Suzuki GSF1200 2001 Service Manual Download Page 304

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SERVICING INFORMATION

7-33

09913-75520
Bearing installer

09913-75830
Bearing remover

09914-25811
“T” type hexagon
wrench (6 mm)

09915-40610
Oil filter wrench

09915-64510
Compression gauge
set
09913-10750
(Adaptor)

09915-74510
Oil pressure gauge
09915-77330
Meter (for high
pressure)

09915-74540
Oil pressure gauge
attachment

09916-10911
Valve lapper set

09916-14510
Valve lifter

09916-14910
Valve lifter attachment

09916-21111
Valve seat cutter set

09916-20610
Valve seat cutter
head (N-121)

09916-20620
Valve seat cutter
head (N-122)

09916-24311
Solid pilot
(N-100-5.0)

09916-34570
Valve guide reamer
(4.95 mm)

09916-34542
Valve guide reamer
handle

09916-34580
Valve guide reamer
(10.8 mm)

09916-44310
Valve guide
remover/installer

09916-74521
Holder body

09916-74550
Band (73 – 85 mm)

09916-84511
Tweezers

09917-14920
Valve adjuster driver

09920-34820
Clutch pressure plate
holder

09920-34840
Starter clutch holder

09923-73210
Bearing remover

Summary of Contents for GSF1200 2001

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

Page 2: ...injury to the mechanic and may render the motorcycle unsafe for the rider and passenger 2 3 4 5 GENERAL INFORMATION This manual has been prepared on the basis of the latest specifications at the time...

Page 3: ...the manual as shown at the right will allow you to find the first page of the section easily 4 The contents are listed on the first page of each section to help find the item and page you need COMPON...

Page 4: ...42 99000 32050 Apply THREAD LOCK SUPER 1360 99000 32130 Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 Apply SUZUKI BOND 1207B 99000 31140 Apply THREAD LOCK SUPER 1303 99000 32030 Measur...

Page 5: ...ONS 1 2 SUZUKI GSF1200SK1 2001 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 BREAK IN PROCEDURES 1 5 CYLINDER IDENTIFI...

Page 6: ...ust use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for ad vice GENERAL PRECAUTIONS Prop...

Page 7: ...lts and nuts tighten the larger sizes first Al ways tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque Whenever you remove oil seals gaskets packi...

Page 8: ...aining MTBE Methyl Tertiary Butyl Ether is permitted 4 Use of blended gasoline alcohol fuel is permitted provided that the fuel contains not more than 10 etha nol Gasoline alcohol fuel may contain up...

Page 9: ...r a long period MULTIGRADE TEMP FRONT FORK OIL Use fork oil 10 or equivalent fork oil BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finish...

Page 10: ...ttached on the left frame pipe Attached on the right side of the rear fender 1 Noise label For E 03 33 2 Information label For E 03 28 33 3 Vacuum hose routing label For E 33 4 Fuel caution label For...

Page 11: ...Bore 79 0 mm 3 110 in Stroke 59 0 mm 2 323 in Compression ratio 9 5 1 Piston diplacement 1 157 cm3 70 6 cu in Carburetor MIKUNI BSR36SS four Air cleaner Non woven fabric element Starter system Electr...

Page 12: ...k plug NGK JR9B Battery 12 V 36 0 kC 10 Ah 10HR Generator Three phase A C Generator Main fuse 30 A Fuse 15 15 15 10 10 A Headlight 12 V 51 60 51 W Position light 12 V 5 W Except for E 03 24 28 33 Turn...

Page 13: ...1 9 CODE COUNTRY or AREA E 02 England UK E 03 USA E 19 European markets E 24 Australia E 28 Canada E 33 California USA E 54 Israel COUNTRY OR AREA CODES The following codes stand for the applicable co...

Page 14: ...EANER 2 7 ENGINE OIL AND OIL FILTER 2 9 FUEL HOSE 2 10 FUEL FILTER 2 11 ENGINE IDLE SPEED 2 11 THROTTLE CABLE PLAY 2 11 CARBURETOR SYNCHRONIZATION 2 12 EVAPORATIVE EMISSION CONTROL SYSTEM E 33 ONLY 2...

Page 15: ...R I R Exhaust pipe bolts and muffler bolts T T T Air cleaner I I R I Engine oil R R R R R Engine oil filter R R Fuel hose I I I I Replace every four years Engine idle speed I I I I I Throttle cable p...

Page 16: ...clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially whenever the motorcycle has been operate...

Page 17: ...chanism is serviced and 3 when the camshafts are removed for servicing 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...

Page 18: ...coil Also position the notches 1 on the right end of each camshaft as shown Measure the valve clearances of the remaining valves D and adjust them if necessary Camshaft position Notch 1 position Intak...

Page 19: ...e damage may result SPARK PLUG INSTALLATION To avoid damaging the cylinder head threads first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench Install...

Page 20: ...R CLEANER Inspect every 6 000 km 4 000 miles 6 months and re place every 18 000 km 11 000 miles 18 months Remove the seat and fuel tank 4 3 Remove the fuel tank mounting bracket 1 Remove the air clean...

Page 21: ...nts up If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element Ma...

Page 22: ...in the oil by remov ing the oil drain plug 1 and filler cap 2 Tighten the oil drain plug 3 to the specified torque and pour new oil through the oil filler When performing an oil change without oil fil...

Page 23: ...el as described in the engine oil replacement procedure NECESSARY AMOUNT OF ENGINE OIL Oil change 3 3 L 3 5 2 9 US Imp qt Oil and filter change 3 5 L 3 7 3 1 US Imp qt Engine overhaul 4 6 L 4 9 4 0 US...

Page 24: ...300 100 r min for Canada THROTTLE CABLE PLAY Inspect initially at 1 000 km 600 miles 1 month and ev ery 6 000 km 4 000 miles 6 months thereafter Adjust the throttle cable play A as follows 1st step Lo...

Page 25: ...hat handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically NOTE Major adjustments can be made at the carburetor side adjuster CARBURETOR...

Page 26: ...r cracks and fluid leakage BLEEDING AIR FROM THE CLUTCH FLUID CIRCUIT The clutch fluid circuit may be purged of air in the following man ner Keep the motorcycle upright and place the handlebars straig...

Page 27: ...Missing O ring seals Kinked or binding links If any defects are found the drive chain must be replaced NOTE When replacing the drive chain replace the drive chain and sprockets as a set CHECKING Remo...

Page 28: ...chain adjuster lock nuts 3 securely Rear axle nut 100 N m 10 0 kgf m 72 5 lb ft Install a new cotter pin For E 03 28 33 20 30 mm 0 8 1 2 in CLEANING AND LUBRICATING Clean the drive chain with kerosine...

Page 29: ...e fluid level is below the lower limit line replen ish with brake fluid that meets the following specification Specification and Classification DOT 4 The brake system of this motorcycle is filled with...

Page 30: ...ke pads as a set otherwise braking per formance will be adversely affected BRAKE PEDAL HEIGHT Loosen the locknut 1 Turn the push rod 2 until the brake pedal is 55 mm 2 2 in A below the top of the foot...

Page 31: ...e free end of the hose into a receptacle Front brake Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing...

Page 32: ...miles 6 months TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to repla...

Page 33: ...55 ZR17 73 W for the rear MICHELIN MAC ADAM 90XM The use of tires other than those specified may cause instability It is highly recommended to use the specified tires STEERING Inspect initially at 1...

Page 34: ...ront fork for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 5 12 REAR SUSPENSION Inspect every 12 000 km 7 500 miles 12 months Inspe...

Page 35: ...hose union bolt front rear 23 2 3 16 5 B Air bleeder valve brake clutch 8 0 8 6 0 C Brake disc bolt front rear 23 2 3 16 5 D Rear brake caliper mounting bolt 25 2 5 18 0 E Rear brake caliper housing...

Page 36: ...PERIODIC MAINTENANCE 2 23...

Page 37: ...124 psi The difference in compression pressure between any two cyl inders is more than 200 kPa 2 kgf cm2 28 psi All compression pressure readings are below 1 000 kPa 10 kgf cm2 142 psi even when they...

Page 38: ...too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If the light stays on check the oil...

Page 39: ...SSEMBLY 3 12 ENGINE REASSEMBLY 3 26 ENGINE COMPONENTS INSPECTION AND SERVICE 3 50 CAMSHAFT CYLINDER HEAD 3 50 CAM CHAIN TENSIONER 3 52 VALVE 3 53 VALVE GUIDE 3 56 VALVE SEAT 3 57 VALVE SPRING 3 60 CYL...

Page 40: ...d 3 14 and 42 Cylinder 3 15 and 42 Pistons 3 15 and 41 Starter motor 3 16 and 40 Generator 3 16 and 40 PAIR system 3 4 12 49 and 98 ENGINE LEFT SIDE See page Gearshift lever 3 5 and 11 Engine sprocket...

Page 41: ...e seat and frame side covers 5 5 and 6 Remove the fuel tank 4 3 Remove the fuel tank mounting bracket bolts 1 Remove the air cleaner box mounting bolts 2 Remove the document tray 3 Remove the battery...

Page 42: ...sconnect the throttle position sensor lead wire coupler 5 Slightly move the air cleaner box backward Remove the carburetor assembly by disconnecting the throttle cables 6 and 7 and starter cable 8 Rem...

Page 43: ...ift lever by removing its mounting bolt Remove the engine sprocket cover by removing the bolts Remove the speed sensor rotor 4 Remove the engine sprocket nut 5 while depressing the rear brake pedal En...

Page 44: ...ENGINE Remove the eight exhaust pipe bolts Remove the muffler mounting bolts Remove the exhaust pipe muffler Remove the oil cooler hose union bolts 1 Remove the oil cooler by removing the mounting bol...

