Suzuki GSF650 Service Manual Download Page 213

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CHASSIS 5-51

BRAKE CALIPER REASSEMBLY AND
INSTALLATION

Reassemble and install the brake caliper in the reverse order of
removal and disassembly. Pay attention to the following points:

• Wash the caliper bores and pistons with the specified brake

fluid. Particularly wash the dust seal grooves and piston seal
grooves.

Specification and classification: DOT 4

PISTON SEAL

• Install the piston seals as shown in the illustration.
• Install the piston to the caliper.

Dust seal

Piston seal

Caliper

BRAKE CALIPER HOLDER

• Apply SUZUKI SILICONE GREASE to the caliper holder pins.

99000-25100: SUZUKI SILICONE GREASE

* Wash the brake caliper 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 solvents such as gasoline, kerosine, etc.

* Replace the piston seals and dust seals with new

ones.

* Apply brake fluid to all of the seals, brake caliper

bores and pistons before reassembly.

Summary of Contents for GSF650

Page 1: ...GSF650 S...

Page 2: ...N 2004 This manual has been prepared on the basis of the latest specifications at the time of publica tion If modifications have been made since then differences may exist between the content of this...

Page 3: ...ach section to help find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such...

Page 4: ...ion mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Use fork oil 99000 99044 10G Apply SUZUKI SUPER GREASE A 99000 25010 Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 Meas...

Page 5: ...d UK European markets Canada WARNING CAUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI GSF650 2005 MODEL 1 4 SUZUKI GSF650S 2005 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATION 1 5 FUEL...

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 advice GENERAL PRECAUTIONS Prope...

Page 7: ...d nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque Whenever you remove oil seals gaskets packing O ri...

Page 8: ...aphs and actual motorcycles may exist depending on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number 1 is stamped on the right side of the steering head...

Page 9: ...e oil Use SF SG or SH SJ with JASO MA in API American Petroleum Institute classification Suzuki recommends the use of SAE 10W 40 engine oil If SAE 10W 40 engine oil is not available select an alternat...

Page 10: ...e and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km Below 6 000 r min Up to 1 600 km Below 9 000 r min Over 1 600...

Page 11: ...GSF650S GSF600SA GSF650SU GSF650SUA 1 Information label E 28 E 28 2 Fuel caution label E 02 E 02 E 02 E 02 3 Screen label 4 Warning steering label 5 Tire information label 6 General warning label 7 I...

Page 12: ...ders 4 Bore 65 5 mm Stroke 48 7 mm Displacement 656 cm 3 Compression ratio 10 5 1 Carburetor KEIHIN CVR32 Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet sump Idle...

Page 13: ...Spark plug NGK CR8EK or DENSO U24ETR Battery 12 V 28 8 kC 8 Ah 10 HR Generator Three phase A C generator Main fuse 30 A Fuse 10 15 15 10 10 A Headlight 12 V 60 55 W H4 GSF650 12 V 55 W H7 Upper and L...

Page 14: ...TS 2 7 AIR CLEANER 2 8 ENGINE OIL AND OIL FILTER 2 9 FUEL LINE 2 11 ENGINE IDLE SPEED 2 11 THROTTLE CABLE PLAY 2 11 CARBURETOR SYNCHRONIZATION 2 12 PAIR AIR SUPPLY SYSTEM 2 12 FUEL FILTER 2 12 CLUTCH...

Page 15: ...lubricate as necessary R Replace T Tighten Interval Item km 1 000 6 000 12 000 18 000 24 000 months 2 12 24 36 48 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance...

Page 16: ...ot and left footrest pivot 2 Brake pedal pivot and right footrest pivot 6 Center stand pivot and spring hook 3 Clutch lever holder and clutch cable 7 Drive chain 4 Side stand pivot and spring hook NOT...

Page 17: ...cing Valve clearance when cold IN 0 10 0 15 mm EX 0 18 0 23 mm 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 wit...

Page 18: ...with the center of the pickup coil Also position the notches 2 on the right end of each camshaft as shown Measure the valve clearances of the remaining valves D and adjust them if necessary When inst...

Page 19: ...here are carbon deposits on the spark plug If carbon is deposited remove it using a spark plug cleaner machine or carefully use a tool with a pointed end SPARK PLUG GAP Measure the spark plug gap usin...

Page 20: ...Tighten the exhaust pipe bolts and muffler bolts to the speci fied torque Exhaust pipe bolt 23 N m 2 3 kgf m Muffler mounting bolt 1 23 N m 2 3 kgf m Muffler connecting bolt 2 23 N m 2 3 kgf m Check t...

Page 21: ...nd replace every 18 000 km 36 months Always apply compressed air to the inside of the air cleaner element If compressed air is applied to the outside dirt will be forced into the pores of the air clea...

Page 22: ...ngine and drain engine oil by removing the oil drain plug 1 and filler cap 2 Tighten the oil drain plug 1 to the specified torque and pour new oil through the oil filler When performing an oil change...

Page 23: ...d until you feel that the oil filter O ring has contacted the oil filter mounting surface Then tighten the oil filter two full turns using the special tool NOTE Before installing the oil filter apply...

Page 24: ...play A as follows Loosen the locknut 1 of the throttle pulling cable 2 Turn the adjuster 3 in or out until the throttle cable play at the throttle grip A is between 2 4 mm Tighten the locknut 1 while...

Page 25: ...en the locknut 3 and turn out the adjusting screw 4 two or three rotations Then slowly turn in the adjusting screw 4 until resistance is felt Then turn out the adjusting screw 4 1 4 of a turn and tigh...

Page 26: ...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 Remove the cotter pin E 28 Loosen the axle nut 1 Tense th...

Page 27: ...curely Rear axle nut 100 N m 10 0 kgf m Replace the cotter pin with a new one E 28 CLEANING AND LUBRICATING Clean the drive chain with kerosine If the drive chain tends to rust quickly the intervals m...

Page 28: ...months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 12 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a glycol based...

Page 29: ...t 1 Turn the push rod 2 until the brake pedal is 60 mm A below the top of the footrest Tighten the locknut 1 securely Brake pedal height A Standard 60 mm Master cylinder push rod locknut 18 N m 1 8 kg...

Page 30: ...the free end of the hose into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the air bleeder valve by turnin...

Page 31: ...operation Overtighten steering pre vents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in the front fork Support the motorcycle so that...

Page 32: ...or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 5 15 REAR SUSPENSION Inspect the rear shock absorbers for oil leakage and check that there is no play in t...

Page 33: ...lder bolt 23 2 3 8 Front brake master cylinder mounting bolt 10 1 0 9 Front brake caliper mounting bolt 39 3 9 0 Brake hose union bolt front rear 23 2 3 A Air bleeder valve front rear 8 0 8 B Brake di...

Page 34: ...PERIODIC MAINTENANCE 2 21...

Page 35: ...2 kgf cm2 All compression pressure readings are below 1 000 kPa 10 kgf cm2 even when they measure more than 800 kPa 8 kgf cm2 COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression...

Page 36: ...Start the engine and check if the oil pressure indicator light is turned on If the light stays on check the oil pressure indicator light circuit If the circuit is OK check the oil pressure in the fol...

Page 37: ...INSPECTION AND SERVICE 3 47 CONROD CRANKSHAFT INSPECTION 3 55 CONROD CRANK PIN BEARING INSPECTION AND SERVICE 3 55 CRANKCASE CRANKSHAFT BEARING INSPECTION AND SERVICE 3 58 CRANKSHAFT THRUST CLEARANCE...

Page 38: ...30 3 83 Camshafts 3 13 3 26 3 79 Cylinder head 3 14 3 29 3 78 Cylinder 3 14 3 39 3 77 Pistons 3 15 3 40 3 76 Starter motor 3 16 6 24 3 75 Generator 3 16 6 15 3 75 PAIR system 3 12 97 3 97 3 85 98 ITEM...

Page 39: ...seat and frame covers 5 4 Remove the frame head covers GSF650 5 5 Remove the cowling GSF650S 5 5 Remove the fuel tank 4 3 Remove the air cleaner box mounting bolts 1 Remove the luggage box 2 5 4 Disc...

Page 40: ...sition switch Open the clamps Disconnect the starter motor lead wire 5 Disconnect the generator lead wire 6 and coupler 7 Disengage the gearshift lever link by removing the bolt Remove the engine spro...

