...001 1 4 7 8 4 5 6 1 b 3 a A 2 b I649G1620001 04 1 Throttle grip 5 Handle expander A Apply handle grip bond 2 Handlebars 6 Handle balancer expander 23 N m 2 3 kgf m 16 5 lb ft 3 Handlebar holder Upper 7 Right handlebar switch box 10 N m 1 0 kgf m 7 0 lb ft 4 Grip rubber 8 Left handlebar switch box ...

Page 389: ...nder upside down c Right handlebar switch box 6 d Handlebar balancer 7 e Throttle grip 8 3 Remove the caps and handlebar holder bolts Installation Install the handlebars in the reverse order of removal Pay attention to the following points Set the handlebars so that its punch mark A aligns with the mating surface of the left handlebar holder Set the handlebar holders with their punch marks B forwa...

Page 390: ...R GREASE to the starter cable and cable pulley Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Insert the projection D of the left handlebar switch box into the hole of the handlebars Install the clutch master cylinder Refer to Clutch Master Cylinder Assembly Removal and Installation in Section 5C After installing the steering the following adjustments are required before driving Cable rout...

Page 391: ...andlebar holder Upper 9 Handlebar holder set nut A For GSF1200 3 Handlebars 10 Steering stem nut 23 N m 2 3 kgf m 16 5 lb ft 4 Handlebar holder Lower 11 Dust seal 65 N m 6 5 kgf m 47 0 lb ft 5 Steering stem head nut 12 Steering stem upper bearing 45 N m 4 5 kgf m 32 5 lb ft 6 Steering stem upper bracket 13 Steering stem lower bearing Apply grease to bearing 7 Washer 14 Steering stem lower bracket ...

Page 392: ...9B 5 Disconnect the couplers 6 Remove the headlight housing 1 7 Remove the headlight housing brackets 2 8 Remove the brake hose clamp 3 9 Remove the combination meter unit 4 10 Remove the ignition switch 5 using the special tools Special tool A 09930 11920 Torx bit JT 40H B 09930 11940 Bit holder 11 Dismount the handlebars by removing the handlebar holder set nuts NOTE Place a rag on the fuel tank...

Page 393: ... Remove the front wheel assembly Refer to Front Wheel Assembly Removal and Installation in Section 2D 3 Remove the front forks Refer to Front Fork Removal and Installation in Section 2B 4 Remove the brake hose clamp 1 5 Remove the cable guides 2 6 Remove the ignition switch using the special tools Special tool A 09930 11920 Torx bit JT 40H B 09930 11940 Bit holder 7 Dismount the handlebars by remo...

Page 394: ...pper bearing 5 Installation Install the steering in the reverse order of removal Pay attention to the following points Bearing Apply SUZUKI SUPER GREASE to the bearings races and dust seals before remounting the steering stem Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Steering stem nut Tighten the steering stem nut to the specified torque using the special tool Special tool A 09940 149...

Page 395: ...head nut 1 Tightening torque Steering stem head nut a 65 N m 6 5 kgf m 47 0 lb ft 5 Tighten the front fork upper and lower clamp bolts Refer to Front Fork Removal and Installation in Section 2B Ignition switch Apply THREAD LOCK SUPER 1322 to the ignition switch mounting bolts Thread lock cement 99000 32110 Thread Lock Cement Super 1322 or equivalent Install the ignition switch Special tool 09930 1...

Page 396: ...on B649G16206017 Refer to Steering System Inspection in Section 0B Steering Stem Bearing Removal and Installation B649G16206014 Removal 1 Remove the steering stem lower bracket Refer to Steering Removal and Installation 2 Remove the dust seal 1 and steering stem upper bearing 2 3 Remove the steering stem lower bearing and inner race using a chisel 4 Remove the steering stem upper and lower bearing...

Page 397: ...unting the steering stem Grease 99000 25010 SUZUKI SUPER GREASE A or equivalent Instal the steering Refer to Steering Removal and Installation Steering Tension Adjustment B649G16206016 Check the steering movement in the following procedures 1 By supporting the motorcycle with a jack lift the front wheel unit is off the floor 20 30 mm 0 8 1 2 in 2 Check to make sure that the cables and wire harness...

Page 398: ...adjust the steering stem nut by loosening or tightening it Special tool B 09910 60611 Universal clamp wrench b Tighten the steering stem nut stem head nut and front fork upper and lower clamp bolts to the specified torque and recheck the initial force with the spring scale according to the previously described procedure c If the initial force is found within the specified range adjustment has been...