Page 45: ...move the frame down tube mounting bolts and nuts Remove the frame down tube 1 Remove the engine mounting bolts nuts spacer and brackets Gradually lower the engine NOTE Only for E 28 model The engine m...

Page 46: ...torque NOTE When reusing the removed engine mounting bolts 4 5 and 6 apply a small quantity of the THREAD LOCK 1342 to their threads 99000 32050 THREAD LOCK 1342 Only for E 28 model The engine mounti...

Page 47: ...sembly connector remove all of the old sealer from the exhaust pipe and from inside the muffler Apply the exhaust gas sealer to both the inside and outside of the new exhaust pipe muffler assembly con...

Page 48: ...peed sensor rotor bolt 2 99000 32050 THREAD LOCK 1342 Tighten the speed sensor rotor bolt 2 to the specified torque Speed sensor rotor bolt 2 20 N m 2 0 kgf m 14 5 lb ft Before installing the engine s...

Page 49: ...engine oil with a viscosity rating of 10W40 SAE into the en gine after overhauling it Start up the engine and allow it run for several minutes at idle speed and then stop the engine Wait three minute...

Page 50: ...reinstalled in their original positions ENGINE DISASSEMBLY Remove each PAIR valve pipe and hose Remove the oil filter 1 using the special tool 09915 40610 Oil filter wrench NOTE Refer to page 2 10 for...

Page 51: ...ickup coil Also position the notches 2 on the right end of each camshaft as shown After removing the spring holder bolt 3 and spring 4 remove the cam chain tensioner 5 09911 73730 5 mm T type hexagon...

Page 52: ...ording to the numbers cast on the cylinder head Remove the cylinder head plate A Firmly grip the cylinder head at both ends and lift it straight up If the cylinder head does not come off lightly tap o...

Page 53: ...less portions of it using a plastic mallet Be careful not to damage the fins when removing or han dling the cylinder block Scribe the cylinder number on the head of the respective pis tons Place a cle...

Page 54: ...al generator rotor 3 using the special tool 09900 00410 Hexagon wrench set Disconnect the oil pressure switch lead wire 4 Remove the signal generator stator along with the pickup coil 5 and oil pressu...

Page 55: ...ch push piece 4 and pull out the clutch push rods 5 and 6 NOTE If it is difficult to pull out the push rod 5 use a magnetic hand or wire Hold the clutch pressure plate with the special tool and loosen...

Page 56: ...sleeve hub Remove the thrust washer 4 With the spacer and bearing removed the primary driven gear integral with the clutch housing is free to disengage from the primary drive gear Remove the primary...

Page 57: ...irclip 6 09900 06107 Snap ring pliers Remove the washers 7 oil pump driven gear 8 and pin 9 NOTE Do not lose the circlip pin and the washers Remove the starter clutch cover Remove the starter idle gea...

Page 58: ...o use it in conjunction with the special tool when removing the starter clutch assembly Remove the starter clutch assembly 1 from the crankshaft using the special tool 09930 30720 Rotor remover NOTE S...

Page 59: ...aft bearing retainer 1 Remove the plug 2 Remove the upper crankcase bolts and nut Remove the oil pan 3 Remove the shim 4 and O ring 5 Remove the oil sump filter 6 Remove the oil return pipe 7 Remove t...

Page 60: ...ankcase bolts in descending numerical order and then remove them NOTE Two allen bolts are located at position A to tighten the crank shaft 09914 25811 6 mm T type hexagon wrench Remove the oil return...

Page 61: ...nstalled in their original po sitions When removing the crankshaft journal bearings be care ful not to scratch the crankcase and the crankshaft jour nal bearings Remove the countershaft assembly 5 and...

Page 62: ...m 3 from the opposite side 09900 06107 Snap ring pliers Remove the circlip 4 and gearshift cam stopper 5 09900 06107 Snap ring pliers NOTE Rotate the bearing 6 in the crankcase by hand to inspect for...

Page 63: ...ENGINE 3 25 Remove the oil pump 1 09900 00410 Hexagon wrench set Remove the O rings and dowel pins...

Page 64: ...ings with new ones to prevent oil leak age Install the oil pump 4 into the lower crankcase with the three bolts and then tighten them to the specified torque NOTE Apply a small quantity of THREAD LOCK...

Page 65: ...4 Circlip 5 Spring 6 Circlip Always use new circlips 4 4 4 4 4 and 6 6 6 6 6 Position the gearshift cam in the neutral position as shown This will allow the gearshift forks and transmission gears to...

Page 66: ...e 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 When installing the crankshaft journa...

Page 67: ...haft assembly along with the cam chain into the upper crankcase Insert the right and left thrust bearings with the oil grooves fac ing towards the crankshaft web 3 85 Clean the mating surfaces of the...

Page 68: ...3 30 ENGINE BOND 1207B should be applied to the following locations The line of BOND...

Page 69: ...hten the main oil gallery plug 1 to the specified torque Replace the O ring with a new one 09900 00410 Hexagon wrench set Main oil gallery plug 40 N m 4 0 kgf m 29 0 lb ft Tighten the lower and upper...

Page 70: ...0 lb ft Replace the oil pan gasket with a new one to prevent oil leakage NOTE Install a new gasket washer A to the oil pan bolt as shown Use a new gasket washer to prevent oil leakage Install the cou...

Page 71: ...r clutch mounting bolt 99000 32030 THREAD LOCK SUPER 1303 Hold the starter clutch assembly using the special tool and then tighten the starter clutch mounting bolt to the specified torque 09920 34840...

Page 72: ...mp driven gear 8 and washer 9 Fix the oil pump driven gear with the circlip 09900 06107 Snap ring pliers Install the thrust washer 0 onto the countershaft NOTE The flat surface of the thrust washer sh...

Page 73: ...ATE Three kinds of the drive plate No 1 No 2 and No 3 are equipped in the clutch system they can be distinguished by the inside di ameter and clutch facing 3 36 DRIVEN PLATE Two kinds of the driven pl...

Page 74: ...se curely Put the clutch diaphragm spring seat 1 and clutch diaphragm springs 2 onto the clutch pressure plate properly NOTE Pay attention to the direction of the clutch diaphragm springs 3 38 Install...

Page 75: ...108 Snap ring pliers NOTE When fitting the circlip make sure that the sharp edge of the circlip faces outside Apply a light coat of the recommended bond to the clutch cover gasket mating surface A as...

Page 76: ...3 38 ENGINE Diaphragm spring holder Diaphragm springs 150 N m 15 0 kgf m 108 5 lb ft...

Page 77: ...the end of crankshaft Install the signal generator stator along with the pickup coil 1 Connect the oil pressure switch lead wire 2 NOTE The recommended bond should be applied to the groove of the sig...

Page 78: ...ft NOTE Apply SUZUKI SUPER GREASE A to the starter motor O ring Apply a small quantity of THREAD LOCK 1342 to the two bolts 99000 32050 THREAD LOCK 1342 99000 25010 SUZUKI SUPER GREASE A CYLINDER BLOC...

Page 79: ...RRECT EX Top ring 2nd ring 2nd ring Lower side rail Upper side rail 120 Top ring Spacer IN 120 120 Install the piston rings in the order of oil ring 2nd ring and top ring Top ring and 2nd middle ring...

Page 80: ...Copper washer with normal nut 4 pcs UP Install each special tool as shown Some light resistance must be overcome to lower the cylinder block over the pistons With pistons 2 and 3 in place install pis...

Page 81: ...e cam chain guide 2 as shown While holding down the cam chain rotate the crankshaft clock wise and align the T mark on the signal generator rotor with the center of the pickup coil Turn the crankshaft...

Page 82: ...h roller pin B on the cam chain with the arrow marked 3 on the intake sprocket Refer to the right illustrations NOTE The cam chain should now be on all three sprockets Be careful not to move the crank...

Page 83: ...ENGINE 3 45 24th pin 1st pin...

Page 84: ...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 Camshaft journal holder bolt 10 N m...

Page 85: ...bolts to the specified torque Cam chain tensioner mounting bolt 7 N m 0 7 kgf m 5 0 lb ft Insert the spring into the cam chain tensioner and tighten the spring holder bolt 4 to the specified torque S...

Page 86: ...ion bolt 1 16 N m 1 6 kgf m 11 5 lb ft Install the eight gaskets in the correct locations Tighten the cylinder head cover bolts 2 to the specified torque Replace the gaskets with new ones to prevent o...

Page 87: ...oil filter gasket O ring has contacted the oil filter mounting surface Then tighten the oil filter two full turns using the special tool 09915 40610 Oil filter wrench NOTE Before installing the oil f...

Page 88: ...often the cause of mistimed valve opera tion resulting in reduced power output Measure the cam height H using the micrometer Replace a cam shaft if the cams are worn to the service limit 09900 20202 M...

Page 89: ...widest part of the compressed plastigauge If the camshaft journal oil clearance exceeds the limit measure the inside diameter of the camshaft journal holder and the out side diameter of the camshaft...

Page 90: ...ratchet mechanism is worn or damaged replace the cam chain tensioner with a new one CAM CHAIN GUIDE Check the contacting surface of the cam chain guide If it is worn or damaged replace it with a new...

Page 91: ...spring 3 NOTE To remove the rocker arm shaft screw a 8 mm bolt into the rocker arm shaft end and then pull out the shaft Using the special tools compress the valve spring and remove the valve cotters...

Page 92: ...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 09900 20606 Dial gauge 1 1...

Page 93: ...wn If the deflection exceeds the service limit then determine whether the valve or the guide should be replaced with a new one 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Valve stem def...