Page 41: ...itional chain slack Remove the engine sprocket B Remove the exhaust pipe bolts Loosen the muffler connecting bolt C Remove the muffler mounting bolts D Remove the muffler assembly NOTE Support the muf...

Page 42: ...3 6 ENGINE Remove the oil cooler Support the engine with a proper jack Remove the frame down tube F Remove the engine mounting bolts nuts and spacer G Gradually lower the engine...

Page 43: ...s have been removed they are no longer of any use Be sure to use new nuts and tighten them to the specified torque NOTE When reusing the removed engine mounting bolts 1 and 2 apply a small quantity of...

Page 44: ...the exhaust pipes and from inside the muffler Apply the exhaust gas sealer to both the inside and outside of the new exhaust pipe muffler assembly connectors EXHAUST GAS SEALER PREMATEX 1372 Install...

Page 45: ...EAD 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 Before installing the engine sprocket cover apply a small quantity of SUZUKI SUPE...

Page 46: ...erly 7 12 to 19 Install the gearshift lever to the gearshift shaft in the correct position Gearshift lever height A Standard 55 mm Tighten the oil drain plug 1 to the specified torque Oil drain plug 2...

Page 47: ...at idle speed and then stop the engine Wait three minutes and then check that the oil level remains between the marks on the oil level inspection window 2 Adjust the following items to specification T...

Page 48: ...lter 1 using the special tool 09915 40610 Oil filter wrench Remove the oil hoses 2 Remove the cylinder head cover 3 Identify the position of each removed part Organize the parts in their respective gr...

Page 49: ...the center of the pickup coil Also position the notches A on the right end of each camshaft as shown Remove the cam chain guide 5 After removing the spring holder bolt 6 and spring 7 remove the cam c...

Page 50: ...ittle by little in descending order according to the numbers cast on the cylinder head Firmly grip the cylinder head at both ends and lift it straight up If the cylinder head does not come off lightly...

Page 51: ...ortions of it using a plastic mallet PISTONS Scribe the cylinder number on the head of the respective pis tons Place a clean rag over the cylinder to prevent any parts from falling into the crankcase...

Page 52: ...RATOR Remove the generator 1 Remove the signal generator rotor 2 using the special tool Disconnect the oil pressure switch lead wire 3 Remove the signal generator stator along with the pickup coil 4 a...

Page 53: ...ts in a crisscross pattern Then remove the bolts 09920 34810 Starter clutch holder Remove the clutch pressure plate 3 clutch drive plates and clutch driven plates Remove the spring washer 4 and spring...

Page 54: ...der Remove the washer A washer seat B and clutch sleeve hub C Remove the thrust washer D With the spacer and bearing removed the primary driven gear assembly is free to disengage from the primary driv...

Page 55: ...ven 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 Remove the circlip 1 09900 06107 Snap ring pliers Remove the was...

Page 56: ...to use it in conjunction with the special tool when removing the starter clutch assembly Remove the starter clutch assembly 3 from the crankshaft using the special tool 09930 33720 Rotor remover GEAR...

Page 57: ...21 CRANKCASE Remove the countershaft bearing retainer 1 Remove the upper crankcase bolts and nut Remove the oil pan 2 Remove the shim 3 and O ring 4 Remove the oil sump filter 5 Remove the oil return...

Page 58: ...en bolts are located at position A to tighten the crank shaft Remove the oil return pipe B Make sure that all of the bolts are removed Then tap the sides of the lower crankcase using a plastic mallet...

Page 59: ...tween the crankshaft assembly and upper crankcase Remove the dampers 3 and cam chain tensioner 4 Remove the O rings 5 and 6 NOTE Do not remove the crankshaft journal bearings unless abso lutely necess...

Page 60: ...spring C from the lower crankcase Remove the circlip D from the gearshift cam then draw out the gearshift cam E from the opposite side 09900 06107 Snap ring pliers Remove the circlip F and gearshift...

Page 61: ...ENGINE 3 25 Remove the gearshift cam stopper bolt I OIL PUMP Remove the oil pump 1 Remove the O rings and dowel pins Oil pump inspection 3 86...

Page 62: ...the cam height H using the micrometer Replace a camshaft if the cams are worn to the service limit 09900 20202 Micrometer 25 50 mm Cam height H Service Limit IN 32 30 mm EX 32 35 mm CAMSHAFT JOURNAL...

Page 63: ...measure the inside diameter of the camshaft journal holder and the out side diameter of the camshaft journal Replace the camshaft or the cylinder head depending upon which one exceeds the spec ificati...

Page 64: ...al 16 N m 1 6 kgf m Final 25 N m 2 5 kgf m CAM CHAIN TENSIONER ADJUSTER The cam chain tensioner adjuster is maintained at the proper tension by an automatically adjusted tensioner Unlock the ratchet m...

Page 65: ...o 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 6 from the valv...

Page 66: ...vice Limit 0 2 mm 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...

Page 67: ...uge 1 100 mm 09900 20701 Magnetic stand Valve stem deflection IN EX Service Limit 0 35 mm VALVE STEM WEAR Measure the valve stem O D using the micrometer If it is out of specification replace the valv...

Page 68: ...finish their guiding bores using the reamer Be sure to clean and oil the guides after reaming 09916 34570 Valve guide reamer 09916 34542 Valve guide reamer handle NOTE Insert the reamer from the comb...

Page 69: ...VICING The valve seats 1 for both the intake and exhaust valves are machined to two different angles The seat contact surface is cut at 45 09916 21111 Valve seat cutter set 09916 20610 Valve seat cutt...

Page 70: ...e seat is pitted or burned use the 45 cutter to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close...

Page 71: ...ect the valve seat and face for burrs or other things that could prevent the valve from sealing NOTE After servicing the valve seats be sure to check the valve clear ance after the cylinder head has b...

Page 72: ...alve spring free length IN EX Service Limit INNER 35 0 mm OUTER 38 4 mm Valve spring tension IN EX Standard INNER 5 6 6 6 kgf 28 0 mm OUTER 12 8 15 0 kgf 31 5 mm ROCKER ARM SHAFT OUTSIDE DIAMETER On t...

Page 73: ...h valve spring seat 2 for intake side and 3 for exhaust side 09916 44310 Valve guide remover installer Insert the valves with their stems coated with molybdenum oil solution mixed engine oil moly past...

Page 74: ...e sure that the rounded lip A of the cotter fits snugly into the groove B in the stem end 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers Apply engine oil to the rock...

Page 75: ...DER BLOCK PISTON INSPECTION CYLINDER BLOCK DISTORTION Check the gasket surface of the cylinder block for distortion Use a straightedge and thickness gauge Take clearance readings at several places If...

Page 76: ...ER CLEARANCE Subtract the piston diameter from the cylinder bore diameter If the piston to cylinder clearance exceeds the service limit replace both the cylinder and piston Piston to cylinder clearanc...

Page 77: ...of the measurements exceed the service limit replace the piston ring with a new one 09900 20102 Vernier calipers Piston ring free end gap Service Limit 1st 7 3 mm 2nd 7 3 mm 09900 20803 Thickness gau...

Page 78: ...rst then the 2nd ring and finally the 1st ring NOTE The 1st 1 and 2nd piston rings 2 differ in shape The 1st 1 and 2nd 2 piston rings should be installed with the mark facing up First install a spacer...

Page 79: ...ch drive plates using a clean rag Measure the thickness of the clutch drive plates using vernier calipers If a clutch drive plate thickness is thinner than the service limit replace the clutch plates...

Page 80: ...20102 Vernier calipers Clutch spring free length Service Limit 47 5 mm CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality espe cially cracks When removing the bearing from...

Page 81: ...ar or damage If any wear or damage is found replace the defective part s STARTER DRIVEN GEAR BEARING Inspect the starter driven gear bearing for wear or damage GEARSHIFT LINKAGE INSPECTION GEARSHIFT S...

Page 82: ...oil seal damage when installing the lower crankcase 99000 25010 SUZUKI SUPER GREASE A GEARSHIFT SHAFT HOLE Check the gearshift shaft hole for damage or wear GEARSHIFT SHAFT REASSEMBLY When installing...

Page 83: ...plays an important role in the smoothness and positiveness of the shifting action 09900 20803 Thickness gauge 09900 20102 Vernier calipers Gearshift fork to gearshift fork groove clearance Standard 0...