Page 399: ...ponents Steering Components Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Fastening part Tightening torque Note N m kgf m lb ft Handlebar holder bolt 23 2 3 16 5 Steering stem nut 45 4 5 32 5 then turn back 1 2 1 4 Steering stem head nut 65 6 5 47 0 Handlebar holder set nut 45 4 5 32 5 ...

Page 400: ... Note Grease SUZUKI SUPER GREASE A or equivalent P No 99000 25010 Handle grip bond Handle grip bond commercial available Thread lock cement Thread Lock Cement Super 1322 or equivalent P No 99000 32110 09910 60611 09930 11920 Universal clamp wrench Torx bit JT 40H 09930 11940 09940 14911 Bit holder Steering stem nut wrench 09940 92720 09941 34513 Spring scale Steering race installer 09941 54911 099...

Page 401: ...sing Light Switch Inspection 9B 11 Dimmer Switch Inspection 9B 12 Specifications 9B 13 Service Data 9B 13 Tightening Torque Specifications 9B 13 Special Tools and Equipment 9B 13 Special Tool 9B 13 Combination Meter Fuel Meter Horn 9C 1 Repair Instructions 9C 1 Combination Meter Components 9C 1 Combination Meter Removal and Installation 9C 3 Combination Meter Disassembly and Assembly 9C 3 Combinat...

Page 402: ... of Contents Center Stand Construction 9E 4 Center Stand Removal and Installation 9E 4 Specifications 9E 5 Tightening Torque Specifications 9E 5 Special Tools and Equipment 9E 5 Recommended Service Material 9E 5 ...

Page 403: ...r Electrical System B649G19000001 Refer to General Precautions in Section 00 and Precautions for Electrical Circuit Service in Section 00 Component Location Electrical Components Location B649G19003001 Refer to Electrical Components Location in Section 0A ...

Page 404: ...9A 1 Wiring Systems Wiring Systems Schematic and Routing Diagram Wiring Diagram B649G19102004 Refer to Wire Color Symbols in Section 0A ...

Page 405: ...EVER POSITION SWITCH HANDLE SWITCH L HANDLE SWITCH R 1 HEAD HI 10 A 2 HEAD LO 10 A 3 IGNITION 15 A 4 SIGNAL 15 A 5 METER 10 A IGNITION SWITCH REAR TURN SIGNAL LIGHT R BREAKE LIGHT TAIL LIGHT REAR TURN SIGNAL LIGHT L LICENSE PLATE LIGHT R L N H O Bl B Y Lg B B W O G Y B O R P B R W B Y G Y B Bl B R B G B Bl B B O G B B R B O G B B W B G Br B B Y B W W B B Br G Bl R B G B Y W B Bl Y Bl B R B O G B B...

Page 406: ...POSITION SWITCH HANDLE SWITCH L HANDLE SWITCH R 1 HEAD HI 10 A 2 HEAD LO 10 A 3 IGNITION 15 A 4 SIGNAL 15 A 5 METER 10 A IGNITION SWITCH REAR TURN SIGNAL LIGHT R BREAKE LIGHT TAIL LIGHT REAR TURN SIGNAL LIGHT L LICENSE PLATE LIGHT R L N H O Bl B Y Lg B B W O G Y B O R P B R W B Y G Y B Bl B R B G B Bl B B O G B B R B O G B B W B G Br B B Y B W W B B Br G Bl R B G B Y W B Bl Y Bl B R B O G B B W B ...

Page 407: ...ER POSITION SWITCH HANDLE SWITCH L HANDLE SWITCH R 1 HEAD HI 10 A 2 HEAD LO 10 A 3 IGNITION 15 A 4 SIGNAL 15 A 5 METER 10 A IGNITION SWITCH REAR TURN SIGNAL LIGHT R BREAKE LIGHT TAIL LIGHT REAR TURN SIGNAL LIGHT L LICENSE PLATE LIGHT R L N H O Bl B Y Lg B B W O G Y B O R P B R W B Y G Y B Bl B R B G B Bl B B O G B B R B O G B B W B G Br B B Y B W W B B Br G Bl R B G B Y W B Bl Y Bl B R B O G B B W...

Page 408: ... TPS 17 Carburetor heater lead wire For E02 19 4 Spark plug cap No 1 11 Handlebar switch coupler LH and RH Ignition switch coupler 18 Wire clamp Cut the tip of wire clamp 5 Spark plug cap No 2 12 Wiring harness Be careful not to pinch the wiring harness with the frame and fender A Be careful not to twist the wiring harness when setting the TPS lead wire 6 Spark plug cap No 3 13 Wire clamp Cut the ...