Page 94: ...dle Install a ring onto each valve guide Be sure to use new rings Oil the stem hole of each valve guide and drive the guide into the guide hole using the valve guide installer 2 Valve guide 3 Cylinder...

Page 95: ...ust be within the following specification Valve seat width W Standard 0 9 1 1 mm 0 035 0 043 in If the valve seat is out of specification re cut the seat VALVE SEAT SERVICING The valve seats 1 for bot...

Page 96: ...tter one or two turns Measure the valve seat width W after every cut If the valve seat is pitted or burned use the 45 cutter to condi tion the seat some more NOTE Cut only the minimum amount necessary...

Page 97: ...y to clean up any burrs caused by the previ ous cutting operations Do not use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly...

Page 98: ...sure that the length 1 is not less than 2 5 mm 0 10 in If this length becomes less than 2 5 mm 0 10 in replace the valve Valve stem end length Service Limit 2 5 mm 0 10 in VALVE SPRINGS The force of...

Page 99: ...dard value replace the shaft Rocker arm shaft O D Standard 11 973 11 984 mm 0 4714 0 4718 in 09900 20205 Micrometer 0 25 mm ROCKER ARM INSIDE DIAMETER INSPECTION Measure the rocker arm inside diameter...

Page 100: ...staller Do not reuse the oil seals Insert the valves with their stems coated with molybdenum oil solution mixed engine oil moly paste Coat the entire stem making sure that there are no gaps When inser...

Page 101: ...Valve lifter attachment 09916 84511 Tweezers Be sure to install all of the parts in their original posi tions Apply engine oil to the rocker arm shaft sufficiently Install the rocker arms 2 the sprin...

Page 102: ...0 32050 THREAD LOCK 1342 Use a new O ring to prevent the joint from sucking in any air NOTE When replacing the intake pipes identify the different intake pipes according to each I D code 1 1 32F0 for...

Page 103: ...six places If any one of the measurements exceed the limit overhaul the cylinder and replace the piston with an oversize piston The remaining cylin ders must also be rebored accordingly otherwise the...

Page 104: ...oove clearance Service Limit 1st 0 18 mm 0 007 in 2nd 0 15 mm 0 006 in Piston ring groove width Standard 1st 1 01 1 03 mm 0 040 0 041 in 2nd 1 01 1 03 mm 0 040 0 041 in Oil 2 01 2 03 mm 0 079 0 080 in...

Page 105: ...bore gauge If either is out of specification or the difference between these measurement is more than the limits replace the piston 09900 20602 Dial gauge 1 1000 mm 09900 22403 Small bore gauge 18 35...

Page 106: ...can be installed in any posi tion When installing the spacer be careful not to allow its two ends to overlap in the groove A INCORRECT B CORRECT NOTE Install the pistons with the arrow mark facing to...

Page 107: ...g Measure the thickness of drive plates with a vernier calipers If each drive plate is not within the standard range replace it with a new one 09900 20102 Vernier calipers Clutch drive plate thickness...

Page 108: ...atches or other damage REASSEMBLY Reassemble the clutch cylinder in the reverse order of disassem bly and by taking the following steps Wash the clutch cylinder components with fresh brake fluid befor...

Page 109: ...wear If any defects are found replace the oil seal with a new one OIL SEAL REPLACEMENT Remove the gearshift shaft oil seal from the lower crankcase Install the new oil seal using the special tool 099...

Page 110: ...HAFT HOLE INSPECTION Check the gearshift shaft hole for damage or wear GEARSHIFT SHAFT REASSEMBLY When installing the gearshift shaft return spring position the stop per between the ends of the gearsh...

Page 111: ...ce exceeds the specification replace the fork its respective gear or both The clearance for each of the three gearshift forks plays an im portant role in the smoothness and positiveness of the shiftin...

Page 112: ...nap ring pliers Slide the lock washer 5 towards the 5th top drive gear 6 then turn the lock washer 7 and slide it towards the 5th top drive gear 6 Slide the 2nd drive gear 8 towards the 5th top drive...

Page 113: ...ER GREASE A to the oil seal lip 99000 25140 SUZUKI MOLY PASTE 99000 25010 SUZUKI SUPER GREASE A Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new cir...

Page 114: ...e A align the cutout B of the lock washer with the tab C on the gear bushing Install the spacer 3 after installing the O ring 4 Countershaft assembly Align the bushing oil hole 1 with the shaft oil ho...

Page 115: ...ve gear 4 Countershaft 1 1st low driven gear 2 4th driven gear 3 3rd driven gear 4 5th top driven gear 5 2nd driven gear 6 Driveshaft 7 Countershaft 1st low drive gear 8 4th drive gear 9 3rd drive gea...

Page 116: ...3 78 ENGINE...

Page 117: ...ckness gauge If the clearance exceeds the limit measure the conrod big end width and crank pin width If any of the measurements are out of specification replace the defective part s 09900 20803 Thickn...

Page 118: ...faces towards the intake side Conrod cap nut Initial 25 N m 2 5 kgf m 18 0 lb ft Final 50 N m 5 0 kgf m 36 0 lb ft 09900 22301 Plastigauge NOTE Never rotate the crankshaft or conrod when a piece of p...

Page 119: ...O D specification Code 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 09900 20202 Micrometer 25 50 mm Bearing thickness...

Page 120: ...side Tighten the conrod cap nuts to the specified torque Conrod cap nut Initial 25 N m 2 5 kgf m 18 0 lb ft Final 50 N m 5 0 kgf m 36 0 lb ft Check that the conrod moves smoothly CRANKCASE CRANKSHAFT...

Page 121: ...gauge Crankshaft journal oil clearance Standard 0 020 0 044 mm 0 0008 0 0017 in Crankshaft journal oil clearance Service Limit 0 08 mm 0 0031 in If the width at the widest part of the compressed plast...

Page 122: ...1 4164 1 4167 in 09900 20202 Micrometer 25 50 mm Bearing thickness specification Color Part No Thickness Green 12229 06B00 0A0 1 1 486 1 490 mm 12229 06B10 0A0 2 0 0585 0 0587 in Black 12229 06B00 0B...

Page 123: ...ust clearance exceeds the standard range adjust the thrust clearance as follows Remove the right side thrust bearing and measure its thick ness using the micrometer If the thickness of the right side...

Page 124: ...0992 0 1000 in 12228 48B00 0C0 0 0969 0 0976 in 2 54 2 56 mm Brown 2 48 2 50 mm 0 1000 0 1008 in 12228 48B00 0B0 0 0976 0 0984 in 2 56 2 57 mm Pink 2 50 2 52 mm 0 04 0 07 mm 0 1008 0 1012 in 12228 48...

Page 125: ...embly Do not attempt to disassemble the oil pump assembly The oil pump is available only as an assembly INSTALLATION Refer to the engine reassembly and the engine installation sec tions to install the...

Page 126: ...e operation of the oil pressure regulator by pushing on the piston with an appropriately shaped tool If the piston does not operate replace the oil pressure regulator with a new one OIL SUMP FILTER CL...

Page 127: ...l Oil sump filter NOTE When installing the oil sump filter make sure that the arrow mark A points towards the front of the motorcycle Do not loose the O ring 1 and shim 2 Oil pressure regulator Oil pr...

Page 128: ...draining the engine oil remove the oil pressure switch and the oil cooler NOTE Refer to the following pages for the details of each step Drain Engine oil 2 9 Remove Signal generator cover Oil pressur...

Page 129: ...uck in the oil cooler fins us ing compressed air Inspect the oil cooler for oil leaks If any defects are found re place the oil cooler with a new one If the fins are bent or dented repair them by care...

Page 130: ...FILTER 2 10 OIL PRESSURE 2 25 OIL JET OIL JET for the cylinder head REMOVAL The oil jet for the cylinder head can be removed after remov ing the cylinder block NOTE Refer to the following pages for th...

Page 131: ...iston cooling 1 Oil jet for the transmission 2 INSPECTION Make sure that the oil jets are not clogged If they are clogged clean their oil passage using a wire of the proper size and com pressed air IN...

Page 132: ...T 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 SHAFT...

Page 133: ...ENGINE 3 95 ENGINE LUBRICATION SYSTEM...

Page 134: ...3 96 ENGINE CYLINDER HEAD COOLING SYSTEM CHART...

Page 135: ...ENGINE 3 97 CYLINDER HEAD COOLING SYSTEM...

Page 136: ...o 4 Remove the PAIR valve Remove the PAIR pipes from each cylinder PAIR SYSTEM INSTALLATION Installation is in the reverse order of removal 3 100 Tighten the PAIR valve mounting bolt to the specified...

Page 137: ...the vacuum port of the PAIR valve as shown in the photograph Apply negative pressure slowly to the PAIR valve and inspect the air flow If air does not flow out within the specification the PAIR valve...

Page 138: ...0 ENGINE PAIR Valve Clamp No 4 cy No 3 cy No 2 cy No 1 cy 10 N m 1 0 kgf m 7 0 lb ft Clamp 10 N m 1 0 kgf m 7 0 lb ft Vacuum hose To No 3 carburetor To air cleaner box PAIR AIR SUPPLY SYSTEM HOSE ROUT...

Page 139: ...STALLATION 4 6 CARBURETOR 4 7 CONSTRUCTION 4 7 SPECIFICATIONS 4 8 I D NO LOCATION 4 9 DIAPHRAGM AND PISTON OPERATION 4 10 SLOW SYSTEM 4 11 MAIN SYSTEM 4 12 STARTER ENRICHER SYSTEM 4 13 FLOAT SYSTEM 4...

Page 140: ...L SYSTEM The fuel system consists of a fuel tank 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...