Page 84: ...3rd 4th drive gears 5 09900 06107 Snap ring pliers Slide the 6th top and 2nd drive gears toward the 3rd 4th drive gears then remove the 2nd drive gear circlip 6 Remove the 2nd 6th top washer circlip...

Page 85: ...e 5th driven gear 4 Remove the circlip washer and 4th driven gear 5 Remove the 4th driven gear bushing 6 lock washers 3rd driven gear 7 3rd driven gear bushing 8 and washer Remove the circlip and 6th...

Page 86: ...3 50 ENGINE Remove the 2nd driven gear bushing A Remove the oil seal B...

Page 87: ...OTE When reassembling the transmission attention must be given to the locations and positions of washers and circlips The cross sectional view shows the correct position of the gears bushings washers...

Page 88: ...on it so it fits into the groove Then fit lock washer 1 4 into lock washer 2 3 1 Left end bearing 2 Oil seal 3 2nd drive gear 4 Countershaft When installing the 3rd and 4th driven gear bushings onto t...

Page 89: ...gear 3 4th driven gear 4 3rd driven gear 5 6th top driven gear 6 2nd driven gear 7 Driveshaft 8 Countershaft 1st low drive gear 9 5th drive gear 0 3rd 4th drive gear A 6th top drive gear B 2nd drive g...

Page 90: ...3 54 ENGINE...

Page 91: ...ng the thickness 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 20...

Page 92: ...e number 1 on the conrod faces towards the intake side Conrod cap nut Initial 19 N m 1 9 kgf m Final 35 N m 3 5 kgf m 09900 22301 Plastigauge NOTE Never rotate the crankshaft or conrod when a piece of...

Page 93: ...k pin O D 3 Code 1 2 3 Conrod I D 2 1 Green Black Brown 2 Black Brown Yellow Code I D specification 1 37 000 37 008 mm 2 37 008 37 016 mm Code O D specification 1 33 992 34 000 mm 2 33 984 33 992 mm 3...

Page 94: ...owards the intake side Tighten the conrod cap nuts to the specified torque Conrod cap nut Initial 19 N m 1 9 kgf m Final 35 N m 3 5 kgf m Check that the conrod moves smoothly CRANKCASE CRANKSHAFT BEAR...

Page 95: ...stigauge Crankshaft journal oil clearance Standard 0 020 0 044 mm Crankshaft journal oil clearance Service Limit 0 08 mm If the width at the widest part of the compressed plastigauge exceeds the limit...

Page 96: ...ase measure the thrust clear ance between the left side thrust bearing and the crankshaft using the thickness gauge R Right side thrust bearing L Left side thrust bearing A Front Code I D specificatio...

Page 97: ...e right side thrust bearing is within the standard range reinsert the right side thrust bearing and remove the left side thrust bearing With the left side thrust bearing removed measure the clear ance...

Page 98: ...28 43414 CRANKSHAFT RUNOUT Support the crankshaft using V blocks as shown with the two end journals resting on the blocks Set up the dial gauge as shown and rotate the crankshaft slowly to read the ru...

Page 99: ...olts and then tighten them to the specified torque NOTE Apply a small quantity of THREAD LOCK 1342 to the bolts 99000 32050 THREAD LOCK 1342 Oil pump mounting bolt 10 N m 1 0 kgf m NOTE Make sure that...

Page 100: ...shown This will allow the gearshift forks and transmission gears to be installed easily Install the gearshift forks into the crankcase in the correct position and direction 8 For the 6th top driven ge...

Page 101: ...e gearshift cam to the neutral position NOTE Before installing the crankshaft journal bearings make sure that the oil jets I in the upper crankcase are not clogged I Oil jet 4 pcs In the upper crankca...

Page 102: ...haft web 3 60 Clean the mating surfaces of the crankcases Install the dowel pins in the upper crankcase CRANKCASE Apply the recommended bond to the mating surface of the lower crankcase as follows 990...

Page 103: ...ENGINE 3 67 BOND 1207B should be applied to the following locations The line of BOND...

Page 104: ...m 1 3 kgf m Final 23 N m 2 3 kgf m Tighten the main oil gallery plug B to the specified torque Main oil gallery plug 40 N m 4 0 kgf m Tighten the lower and upper crankcase bolts 6 mm and nuts to the...

Page 105: ...countershaft bearing retainer I NOTE Apply a small quantity of THREAD LOCK 1342 to the two screws 99000 32050 THREAD LOCK 1342 GEAR POSITION SWITCH Install the gear position switch NOTE When installi...

Page 106: ...small quantity of THREAD LOCK SUPER 1303 to the threads of the starter clutch mounting bolt 99000 32030 THREAD LOCK SUPER 1303 Hold the starter clutch assembly using the special tool and then tighten...

Page 107: ...he circlip 09900 06107 Snap ring pliers OIL PUMP DRIVEN GEAR Install the washer 1 pin 2 oil pump driven gear 3 and washer 4 Fix the oil pump driven gear with the circlip 09900 06107 Snap ring pliers I...

Page 108: ...hub holder Clutch sleeve hub nut 95 N m 9 5 kgf m Install the spring washer seat 7 and spring washer 8 onto the clutch sleeve hub as shown Insert the clutch drive plates and driven plates one by one...

Page 109: ...utch pressure plate and then tighten the clutch spring set bolts in a crisscross pattern to the specified torque 09920 34810 Starter clutch holder Clutch spring set bolt 12 N m 1 2 kgf m Apply a light...

Page 110: ...specified torque 99000 31140 SUZUKI BOND 1207B Oil pressure switch 14 N m 1 4 kgf m Install the signal generator stator along with the pickup coil 1 Be sure to fit the slot B on the back surface of t...

Page 111: ...10 SUZUKI SUPER GREASE A Install the starter motor 2 Starter motor mounting bolt 6 N m 0 6 kgf m NOTE Apply SUZUKI SUPER GREASE A to the starter motor O ring Apply a small quantity of THREAD LOCK 1342...

Page 112: ...on each piston Before installing the piston pins apply molybdenum oil solu tion to their surfaces 99000 25140 SUZUKI MOLY PASTE Place a cloth beneath the piston and install the circlips 1 NOTE Install...

Page 113: ...ers 09916 74521 Holder body 09916 74530 Band bore 55 65 mm NOTE Do not overtighten the bands or piston installation into the cylin ders will be difficult CYLINDER Tighten the cylinder base nut 1 to th...

Page 114: ...to the specified torque Cylinder head nut 37 N m 3 7 kgf m After firmly tightening the twelve 10 mm nuts install the cylin der head bolt 6 mm 1 and tighten it to the specified torque Cylinder head bo...

Page 115: ...40 SUZUKI MOLY PASTE 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 E When the T mark on the signa...

Page 116: ...Starting from the roller pin F 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 G on...

Page 117: ...shaft 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...

Page 118: ...nting bolt 7 N m 0 7 kgf m Insert the spring into the cam chain tensioner adjuster and tighten the spring holder bolt 4 to the specified torque Spring holder bolt 35 N m 3 5 kgf m Recheck the camshaft...

Page 119: ...Apply a small quantity of THREAD LOCK 1342 to the signal generator cover bolts 99000 32050 THREAD LOCK 1342 CYLINDER HEAD COVER Before installing the cylinder head cover gasket onto the cylin der head...

Page 120: ...ets in the correct locations Tighten the cylinder head cover bolts 2 to the specified torque Cylinder head cover bolt 2 14 N m 1 4 kgf m Install all of the spark plugs Install the left and right oil h...

Page 121: ...il filter wrench NOTE Before installing the oil filter apply a light coat of engine oil onto its O ring To properly tighten the oil filter use the special tool Never tighten the oil filter by hand onl...

Page 122: ...mbly INSTALLATION Refer to the engine reassembly and the engine installation sections to install the oil pump 3 63 OIL SUMP FILTER OIL PRESSURE REGULATOR REMOVAL After draining engine oil the followin...

Page 123: ...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 CLEANING Oil sump...

Page 124: ...pages for the details of each step Install Oil sump filter NOTE Do not loose the O ring 1 and shim 2 Oil pressure regulator Oil pressure regulator 28 N m 2 8 kgf m Oil pan 3 69 Oil cooler hose union b...

