Suzuki GSX1200 1999 Service Manual Download Page 97

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3-62 ENGINE

• Coat SUZUKI BOND NO.1207B lightly to the mating surfaces

between upper and lower crankcases.

99000-31140: SUZUKI BOND NO. 1207B

Diaphragm spring holder

Diaphragm springs

• Install the dowel pins, a new gasket and clutch cover.
• Tighten the clutch cover bolts securely.

NOTE:
Fit the two gaskets to the clutch cover bolts

correctly as shown

in the figure.

Use only new gasket to prevent oil leakage.

NOTE:
When installing the oil pressure switch, apply SUZUKI BOND
NO.1207B to its thread lightly.

99000-31140: SUZUKI BOND NO. 1207B

Oil pressure switch: 14 N.m (1.4 kgf-m)

150 N.m (15.0 kgf-m)

Summary of Contents for GSX1200 1999

Page 1: ......

Page 2: ...injury to the mechanic and may render the motorcycle unsafe for the rider and passenger 2 3 4 5 6 7 GENERAL INFORMATION This manual has been prepared on the basis of the latest specifications at the...

Page 3: ...of each 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 s...

Page 4: ...SE A 99000 25010 Apply THREAD LOCK 1322 99000 32110 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 THRE...

Page 5: ...TIONS 1 2 SUZUKI GSX1200X 99 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 IDENTIFICA...

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: ...olts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside working out and to the speci fied tightening torque Whenever you remove oil seals gaskets pack...

Page 8: ...tification Number 1 is stamped on the right side of the steering head pipe The engine serial number 2 is located on the right side of the crankcase These num bers are required especially for registeri...

Page 9: ...h has been stored for a long period MULTIGRADE TEMP FRONT FORK OIL Use fork oil SS 08 10 or equivalent fork oil BREAK IN PROCEDURES During manufacture only the best possible materials are used and all...

Page 10: ...1 6 GENERAL INFORMATION INFORMATION LABELS 1 Noise label For E 34 2 Tire pressure label 3 Warning safety label 4 ID label Frame right side...

Page 11: ...mm Stroke 59 0 mm Compression ratio 9 5 1 Piston diplacement 1 157 cm3 Carburetor KEIHIN CVK32 four Air cleaner Non woven fabric element Starter system Electric starter Lubrication system Wet sump TRA...

Page 12: ...rized Ignition timing 7 B T D C at 1 200 r min Spark plug NGK JR8B Battery 12V 36 kC 10 Ah 10HR Generator Three phase A C Generator Main fuse 30A Fuse 15 15 15 10 10A Headlight 12V 60 55W Position lig...

Page 13: ...L INFORMATION 1 9 CODE COUNTRY or AREA E 04 France E 22 Germany E 25 Netherlands E 34 Italy Belgium E 21 Spain E 53 COUNTRY OR AREA CODES The following codes stand for the applicable country ies and a...

Page 14: ...RANCE 2 4 SPARK PLUG 2 5 EXHAUST PIPE BOLT AND MUFFLER BOLT 2 6 AIR CLEANER ELEMENT 2 7 ENGINE OIL AND OIL FILTER 2 8 FUEL HOSE 2 9 ENGINE IDLE SPEED 2 10 THROTTLE CABLE PLAY 2 10 CARBURETOR SYNCHRONI...

Page 15: ...ery 1 000 km Brake I I I I I Brake hose I I I I Replace every 4 years Brake fluid I I I I Replace every 2 years Tire I I I I Steering I I I Front fork I I Rear suspension I I Chassis bolt and nut T T...

Page 16: ...part 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 whenever the motorcycle has been operated und...

Page 17: ...23 mm NOTE The cam must be at positions A or B in order to check the valve clearance or to adjust valve clearance Clearance read ings should not be taken with the cam in any other position than these...

Page 18: ...ead cover groove and cam end caps 3 73 99000 31140 SUZUKI BOND NO 1207B Tighten the cylinder head cover bolts to the specified torque Cylinder head cover bolt 14 N m 1 4 kgf m Both the right and left...

Page 19: ...replace the plug if it has a broken insulator damaged thread etc Confirm the thread size and reach when replacing the plug If the reach is too short carbon will be deposited on the screw portion of t...

Page 20: ...tion at all times Life of the engine de pends largely on this component NOTE When cleaning the air cleaner element drain water from the air cleaner drain hose by removing the drain plug AIR CLEANER EL...

Page 21: ...ol Apply engine oil lightly to the gasket of the new oil filter before installation Install the new oil filter turning it by hand until you feel that the filter gasket contacts the mounting surface Th...

Page 22: ...ty Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about three minutes then check the oil level through the inspection window 2 If the level is...

Page 23: ...4 fully into the threads Second step Loosen the lock nut 5 of the throttle pulling cable 2 Turn the adjuster 6 in or out until the throttle cable play A should be 2 0 4 0 mm at the throttle grip Tigh...