Page 409: ...position lead Starter motor lead Speed sensor lead Wiring harness A For GSF1200 GSF1200A 2 Side stand switch 7 Starter motor lead Clutch hose B For GSF1200S GSF1200SA 3 Starter motor 8 Ices label Only for E 28 14 N m 1 4 kgf m 10 0 lb ft 4 Turn signal lead For RH a 10 mm 0 4 in 5 Turn signal lead For LH b Max 10 mm 0 4 in ...

Page 410: ...tening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C 2 6 7 3 5 4 FWD a b 1 I649G1910906 03 1 Generator 4 Gear position switch 7 Cooling hose 2 Starter motor 5 Engine ground wire 6 N m 0 6 kgf m 4 5 lb ft 3 Starter motor lead wire 6 CKP sensor lead wire 25 N m 2 5 kgf m 18 0 lb ft Item Specification Note Fuse size Headlight HI 10 A LO 10 A ...

Page 411: ...SF1200 GSF1200S 4 3 2 1 5 I649G1920001 02 1 Headlight rim 4 Headlight housing 2 Headlight unit 5 Position light bulb 12 V 5 W 3 Headlight bulb 12 V 60 55 W H4 1 3 2 3 I649G1920002 03 1 Headlight high beam bulb 12 V 55 W H7 2 Headlight low beam bulb 12 V 55 W H7 3 Position light bulb 12 V 5 W x 2 ...

Page 412: ...dlight and position light couplers 3 Remove the headlight assembly Installation Installation is in the reverse order of removal Pay attention to the following point After installing be sure to inspect the headlight beam Refer to Headlight Beam Adjustment Headlight Bulb Replacement B649G19206002 CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or...

Page 413: ... Install the headlight assembly so that the hook A on the headlight bezel engages with B of the housing GSF1200S 1 Remove the combination meter assembly Refer to Combination Meter Removal and Installation in Section 9C 2 Remove the position light sockets 1 and replace the position light bulbs 3 Disconnect the headlight Low beam coupler 2 and remove the bulb socket rubber cap 3 1 2 I649G1920004 01 ...

Page 414: ...ght beam adjust the beam horizontally first then vertically GSF1200S 1 Insert 5 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally NOTE To adjust the headlight beam adjust the beam horizontally first then vertically 2 Adjust the Low and High headlight beam vertically from the lower side 1 Horizontal adjuster 2 Vertical adjuster 4 5 I649G1920012 01 I649G1920013 01 1 ...

Page 415: ...Components B649G19206004 Rear Combination Light Construction B649G19206015 1 2 I649G1920017 02 1 Brake light Taillight bulb 12 V 21 5 W 2 Lens a 2 3 1 I649G1920018 01 1 Seat tail cover 3 Rear combination light 2 Cushion 2 0 N m 0 2 kgf m 1 5 lb ft ...

Page 416: ...ng bolts to the specified torque Tightening torque Rear combination light mounting bolt 2 0 N m 0 2 kgf m 1 5 lb ft Brake Light Bulb Taillight Bulb Replacement B649G19206017 CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure 1 Remove the seat Refer to Exterior Parts Removal and Installation in Secti...

Page 417: ...the license plate light by removing the nuts Installation Install the license plate light in the reverse order of removal License Plate Light Bulb Replacement B649G19206020 1 Remove the license plate light Refer to License Plate Light Removal and Installation 2 Remove the lens by removing the screws 3 Replace the bulb 1 4 Reinstall the removed parts 2 3 1 I649G1920023 02 1 License plate light bulb...

Page 418: ...urn signal light 1 by removing the nut GSF1200S 1 Remove the wind screen and upper panel Refer to Exterior Parts Removal and Installation in Section 9D 2 Disconnect the turn signal light coupler 3 Remove the front turn signal light 1 by removing the nut Installation Install the front turn signal light in the reverse order of removal 2 2 1 1 I649G1920028 03 1 Turn signal light bulb 12 V 21 W x 4 2 ...

Page 419: ...ignal light 3 by removing the nut Installation Install the rear turn signal light in the reverse order of removal Turn Signal Light Bulb Replacement B649G19206024 CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure 1 Remove the lens by removing the screw 2 Replace the bulb 1 3 Install the lens 1 2 I6...