Page 125: ...o the following pages for the details of each step Drain Engine oil 2 9 Remove Signal generator cover Oil pressure switch INSPECTION 6 40 INSTALLATION Installation is in the reverse order of removal O...

Page 126: ...e bent or dented repair them by carefully straighten ing them with the blade of a small screwdriver Blow out any foreign matter that is stuck in the oil cooler fins using compressed air REMOVAL AND IN...

Page 127: ...Remove Cylinder block 3 14 Oil jet for the cylinder head 1 OIL JET for piston cooling and the transmission REMOVAL The oil jet for piston cooling and the transmission can be removed after separating t...

Page 128: ...3 92 ENGINE INSTALLATION Refer to the cylinder block installation engine reassembly and engine installation sections NOTE Before installing the oil jets apply a light coat of engine oil to the O rings...

Page 129: ...L 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 S...

Page 130: ...3 94 ENGINE ENGINE LUBRICATION SYSTEM...

Page 131: ...SYSTEM CHART UNION BOLT UNION BOLT OIL POOL OIL PIPE STUD BOLT STUD BOLT OIL PIPE OIL POOL OIL POOL OIL POOL ORIFICE ORIFICE UNION BOLT UNION BOLT OIL GALLERY OIL PUMP OIL SUMP FILTER CYLINDER HEAD C...

Page 132: ...3 96 ENGINE CYLINDER HEAD COOLING SYSTEM...

Page 133: ...PAIR hose No 1 4 PAIR hose No 2 5 PAIR hose No 4 6 PAIR hose No 3 Remove the PAIR valve 7 Remove the PAIR pipes 8 from each cylinder INSPECTION HOSES AND PIPES Inspect the hoses and pipes for wear or...

Page 134: ...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 is in norma...

Page 135: ...ENGINE 3 99 Tighten the PAIR pipe mounting nuts to the specified torque PAIR pipe mounting nut 10 N m 1 0 kgf m Rout the hoses properly 7 19 Use a new gasket 1 to prevent exhaust gas leakage...

Page 136: ...6 INSPECTION 4 6 INSTALLATION 4 6 FUEL LEVEL GAUGE 4 7 REMOVAL AND INSTALLATION 4 7 CARBURETOR 4 8 CONSTRUCTION 4 8 SPECIFICATIONS 4 9 I D NO LOCATION 4 10 DIAPHRAGM AND PISTON OPERATION 4 11 SLOW SY...

Page 137: ...hose fuel filter fuel hose and carburetor assem bly 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...

Page 138: ...ect the fuel tank air breather hose 3 and water drain hose 4 Disconnect the fuel level gauge lead wire coupler 5 Remove the fuel tank REMOUNTING Remount the fuel tank in the reverse order of removal G...

Page 139: ...e 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 nega tive pres...

Page 140: ...with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel fil ter with compressed air INSTALLATION Install the fuel valve in the reverse order of removal Ga...

Page 141: ...r is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Replace the fuel filter if necessary INSTALLATION Install the fuel filter in the reverse order of remov...

Page 142: ...fuel level gauge 1 Install the fuel level gauge in the reverse order of removal Pay attention to the following points Set the triangle mark forward FUEL LEVEL GAUGE INSPECTION 6 39 Gasoline is very ex...

Page 143: ...t pipe No 1 5 Diaphragm Piston valve G Drain screw Q Fuel joint pipe No 2 6 Needle jet H Vacuum inlet cap R Starter enricher plate 7 Needle jet holder I Vacuum hose for fuel valve S Throttle stop scre...

Page 144: ...k Throttle cable play pulling cable 2 0 4 0 mm Starter enricher plunger cable play 0 5 1 0 mm ITEM SPECIFICATION E 28 P 37 Carburetor type KEIHIN CVR32 Bore size 32 5 I D No 38G1 38G0 Idle r min 1 200...

Page 145: ...4 10 FUEL SYSTEM I D NO LOCATION Each carburetor has an I D number 1 printed on its body...

Page 146: ...ri 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 piston valve 1 to...

Page 147: ...d by the slow jet 3 where it mixes with air coming in through the slow air jet 4 This mixture rich with fuel then goes up through the pilot passage to the pilot screw 5 Part of the mixture is discharg...

Page 148: ...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 jet needle 7 and is dischar...

Page 149: ...he 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 float 1 and needle valve 2 work in...

Page 150: ...olts Disconnect the throttle position sensor coupler 1 Loosen the respective carburetor clamp screws Move the air cleaner box backward Disconnect the carburetor heater lead wire coupler 2 Unhook the s...

Page 151: ...onnect the hoses A Fuel hose B Vacuum hose for fuel valve C Vacuum hose for PAIR valve D Air vent hose Disconnect the carburetor heater terminal lead wires 2 Remove the throttle stop screw 3 Remove th...

Page 152: ...5 Remove the jet needle stopper 6 washer 7 E ring 8 and jet needle 9 from the piston valve Remove the float chamber 0 Remove the carburetor heater A Remove the O ring B Do not use compressed air on t...

Page 153: ...t screw K its setting must be deter mined Slowly turn the pilot screw clockwise and count the num ber of turns until it lightly seats Make a note of how many turns were made When reassembling the pilo...

Page 154: ...ing reassemble the carburetor with new seals and gaskets Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the che...

Page 155: ...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 chamber using compressed air CARBURETOR H...

Page 156: ...ance Approx 5 k 09900 25008 Multi circuit tester set Tester knob indication Resistance NOTE When performing this test it is not necessary to remove the throttle position sensor REASSEMBLY Reassemble t...

Page 157: ...e number of turns counted during disassembly CARBURETOR ENGAGEMENT Position the throttle valve control lever 1 between the throttle valve synchronizing screw and spring as shown CARBURETOR HEATER E 02...

Page 158: ...sistance Measure the resistance between the throttle position sensor terminals as shown Fully open the throttle valve with the throttle lever Position the throttle position sensor until resistance rea...

Page 159: ...pulling cable Turn the pulling cable adjuster 4 in or out until the throttle cable play A of 2 0 4 0 mm at the throttle grip is obtained Tighten the locknut 3 securely while holding the adjuster 4 Whi...

Page 160: ...warmed up engine Disconnect the vacuum hoses 1 for fuel valve and 2 for PAIR valve from carburetor 1 and 3 and install a cap of the proper size to each carburetor s vacuum inlet Remove the vacuum inl...

Page 161: ...8 is at the center line of its respective tube Repeat the above procedure on the third and fourth hoses The carburetor balancer is now ready to be used to synchronize the carburetors CARBURETOR SYNCHR...

Page 162: ...same level adjust the throttle valve synchronizing screws 1 2 and 3 Adjusting order is as follows 1 2 3 After balancing the carburetor set the engine speed by turn ing the throttle stop screw Observe...

Page 163: ...ON 5 16 REASSEMBLY AND INSTALLATION 5 17 HANDLEBARS AND STEERING 5 21 CONSTRUCTION 5 21 HANDLEBARS 5 22 STEERING 5 24 STEERING TENSION ADJUSTMENT 5 28 REAR WHEEL 5 29 CONSTRUCTION 5 29 REMOVAL 5 30 IN...

Page 164: ...AND INSTALLATION 5 55 REAR BRAKE 5 57 CONSTRUCTION 5 57 BRAKE PAD REPLACEMENT 5 58 BRAKE FLUID REPLACEMENT 5 59 BRAKE CALIPER REMOVAL AND DISASSEMBLY 5 60 BRAKE CALIPER INSPECTION 5 61 BRAKE CALIPER...

Page 165: ...CHASSIS 5 3 EXTERIOR PARTS CONSTRUCTION 1 Frame head cover 4 Upper panel 7 Cowling brace 2 Cowling body 5 Lower panel 8 Cowling side bracket 3 Wind screen 6 Combination meter GSF650 GSF650S...

Page 166: ...JUSTMENT 5 74 LUGGAGE BOX Remove the seat Above Remove the luggage box lid 1 Pull out the starter relay 2 Remove the bolts and luggage box 3 FRAME COVER Remove the frame cover 1 LH and RH Hooked point...

Page 167: ...lock cable 3 Remove the seat tail cover FRAME HEAD COVER GSF650 Remove the frame head cover 1 LH and RH Hooked point COWLING AND COWLING BRACE GSF650S Remove the caps Remove the rear view mirrors LH...