Page 24: ...s for 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 st...

Page 25: ...set 20 30 mm CHECKING Loosen the axle nut 1 Tense the drive chain fully by turning both chain adjuster bolts 2 Count out 21 pins 20 pitches on the chain and measure the distance between the two points...

Page 26: ...more important they can damage the O rings or seals confining the grease in the bush to pin clearance Remember high durability comes from the presence of grease in that clearance After washing and dr...

Page 27: ...The brake system of this motorcycle is filled with a gly col based brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken fr...

Page 28: ...pedal 45 mm A below the top face of the footrest Retighten the lock nut 1 to secure the push rod 2 in the proper position Brake pedal height A A A A A 40 50 mm BRAKE LIGHT SWITCH Adjust the rear brake...

Page 29: ...from the air bleeder valve Squeeze and release the brake lever several times in rapid suc cession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of...

Page 30: ...DING TIRE PRESSURE kPa kgf cm2 kPa kgf cm2 FRONT 250 2 50 250 2 50 REAR 250 2 50 250 2 50 The standard tire fitted on this motorcycle is 120 70 ZR17 58W for front BRIDGESTONE BT 54F J and 170 60 ZR17...

Page 31: ...front fork assembly by supporting the machine so that the front wheel is off the ground with the wheel straight ahead grasp the lower fork tubes near the axle and pull forward If play is found perfor...

Page 32: ...p 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 Brake Clutch 7 5 0 75 B Brake...

Page 33: ...2 20 PERIODIC MAINTENANCE...

Page 34: ...ifference in compression pressure between any two cylinders is more than 200 kPa 2 kgf cm2 All compression pressure are below 1 000 kPa 10 kgf cm2 even when they measure more than 875 kPa 8 75 kgf cm2...

Page 35: ...which is too high viscosity Clogged oil passage way Combination of above items OIL PRESSURE TEST PROCEDURE Start the engine and check if the oil pressure indicator light is turned on If it keeps on li...

Page 36: ...GINE REINSTALLATION 3 8 ENGINE DISASSEMBLY 3 11 ENGINE COMPONENTS INSPECTION AND SERVICE 3 23 CYLINDER HEAD 3 23 VALVE 3 24 CAMSHAFT 3 33 CAM CHAIN TENSION ADJUSTER 3 35 CYLINDER 3 36 PISTON 3 37 PIST...

Page 37: ...and 63 Oil pressure switch 3 62 Clutch pressure drive and driven plates 3 15 16 60 and 61 Clutch sleeve hub 3 16 and 60 Oil pump driven gear 3 16 and 59 Generator oil pump drive gears 3 16 and 59 Pri...

Page 38: ...ove the seat and frame covers 5 2 and 3 Remove the fuel tank 4 3 Remove the document tray 1 Remove the battery NOTE First disconnect the battery lead wire then disconnect the bat tery lead wire Remove...

Page 39: ...or assembly by disconnecting the starter cable 3 and throttle cables 4 Disconnect all of the spark plug caps Disconnect the breather hose 5 Remove the cylinder head breather cover 6 by removing the bo...

Page 40: ...ing bolt Remove the engine sprocket cover by removing the bolts Do not operate the clutch lever to prevent clutch piston retainer damage Loosen the rear axle nut 5 and chain adjusters 6 to provide add...

Page 41: ...3 6 ENGINE Remove the oil cooler hose union bolts 1 Remove the oil cooler by removing the mounting bolts 2 Remove the eight exhaust pipe bolts Remove the muffler mounting bolts...

Page 42: ...to both the inside and outside of the exhaust pipe muffler connector EXHAUST GAS SEALER PERMATEX 1372 Exhaust muffler mounting bolt 29 N m 2 9 kgf m Remove the exhaust pipe gaskets 2 Be sure to face t...

Page 43: ...ide Install the brackets spacer bolts and nuts properly as shown in the following illustration NOTE The engine mounting nuts are self locking Once the nut has been removed it is no longer of any use B...

Page 44: ...n the illustration Replace the carburetor air vent hoses 1 and breather hose 2 to the exact positions 5 10 5 10 1 2 3 4 Carburetor clamp position Air cleaner side L H R H Carburetor clamp position Eng...

Page 45: ...ly by referring to the sections for wire routing cable routing and hose routing 7 11 through 24 Adjust the following items to the specification Page Throttle cable play 2 10 Idling adjustment 4 10 Car...

Page 46: ...r removing the spring holder bolt 3 and spring 4 remove the cam chain tension adjuster 5 by removing the mounting bolts 09911 73730 5 mm T type hexagon wrench Remove the cylinder head cover by removin...