Page 141: ...ct the vacuum hose 3 and fuel hose 4 Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline REMOUNTING Remount the fuel tank in the reverse order of removal Be caref...

Page 142: ...tors When the engine has started negative 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 ne...

Page 143: ...The gaskets 2 and O ring 3 must be replaced with new ones to prevent fuel leakage INSPECTION AND CLEANING If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engi...

Page 144: ...nce measured is out of the specification replace the gauge assembly with a new one INSTALLATION Install the fuel level gauge in the reverse order of removal Pay attention to the following points Apply...

Page 145: ...t holder K Main jet L Pilot jet M Starter jet N Gasket O ring O Drain screw P Pilot screw Q Spring R Washer S O ring T Vacuum inlet cap U Vacuum hose for fuel valve V Fuel hose W Fuel joint pipe No 1...

Page 146: ...mm pulling cable 0 08 0 16 in Starter enricher plunger cable 0 5 1 0 mm play 0 02 0 04 in ITEM SPECIFICATION E 33 Carburetor type MIKUNI BSR36SS Bore size 36 mm I D No 32F2 Idle r min 1 200 100 r min...

Page 147: ...FUEL SYSTEM 4 9 I D NO LOCATION Each carburetor has an I D number 1 printed on its body...

Page 148: ...side of the venturi A Negative pressure is admitted into the diaphragm chamber 2 through an orifice 3 provided in the piston valve 1 Rising negative pressure overcomes the spring 4 force causing the p...

Page 149: ...float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4 This mixture rich with fuel then goes up through the pilot passage to the pilot screw 5 Part...

Page 150: ...e metered fuel enters the needle jet 5 mixes with the air admitted through the main air jet 6 and forms an emulsion The emulsified fuel then passes through the clearance between the needle jet 5 and j...

Page 151: ...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 FLOAT SYSTEM The flo...

Page 152: ...uel tank bracket bolts 1 Remove the air cleaner box mounting bolts 2 Disconnect the throttle position sensor coupler 3 Loosen the respective carburetor clamp screws Slightly move the air cleaner box 4...

Page 153: ...and 13 The throttle position sensor is preset at the factory Prior to disassembly mark the throttle position sensor s origi nal position with paint or a scribe for accurate reinstalla tion Avoid remo...

Page 154: ...m this may damage the dia phragm Remove the spring 2 and the piston valve along with its dia phragm 3 Remove the O ring 4 Remove the jet needle stopper 5 spring 6 washer 7 spacer 8 and jet needle 9 Re...

Page 155: ...d Slowly turn the pilot screw clockwise 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 it...

Page 156: ...the plug Pull on the screw head with pliers to remove the plug Carefully clean any metal shavings from the area Slowly turn the pilot screw clockwise and count the number of turns until the screw is l...

Page 157: ...ecessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and cleaning of the carburetor components After cleaning reass...

Page 158: ...at chamber Clean the float chamber and float parts with gasoline If the needle valve is worn as shown in the illustration replace it along with a new valve seat Clean the fuel passage of the mixing ch...

Page 159: ...READ LOCK 1342 Face the stamped side of the throttle valve out Carburetor body Pilot screw PILOT SCREW After cleaning reinstall the pilot screw to the original setting by turning the screw in until it...

Page 160: ...ottle valve control lever 1 between the throttle valve synchronizing screw and spring as shown Apply thin coat of the grease A to the fuel joint pipe O rings 99000 25010 SUZUKI SUPER GREASE A Replace...

Page 161: ...til resistance is 2 66 4 94 k When the resistance is within specification tighten the throttle position sensor mounting screws Throttle position sensor resistance 2 66 4 94 k Throttle position sensor...

Page 162: ...ion slowly turn the returning cable adjuster 2 to obtain a cable slack B of 1 0 mm 0 04 in Tighten the lock nut 1 securely After all of the work has been completed install the carburetor assembly onto...

Page 163: ...1 750 r min Adjust the engine speed by turning the throttle stop screw Turn the air screw 1 of the carburetor balancer so that the vacuum pressure causes the steel ball 2 to rise to the center line 3...

Page 164: ...ng the carburetors Connect the carburetor balancer hoses to these vacuum inlets and then adjust the carburetors as follows Start the engine and keep it running at 1 750 r min Observe the tachometer re...

Page 165: ...AND ADJUSTMENT 5 42 SUSPENSION SETTING 5 42 FRONT BRAKE 5 43 CONSTRUCTION 5 43 BRAKE PAD REPLACEMENT 5 44 BRAKE FLUID REPLACEMENT 5 44 BRAKE CALIPER REMOVAL AND DISASSEMBLY 5 45 BRAKE CALIPER INSPECT...

Page 166: ...SSIS 3 5 kgf m 25 5 lb ft 35 N m Side cowling RH Wind screen Side cowling LH Front cowling Meter panel Center cowling Cowling brace Side cowling bracket RH Side cowling bracket LH EXTERIOR PARTS CONST...

Page 167: ...pt for GSF1200 Remove the two screws Remove the rear view mirrors 1 and the front cowling 2 Hooked part Remove the side cowlings 4 left and right Disconnect the turn signal lead wire coupler Remove th...

Page 168: ...tion light lead wire couplers Remove the headlight assy 6 Remove the nuts at both left and right sides Remove the combination meter 7 6 33 Remove the three screws and the upper panel 8 Remove the wiri...

Page 169: ...using the ignition key DOCUMENT TRAY Remove the seat 5 5 Remove the document tray 1 FRAME COVER Remove the seat 5 5 Remove the passenger grab handle 1 Disconnect the brake light taillight coupler 2 Re...

Page 170: ...5 6 CHASSIS FRAME SIDE COVER Remove the frame side covers 1 left and right REMOUNTING Remount the cowling cowling brace seat and frame covers in the reverse order of removal Hooked part...

Page 171: ...S 5 7 Collar Brake disc R Bearing R Spacer Bearing L Brake disc L Collar Front wheel Air valve Balancer Axle shaft Brake disc bolt FRONT WHEEL CONSTRUCTION ITEM N m kgf m lb ft A 100 10 0 72 5 B 23 2...

Page 172: ...N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 100 N m 10 0 kgf m 72 5 lb ft Left Right Left Use old part Use old part Use old part Spacer Clearance Bearing installe...

Page 173: ...EEL BEARINGS Inspect the play of the wheel bearings by hand while they are in the wheel Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation Replace the wheel bearings if...

Page 174: ...uge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Wheel axle runout Service Limit 0 25 mm 0 010 in REASSEMBLY Apply SUZUKI SUPER GREASE A to the bearings before installation For U...

Page 175: ...100 N m 10 0 kgf m 72 5 lb ft Tighten the front axle pinch bolts 2 to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE Before tightening the front axle nut and front axle nu...

Page 176: ...Outer tube R Gasket O ring Spring adjuster Collar O ring Spring seat Spacer Washer Spring Damper rod Inner rod cylinder Inner tube Inner tube slide metal Front fork cap bolt Front axle pinch bolt Damp...

Page 177: ...and right Remove the front fender 2 Remove the brake hose clamp bolts 3 left and right Loosen the front fork upper clamp bolts 4 left and right NOTE Slightly loosen the front fork cap bolt 5 to facili...

Page 178: ...ng adjuster 1 by loos ening the inner rod lock nut Remove the spring seat 2 Remove the spacer washer and spring Invert the fork and stroke it several times to drain out fork oil Hold the fork inverted...

Page 179: ...owly pulling out the inner tube NOTE Be careful not to damage the inner tube The outer and inner tube s slide metals must be replaced along with the oil seal and dust seal when assembling the front fo...

Page 180: ...not damage the Teflon coated surface of the inner tube s slide metal when mounting it INSPECTION INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding surface for scuffin...

Page 181: ...is fitted securely Install the dust seal 3 DAMPER ROD BOLT Insert the inner rod damper rod cartridge 1 and the oil lock piece 2 into the inner tube Apply THREAD LOCK 1342 to the damper rod bolt and ti...

Page 182: ...ely Hold the front fork vertically and adjust fork oil level with the special tool NOTE When adjusting the fork oil level remove the fork spring and com press the outer tube fully 09943 74111 Front fo...

Page 183: ...er Install the front fork cap NOTE Before installing the front fork cap turn the inner rod lock nut 1 completely to the lower position as shown in the photograph Tighten the lock nut to the specified...

Page 184: ...k lower clamp bolts to the specified torque Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 lb ft Height C 2 0 mm 0 08 in For E 03 28 33 3 0 mm 0 12 in For the others Tighten the front fork cap bolt...

Page 185: ...bolts move the front fork up and down four or five times SUSPENSION SETTING After installing the front fork adjust the spring pre load as fol lows SPRING PRE LOAD ADJUSTMENT There are four grooved li...

Page 186: ...Handlebar switch assy L 0 Handlebar switch assy R A Steering stem head nut B Handlebar holder bolt C Front fork upper clamp bolt D Steering stem nut E Front fork lower clamp bolt F Handlebar holder se...

Page 187: ...teering stem upper bracket 2 Remove the steering stem nut using the special tool 09940 14911 Steering stem nut wrench Remove the steering stem lower bracket NOTE Hold the steering stem lower bracket t...

Page 188: ...lower bearing inner race using a chisel The removed bearing inner race should be replaced with a new one Remove the steering stem upper and lower bearing races using the special tools 09941 54911 Bea...

Page 189: ...A For the other countries 99000 25010 SUZUKI SUPER GREASE A Install the bearings STEERING STEM NUT Tighten the steering stem nut to the specified torque using the special tool 09940 14911 Steering ste...