Page 168: ...e cowling 4 along with the lower panel 5 and turn signal assemblies Disconnect the headlight and position light couplers Remove the headlight assembly 6 Remove the cowling brace 7 FRONT FENDER 5 14 IN...

Page 169: ...T WHEEL CONSTRUCTION 1 Front axle 6 Bearing LH A Balancer 2 Dust seal 7 Brake disc LH A Front axle 3 Brake disc RH 8 Collar B Brake disc bolt 4 Bearing RH 9 Front wheel 5 Spacer 0 Air bleeder valve IT...

Page 170: ...fit the calipers temporarily on their original positions INSPECTION AND DISASSEMBLY TIRE 2 18 5 66 BRAKE DISC 5 52 DUST SEAL Inspect the dust seal lip for wear or damage If any damages are found repla...

Page 171: ...Replace the front axle if the runout exceeds the service limit 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Wheel axle runout Service Limit 0 25 mm WHEEL B...

Page 172: ...sassembly Pay attention to the follow ing points Left Use old part Use old part Use old part Spacer Clearance Bearing installer Left bearing new Left bearing new Right bearing new Right Left Right Lef...

Page 173: ...ase 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 bolts 23 N m 2 3 kgf m WHEEL Install the front wheel and...

Page 174: ...ont fork up and down four or five times Tighten the front axle pinch bolt 2 to the specified torque Front axle pinch bolt 23 N m 2 3 kgf m BRAKE CALIPERS Tighten the brake caliper mounting bolts to th...

Page 175: ...seal retainer 6 Outer tube slide metal 7 Oil lock piece 8 Outer tube R 9 Outer tube L 0 Gasket A Ring B Cylinder C Spring D Inner tube E Inner tube slide metal F O ring G Spring seat H Spacer I Washer...

Page 176: ...ender mounting bolts and plates behind LH and RH Disconnect the brake hose clamp 2 from the front fender FRONT FORK Loosen the front fork upper clamp bolt 1 NOTE Slightly loosen the front fork cap bol...

Page 177: ...es to drain out fork oil Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain Remove the dust seal 0 and oil seal stopper ring A Remove the cylinder bolt...

Page 178: ...Oil seal INSPECTION INNER AND OUTER TUBES Inspect the inner tube sliding surface and outer tube sliding sur face for scuffing If any defects are found replace them with new ones FORK SPRING Measure t...

Page 179: ...nner tube 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer 99000 99044 10G SUZUKI FORK OIL 10 Hold the inner tube vertically clean the metal groove and install the inner tube slide m...

Page 180: ...r bolt and tighten it to the specified torque using a 6 mm hexagon wrench and the special tools 99000 32050 THREAD LOCK 1342 09940 34520 T Handle 09940 34531 Attachment A Cylinder bolt 30 N m 3 0 kgf...

Page 181: ...tion to pump out air completely Hold the front fork in a vertical position and adjust the fork oil level using the special tool 09943 74111 Fork oil level gauge Oil level 108 mm GSF650 104 mm GSF650S...

Page 182: ...Front fork cap bolt 2 23 N m 2 3 kgf m Front fork upper clamp bolt 3 23 N m 2 3 kgf m FRONT FENDER Install the front fender NOTE Face the triangle mark on the front fender plate to the front side Remo...

Page 183: ...eering stem upper bearing 9 Handlebar switch assembly LH C Front fork upper pinch bolt 4 Steering stem lower bearing 0 Handlebar switch assembly RH D Steering stem nut 5 Steering stem A Clutch switch...

Page 184: ...r holder Clutch lever 7 Rear view mirror 8 Brake light switch lead wires 9 Front brake master cylinder Front brake lever 0 Right handlebar switch box A Handlebar balancer B Throttle grip Remove the ca...

Page 185: ...UZUKI SUPER GREASE A Insert the projection D of the right handlebar switch into hole of the handlebar Adjust the throttle cable play 2 11 Align the clutch lever holder s matching surface with the punc...

Page 186: ...5 using the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder Dismount the handlebars by removing the handlebar holder nuts HANDLEBAR HEIGHT ADJUSTMENT 5 75 Remove the steering stem head...

Page 187: ...clamp 1 Remove the cable guides 2 Remove the ignition switch using the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder Dismount the handlebars by removing the handlebar holder nuts NOT...

Page 188: ...e parts with new ones Remove the steering stem lower bearing and inner race using a chisel Remove the steering stem upper and lower bearing races using the special tools 09941 54911 Bearing outer race...

Page 189: ...ified torque using the special tool 09940 14911 Steering stem nut wrench Steering stem nut 45 N m 4 5 kgf m Turn the steering stem lower bracket about five or six times to the left and right so that t...

Page 190: ...as the initial force Repeat the same procedure on the end of the other handle bar Initial force 200 500 grams 09940 92720 Spring scale If the initial force reading is out of specification adjust the s...

Page 191: ...H Rear wheel 3 Brake disc A Rear sprocket bolt I Air valve 4 Collar B Rear sprocket mounting drum J Balancer 5 Dust seal C Rear sprocket K Cotter pin For E 28 6 Bearing RH D Bearing A Rear axle nut 7...

Page 192: ...Remove the rear wheel Remove the spacer 2 LH and collar 3 RH Remove the rear sprocket mounting drum assembly 4 from the rear wheel NOTE Before removing the rear sprocket mounting drum slightly loosen...

Page 193: ...damage If any damage is found replace the dust seal with a new one BEARING Inspect the play of the wheel and sprocket mounting drum bear ings by hand while they are in the wheel and drum Rotate the in...

Page 194: ...pect the dampers for wear and damage Replace the damper if there is anything unusual Remove the brake disc REAR SPROCKET Inspect the rear sprocket teeth for wear If they are worn as shown replace the...

Page 195: ...LLATION Reassembly and installation is in the reverse order of removal and disassembly Pay attention to the follow ing points Clearance Right Light Left Right Spacer Clearance Bearing installer Left R...

Page 196: ...g installer set Make sure that the brake disc is clean and 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 SUPE...

Page 197: ...wheel Adjust the drive chain slack after installing the rear wheel 2 14 Tighten the rear axle nut 1 to the specified torque Rear axle nut 100 N m 10 0 kgf m Install a new cotter pin E 28 The direction...

Page 198: ...Bearing 9 Spacer 0 Spacer A Spacer B Bearing C Spacer D Pivot shaft E Bearing F Chain buffer G Swingarm H Chain cover I Chain adjuster J Chain adjuster guide K Chain adjuster bolt A Rear shock absorbe...

Page 199: ...shock absorber upper mounting bolt nut 3 Remove the cushion lever mounting bolt nut 4 NOTE Slightly loosen the cushion lever rod mounting nuts and rear shock absorber lower mounting nut to facilitate...

Page 200: ...hion lever Inspect the spacers for any flaws or other damage If any defects are found replace the spacer with a new one CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are fou...

Page 201: ...damage CUSHION LEVER BEARINGS Insert the spacers into bearings check the play by moving the spacers up and down If excessive play is noted replace the bearing with a new one Remove the cushion lever...

Page 202: ...BER Inspect the rear shock absorber for damage and oil leakage If any defects are found replace the rear shock absorber with a new one REASSEMBLY SWINGARM BEARINGS Before installing the swingarm pivot...

Page 203: ...sing the special tool 09913 70210 Bearing installer set Apply grease to the spacers and needle bearings 99000 25010 SUZUKI SUPER GREASE A REAR SHOCK ABSORBER DISPOSAL GAS PRESSURE RELEASE Mark the dri...

Page 204: ...When remount the rear shock absorber and cushion lever set the index line rearward Tighten the cushion lever rod mounting nuts 1 and rear shock absorber lower mounting nut 2 to the specified torque C...

Page 205: ...kgf m Tighten the rear shock absorber upper mounting nut 5 to the specified torque Rear shock absorber upper mounting nut 50 N m 5 0 kgf m REAR BRAKE Remount the rear wheel 5 35 Tighten the brake hos...

Page 206: ...5 44 CHASSIS Left side Right side 50 N m 78 N m 50 N m 78 N m 78 N m 100 N m 5 0 kgf m 5 0 kgf m 7 8 kgf m 10 0 kgf m 7 8 kgf m 7 8 kgf m...