Page 47: ...ne 6 mm bolt A and twelve 10 mm nuts are removed 09911 74510 Long socket 14 mm 09914 24510 T handle NOTE When loosening the cylinder head nuts loosen each nut little by little in a descending order ac...

Page 48: ...k with a plastic mallet to make the gasketed joint loose 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 to...

Page 49: ...ts Remove the signal generator rotor by removing the bolt 09900 00410 Hexagon wrench set Disconnect the oil pressure switch lead wire 1 Remove the grommet 2 Remove the signal generator stator by remov...

Page 50: ...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 51: ...clutch drive and driven plates along with the clutch 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 dise...

Page 52: ...en gear 2 do not lose the gearshift pawl 3 pin 4 and spring 5 Remove the oil pump driven gear by removing the circlip 6 09900 06107 Snap ring pliers NOTE Do not lose the circlip pin 7 and two washers...

Page 53: ...ause it is used in conjuction with the special tool Remove the starter clutch assembly from the crankshaft with the special tool 09930 30720 Rotor remover Flatten the lock portion of the oil seal reta...

Page 54: ...the upper crankcase tightening bolts and nut 09911 73730 5 mm T type hexagon wrench Remove the oil pan by removing the bolts Remove the shim 2 and O ring 3 Remove the oil sump filter 4 by removing the...

Page 55: ...it to the specified torque 09914 25811 6 mm T type hexagon wrench 09900 00410 Hexagon wrench set Main oil gallery plug A 40 N m 4 0 kgf m Remove the right oil pipe C Make sure that all bolts are remo...

Page 56: ...re located between shaft and case Remove the two dampers 1 and cam chain tensioner 2 Remove the O rings 3 and 4 Remove the countershaft assembly 5 and driveshaft assem bly 6 NOTE Do not lose the C rin...

Page 57: ...ity of THREAD LOCK 1342 to the bolt 99000 32050 THREAD LOCK 1342 Gearshift cam stopper bolt 10 N m 1 0 kgf m Remove the gearshift cam stopper 3 by removing the circlip 4 09900 06107 Snap ring pliers N...

Page 58: ...plug 2 to the specified torque Removal of valves completes ordinary disassem bling work If valve guides have to be removed for replacement after inspecting related parts carry out the steps shown in v...

Page 59: ...out If it measures more than the limit replace the valve 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm Valve head radial runout Service Limit 0 03 mm VALVE FACE...

Page 60: ...card the removed valve guide subassemblies Only oversized valve guides are available as replacement parts Part No 11116 06B70 Re finish the valve guide holes in cylinder head with the reamer and handl...

Page 61: ...be within the following specification Valve seat width W W W W W Standard 0 9 1 1 mm If either requirement is not met correct the seat by servicing is as follows VALVE SEAT SERVICING The valve seats 1...

Page 62: ...di tion 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 to the rocker arm for correct valve contact angle T...

Page 63: ...htly 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 high...

Page 64: ...em end length Service Limit 2 5 mm VALVE SPRING The force of the coil spring keeps the valve seat tight A weakened spring results in reduced engine power output and often accounts for the chattering n...

Page 65: ...000 12 018 mm 09900 20605 Dial calipers ROCKER ARM AND SHAFT ROCKER ARM SHAFT OUTSIDE DIAMETER INSPECTION On the sliding surface take two measurements at right angle to each other If the outside diame...

Page 66: ...lower seat with the spring retainer 3 For Exhaust side Insert the valves with their stems coated with mixed engine oil moly paste all around and along the full stem length without any break When inser...

Page 67: ...shaft set bolt 6 6 6 6 6 9 N m 0 9 kgf m Cylinder head plug 7 7 7 7 7 28 N m 2 8 kgf m Put on the valve spring retainer and using the valve lifter press down the springs fit the cotter halves to the...

Page 68: ...ake by the embossed letters EX for exhaust as against letters IN for intake Similarly the right end can be distinguished by the notch from the left end CAM WEAR Worn down cams are often the cause of m...

Page 69: ...N m 1 0 kgf m NOTE Do not rotate the camshafts with the plastigauge in place Remove the camshaft holders and read the width of the com pressed plastigauge with envelope scale This measurement should b...

Page 70: ...s shown in refer ence to the notch 1 in the right end of each camshaft REASSEMBLY Apply THREAD LOCK SUPER 1303 to the threads of cam sprocket bolts and tighten them to the following torque value 99000...

Page 71: ...traightedge and thickness gauge taking a clearance read ing at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder block 09900...

Page 72: ...surement is less than the limit re place the piston Piston diam Service Limit 78 880 mm 09900 20204 Micrometer 75 100 mm PISTON CYLINDER CLEARANCE As a result of the above measurement if the piston cl...

Page 73: ...ring Piston ring free end gap Service Limit 1st 8 0 mm 2nd 9 6 mm 09900 20102 Vernier calipers Piston ring end gap Service Limit 1st 0 5 mm 2nd 1 0 mm 09900 20803 Thickness gauge Oversize piston ring...

