Suzuki GSF1200SK6 Setup Manual Download Page 32

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CABLE ROUTING

Cable guide

3 - 5 mm

0 mm

Throttle cable (Pulling cable)

Throttle cable (Returning cable)

Cable guide

Throttle cable (Pulling cable)

Throttle cable (Returning cable)

Choke cable

Clutch hose

Cable adjuster

Pass the throttle cable through the right lower of hose

Cable guide

Pass the choke cable through between the
pulsed secondary air injection hoses

Pulsed secondary air injection valve

Summary of Contents for GSF1200SK6

Page 1: ...performing any work Take spe cial care to properly perform the required assembly and servicing marked by either a Warning or a Caution Failure to follow the directions in either of these two 2 cat eg...

Page 2: ...the bracket A Bolt The workshop where the machine is assembled should be clean spacious and have a level floor The technician should wear protective clothing such as leather gloves a long sleeve shir...

Page 3: ...t the steel frame to separate it from the base of the crate Carefully remove the various component parts pack aged around the motorcycle A Steel frame B Crate base Handling crates requires two operato...

Page 4: ...er 1 Strap 2 L 140 C Holder 2 For master cylinder Flange bolt 4 6 22 mm D Cable guide 1 Flange bolt 1 6 12 mm Item Part Name Q ty Remarks E Handlebar balancer weight 2 Right and Left Screw 2 6 105 mm...

Page 5: ...ates the parts dis mounted from the motorcycle in addition to the items shown in the preceding page A Front brake master cylinder B Throttle assembly C Left switch Choke cable D Clutch master cylinder...

Page 6: ...ke off the front brake and clutch master cylinder from the bracket A Front brake master cylinder B Clutch master cylinder C Bolt D Bracket Remove the bracket from the handlebar mounting position A Bra...

Page 7: ...kgf m After installing the handlebars fit the plastic cap on the head of each bolt A 8 30 mm Allen bolt B 8 30 mm Allen bolt C Plastic cap OD 11 0 mm D Punch mark NOTE Install the burring washer in th...

Page 8: ...r to holder fitting surface Tighten the master cylinder mounting bolts to the specified torque Front brake master cylinder mounting bolt 10 N m 1 0 kgf m A Holder B Front brake master cylinder C 6 22...

Page 9: ...ire coupler FRONT BRAKE HOSE Install the brake hose to the brake hose guide A Front brake hose B Front brake hose guide LEFT SWITCH A Choke cable B Holder NOTE Install the holder in position according...

Page 10: ...w D 5 25 mm screw E Cable holder CLUTCH MASTER CYLINDER Install the clutch master cylinder onto the handlebars Align the dot mark on the handlebars with the master cylinder to holder fitting surface T...

Page 11: ...mm B Front brake hose union C Right switch wiring harness LEFT Clamp the handlebar left switch wiring harness and choke cable with strap A Strap L 140 0 mm B Choke cable C Left switch wiring harness N...

Page 12: ...balancer parts as shown A 6 105 mm screw B Balancer weight C Flange rubber cushion D Spacer L 50 0 mm E Washer OD 16 0 mm ID 6 5 mm T 4 0 mm F Rubber cushion G 6 mm spacer nut With the screw not tight...

Page 13: ...tepped Allen screw Remove the boss and hook of meter assembly Disconnect the meter assembly coupler to take off the meter assembly A Meter assembly B Boss C Hook D Meter assembly coupler While pulling...

Page 14: ...ix the windscreen to the meter panel A Windscreen B Meter panel C Meter brace D Rubber cushion with nut E 5 18 mm stepped Allen screw Connect the meter assembly coupler Install the rubber boot Install...

Page 15: ...hole D Plastic cap REMOVING THE TAPE Remove the tape from the muffler A Muffler B Tape FRONT REAR BRAKE DISC To prevent brake squeaking and pad contamination carefully clean the front and rear brake d...

Page 16: ...abel General warning D Warning label Windscreen E Side fairing F Fuel tank OWNER S MANUAL Store the owner s manual in place A Owner s manual B Document tray NOTE For E 19 CC selection seven kinds of l...

Page 17: ...Remove the seat using the key A Seat lock B Seat Remove the rubber band Remove the battery from the motorcycle A Rubber band Filling electrolyte Remove the aluminium tape sealing the battery elec trol...

Page 18: ...precaution not to allow any of the fluid to spill A Electrolyte containers Make sure air bubbles are coming up in each electro lyte container and leave in this position for about 20 minutes A Air bub...

Page 19: ...y in the motorcycle as follows Never use anything except the specified battery electrolyte Once the sealing cap has been installed in the battery do not remove the sealing cap For charging the battery...

Page 20: ...of the battery 3 Cover terminal with rubber boot 4 Connect the lead to the negative terminal of the battery 5 Fix the battery with rubber band 6 Reinstall the frame cover A lead B lead C Rubber boot...

Page 21: ...he hose into a suitable clear container 2 Pour approximately 1 2 in of brake fluid into the con tainer so that the end of the clear hose is sub merged and cannot draw any additional air back into the...

Page 22: ...in the clutch fluid circuit must be bled completely If the clutch lever feels spongy or weak then most likely there is air in the hydraulic circuit Bleed the clutch fluid circuit in the same manner as...

Page 23: ...is for pulling cable and cable B is for return ing Check the throttle cable play at the throttle grip Throttle cable play 2 0 4 0 mm If adjustment is necessary carry out the procedure below 1 Loosen...

Page 24: ...cotter pin for Canada and loosen the axle nut 2 Loosen the lock nut 3 Adjust the slack in the drive chain by turning the right and left chain adjuster bolts 4 Proper chain slack is obtained when the...

Page 25: ...cycle is as indicated in the table below A Adjuster Rebound Damping Force Adjustment Adjust the setting of the rebound damping force to the standard position To adjust turn the adjuster B clockwise un...

Page 26: ...ically on level ground 1 Start the engine and allow it to run for a few minutes at idling speed 2 Turn off the engine and wait about three minutes then check the oil level through the inspection win d...

Page 27: ...stroke motorcycle and ATV engines Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil JASO T903 specifies performance requirements for motorcycle and ATV clutches and t...

Page 28: ...crew knob FOR LIMITED MARKET Set the meter to total then push the SEL button for 2 seconds to switch the display Select km h and mph properly to comply with traffic regulations Check km h and mph disp...

Page 29: ...Part Name N m kgf m K Rear brake push rod lock nut 18 1 8 L Brake caliper air bleeder Front 7 5 0 75 M Brake caliper air bleeder Rear 6 0 0 60 AXLE N Front axle bolt 100 10 0 O Rear axle nut 100 10 0...

Page 30: ...r Ignition coil Throttle cable Choke cable Clamp Clamp Gear position switch coupler Speed sensor lead wire Carburetor heater lead wire Throttle cable Handlebar switch lead wire L Handlebar switch lead...

Page 31: ...tarter motor lead wire Speed sensor lead wire Wiring harness Clamp Clamp Clamp Clamp Signal generator lead wire Neutral switch lead wire Wiring harness Speed sensor lead wire Neutral switch lead wire...

Page 32: ...ning cable Cable guide Throttle cable Pulling cable Throttle cable Returning cable Choke cable Clutch hose Cable adjuster Pass the throttle cable through the right lower of hose Cable guide Pass the c...

Page 33: ...rber Operation SP Position 4 DF 1 1 4 turn back Tighten all nuts and bolts Torque those listed in this manual Cotter pins and circlip Fasteners Check Paint and chrome Inspect Wash and polish Warning l...

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Suzuki GSF1200SK6, Setup Manual

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