Page 190: ...5 20 Tighten the front fork lower clamp bolts 1 and front fork upper clamp bolt 2 to the specified torque Front fork lower clamp bolt 1 23 N m 2 3 kgf m 16 5 lb ft Front fork upper clamp bolt 2 23 N m...

Page 191: ...same procedure on the end of the other handlebar 09940 92720 Spring scale Initial force 200 500 grams If the initial force reading is out of specification adjust the steering tension as follows 1 Firs...

Page 192: ...le 2 Brake caliper bracket 3 Brake disc 4 Collar 5 Dust seal 6 Bearing R 7 Spacer 8 Bearing L 9 Retainer 0 Cushion A Rear sprocket bolt B Rear sprocket mounting drum C Rear sprocket D Bearing E Dust s...

Page 193: ...5 29 Left Right Spacer Clearance Bearing installer Left Right Right Left 10 0 kgf m 72 5 lb ft 100 N m 6 0 kgf m 43 5 lb ft 60 N m 2 3 kgf m 16 5 lb ft 23 N m 2 5 kgf m 18 0 lb ft 25 N m For E 03 E 2...

Page 194: ...sprocket Remove the rear wheel Do not operate the brake pedal during or after rear wheel removal Draw out the rear sprocket mounting drum along with the rear sprocket from the rear wheel NOTE Before...

Page 195: ...d while it is in the rear sprocket mounting drum Rotate the inner race by hand to inspect it for abnormal noise and smooth rotation Replace the bearing if there is anything unusual Remove the rear spr...

Page 196: ...al REAR SPROCKET Inspect the rear sprocket s teeth for wear If they are worn replace the sprockets and drive chain as a set A Normal wear B Excessive wear REASSEMBLY WHEEL BEARINGS Apply SUZUKI SUPER...

Page 197: ...nd free of any grease Apply THREAD LOCK SUPER 1360 to the brake disc bolts and tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m 16 5 lb ft Tight...

Page 198: ...3 Rear cushion lever rod 4 Bearing 5 Spacer 6 Bearing 7 Spacer 8 Bearing 9 Spacer 0 Spacer A Chain adjuster plate B Washer C Spacer D Bearing E Spacer F Pivot shaft G Bearing H Chain buffer I Swingarm...

Page 199: ...ASSIS 5 35 Left side Right side 50 N m 5 0 kgf m 36 0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 50 N m 5 0 kgf m 36 0 lb ft 78 N m 7 8 kgf m 56 5 lb ft 78 N m 7 8 kgf m 56 5 lb ft 100 N m 10 0 kgf m 72 5 lb f...

Page 200: ...d hose clamps Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc Remove frame side cover left side only 5 6 Remove the rear shock absorber upper mounting...

Page 201: ...pacers from the swingarm and cushion lever Inspect the spacers for any flaws or other damage If any defects are found replace the spacers with new ones CHAIN BUFFER Remove the chain buffer 1 Inspect t...

Page 202: ...NGARM Inspect the swingarm for damage CUSHION LEVER NEEDLE BEARINGS Insert the spacers into the needle bearings move the spacer up and down and check for any play If there is excessive play replace th...

Page 203: ...a new one Do not attempt to disassemble the rear shock absorber It is unserviceable REASSEMBLY SWINGARM NEEDLE BEARINGS Before installing the needle bearings install the spacer Press the needle bearin...

Page 204: ...EDLE BEARINGS Press the needle bearings into the cushion lever using the special tool 09941 34513 Steering outer race installer Apply SUZUKI SUPER GREASE A to the spacers and needle bearings For USA 9...

Page 205: ...2 to the specified torque Cushion lever rod mounting nut 1 78 N m 7 8 kgf m 56 5 lb ft Rear shock absorber lower mounting nut 2 50 N m 5 0 kgf m 36 0 lb ft Tighten the pivot shaft nut 3 to the specifi...

Page 206: ...EAR WHEEL 5 33 REAR BRAKE Bleed air from the brake system after remounting the brake caliper 2 18 FINAL INSPECTION AND ADJUSTMENT After installing the rear suspension and rear wheel adjust the followi...

Page 207: ...Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent Handle...

Page 208: ...REPLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reser...

Page 209: ...ng periods of time Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Remove the O rings Replace t...

Page 210: ...Particularly wash the dust seal grooves and piston seal grooves Specification and Classification DOT 4 Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent o...

Page 211: ...1 N m 2 1 kgf m 15 0 lb ft Front brake caliper mounting bolt 2 39 N m 3 9 kgf m 28 0 lb ft Front brake hose union bolt 3 23 N m 2 3 kgf m 16 5 lb ft NOTE Before remounting the caliper push the piston...

Page 212: ...Replace the disc if the runout exceeds the service limit 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand Brake disc runout Service Limit front and rear 0 3 mm 0 012 in BRAKE DISC REMOVAL A...

Page 213: ...d Remove the brake hose union bolt and disconnect the brake hose Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemically with paint plastics and ru...

Page 214: ...ary cup and spring 3 Secondary cup 4 Piston 5 Primary cup 6 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other damage PISTON Inspect the pist...

Page 215: ...vents such as gasoline kerosine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassembly Specification and classification DOT 4 When installing the...

Page 216: ...5 52 CHASSIS Tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft Bleed air from the brake system after reassembling the master cylinder 2 18...

Page 217: ...aminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent Handle brake fluid with care the fluid...

Page 218: ...e pads as a set otherwise braking performance will be adversely affected Install the new brake pads and shims Be sure to properly install the shims 4 5 as shown in the illustration NOTE After replacin...

Page 219: ...later disassembly before removing the brake caliper mounting bolts Never reuse the brake fluid left over from previous servicing and which has been stored for long periods of time Brake fluid if it le...

Page 220: ...unout rear Service Limit 0 30 mm 0 012 in BRAKE CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly Pay attention to the followin...

Page 221: ...iper pistons all the way into the caliper Bleed air from the system after reassembling the brake caliper 2 18 Remove the reservoir mounting bolt 2 Place a rag underneath the brake hose union bolt on t...

Page 222: ...circlip 3 09900 06108 Snap ring pliers Remove the push rod 4 piston primary cup 5 and spring 6 MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other d...

Page 223: ...omponents When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Apply brake fluid to the master cylinder bore...

Page 224: ...ion bolt and disconnect the clutch hose from the master cylinder Completely wipe off any brake fluid adhering to any parts of motorcycle The fluid reacts chemically with paint plas tics rubber materia...

Page 225: ...Tire tread depth Service Limit Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in Ply separation Tread separation Tread wear is extraordinarily deformed or distributed around the tire TIRE AND WHEEL TIRE REMOVA...

Page 226: ...ire lubricant to the tire bead When installing the tire onto the wheel observe the following points Do not reuse the valve which has been once removed NOTE When repairing a flat tire follow the repair...

Page 227: ...it the tire can burst and possibly cause injury Do not stand directly over the tire while inflating In the case of preset pressure air inflator pay special care for the set pressure adjustment In this...

Page 228: ...0 STARTER MOTOR REMOVAL AND DISASSEMBLY 6 21 STARTER MOTOR INSPECTION 6 21 STARTER MOTOR REASSEMBLY AND REMOUNTING 6 22 STARTER RELAY INSPECTION 6 23 SIDE STAND IGNITION INTERLOCK SYSTEM PART INSPECTI...

Page 229: ...each terminal for corrosion and contamination CLAMPS Refer to WIRE HARNESS CABLE AND HOSE ROUTING 7 12 for proper clamping procedures Bend the clamp properly as shown in the illustration When clampin...

Page 230: ...the MF battery is different from that of a conventional battery Do not replace the MF bat tery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disa...

Page 231: ...rcycle and tester If the voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure that no voltage is applied If voltage is applied the tes...

Page 232: ...ELECTRICAL COMPONENTS 1 Turn signal side stand relay 2 Fuse box 3 Ignition switch 4 Handlebar switch R 5 Front brake light switch 6 Battery 7 Rear brake light switch 8 Throttle position sensor 9 Signa...

Page 233: ...A Clutch lever position switch B Handlebar switch L C Ignition coil D Main fuse E Starter relay F Ignitor G Horn H Starter motor I Generator J Speed sensor K Side stand switch L Gear position switch...

Page 234: ...h 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 cont...

Page 235: ...ed wires Faulty battery Faulty battery Abnormal driving condition Faulty battery Measure the charging voltage between the battery terminals 6 9 Incorrect Faulty stator coil or disconnected lead wires...

Page 236: ...ition when measuring the current When checking to find the excessive current leak remove the couplers and connectors one by one checking each part CHARGING OUTPUT INSPECTION Remove the seat 5 5 Remove...

Page 237: ...mper 4 pcs 3 Damper housing 4 Oil seal 5 O ring 6 Spacer 7 Generator end housing 8 Bearing 9 Stud bolt 0 Retainer A Rotor B Bearing cover 2 C Slip ring side bearing D Bearing cover 1 E Generator housi...

Page 238: ...wire disconnect the battery lead wire Remove the generator 3 Hold the generator driven gear using a vise 4 and two pieces of wood 5 as shown Then remove the generator driven gear nut Do not hold the d...

Page 239: ...g screws 3 Remove the rectifier 4 NOTE Straighten the stator coil lead wires using long nose pliers then remove the rectifier Remove the generator housing nuts Separate the generator housing 5 from th...

Page 240: ...INSPECTION ROTOR BEARINGS Inspect the rotor bearings for abnormal noise Also rotate the rotor bearings by hand and make sure that they rotate smoothly If there is anything unusual remove the bearing s...

Page 241: ...ck that the stator is properly insulated 09900 25008 Multi circuit tester set Tester knob indication Continuity test ROTOR COIL CONTINUITY CHECK Measure the continuity between the two slip rings 1 on...