Page 74: ...00 20205 Micrometer 0 25 mm CONROD SMALL END I D Using a small bore gauge measure the conrod small end inside diameter 09900 20602 Dial gauge 1 1000 mm 1 mm 09900 22403 Small bore gauge 18 35 mm Conro...

Page 75: ...Initial tightening torque 25 N m 2 5 kgf m Final tightening torque 51 N m 5 1 kgf m 09900 22301 Plastigauge NOTE When fitting bearing cap to crank pin be sure to discriminate one end from the other n...

Page 76: ...de O D specification 1 37 992 38 000 mm 2 37 984 37 992 mm 3 37 976 37 984 mm 09900 20202 Micrometer 25 50 mm Bearing thickness Color Part No Thickness Green 1 480 1 484 mm 12164 46E01 0A0 Black 1 484...

Page 77: ...ement for smooth turning CRANKCASE CRANKSHAFT BEARING SELECTION Inspect each bearing of upper and lower crankcases for any damage Place the plastigauge on each crankshaft journal in the usual manner 0...

Page 78: ...crankcase journal I D code number 1 A or B which are stamped on the rear of upper crankcase Check the corresponding crankshaft journal O D code number 2 A B or C which are stamped on the crankshaft B...

Page 79: ...on the left side R Right side thrust bearing L Left side thrust bearing NOTE Push the crankshaft to the left side so that there is no clearance on the right side thrust bearing Crankshaft thrust clear...

Page 80: ...8 48B00 0E0 2 50 2 52 mm Yellow 2 44 2 46 mm 12228 48B00 0D0 2 52 2 54 mm Red 2 46 2 48 mm 12228 48B00 0C0 2 54 2 56 mm Brown 2 48 2 50 mm 12228 48B00 0B0 2 56 2 57 mm Pink 2 50 2 52 mm 0 04 0 07 mm 1...

Page 81: ...rive plate thickness Standard No 1 and No 2 drive plates 2 92 3 08 mm Measure the claw width of drive plates with a vernier calipers Replace the drive plates found to have worn down to the limit 09900...

Page 82: ...air to prevent piston damage INSPECTION Inspect the clutch cylinder bore wall for nicks scratches or other damage Inspect the oil seal for damage and wear Inspect the piston surface for any scratches...

Page 83: ...ssion gears as shown in the illustration 1 Low driven gear 2 4th driven gear 3 3rd driven gear 4 Top driven gear 5 2nd driven gear 6 Driveshaft 7 Countershaft Low drive gear 8 4th drive gear 9 3rd dri...

Page 84: ...hould be discarded a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip over the shaft After installing a...

Page 85: ...3 50 ENGINE...

Page 86: ...s of the shifting ac tion Gearshift fork Groove clearance Standard 0 10 0 30 mm Service Limit 0 50 mm Checking clearance Checking groove width Checking thickness If the clearance checked is noted to e...

Page 87: ...r a smooth movement The gear turns one direction only If a large resistance is felt to rotation inspect the starter clutch for damage or inspect the starter clutch contacting surface of the starter dr...

Page 88: ...ft cam stopper plate A align the pin groove B with the pin C as shown in the figure Install the gearshift cam related parts 1 Gearshift cam 2 Gearshift cam stopper 3 Circlip 4 Circlip 5 Spring Always...

Page 89: ...the oil jets 4 fitted on the lower crankcase for clogging Fit the bearing pins 5 and C rings 6 on the upper crankcase Install the countershaft assembly and driveshaft assembly on the upper crankcase N...

Page 90: ...9000 25140 SUZUKI MOLY PASTE Install the crankshaft with the cam chain to the upper crank case Insert the right and left thrust bearings 6 with oil grooved fac ing the crank web 3 45 Clean the mating...

Page 91: ...3 56 ENGINE BOND 1207B should be applied to the following locations The line of BOND...

Page 92: ...ied torque values Crankcase bolt Initial tightening Final tightening N m kgf m N m kgf m 6 mm bolt 6 0 6 13 1 3 8 mm bolt 13 1 3 22 2 2 NOTE Install the main oil gallery plug 3 20 Fit the engine groun...

Page 93: ...iner with two screws NOTE Apply a small quantity ofTHREAD LOCK 1342 to the two screws 99000 32050 THREAD LOCK 1342 Install each gearshift pawl 1 into the cam driven gear 2 The large shoulder A must fa...

Page 94: ...tershaft NOTE Flat surface of washer is positioned outside Install the generator oil pump drive gears 6 onto the primary driven gear 7 Install the primary driven gear assembly onto the countershaft an...