Page 207: ...ar wheel adjust the following before riding Drive chain slack 2 14 Tire pressure 2 18 SUSPENSION SETTING After installing the rear suspension adjust the spring pre load and damping force as follows Sp...

Page 208: ...Brake caliper 3 Diaphragm 0 Brake pad mounting pin G Brake caliper holder 4 Piston cup set A Clip A Master cylinder holder bolt 5 Master cylinder holder B Spring B Brake hose union bolt 6 Master cyli...

Page 209: ...al 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 s...

Page 210: ...Specification and classification DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until...

Page 211: ...pads 5 47 Remove the brake caliper holder 1 and rubber parts 2 Remove the pad spring 3 Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air...

Page 212: ...nspect the caliper pistons for scratches and other damage If any damage is found replace the caliper pistons with new ones CALIPER HOLDER Inspect the caliper holder for damage If any damage is found r...

Page 213: ...tration Install the piston to the caliper 1 Dust seal 2 Piston seal 3 Caliper BRAKE CALIPER HOLDER Apply SUZUKI SILICONE GREASE to the caliper holder pins 99000 25100 SUZUKI SILICONE GREASE Wash the b...

Page 214: ...using the micrometer Replace the brake disc if the thickness is less than the service limit or if damage is found 09900 20205 Micrometer 0 25 mm Brake disc thickness Service Limit front 4 0 mm rear 4...

Page 215: ...he brake hose union bolt 2 and disconnect the brake hose Remove the right rear view mirror Remove the master cylinder assembly Remove the brake lever 3 and brake light switch 4 Remove the reservoir ca...

Page 216: ...ary cup and spring 0 Secondary cup A Piston B Primary cup C Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam age PISTON Inspect the pis...

Page 217: ...n the master cylinder Apply SUZUKI SUPER GREASE to the brake lever pivot bolt when installing 99000 25010 SUZUKI SUPER GREASE A Wash the master cylinder components with new brake fluid before reassemb...

Page 218: ...h mark C Master cylinder D Handlebar E Upper holder bolt F Clearance Master cylinder holder bolt upper and lower 10 N m 1 0 kgf m After setting the brake hose union to the stopper tighten the union bo...

Page 219: ...caliper mounting bolt 4 Dust seals B Brake hose C Brake caliper housing bolt 5 Brake pads C Master cylinder D Brake hose union bolt 6 Springs D Piston cup set E Master cylinder mounting bolt 7 Brake p...

Page 220: ...rake fluid left over from the last servicing 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 b...

Page 221: ...n DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle NOTE Rear brake caliper has two bleeder valves Loosen the air bleeder valve and pump the br...

Page 222: ...brake hose union bolt 2 NOTE Place a rag underneath the union bolt to catch any spilt of brake fluid Remove the brake caliper mounting bolts 3 Remove the brake pads 5 58 Remove the brake caliper hous...

Page 223: ...r in the reverse order of removal and disassembly Pay attention to the following points Specification and classification DOT 4 Do not use high pressure air to prevent brake caliper piston damage Do no...

Page 224: ...orque After setting the brake hose union to the stopper tighten the union bolt 6 to the specified torque Brake caliper mounting bolt 4 26 N m 2 6 kgf m Brake caliper housing bolt 5 37 N m 3 7 kgf m Br...

Page 225: ...the locknut 3 Remove the master cylinder mounting bolts 4 Remove the master cylinder along with the reservoir by turn ing the push rod 5 Disconnect the reservoir hose Remove the brake hose connector 6...

Page 226: ...ter cylinder in the reverse order of removal and disassembly Pay attention to the following points Specification and classification DOT 4 Apply SUZUKI SILICONE GREASE to the push rod end 99000 25100 S...

Page 227: ...e union to the stopper tighten the union bolt 3 to the specified torque Master cylinder mounting bolt 1 25 N m 2 5 kgf m Master cylinder push rod locknut 2 18 N m 1 8 kgf m Brake hose union bolt 3 23...

Page 228: ...ire with a chalk to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced again...

Page 229: ...abnormal con dition removing of the valve is not necessary If the seal has abnormal deformation replace the valve with a new one INSTALLATION VALVE Any dust or rust around the valve hole B must be cle...

Page 230: ...the tire changer manufacturer Bounce the tire several times while rotating This makes the tire bead expand outward to contact the wheel thereby facili tating air inflation Inflate the tire Do not reu...

Page 231: ...ad with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire balance Cold inflation tire pressure BALANCER WEIGHT W...

Page 232: ...o the threaded parts of the special tool CUTTING Set up the special tool as shown in the illustration 1 Tool body 2 Grip handle 3 Pressure bolt A 4 Pressure bolt B 5 Bar 6 Adjuster bolt with through h...

Page 233: ...uster bolt 2 Grip handle without hole 3 Joint plate holder 6 Pressure bolt A engraved mark F50 7 Bar 4 Wedge holder wedge pin Connect both ends of the drive chain with the joint pin 8 inserted from th...

Page 234: ...6 further using the bar 7 to press the joint plate over the joint pins Continue pressing the joint plate until the distance between the two joint plates come to the specification Joint plate distance...

Page 235: ...the specified dimension Pin end diameter specification D Adjust the drive chain after connecting it 2 14 RK 5 45 5 85 mm After joining of the chain has been completed check to make sure that the link...

Page 236: ...MENT Remove the seat assembly 5 4 Remove the dampers Remove the front seat Adjust the position of bracket 1 A For low normal position B For high position Reinstall the front seat and set the position...

Page 237: ...mount the handlebars NOTE Place a rag on the fuel tank to prevent the fuel tank scratched Insert the spacers between the steering upper bracket and handlebar holders Tighten the handlebar holder nuts...

Page 238: ...CTION 6 11 GENERATOR 6 12 REMOVAL AND DISASSEMBLY 6 13 INSPECTION 6 15 GENERATOR REASSEMBLY AND REMOUNTING 6 18 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 6 20 STARTER SYSTEM DESCRIPTION...

Page 239: ...HEADLIGHT 6 41 BRAKE LIGHT TAILLIGHT AND LICENSE PLATE LIGHT 6 45 TURN SIGNAL LIGHTS 6 45 RELAYS 6 46 TURN SIGNAL SIDE STAND RELAY 6 46 STARTER RELAY 6 46 SWITCHES 6 47 IGNITION SWITCH REMOVAL AND IN...

Page 240: ...e coupler itself and do not pull the lead wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such...

Page 241: ...battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF batte...

Page 242: ...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 tester will be damaged After...

Page 243: ...YSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Ignition coil 5 Rear brake light switch 2 Ignition switch 6 Throttle position sensor 3 Handlebar switch RH 7 Signal generator 4 Front brake light switch 8 Oil...

Page 244: ...sition switch D Main fuse I Generator 0 Handlebar switch LH E Battery J Speed sensor A Fuse box F Ignitor K Speed sensor rotor B Turn signal side stand relay G Horn L Gear position switch C Starter re...

Page 245: ...h is mounted on the rotor The stator windings are assembled on the inside of a laminated core that forms part of the generator hous ing A rectifier bridge which is connected to the stator windings con...

Page 246: ...tor coil 6 16 Is the continuity of the stator coil and rotor coil OK Step 5 1 Inspect the slip rings and brushes 6 16 17 Is the slip rings and brushes OK Step 6 1 Inspect the rectifier and IC regulato...

Page 247: ...tep 7 1 Inspect wirings Is the wirings OK Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of generator lead wire coupler YES Faulty battery NO Short circuit of wire harness...

Page 248: ...NG OUTPUT Remove the seat 5 4 Remove the luggage box 5 4 Start the engine and keep it running at 5 000 r min with the dimmer switch turned HI position Measure the DC voltage between the and battery te...

Page 249: ...Rotor I Generator end cover 4 Oil seal B Bearing cover 2 A Generator driven gear nut 5 O ring C Slip ring side bearing B Generator mounting bolt 6 Spacer D Bearing cover 1 C Generator housing nut 7 G...

Page 250: ...and coupler 3 Remove the generator Hold the generator driven gear using a vise 4 and two pieces of wood 5 as shown Then remove the generator driven gear nut Remove the damper housing 6 using the spec...

Page 251: ...ng screws 0 Remove the rectifier A NOTE Straighten the stator coil lead wires using long nose pliers then remove the rectifier Remove the generator housing nuts Separate the generator housing B from t...