Page 242: ...5 V P1 P2 P3 P4 1 1 4 1 5 V 2 P1 P2 P3 P4 1 4 1 5 V P1 P2 P3 P4 2 0 4 0 5 V RECTIFIER Measure the voltage among the terminal 1 and the other termi nals P1 P2 P3 and P4 Put the tester lead on the termi...

Page 243: ...A to the lip of the oil seal For USA 99000 25030 SUZUKI SUPER GREASE A For the other countries 99000 25010 SUZUKI SUPER GREASE A Apply a small quantity of THREAD LOCK 1342 to the bearing retainer scre...

Page 244: ...nut 4 5 N m 0 45 kgf m 3 5 lb ft Tighten the generator driven gear nut to the specified torque Generator driven gear nut 55 N m 5 5 kgf m 40 0 lb ft NOTE After tightening the generator driven gear nut...

Page 245: ...E STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stand ignition interlock system prevents the motorcycle from being started with the side stand down The system is operated by an electric circui...

Page 246: ...Side stand Down OFF 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 2 Side stand Up ON The current flow...

Page 247: ...is pushed Faulty clutch lever position switch No good Voltage Faulty gear position switch Check the starter relay 6 24 OK Others Faulty side stand switch Check the side stand switch 6 26 Check if the...

Page 248: ...ARBON BRUSHES Inspect the carbon brushes for abnormal wear cracks or smooth ness in the brush holder If either carbon brush is defective replace the brush assembly 1 O ring 2 Housing end inside 3 Wash...

Page 249: ...here is con tinuity between the segments and shaft replace the armature with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test OIL SEAL Check the seal lip for damag...

Page 250: ...nd Apply a small quantity of THREAD LOCK 1342 to the starter motor housing bolts 99000 32050 THREAD LOCK 1342 Install the starter motor 3 40 STARTER RELAY INSPECTION Remove the frame side cover left s...

Page 251: ...not apply battery voltage to the starter relay for more than five seconds This may overheat and damage the relay coil Check the relay coil for opens grounds and the specified re sistance 0 Tester knob...

Page 252: ...ler and measure the volt age between Green and Black White lead wires 09900 25008 Multi circuit tester set Tester knob indication Diode test Blue Ground ON in neutral OFF not in neutral 09900 25008 Mu...

Page 253: ...ter Refer to the following table 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the multi circuit tester reads under 1 4 V replace its battery when the tester probes ar...

Page 254: ...s 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 th...

Page 255: ...oor connection of related circuit couplers Faulty spark plugs Faulty ignitor Poor connection of ignition couplers Measure the ignition coil primary peak voltage 6 29 NOTE The ignition coil peak voltag...

Page 256: ...obe NOTE Do not disconnect the ignition coil primary wire 09900 25008 Multi circuit tester set When using the multi circuit tester and peak volt adap tor refer to the appropriate instruction manual Sh...

Page 257: ...Voltage Ignition coil primary peak voltage More than 140 V If the voltages are lower than the standard values inspect the ignition coil and the signal generator IGNITION COIL RESISTANCE Measure the ig...

Page 258: ...ulti circuit tester and peak volt adap tor refer to the appropriate instruction manual Shift the transmission into neutral turn the ignition switch to the ON position and grasp the clutch lever Press...

Page 259: ...ation but on the ignitor coupler is out of speci fication the wire harness must be replaced If both peak voltages are out of specification the signal generator must be replaced and re checked SIGNAL G...

Page 260: ...ombination meter mounting nuts 2 Remove the combination meter 3 DISASSEMBLY Disassemble the combination meter as follows INSPECTION Measure the continuity between the lead wires in the diagram on the...

Page 261: ...UND PILOT LAMP 11 NEUTRAL 12 HIGH BEAM 13 TURN L 14 IGNITION 15 FUEL 16 GROUND TACHOMETER 11 10 9 8 7 6 5 4 3 2 1 12 14 13 15 16 HIGH BEAM TURN SIGNAL L TURN SIGNAL R NEUTRAL OIL TACHOMETER SPEEDOMETE...

Page 262: ...screwdriver back and forth across the pick up surface of the speed sensor The voltage readings should cycle as fol lows 0 V 12 V or 12 V 0 V If the voltage reading does not change replace the speed se...

Page 263: ...the meter indication wait at least for 20 seconds after the float position has been changed Resistance Float position 90 93 Empty E 8 10 Full F Connect a new fuel level gauge or correct fuel level gau...

Page 264: ...clean the bulb with a cloth moistened with alcohol or soapy wa ter to prevent premature bulb failure Headlight bulb 12 V 51 60 51 W Position light bulb 12 V 5 W Except for E 03 24 28 33 NOTE Adjust th...

Page 265: ...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 Turn signal light bulb 12 V 21 W Do not overtighten the lens...

Page 266: ...Remove the seat 5 5 INSPECTION Before removing the turn signal side stand relay check the op eration of the turn signal light If the turn signal light does not illuminate inspect the bulb turn signal...

Page 267: ...SSURE SWITCH G Y Ground ON engine is stopped OFF engine is running NOTE Before inspecting the oil pressure switch check if the engine oil is at the proper level 2 9 WIRE COLOR B Black Lbl Light blue R...

Page 268: ...NOTE First disconnect the battery lead wire A REMOUNTING Remount the battery in the reverse order of removal Type designation YTX12 BS Capacity 12 V 36 kC 10 Ah 10HR Standard electrolyte S G 1 320 at...

Page 269: ...t the nozzles of the electrolyte container 5 into the battery s electrolyte filler holes Hold the electrolyte container firmly so that it does not fall Do not allow any of the electrolyte to spill Mak...

Page 270: ...the battery Measure the battery voltage with a tester The tester should indicate more than 12 6 V DC as shown If the battery volt age is lower than specification charge the battery with a bat tery cha...

Page 271: ...ng current to exceed 4 A at any time After recharging wait at least 30 minutes and then measure the battery voltage using a tester If the battery voltage is less than 12 5 V recharge the battery again...

Page 272: ...ROUTING 7 19 FRONT BRAKE HOSE ROUTING 7 20 REAR BRAKE HOSE ROUTING 7 21 FRONT FOOTREST BRACKET SET UP 7 22 FUEL TANK SET UP 7 23 HIGH TENSION CORD ROUTING 7 24 MUFFLER MOUNTING 7 24 SIDE STAND AND CEN...

Page 273: ...tension cord 7 Defective signal generator 8 Defective ignitor No fuel reaching a carburetor 1 Clogged fuel tank vent hose 2 Clogged or defective fuel valve 3 Defective needle valve 4 Clogged fuel hose...

Page 274: ...clearance Noise seems to come from the transmission 1 Worn or rubbing gear 2 Worn countershaft spline 3 Worn driveshaft spline 4 Worn or rubbing primary gear 5 Worn bearing Adjust Replace Replace Repl...

Page 275: ...ace Replace Adjust or replace Replace Replace Replace Adjust float height Clean Synchronize Engine runs poorly in high speed range 1 Weak valve spring 2 Worn camshaft 3 Insufficient spark plug gap 4 M...

Page 276: ...e synchronizing screw 13 Air leakage from intake pipe 14 Excessive amount of engine oil Adjust Replace Adjust Rebore or replace Replace Repair or replace Clean or replace Replace Clean Adjust float he...

Page 277: ...jet 4 Improperly working throttle valve 5 Clogged fuel filter Clean Clean Clean Adjust Clean or replace Overflow and fuel level fluctuations 1 Worn or damaged needle valve 2 Broken needle valve sprin...

Page 278: ...related bearings Adjust Replace Replace Replace Rear suspension too noisy 1 Loose rear suspension fastener 2 Worn rear suspension bush 3 Worn swingarm bearing Tighten Replace Replace BRAKES Complaint...

Page 279: ...e Change to cold type spark plug Tune up Tighten Adjust carburetor Generator does not charge 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open generator coil 3 Shorted...

Page 280: ...is too old 6 Dirty container top and sides Check generator IC regulator or rectifier circuit connections and make necessary adjustment to obtain specified charging operation Replace battery and corre...

Page 281: ...B Y B W W O W G Bl R B O Y Y W B Bl Y Bl O G W B G B W G B W B Y B Y O W O W O W O W W W B Y O W O W W R R O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br R R O O O Y O Y B W B W Gr Gr Br Br R O O...

Page 282: ...Y O O O G O G R R R Bl B Bl B Bl Bl G O Y O Y O B O B O G O G Lb Lbl Y W Y Y W O Y O O G R R Bl B Bl G O Y O B O G Lbl B Y B Y B W B W R R R R B Y B W R R B W B W B W B W Bl Y B W Bl Bl Y B Bl Y B B Y...

Page 283: ...y Clamp Wiring harness Rear turn signal RH Clamp Wiring harness Rear turn signal RH Clamp Wiring harness Clamp Wiring harness Clamp Wiring harness To rear turn signal LH To rear turn signal RH To igni...

Page 284: ...sor To side stand switch Starter motor terminal To signal generator Clamp Speedometer Clamp Clamp Clamp Wiring harness Clamp Wiring harness To speedometer To turn signal RH Wiring harness Speedometer...

Page 285: ...Clamp Speed sensor Clamp Clamp Gear position switch lead wire Side stand switch lead wire Starter motor lead wire Engine oil hose Signal generator lead wire Engine ground wire Generator lead wire Engi...

Page 286: ...le guide Cable guide LH Cable guide Throttle cable No 1 Throttle cable No 2 Throttle cable No 1 Throttle cable No 2 Throttle cable No 2 Throttle cable No 1 Fuel hose 0 mm 0 mm Throttle cable No 2 Thro...