Page 95: ...e Diameter 101 mm 9 pcs B No 2 Drive Plate Inside Diameter 108 mm 1 pc DRIVEN PLATE Two kinds of the driven plate No 1 and No 2 are equipped in the clutch system they can be distin guished by the thic...

Page 96: ...lutch pressure plate holder Clutch sleeve hub nut 150 N m 15 0 kgf m Lock the clutch sleeve hub nut with a center punch Insert the clutch push rod 3 into the countershaft Install the clutch push piece...

Page 97: ...dowel pins a new gasket and clutch cover Tighten the clutch cover bolts securely NOTE Fit the two gaskets to the clutch cover bolts B correctly as shown in the figure Use only new gasket to prevent oi...

Page 98: ...rning nut and tighten the rotor bolt to the specified torque 09900 00410 Hexagon wrench set Signal generator rotor bolt 25 N m 2 5 kgf m Pass the signal generator lead wire through upper crankcase as...

Page 99: ...mounting bolt to the specified torque with the special tool Starter clutch mounting bolt 150 N m 15 0 kgf m 09920 34840 Starter clutch holder Install the starter idle gear 1 and its shaft 2 Coat SUZU...

Page 100: ...of ring face and the face of top ring is chrome plated where as that of ring is not Top and 2nd middle rings have letter N marked on the upper side NOTE Be sure to bring the marked side to top when fi...

Page 101: ...e Be sure to install the pistons in the cylinder from which they were removed in disassembly refer to the letter mark 1 through 4 scribed on the piston Have each piston pin moly paste oiled lightly be...

Page 102: ...the cylinder NOTE Be sure to identify the top surface UP mark 1 on the cylinder head gasket as shown in the Fig Replace the O rings and gasket with new ones to prevent oil leakage and gas leakage Fit...

Page 103: ...m chain guide 1 properly While holding down the cam chain rotate the crankshaft in normal direction to bring the T mark on the rotor to the center of pick up coil To turn over crankshaft torque nut wi...

Page 104: ...Turn over the exhaust camshaft so that the arrow points flush with the gasketed surface of the cylinder head Engage the cam chain with this sprocket The other arrow marked 2 is now pointing straight u...

Page 105: ...3 70 ENGINE 24th pin 1st pin...

Page 106: ...OTE Damage to head or camshaft journal holder thrust surfaces may result if the camshaft journal holders are not drawn down evenly Tighten the camshaft journal holder bolts to the specified torque Cam...

Page 107: ...he cam chain tension adjuster to the cylinder block with two bolts and tighten them to the specified torque Cam chain tension adjuster mounting bolt 7 N m 0 7 kgf m Insert the spring into the cam chai...

Page 108: ...thin coat of the engine oil to new gaskets Replace the gaskets with new ones to prevent oil leak age Head cover union bolt 1 1 1 1 1 16 N m 1 6 kgf m Place the eight gaskets to each position correctl...

Page 109: ...es identify the different intake pipes according to each I D code 1 03F2 for No 1 1 03F2 for No 2 3 03F2 for No 3 3 03F2 for No 4 Use a new O ring to prevent sucking air from the joint Install the oil...

Page 110: ...9 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 13 REMOVAL 4 14 DISASSEMBLY 4 15 CARBURETOR CLEANING 4 18 CARBUR...

Page 111: ...ws into the float chamber when the float of the carburetor has dropped and the needle valve is open When the needle valve closes the pressure of the fuel in the hose connecting the carburetor and the...

Page 112: ...ISM When voltage is applied between the fuel pump terminals cur rent flows into the solenoid coil which then pulls up the plunger together with the diaphragm allowing fuel to be drawn into the pump At...

Page 113: ...he ignitor lead wire couplers Disconnect the fuel hoses Remove the fuel pump by removing the two mounting bolts As gasoline leakage may occur in this operation keep away from fire and sparks INSPECTIO...

Page 114: ...ght illustration Battery to Brown white Battery to Black white Discharge amount More than 600 ml min If the measurement is less than the standard value replace the fuel pump with a new one Do not use...

Page 115: ...4 6 FUEL AND LUBRICATION SYSTEM FUEL VALVE REMOVAL Remove the fuel tank 4 3 Remove the fuel valve by removing the mounting bolts ON position RES position OFF position...

Page 116: ...ING Remount the fuel valve in the reverse order of removal FUEL LEVEL GAUGE REMOVAL Remove the fuel tank 4 3 Remove the fuel level gauge 3 Gasoline is very explosive Extreme care must be taken The gas...

Page 117: ...t A Float I Vacuum inlet cap P Starter enricher plate 4 Jet needle B Float pin J Throttle valve synchronizing Q Spring 5 Diaphragm piston valve C Pilot screw screw R Carburetor set plate 6 Needle jet...

Page 118: ...le valve Th V Pilot jet P J Pilot screw P S Throttle cable play pulling cable SPECIFICATION Float height Fuel level Starter enricher plunger cable play I D NO LOCATION Each carburetor has an I D Numbe...