Page 252: ...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 253: ...stator Also check 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...

Page 254: ...P4 as described below If the voltage measured is excessively out of specification replace the rectifier 09900 25008 Multi circuit tester set Tester knob indication Diode test IC REGULATOR Measure the...

Page 255: ...he oil seal 99000 25010 SUZUKI SUPER GREASE A Apply a small quantity of THREAD LOCK 1342 to the bear ing retainer screws and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Bearing r...

Page 256: ...ified torque Generator housing nut 4 5 N m 0 45 kgf m Tighten the generator driven gear nut to the specified torque Generator driven gear nut 55 N m 5 5 kgf m NOTE After tightening the generator drive...

Page 257: ...N 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...

Page 258: ...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 259: ...starter relay OK Starter motor runs but does not crank the engine 1 The starter motor runs when the transmission is in neutral but does not run when the transmission is in any position other than neu...

Page 260: ...DISASSEMBLY Remove the starter motor Disassemble the starter motor as shown 1 O ring 5 Starter motor case 9 Brush spring 2 Housing end inside 6 Armature 0 Housing end outside 3 O ring 7 Brush 4 O rin...

Page 261: ...a saw blade ARMATURE COIL Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or the...

Page 262: ...MOLY PASTE Align the marks on the housing ends with the marks on the starter motor case Apply a small quantity of THREAD LOCK 1342 to the starter motor housing bolts 99000 32050 THREAD LOCK 1342 Appl...

Page 263: ...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 09900 25008 Multi circ...

Page 264: ...uit tester set Tester knob indication Continuity test SIDE STAND SWITCH Remove the frame cover LH 5 4 Disconnect the side stand switch coupler 1 and measure the voltage between Lg and B W lead wires 0...

Page 265: ...ere is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test DIODE INSPECTION Measure the voltage between th...

Page 266: ...nduces the secondary current in the igni tion 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 eng...

Page 267: ...sition Is the voltage OK Step 3 1 Measure the ignition coil primary peak voltage 6 32 NOTE This ignition coil primary peak voltage inspection method is applicable only with the multi circuit tester an...

Page 268: ...and its resistance 6 33 to 35 NOTE The signal generator peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resistance OK YES Faulty...

Page 269: ...not disconnect the ignition coil primary lead wire 09900 25008 Multi circuit tester set Shift the transmission into neutral turn the ignition switch to the ON position and grasp the clutch lever Press...

Page 270: ...esistance should be close to the specified values Ignition coil resistance Primary Approx 2 4 tap tap Secondary Approx 30 40 k spark plug cap spark plug cap 0 Tester knob indication Resistance SIGNAL...

Page 271: ...peak voltage on the signal gen erator coupler as follows Remove the frame cover LH 5 4 Disconnect the signal generator coupler 2 Connect the multi circuit tester with the peak voltage adaptor Bl termi...

Page 272: ...istance between the lead wires and ground If the resistance is not within the specified value the signal gen erator stator must be replaced Pickup coil resistance Approx 135 200 Bl Y Bl Ground 0 Teste...

Page 273: ...EMOVAL GSF650 Remove the headlight 6 41 Disconnect the couplers and remove the headlight housing 1 Remove the combination meter unit 2 GSF650S Remove the combination meter unit 5 5 DISASSEMBLY Disasse...

Page 274: ...elect Turn signal L 11 10 9 8 7 16 15 14 13 12 1 2 3 4 5 6 1 POWER SOURCE OF SPEED SENSOR 2 TACHOMETER 3 OIL 4 SPEED SENSOR SIGNAL 5 BATTERY 6 Blank 7 Blank 8 Lg TURN R 9 Blank 10 Blank 11 Bl B NEUTRA...

Page 275: ...This test will determine if the fuel level indicator is operating Remove the fuel tank mounting bolts Disconnect the fuel level gauge lead wire coupler 1 Connect a jumper wire A between the Y B and B...

Page 276: ...esistance is incorrect replace fuel level gauge with a new one The relation between the position of the fuel level gauge float and resistance is below 09900 25008 Multi circuit tester set 0 Tester kno...

Page 277: ...sensor with a new one NOTE While testing the highest voltage reading should be the same as the battery voltage 12 V OIL PRESSURE INDICATOR NOTE Before inspecting the oil pressure switch check if the e...

Page 278: ...bulb 2 12 V 5 W Headlight beam adjustment Adjust the headlight beam both horizontally and vertically A Horizontal adjuster B Vertical adjuster NOTE To adjust the headlight beam adjust the beam horizon...

Page 279: ...he socket cover 4 Remove the headlight bulb 5 by unhooking the bulb holder spring 6 Install the headlight assembly so that the hook A on the headlight bezel engages with B of the housing If you touch...

Page 280: ...xagon wrench as shown and adjust the Low and Hi headlight beam horizontally A Horizontal adjuster For both Low and Hi beam NOTE To adjust the headlight beam adjust the beam horizontally first then ver...

Page 281: ...emove the rubber boot 3 Remove the headlight bulb Low 4 by unhooking the bulb holder spring 5 Remove the headlight bulb Hi in the same way from under the cowling Reassemble the bulbs in the reverse or...

Page 282: ...12 V 21 W 4 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 Do not overtighten the lens fitting screws I...

Page 283: ...re removing the turn signal side stand relay check the operation of the turn signal light If the turn signal light does not illuminate inspect the bulb turn signal switch and circuit connection If the...

Page 284: ...ion switch using the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder GSF650S Disconnect the ignition switch coupler 1 Remove the ignition switch using the special tools 09930 11920 Tor...

Page 285: ...ON engine is stopped OFF engine is running WIRE COLOR B Black Lbl Light blue R Red Br Brown Lg Light green Y Yellow Gr Gray O Orange W White B Bl Black with Blue tracer O G Orange with Green tracer B...

Page 286: ...st be put on the level ground Remove the caps 3 from the electrolyte container NOTE After filling the electrolyte completely use the removed cap 3 as sealing caps of battery filler holes Do not remove...

Page 287: ...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 top cover For initial charging use the charger specially designed for MF...

Page 288: ...period B Stop charging Recharging time 0 9 A for 5 to 10 hours or 4 A for 1 hour After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester If the battery...

Page 289: ...PAIR AIR SUPPLY SYSTEM HOSE ROUTING 7 19 FRONT BRAKE HOSE ROUTING 7 20 REAR BRAKE HOSE ROUTING 7 21 IGNITION COIL INSTALLATION 7 22 SPARK PLUG CAP INSTALLATION 7 22 FUEL TANK SET UP 7 23 FRONT FOOTRE...

Page 290: ...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 291: ...r 2 Worn countershaft spline 3 Worn driveshaft spline 4 Worn or rubbing primary gear 5 Worn bearing Adjust Replace Replace Replace Replace Rebore or replace Clean Replace Replace Replace cam chain and...

Page 292: ...ow float chamber fuel level 10 Dirty air cleaner element 11 Clogged fuel hose resulting in inadequate fuel supply to carburetor Replace Replace Regap or replace Adjust Replace ignitor Replace Replace...

Page 293: ...1 Carbon build up on piston crown 2 Insufficient amount of engine oil 3 Defective oil pump 4 Clogged oil circuit 5 Float chamber fuel level too low 6 Air leakage from intake pipe 7 Incorrect engine oi...

Page 294: ...or damaged needle valve 2 Broken needle valve spring 3 Improperly working float 4 Foreign matter on the needle valve 5 Incorrect float chamber fuel level Replace Replace Adjust or replace Clean or rep...

Page 295: ...sible causes Remedy Brake power insufficient 1 Leakage of brake fluid 2 Worn brake pad 3 Oil on brake pad surface 4 Worn brake disc 5 Air in hydraulic system Repair or replace Replace Clean brake disc...

Page 296: ...not charge 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open generator coil 3 Shorted or punctured IC regulator or rectifier Repair replace or connect properly Replace...

Page 297: ...is too old 6 Dirty container top and sides Check generator IC regulator or rectifier circuit connections and make necessary adjust ment to obtain specified charg ing operation Replace battery and cor...