Page 287: ...ING INFORMATION PAIR valve Clamp No 4 cy No 3 cy No 2 cy No 1 cy 10 N m 1 0 kgf m 7 0 lb ft Clamp 10 N m 1 0 kgf m 7 0 lb ft Vacuum hose To No 3 carburetor To air cleaner box PAIR AIR SUPPLY SYSTEM HO...

Page 288: ...SERVICING INFORMATION 7 17 Fuel valve Fuel hose clamp Clip Face the WHITE PAINT mark to the backward Carburetor air vent hose Fuel hose must be passed between throttle cables FUEL HOSE ROUTING...

Page 289: ...er motor lead wire must be passed outside of the clutch hose Starter motor lead wire Cable guide Clamp After touching the clutch hose union to the stopper tighten the union bolt to the specified torqu...

Page 290: ...VICING INFORMATION 7 19 OIL HOSE ROUTING 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 23 N m 2 3 kgf m 16 5 lb...

Page 291: ...14 45 5 Throttle cable Brake hose No 1 Brake hose No 2 Clamp Brake caliper After touching the brake hose union to the stopper tighten the union bolt to the specified torque After touching the brake ho...

Page 292: ...After touching the brake hose union to the stopper tighten the union bolt to the specified torque Assemble the clamp as shown Assemble the clamp as shown Assemble the clamp as shown Reservoir tank Wh...

Page 293: ...7 22 SERVICING INFORMATION Frame Footrest bracket Frame Washer Bolt Footrest bracket 2 0 mm FRONT FOOTREST BRACKET SET UP...

Page 294: ...ATION 7 23 Fuel tank cap Fuel tank Adhesive agent Fuel tank molding 4 4 N m 0 44 kgf m 3 0 lb ft Fuel tank front cushion Frame Fuel tank side cushion Fuel tank bracket 4 0 mm 4 0 mm 3 4 mm Fuel valve...

Page 295: ...Cushion Washer Washer RH Outside 29 N m 2 9 kgf m 21 0 lb ft 90 90 90 0 10 0 10 90 Ignition coil No 1 No 4 Ignition coil No 2 No 3 Clamp High tension cord No 2 High tension cord No 4 Plug cap Plug ca...

Page 296: ...SERVICING INFORMATION 7 25 Side stand Spring 40 N m 4 0 kgf m 29 0 lb ft Spring Center stand Spring SIDE STAND SPRINGS CENTER STAND SPRINGS...

Page 297: ...FORMATION 3 5 kgf m 25 5 lb ft 35 N m Side cowling RH Wind screen Side cowling LH Front cowling Meter panel Center cowling Cowling brace Side cowling bracket RH Side cowling bracket LH COWLING AND COW...

Page 298: ...SERVICING INFORMATION 7 27 Frame side cover RH Frame side cover LH Frame cover Passenger grab handle FRAME COVER AND FRAME SIDE COVER SET UP...

Page 299: ...n meter panel Meter panel Meter panel tape No 1 Meter panel tape No 2 VIEW A A COWLING CUSHION AND TAPE Side cowling Reverse face Cushion Cushion Center cowling Reverse face Front cowling Reverse face...

Page 300: ...SERVICING INFORMATION 7 29 FRONT FENDER CUSHION Cushion Front fender 5 mm 2 mm 2 mm 5 mm 2 mm 2 mm Cushion VIEW A A Seat support bracket Frame Seat lock set Clamp SEAT LOCK CABLE ROUTING...

Page 301: ...uel tank drain hose Clamp Fuel tank drain hose Clamp Fuel tank air breather hose FUEL TANK AIR BREATHER HOSE FUEL TANK DRAIN HOSE Avoid bending the fuel tank air breather hose to prevent the stoppage...

Page 302: ...SERVICING INFORMATION 7 31 NOTE...

Page 303: ...0 25 mm 09900 20508 Cylinder gauge set 1 100 mm 40 80 mm 09900 20602 Dial gauge 1 1000 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900...

Page 304: ...ve lifter 09916 14910 Valve lifter attachment 09916 21111 Valve seat cutter set 09916 20610 Valve seat cutter head N 121 09916 20620 Valve seat cutter head N 122 09916 24311 Solid pilot N 100 5 0 0991...

Page 305: ...9930 30720 Rotor remover 09940 14911 Steering stem nut wrench 09940 52861 Front fork oil seal installer 09940 92720 Spring scale 09941 34513 Steering outer race installer 09921 20220 Bearing remover s...

Page 306: ...er clutch mounting bolt 150 15 0 108 5 Signal generator rotor bolt 25 2 5 18 0 Crankcase bolt nut M 6 11 1 1 8 0 M 8 23 2 3 16 5 Main oil gallery plug 40 4 0 29 0 Oil pump mounting bolt 10 1 0 7 0 Oil...

Page 307: ...0 Brake clutch hose union bolt front rear 23 2 3 16 5 Air bleeder valve brake clutch 8 0 8 6 0 Brake disc bolt front rear 23 2 3 16 5 Front footrest bolt 39 3 9 28 0 Front footrest bracket mounting bo...

Page 308: ...or 4 marked bolt 7 marked bolt A mm 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...

Page 309: ...N EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 965 4 980 0 1955 0 1961 EX 4 945 4 960 0 1947 0 1953 Valve stem runout IN EX 0 05 0 002 Valve face thickness IN EX 0 5 0 02 Valve stem end length IN...

Page 310: ...aft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 20 0 008 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 250 kPa 875 kPa 12 5 kgf cm2 8 75 kgf cm...

Page 311: ...TEM STANDARD LIMIT Conrod small end I D 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod big end side clearance 0 10 0 20 0 30 0 004 0 008 0 01 Conrod big end width 20 95 21 00 0 825 0 827 Crank pin w...

Page 312: ...0 5495 0 5506 Clutch release cylinder bore 35 700 35 762 1 4055 1 4079 Clutch release cylinder piston 35 650 35 675 diam 1 4035 1 4045 TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD L...

Page 313: ...SET 3 turns back Throttle cable play 2 0 4 0 mm pulling cable 0 08 0 16 in Starter enricher plunger cable 0 5 1 0 mm play 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 33 Carburetor type MIKUNI BSR36SS...

Page 314: ...tap tap Tester range Approx 2 4 1 Secondary Spark plug cap Spark plug cap Tester range Approx 30 40 k 1 k Ignition coil primary peak More than 140 V voltage Generator Slip ring O D Limit 14 0 0 55 Bru...

Page 315: ...NDARD LIMIT Rear brake pedal height 55 2 2 Brake disc thickness Front 4 5 0 2 4 0 0 177 0 008 0 16 Rear 5 0 0 2 4 5 0 197 0 008 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 15 870 15 9...

Page 316: ...366 14 4 E 03 28 33 370 The other 14 6 countries Front fork oil level 107 4 2 E 03 28 33 105 The other 4 1 countries Rear wheel travel 125 4 9 Swingarm pivot shaft runout 0 3 0 01 TIRE ITEM STANDARD...

Page 317: ...fork oil type Fork oil SS 08 or 10 or equivalent fork oil Front fork oil capacity each leg 507 ml 17 1 17 9 US lmp oz E 03 28 33 509 ml The other 17 2 17 9 US Imp oz countries Brake fluid type DOT 4 R...

Page 318: ...cations and servicing procedures which differ from those of the GSF1200SK1 2001 model NOTE Any differences between the GSF1200SK1 2001 model and GSF1200K1 2001 model in specifications and service data...

Page 319: ...4 Bore 79 0 mm 3 110 in Stroke 59 0 mm 2 323 in Compression ratio 9 5 1 Piston diplacement 1 157 cm3 70 6 cu in Carburetor MIKUNI BSR36SS four Air cleaner Non woven fabric element Starter system Elect...

Page 320: ...g 7 B T D C at 1 500 r min Spark plug NGK JR9B Battery 12 V 36 0 kC 10 Ah 10HR Generator Three phase A C Generator Main fuse 30 A Fuse 15 15 15 10 10 A Headlight 12 V 60 55 W H4 Position light 12 V 5...

Page 321: ...TION METER REMOVAL Remove the headlight by removing the two screws Disconnect the socket 1 and coupler 2 Remove the two clamps from the lead wires and disconnect all the lead wire couplers Remove the...

Page 322: ...ation meter headlight housing headlight in the reverse order of removal and disas sembly COMBINATION METER DISASSEMBLY Disassemble the combination meter as follows COMBINATION METER INSPECTION Measure...

Page 323: ...b 12 V 60 55 W Position light bulb 12 V 5 W NOTE Adjust the headlight vertically and horizontally after reassembling BULB REPLACEMENT Remove the headlight by removing the two screws 8 4 Disconnect the...

Page 324: ...out the bulb 4 Reassemble the headlight in the reverse order of disassembly HEADLIGHT BEAM ADJUSTMENT To adjust the beam horizontally Turn the adjuster 1 clockwise or counterclockwise To adjust the b...

Page 325: ...O W W W R R O O O Y O Y B W B W Gr Gr Br Br O W W R O O Y B W Gr Br R R O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br O G O G Gr Gr O O Y W Y W O B O B O W O W O G O G W B W B Y G Y G O G Gr O Y...

Page 326: ...gnal RH Clamp Wiring harness Rear turn signal RH Clamp Wiring harness Clamp Wiring harness To rear turn signal LH To rear turn signal RH To ignitor unit Wiring harness Clamp Thermo switch E 02 only Cl...

Page 327: ...p Clamp Front turn signal Handle switch RH and LH Speedometer Starter motor Starter motor Clamp Clamp Ignitor unit Clamp Clamp Clamp Wiring harness Starter relay Signal generator Side stand switch Gea...