Page 119: ...enturi 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...

Page 120: ...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 of the mixture is...

Page 121: ...ers 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 jet needle 7 and is...

Page 122: ...urs when the mixture is sprayed through the starter outlet port 6 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...

Page 123: ...s 1 Remove the left and right air cleaner box mounting bolts Loosen the respective carburetor clamp screws Slightly move the air cleaner box 2 backward Remove the lead wire clamp 3 Disconnect the thro...

Page 124: ...with component locations and the different fuel circuits and their routing through the carburetor Prior to disassembly mark with a paint or notch the ini tial position of the throttle sensor which is...

Page 125: ...carburetor assembly 09900 09004 Impact driver set Remove the top cap 3 Do not use compressed air on the carburetor body be fore removing the diaphragm this may damage the dia phragm Remove the spring...

Page 126: ...d pilot jet 7 Remove the pilot screw 8 with the spring washer and O ring Do not use a wire to clean the passages and jets NOTE Before removing the pilot screw 8 its setting must be determined Slowly t...

Page 127: ...ompressed air Clean all circuits of the carburetor thoroughly not just the perceived problem area Clean the circuits in the carburetor body with a spray type cleaner and allow each circuit to soak if...

Page 128: ...l not flow into the float 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 p...

Page 129: ...SCREW After cleaning reinstall the pilot screw to the original setting by turning the screw in until it lightly seats and then backing it out the same number of turns counted during disassembly Replac...

Page 130: ...sistance 3 09 4 63 k CARBURETOR ENGAGEMENT Position the throttle valve control lever A between the throttle valve synchronizing screw and spring as shown TROTTLE CABLE ADJUSTMENT MAJOR ADJUSTMENT NOTE...

Page 131: ...t the carburetor synchronization between the four carburetors as follows NOTE Remove the fuel tank and connect a remote fuel bottle to the fuel hose CARBURETOR CLAMP POSITIONING Locate the carburetor...

Page 132: ...e steel ball remains at the center line disconnect the hose from the vacuum inlet and connect the next hose to the vacuum inlet Turn the air screw for this tube until the steel ball 5 is at the center...

Page 133: ...engine and keep it running at 1 750 r min Observe the tachometer reading When the steel balls in tubes 1 and 4 are at the same level the carburetor is correctly adjusted After balancing the carbureto...

Page 134: ...FUEL AND LUBRICATION SYSTEM 4 25 ENGINE LUBRICATION SYSTEM CHART...

Page 135: ...4 26 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM...

Page 136: ...FUEL AND LUBRICATION SYSTEM 4 27 CYLINDER HEAD COOLING SYSTEM CHART...

Page 137: ...4 28 FUEL AND LUBRICATION SYSTEM CYLINDER HEAD COOLING SYSTEM...

Page 138: ...ENGINE OIL COOLING SYSTEM 10 N m 1 0 kgf m 1 Oil cooler ass y 2 Oil cooler cover 3 Oil cooler hose RH 4 Oil cooler hose LH 5 Oil cooler hose union bolt 6 Oil cooler mounting bolt 7 Oil cooler guard 2...

Page 139: ...EMBLY AND REMOUNTING 5 35 FINAL INSPECTION AND ADJUSTMENT 5 36 SUSPENSION SETTING 5 37 FRONT BRAKE 5 38 CONSTRUCTION 5 38 BRAKE PAD REPLACEMENT 5 39 BRAKE FLUID REPLACEMENT 5 39 BRAKE CALIPER REMOVAL...

Page 140: ...5 2 CHASSIS SEAT FRAME COVER AND SEAT TAIL COVER CONSTRUCTION 1 Seat 2 Passenger grab handle 3 Seat tail cover 4 Seat lock set REMOVAL SEAT Remove the seat with the ignition key...

Page 141: ...on the hooked parts hooked part SEAT TAIL COVER Remove the seat 5 2 Remove the passenger grab handle 1 Remove the seat tail cover mounting screws Disconnect the seat lock cable 2 Disconnect the brake...

Page 142: ...HEEL CONSTRUCTION ITEM N m kgf m A 100 10 0 B 23 2 3 C 23 2 3 1 Spacer 2 Collar 3 Brake disc R 4 Bearing 5 Spacer 6 Front wheel 7 Brake disc L 8 Speedometer gearbox A Front axle B Front axle pinch bol...

Page 143: ...3 9 kgf m 23 N m 2 3 kgf m 100 N m 10 0 kgf m 2 3 N m 2 3 kgf m Left bearing new Used bearing Bearing installer Left bearing new Used bearing Spacer Used bearing Bearing installer Right bearing new Cl...

Page 144: ...le 2 Raise the front wheel off the ground with a jack or wooden block Remove the front axle 3 spacer 4 collar 5 and front wheel Do not operate the brake lever during or after brake cali per removal NO...