Page 420: ...and circuit connection are OK the turn signal relay may be faulty therefore replace the turn signal side stand relay with a new one Refer to Turn Signal Side stand Relay Removal and Installation Turn Signal Side stand Relay Removal and Installation B649G19206027 Removal 1 Remove the left frame cover Refer to Exterior Parts Removal and Installation in Section 9D 2 Remove the turn signal side stand ...

Page 421: ...urn signal switch for continuity with a tester If any abnormality is found replace the left handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the turn signal switch inspection reinstall the removed parts Passing Light Switch Inspection B649G1920603...

Page 422: ...n in Section 9D 2 Disconnect the left handlebar switch coupler 1 3 Inspect the dimmer switch for continuity with a tester If any abnormality is found replace the left handlebar switch assembly with a new one Refer to Handlebars Removal and Installation in Section 6B Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity 4 After finishing the dimmer switch inspection re...

Page 423: ...or the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Special Tools and Equipment Special Tool B649G19208001 Item Specification GSF1200 GSF1200S Headlight HI 60 55 LO 55 55 Parking or position light 5 5 x 2 Brake light Taillight 21 5 Turn signal light 21 x 4 License plate light 5 Fastening part Tightening torque Note N m kgf m lb...

Page 424: ...uel Meter Horn Combination Meter Fuel Meter Horn Repair Instructions Combination Meter Components B649G19306014 GSF1200 1 2 3 5 4 FWD FWD I649G1930001 04 1 Upper case assembly 3 Lower case 5 Bracket 2 Combination meter 4 Cover ...

Page 425: ...Combination Meter Fuel Meter Horn 9C 2 GSF1200S 1 2 3 I649G1930002 02 1 Upper case assembly 2 Combination meter 3 Lower case ...

Page 426: ...d remove the combination meter assembly 3 Remove the combination meter 1 Installation Install the combination meter in the reverse order of removal Combination Meter Disassembly and Assembly B649G19306002 Refer to Combination Meter Removal and Installation Disassembly Disassemble the combination meter as shown in the combination meter components Refer to Combination Meter Components Assembly Assem...

Page 427: ...connect the fuel level gauge wire coupler 1 and remove the fuel tank Refer to Fuel Tank Removal and Installation in Section 1G 2 Connect a jumper wire A between the Y B and B W lead wires from the wire harness 3 Turn the ignition switch to ON 4 Check if the fuel level indicator LCD indicates full position NOTE It takes approx 30 seconds that the fuel level indicator indicates the detected fuel lev...

Page 428: ...el gauge Refer to Fuel Level Gauge Removal and Installation in Section 1G Speedometer Inspection B649G19306018 If the speedometer odometer or tripmeter does not function properly inspect the speed sensor and the coupler connections If the speed sensor and coupler connections are OK replace the combination meter unit with a new one Refer to Combination Meter Removal and Installation Speed Sensor Re...

Page 429: ...NOTE While testing the highest voltage reading should be the same as the battery voltage 12 V Oil Pressure Indicator Inspection B649G19306021 Inspect the oil pressure indicator in the following procedures NOTE Before inspecting the oil pressure switch check if the engine oil level is correct Refer to Engine Oil and Filter Replacement in Section 0B 1 Remove the CKP sensor cover Refer to CKP Sensor ...

Page 430: ...s Removal and Installation in Section 9D 2 Disconnect the ignition switch coupler 1 3 Remove the headlight housing GSF1200 4 Remove the ignition switch using the special tools Special tool 09930 11920 Torx bit JT 40H 09930 11940 Bit holder Installation Install the ignition switch in the reverse order of removal Pay attention to the following point CAUTION When reusing the ignition switch bolt clea...

Page 431: ...knob indication Continuity Horn Inspection 1 Disconnect the horn coupler 1 2 Connect a 12 V battery to terminal A and terminal B If the sound is not heard from the horn replace the horn with a new one 3 Connect the horn coupler Horn Removal and Installation B649G19306028 Removal 1 Disconnect the horn coupler 1 2 Remove the horn 2 by removing the mounting bolt Installation Install the horn in the r...

Page 432: ...1200 GSF1200S Speedometer light LED Tachometer light LED Turn signal indicator light LED x 2 High beam indicator light LED Neutral position indicator light LED Oil pressure indicator light LED Material SUZUKI recommended product or Specification Note Thread lock cement Thread Lock Cement Super 1322 or equivalent P No 99000 32110 09900 25008 09930 11920 Multi circuit tester set Torx bit JT 40H 0993...

Page 433: ...Exterior Parts 9D 1 Exterior Parts Schematic and Routing Diagram Seat Lock Cable Routing Diagram B649G19402002 1 2 3 4 I649G1940001 01 1 Screw 3 Seat lock 2 Seat lock cable 4 Plate ...