Page 328: ...45 5 Throttle cables Brake hose No 1 FWD Brake hose No 2 Clamp Brake caliper After touching the brake hose union to the stopper tighten the union bolt to the specified torque After touching the brake...

Page 329: ...e guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 965 4 980 0 1955 0 1961 EX 4 945 4 960 0 1947 0 1953 Valve stem runout IN EX 0 05 0 002 Valve face thickness IN EX 0 5 0 02 Valve stem e...

Page 330: ...aft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 20 0 008 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 250 kPa 875 kPa 12 5 kgf cm2 8 75 kgf cm...

Page 331: ...EM STANDARD LIMIT Conrod small end I D 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod big end side clearance 0 10 0 20 0 30 0 004 0 008 0 01 Conrod big end width 20 95 21 00 0 825 0 827 Crank pin wi...

Page 332: ...0 5495 0 5506 Clutch release cylinder bore 35 700 35 762 1 4055 1 4079 Clutch release cylinder piston 35 650 35 675 diam 1 4035 1 4045 TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD LI...

Page 333: ...Idle r min 1 200 100 r min Float height 13 0 1 0 mm 0 51 0 04 in Main jet M J 100 Jet needle J N 5C70 3rd Needle jet N J P 0M Throttle valve Th V 100 Pilot jet P J 15 Pilot screw P S PRE SET 3 turns...

Page 334: ...ap tap Tester range Approx 2 4 1 Secondary Spark plug cap Spark plug cap Tester range Approx 30 40 k 1 k Ignition coil primary peak More than 140 V voltage Generator Slip ring O D Limit 14 0 0 55 Brus...

Page 335: ...ake pedal height 55 2 2 Brake disc thickness Front 4 5 0 2 4 0 0 177 0 008 0 16 Rear 5 0 0 2 4 5 0 197 0 008 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Re...

Page 336: ...e 130 5 1 Front fork spring free length 366 14 4 Front fork oil level 107 4 2 Rear wheel travel 125 4 9 Swingarm pivot shaft runout 0 3 0 01 TIRE ITEM STANDARD LIMIT Cold inflation tire pressure Front...

Page 337: ...Engine oil capacity Change 3 300 ml 3 5 2 9 US lmp qt Filter 3 500 ml change 3 7 3 1 US lmp qt 4 600 ml Overhaul 4 9 4 0 US lmp qt Front fork oil type Fork oil SS 08 or 10 or equivalent fork oil Front...

Page 338: ...RAM GSF1200S 9 22 WIRING DIAGRAM GSF1200 9 25 WIRE HARNESS ROUTING GSF1200S 9 27 WIRE HARNESS ROUTING GSF1200 9 28 CONTENTS 9 This chapter describes service data service specifications and servicing p...

Page 339: ...d 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 BSR36SS four Air cleaner Non woven fabric element...

Page 340: ...phase A C generator Main fuse 30A Fuse 15 15 10 15 10 A Headlight 12 V 50 60 51 W GSF1200S 12V 60 51 W GSF1200 Position light 12 V 5 W Except E 03 24 28 33 Turn signal light 12 V 21 W Brake light Tai...

Page 341: ...Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 965 4 980 0 1955 0 1961 EX 4 945 4 960 0 1947 0 1953 Valve stem runout IN EX 0 05 0 002 Valve face thickness IN EX 0 5 0 02 Valve s...

Page 342: ...aft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 20 0 008 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 250 kPa 875 kPa 12 5 kgf cm2 8 75 kgf cm...

Page 343: ...TEM STANDARD LIMIT Conrod small end I D 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod big end side clearance 0 10 0 20 0 30 0 004 0 008 0 01 Conrod big end width 20 95 21 00 0 825 0 827 Crank pin w...

Page 344: ...0 5495 0 5506 Clutch release cylinder bore 35 700 35 762 1 4055 1 4079 Clutch release cylinder piston 35 650 35 675 diam 1 4035 1 4045 TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD L...

Page 345: ...P S PRE SET 3 turns back Throttle cable play 2 0 4 0 mm pulling cable 0 08 0 16 in Starter enricher plunger cable 0 5 1 0 mm play 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 33 Carburetor type MIKUNI...

Page 346: ...tap tap Tester range Approx 2 4 1 Secondary Spark plug cap Spark plug cap Tester range Approx 30 40 k 1 k Ignition coil primary peak More than 140 V voltage Generator Slip ring O D Limit 14 0 0 55 Bru...

Page 347: ...NDARD LIMIT Rear brake pedal height 55 2 2 Brake disc thickness Front 4 5 0 2 4 0 0 177 0 008 0 16 Rear 5 0 0 2 4 5 0 197 0 008 0 18 Brake disc runout 0 30 0 012 Master cylinder bore Front 15 870 15 9...

Page 348: ...4 4 E 03 28 33 370 The other 14 6 countries Front fork oil level 107 4 2 E 03 28 33 105 The other 4 1 countries Rear wheel travel 125 4 9 Swingarm pivot shaft runout 0 3 0 01 TIRE ITEM STANDARD LIMIT...

Page 349: ...fork oil type Fork oil SS 08 or 10 or equivalent fork oil Front fork oil capacity each leg 507 ml 17 1 17 9 US lmp oz E 03 28 33 509 ml The other 17 2 17 9 US Imp oz countries Brake fluid type DOT 4...

Page 350: ...Valve guide I D IN EX 5 000 5 012 0 1969 0 1973 Valve stem O D IN 4 965 4 980 0 1955 0 1961 EX 4 945 4 960 0 1947 0 1953 Valve stem runout IN EX 0 05 0 002 Valve face thickness IN EX 0 5 0 02 Valve s...

Page 351: ...haft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 20 0 008 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 250 kPa 875 kPa 12 5 kgf cm2 8 75 kgf c...

Page 352: ...TEM STANDARD LIMIT Conrod small end I D 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod big end side clearance 0 10 0 20 0 30 0 004 0 008 0 01 Conrod big end width 20 95 21 00 0 825 0 827 Crank pin w...

Page 353: ...0 5495 0 5506 Clutch release cylinder bore 35 700 35 762 1 4055 1 4079 Clutch release cylinder piston 35 650 35 675 diam 1 4035 1 4045 TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD L...

Page 354: ...back Throttle cable play 2 0 4 0 mm pulling cable 0 08 0 16 in Starter enricher plunger cable 0 5 1 0 mm play 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 03 Carburetor type MIKUNI BSR36SS Bore size...

Page 355: ...Generator Slip ring O D Limit 14 0 0 55 Brush length Limit 4 5 0 18 DENSO Generator maximum output More than 550 W at 5 000 r min Regulated voltage 13 5 15 V at 5 000 r min Starter relay resistance 3...

Page 356: ...Turn signal indicator light LED 2 High beam indicator light LED Neutral position indicator light LED Oil pressure indicator light LED License plate light 5 BRAKE WHEEL Unit mm in ITEM STANDARD LIMIT R...

Page 357: ...0 9439 Trailing 26 920 26 970 1 0598 1 0618 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...

Page 358: ...E 02 03 19 Reserve only 4 4 L 1 2 1 0 US lmp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Change 3 300 ml 3 5 2 9 US lmp qt Filter 3 500 ml change 3 7 3 1 US lmp qt 4 600 ml Overhau...

Page 359: ...O B O G O G Lb Lbl Y W Y Bl Y W O O Y O G R R W Bl B Bl G O Y O B O G Lbl B Y B Y B W B W R R R R B Y B W R R B W B W B W B W Bl Y B Br Bl Bl Y B Bl Y B B Y B Y B W B W W W O W O W B Br B Br G Bl G B...

Page 360: ...O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br R R O O O Y O Y B W B W Gr Gr R O O Y B W Gr O G O G Gr Gr O O Y W Y W O B O B O W O W O G O G W B W B Y G Y G O G Gr O Y W O B O W O G W B Y G O L O...

Page 361: ...B Bl B Bl Y Bl Bl B Y B W W O W B Br G Bl R B O Y Y W B Bl Y Bl O G W B G B W G B W B Y B Y O W O W O W O W W W B Y O W O W W R R O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br R R O O O Y O Y B W...

Page 362: ...O O O Y O Y B W B W Gr Gr Br Br O W W R O O Y B W Gr Br R R O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br O G O G Gr Gr O O Y W Y W O B O B O W O W O G O G W B W B Y G Y G O G Gr O Y W O B O W O G...

Page 363: ...W B Y O W O W O W W W R R O O O Y O Y B W B W Gr Gr Br Br O W W R O O Y B W Gr Br R R O O O Y O Y B W B W Gr Gr Br Br R O O Y B W Gr Br O G O G Gr Gr O O Y W Y W O B O B O W O W O G O G W B W B Y G Y...

Page 364: ...mp Wiring harness Rear turn signal RH Clamp Wiring harness Battery Clamp Wiring harness Clamp Wiring harness TPS Carburetor heater E 02 only Clamp Wiring harness Clamp Handle switch LH and RH Carburet...

Page 365: ...p Wiring harness Rear turn signal RH Clamp Wiring harness Battery Clamp Wiring harness Clamp Wiring harness TPS Carburetor heater E 02 only Clamp Wiring harness Clamp Handle switch LH and RH Carbureto...

Page 366: ...DI unit Clamp Neutral switch Side stand switch Wiring harness Starter motor Clamp To signal generator Starter motor terminal Speed sensor To side stand switch Clamp Front turn signal LH Wiring harness...

Page 367: ...Prepared by 2nd Ed February 2002 1st Ed April 2000 Part No 99500 39201 01E Printed in Japan 372...

Page 368: ...Printed in Japan K1 K2...

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