Page 145: ...pect 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 there is anythi...

Page 146: ...32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m SPEEDOMETER GEARBOX Before installing the speedometer gearbox apply grease to the dust seal lip Align the drive lugs 1 with the recesses...

Page 147: ...htening the front axle and front axle pinch bolts move the front fork up and down four or five times BRAKE CALIPERS Tighten the brake caliper mounting bolts to the specified torque Brake caliper mount...

Page 148: ...rod 6 Rebound spring 7 Inner tube 8 Inner tube slide metal 9 Dust seal 0 Oil seal stopper ring A Oil seal B Oil seal retainer C Outer tube slide metal D Oil lock piece E Outer tube A Front fork cap bo...

Page 149: ...front fork upper and lower clamp bolts NOTE Slightly loosen the front fork cap bolt 1 to facilitate later disas sembly Remove the front fork cap bolt spacer 2 washer 3 and fork spring 4 Invert the fro...

Page 150: ...e 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 fork Remove the follo...

Page 151: ...and remount the front fork in the reverse order of removal and disassembly Pay attention to the following point SLIDE METALS AND OIL AND DUST SEALS Hold the inner tube vertically clean the metal groov...

Page 152: ...CK 1342 1 to the damper rod 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 Dam...

Page 153: ...ttom of the front fork When remounting the front fork align the upper surface of the inner tube with the upper surface of the steering stem upper bracket Tighten the front fork lower clamp bolts 1 fro...

Page 154: ...upper bearing 8 Steering stem lower bearing 9 Steering stem 0 Handlebars A Handlebar balancer A Steering stem head nut B Handlebar clamp bolt C Front fork upper clamp bolt D Front fork lower clamp bo...

Page 155: ...the lead wire couplers in the headlight housing Remove the headlight housing Remove the headlight housing holders 1 horns and turn sig nal lights Remove the speedometer cable 2 Remove the speedometer...

Page 156: ...ont brake master cylinder 3 along with brake hose and calipers Remove the right handlebar balancer 4 and the right handle bar switch box 5 Remove the left handlebar switch box and clutch lever positio...

Page 157: ...e steering stem upper bracket by removing the steer ing stem head nut 1 Remove the steering stem nut using the special tool 09940 14911 Steering stem nut wrench Remove the steering stem lower bracket...

Page 158: ...alities Handlebars distortion Race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of the steering stem Remove the steering stem lower bearing inner race using a chisel Th...

Page 159: ...ACES Press in the upper and lower outer races using the special tool 09941 34513 Steering outer race installer BEARINGS Press in the lower bearing using the special tool 09941 74911 Steering bearing i...

Page 160: ...g stem nut 1 4 1 2 of a turn A NOTE This adjustment will vary from motorcycle to motorcycle Set the dust seal Tighten the steering stem nut to the specified torque using the special tool 09940 14911 S...

Page 161: ...ont brake master cylinder 5 45 2 Punch mark FRONT FORK When remount the front fork align the upper surface of the in ner tube with the upper surface of the steering stem upper bracket Tighten the fron...

Page 162: ...ocedure on the other end of the handle bars 09940 92720 Spring scale Initial force 200 500 grams If the initial force reading is out of specification adjust the steer ing tension as follows 1 First lo...

Page 163: ...r bracket 4 Collar 5 Dust seal R 6 Bearing R 7 Rear wheel 8 Spacer 9 Bearing L 0 Cushion A Retainer B Rear sprocket mounting drum C Rear sprocket D Bearing E Dust seal L F Spacer A Brake disc bolt B R...

Page 164: ...5 26 CHASSIS 100 N m 10 0 kgf m 23 N m 2 3 kgf m Bearing installer Spacer Left Right Clearance 26 N m 2 6 kgf m Left Right 50 N m 5 0 kgf m Left Right...

Page 165: ...r Remove the rear wheel Do not operate the brake pedal during or after rear wheel removal Draw out the rear sprocket mounting drum from the rear wheel NOTE Before removing the rear sprocket mounting d...

Page 166: ...ything unusual Remove the rear sprocket mounting drum dust seal 1 and rear wheel dust seal 2 09913 50121 Oil seal remover REAR AXLE Measure the rear axle runout using the dial gauge If the runout exce...

Page 167: ...d disassembly Pay attention to the following points WHEEL BEARING AND DUST SEAL Apply grease to the bearings before installation 99000 25010 SUZUKI SUPER GREASE A Install the wheel bearings using the...

Page 168: ...sure that the brake disc is clean and free of any grease 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m REAR AXLE Adjust the drive chain slack after installing the rear wheel 2 1...