Page 434: ...9D 2 Exterior Parts Repair Instructions Exterior Parts Construction B649G19406001 GSF1200 2 3 3 1 1 I649G1940002 02 1 Frame head cover 2 Headlight housing cover 3 Headlight housing stay ...

Page 435: ...Exterior Parts 9D 3 GSF1200S 2 5 6 3 7 4 1 I649G1940003 05 1 Cowling body 3 Cowling brace 5 Upper panel 7 Head pipe 2 Wind screen 4 Lower panel 6 Meter panel lid ...

Page 436: ...06002 1 2 4 2 1 FWD FWD 3 3 A I649G1940031 02 1 Front fender 3 Washer A Before installing the front fender apply an adhesive agent to the inside of the washer to prevent it from falling 2 Fender plate nut 4 Front fork 2 1 2 I649G1940004 02 1 Frame cover 2 Cushion ...

Page 437: ...allation hole 3 Push in the head of center piece until it becomes flush with the fastener outside face Exterior Parts Removal and Installation B649G19406004 Seat Removal 1 Unlock the seat with the ignition key 2 Remove the front and rear seats as an assembly Installation Slide the seat hooks into the seat hook retainers and push down firmly until the seat snaps into the locked position Frame Cover...

Page 438: ...Install the seat tail cover and pillion rider handle in the reverse order of removal Frame Head Cover GSF1200 Removal Removal the frame head covers 1 left and right Installation Install the frame head covers in the reverse order of removal Headlight Housing Cover GSF1200 Removal Remove the headlight housing cover 1 Installation Install the headlight housing cover in the reverse order of removal Co...

Page 439: ...s 4 left and right Refer to Front Turn Signal Light Removal and Installation in Section 9B 6 Remove the cowling 5 along with the lower panel 6 7 Remove the lower panel 6 from the cowling 5 8 Disconnect the headlight and position light couplers 9 Remove the headlight assembly 7 10 Remove the cowling brace 8 1 I649G1940017 01 2 3 I649G1940018 01 4 I649G1940029 01 5 I649G1940020 01 6 I649G1940019 01 ...

Page 440: ...ove the front seat from the rear seat 4 Adjust the seat height adjuster position A or B 5 Reinstall the front seat and adjust the seat height adjuster position A or B 6 Install the seat height adjust dampers NOTE Dampers are used in two ways A or B Pay attention to the direction of dampers when installing them CAUTION Position of adjuster and direction of dampers must be unified either A or B 7 In...

Page 441: ...place the engine mount bushing if necessary as shown in the body frame construction Refer to Body Frame Construction d 8 c 7 b 6 d 9 10 4 a 5 a 5 3 3 2 1 A I649G1950005 02 1 Frame 6 Engine mounting bolt Front A Except for E 28 2 Crankcase 7 Engine mounting joint bolt 50 N m 5 0 kgf m 36 0 lb ft 3 Engine mount bushing 8 Joint mounting bolt 55 N m 5 5 kgf m 40 0 lb ft 4 Engine mounting bracket bushi...

Page 442: ...9E 2 Body Structure Battery Protector Construction B649G19506001 a a 1 1 FWD 2 1 I649G1950001 01 1 Protector 2 Battery a 50 mm 1 97 in ...

Page 443: ...n B649G19506002 Side stand Construction B649G19506003 1 2 3 3 a 4 I649G1950002 02 1 Frame 3 Washer 23 N m 2 3 kgf m 16 5 lb ft 2 Footrest bracket 4 Bolt 1 Side stand 40 N m 4 0 kgf m 29 0 lb ft 2 Spring Apply grease to sliding surface a 2 1 I649G1950003 02 ...

Page 444: ... stand Construction Center Stand Construction B649G19506005 Center Stand Removal and Installation B649G19506006 Removal 1 Support the motorcycle using a jack CAUTION Make sure that the motorcycle is supported securely 2 Remove the center stand as shown in the center stand construction Refer to Center Stand Construction Installation Install the center stand as shown in the center stand construction...

Page 445: ...Front Footrest Bracket Construction Side stand Construction Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque Specifications in Section 0C Special Tools and Equipment Recommended Service Material B649G19508001 NOTE Required service material is also described in the following Side stand Construction Center Stand Construction ...

Page 446: ...Prepared by December 2005 Part No 99500 39280 01E Printed in Japan 448 ...

Page 447: ...Printed in Japan K6 ...

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