Page 298: ...O W W O W G B W G B W Y B B W Y B B W G B W G B W Y B B W Y B B W O G W B O G W B Y W Y W Y W Y W B B W B B B B B W B B B B W B B W B BRAKE LIGHT TAIL LIGHT 4 3 2 1 REAR TURN SIGNAL LIGHT R REAR TURN...

Page 299: ...W O W G B W G B W Y B B W Y B B W G B W G B W Y B B W Y B B W O G W B O G W B B B W B B B B B W B B B B W B B W B BRAKE LIGHT TAIL LIGHT 4 3 2 1 REAR TURN SIGNAL LIGHT R REAR TURN SIGNAL LIGHT L DIMM...

Page 300: ...tch Wiring harness Except E 02 19 Tube Under side Clamp Thermo switch Clutch cable Starter cable 2nd air hose Throttle cable Cut clamp tip Set the plug cap forward Set the plug cap forward Be careful...

Page 301: ...l LH 10 mm ICES label E 28 only Guide Ignition switch Handle switch LH 14 N m 1 4 kgf m 14 N m 1 4 kgf m Clamp Wiring harness Speed sensor Neutral switch Max 10 mm Clamp Cut clamp tip Signal generator...

Page 302: ...Speed sensor Clamp 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 Eng...

Page 303: ...utch cable behind the 1 carburetor and 2 carburetor Pass through the clutch cable right side PAIR valve Pass through the cluch cable inside of the hose Pass through the clutch cable behind the 1 carbu...

Page 304: ...cable left side of the pipe Clutch cable Starter cable Guide Guide Protector Left side only Pull the clutch cable backward about 20 mm after setting with lever Throttle cable assembling position 0 mm...

Page 305: ...SE ROUTING Strainer Air vent hose Air vent hose Vacuum hose Breather hose Apply heat sink 3 N m 0 3 kgf m For E 02 19 only Carburetor clamp position Right side Air cleaner side Left Right Engine side...

Page 306: ...7 18 SERVICING INFORMATION FUEL TANK DRAIN HOSE ROUTING Breather hose No 1 Drain hose Breather hose No 3 Breather hose No 2 Clamp Air cleaner drain hose...

Page 307: ...ing mark Matching mark 3 4 Matching mark Matching mark Insert firmly Set expansion side to the carburetor Pass through the air cleaner hose inside of the oil hose Pass through the air cleaner hose in...

Page 308: ...tighten the union bolt After the brake hose union touching to the stopper tighten the union bolt After positioning the clamp with the stopper tighten the bolt After positioning the clamp with the sto...

Page 309: ...hose union touching to the stopper tighten the union bolt Face the clamp backward Face the clamp forward After the brake hose union touching to the stopper tighten the union bolt White marking Insert...

Page 310: ...7 22 SERVICING INFORMATION IGNITION COIL INSTALLATION SPARK PLUG CAP INSTALLATION Frame 4 1 3 2 FWD FWD Plug cap Plug cap cover FWD FWD...

Page 311: ...SERVICING INFORMATION 7 23 FUEL TANK SET UP Apply adesive agent to the cushion rubber Be careful for assembling direction 4 4 N m 0 44 kgf m...

Page 312: ...7 24 SERVICING INFORMATION FRONT FOOTREST BRACKET SET UP MUFFLER MOUNTING Footrest bracket Washer Bolt Washer Frame Apply PERMATEX 1372 Muffler connector Chamfer 23 N m 2 3 kgf m 23 N m 2 3 kgf m...

Page 313: ...SERVICING INFORMATION 7 25 SIDE STAND SPRINGS CENTER STAND SPRINGS Side stand Spring 40 N m 4 0 kgf m Spring Center stand Spring...

Page 314: ...7 26 SERVICING INFORMATION EXTERIOR PARTS CONSTRUCTION 1 Cowling body 4 Lower panel 7 Frame 2 Wind screen 5 Upper panel 3 Cowling brace 6 Meter panel lid...

Page 315: ...SERVICING INFORMATION 7 27 FRAME COVER CUSHION SEAT LOCK CABLE ROUTING Cushion Cushion Screw Plate Seat lock cable Seat lock...

Page 316: ...7 28 SERVICING INFORMATION TAILLIGHT INSTALLAION REFLEX REFRECTOR INSTALLATION Seat tail cover Tail lamp 2 0 N m 0 2 kgf m Cusion Reflex refrector 1 8 N m 0 18 kgf m Rear fender...

Page 317: ...SERVICING INFORMATION 7 29 BATTERY PROTECTOR INSTALLATION Protector Protector Battery Protector 50 mm 50 mm...

Page 318: ...0 25 mm 09900 20508 Cylinder gauge set 1 100 mm 40 80 mm 09900 20602 Dial gauge 1 1 000 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900...

Page 319: ...re gauge attachment 09916 10911 Valve lapper set 09916 14510 Valve lifter 09916 14910 Valve lifter attach ment 09916 21111 Valve seat cutter set 09916 24311 Solid pilot N 100 5 0 09916 34570 Valve gui...

Page 320: ...set 09925 98221 Bearing remover 09930 10121 Spark plug wrench set 09930 11920 Torx bit 09930 11940 Bit holder 09930 30102 Sliding shaft 09930 33720 Rotor remover 09940 14911 Steering stem nut wrench 0...

Page 321: ...5 Conrod cap nut 35 3 5 Starter clutch mounting bolt 150 15 0 Signal generator rotor bolt 25 2 5 Crankcase bolt nut M 6 11 1 1 M 8 23 2 3 Main oil gallery plug 40 4 0 Oil pump mounting bolt 10 1 0 Oil...

Page 322: ...t 10 1 0 Front brake caliper mounting bolt 39 3 9 Brake hose union bolt front rear 23 2 3 Air bleeder valve front rear 8 0 8 Brake disc bolt front rear 23 2 3 Front footrest bolt 35 3 5 Front footrest...

Page 323: ...r to this chart Bolt Diameter A mm Conventional or 4 marked bolt 7 marked bolt N m kgf m N m kgf m 4 1 5 0 15 2 3 0 23 5 3 0 3 4 5 0 45 6 5 5 0 55 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45 4 5 85...

Page 324: ...ve stem end length IN EX 2 5 Valve seat width IN EX 0 9 1 1 Valve head radial runout IN EX 0 03 Valve spring free length IN EX INNER 35 0 OUTER 38 4 Valve spring tension IN EX INNER 5 6 6 6 kgf at len...

Page 325: ...Piston ring to piston ring groove clearance 1st 0 180 2nd 0 150 Piston ring groove width 1st 1 01 1 03 2nd 0 81 0 83 Oil 1 51 1 53 Piston ring thickness 1st 0 97 0 99 2nd 0 77 0 79 Piston pin bore 18...

Page 326: ...e claw width No 1 No 2 15 9 16 0 15 4 Clutch driven plate distortion 0 10 Clutch spring free length 47 5 ITEM STANDARD LIMIT Primary reduction ratio 1 744 75 43 Final reduction ratio 3 133 47 15 Gear...

Page 327: ...back Throttle cable play pulling cable 2 0 4 0 mm Starter enricher plunger cable play 0 5 1 0 mm ITEM SPECIFICATION E 28 P 37 Carburetor type KEIHIN CVR32 Bore size 32 5 I D No 38G1 38G0 Idle r min 1...

Page 328: ...ary tap tap Approx 2 4 Tester range 1 Secondary Spark plug cap Spark plug cap Approx 30 40 k Tester range 1 k Ignition coil primary peak voltage 140 V and more Generator Slip ring O D Limit 14 0 DENSO...

Page 329: ...ure indicator light LED ITEM STANDARD LIMIT Rear brake pedal height 60 Brake disc thickness Front 4 5 0 2 4 0 Rear 5 0 0 2 4 5 Brake disc runout 0 30 Master cylinder bore Front 15 870 15 913 Rear 14 0...

Page 330: ...oil level 108 GSF650 104 GSF650S Rear wheel travel 126 Swingarm pivot shaft runout 0 3 ITEM STANDARD LIMIT Cold inflation tire pressure Solo Dual riding Front 250 kPa 2 50 kgf cm2 Rear 250 kPa 2 50 k...

Page 331: ...appropriate cosolvents and corro sion inhibitor is permissible E 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recom mended The other countries Fuel tank capacity...

Page 332: ...Prepared by November 2004 Part No 99500 36150 01E Printed in Japan 340...

Page 333: ...Printed in Japan K5...

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