Page 169: ...case 4 Rear torque link 5 Dust seal 6 Spacer 7 Bearing 8 Swingarm 9 Spacer 0 Chain buffer A Pivot shaft A Rear shock absorber upper mounting bolt B Rear shock absorber lower mounting nut C Rear torque...

Page 170: ...5 32 CHASSIS 23 N m 2 3 kgf m 23 N m 2 3 kgf m Frame 35 N m 3 5 kgf m Rear shock absorber Swingarm 100 N m 10 0 kgf m Pivot shaft...

Page 171: ...lts Remove the drive chain case 2 Remove the rear torque link 3 Remove the brake hose from the brake hose guide and hose clamps by removing the brake hose union bolt Handle brake fluid with care the f...

Page 172: ...for wear and damage If any defects are found replace the chain buffer with a new one SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings move the spacer up and down and check for any...

Page 173: ...ARM NEEDLE BEARINGS Before installing the needle bearings install the center spacer Press the needle bearing into the swingarm pivot using the spe cial tool 09941 34513 Steering race installer NOTE In...

Page 174: ...lower mounting nut 2 to the specified torque Rear shock absorber upper mounting bolt 1 23 N m 2 3 kgf m Rear shock absorber lower mounting nut 2 35 N m 3 5 kgf m FINAL INSPECTION AND ADJUSTMENT After...

Page 175: ...USTMENT Position 1 provides the softest compression damping force Position 4 provides the stiffest compression damping force STD position 1 NOTE If the damping force adjuster position is incorrect wit...

Page 176: ...cone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which has been stored for...

Page 177: ...lace the motorcycle on a level surface and keep the handle bars straight Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with...

Page 178: ...ning and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Remove the brake pads by removing the clips 1 pad mounting pins 2 and spring Do not separate the ca...

Page 179: ...EASSEMBLY AND REMOUNTING Reassemble the caliper in the reverse order of disassembly pro cedures and observe the following points Wash the caliper components with fresh brake fluid before reassembly Do...

Page 180: ...sembling the brake caliper 2 16 BRAKE DISC INSPECTION Check the brake disc for damage or cracks Measure the thick ness using the micrometer Replace the brake disc if the thickness is less than the ser...

Page 181: ...ke fluid 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...

Page 182: ...pring 1 Circlip 2 Dust boot 3 Secondary cap 4 Piston 5 Primary cup 6 Spring MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or other dam age PISTON Inspec...

Page 183: ...ng sol 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 install...

Page 184: ...5 46 CHASSIS Tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m Bleed air from the brake system after reassembling the master cylinder 2 16...

Page 185: ...ing 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 brake fluid wi...

Page 186: ...per formance 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 replacing the brake pads pump the brake...

Page 187: ...caliper mounting bolts 2 and nut 3 NOTE Slightly loosen the brake caliper housing bolts 4 to facilitate later disassembly before removing the brake caliper mounting bolts Remove the brake pads 5 48 R...

Page 188: ...ing the components use the specified brake fluid Never use different types of fluid or cleaning sol vents such as gasoline kerosine etc Replace the piston seals and dust seals with new ones Apply brak...

Page 189: ...brake hose union bolt on the mas ter cylinder to catch any spilt brake fluid Remove the brake hose union bolt 4 and disconnect the brake hose Loosen the locknut 5 Remove the master cylinder along with...

Page 190: ...assembly Pay attention to the following points Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the com ponents When washing the...

Page 191: ...er cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the clutch hose from the master cylinder Completely wipe off any brake fluid adhering to any parts of motorcycle...

Page 192: ...epth Service Limit Front 1 6 mm Rear 2 0 mm Ply separation Tread separation Tread wear is extraordinarily deformed or distrib uted around the tire Scratches at the bead Cord is cut Damage from skiddin...

Page 193: ...t with a new one if the seal 2 is abnormally deformed or worn VALVE INSTALLATION Clean any dust or rust which is around the valve hole 1 and then install the valve in the rim NOTE To properly install...

Page 194: ...eel thereby facilitating air inflation Pump up the tire with air Do not inflate the tire to more than 400 kPa 4 0 kgf cm2 If inflated beyond this limit the tire can burst and possibly cause injury Do...

Page 195: ...NITION INTERLOCK SYSTEM DESCRIPTION 6 17 TROUBLESHOOTING 6 19 STARTER MOTOR REMOVAL AND DISASSEMBLY 6 20 STARTER MOTOR INSPECTION 6 20 STARTER MOTOR REASSEMBLY 6 21 STARTER RELAY INSPECTION 6 22 SIDE...

Page 196: ...h terminal for corrosion and contamination CLAMPS Refer to WIRE CABLE AND HOSE ROUTING 7 11 to 7 18 for proper clamping procedures Bend the clamp properly as shown in the illustration When clamping th...

Page 197: ...isconnect the battery _ lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first If the terminal is corroded remove the battery pour warm wa ter over it an...

Page 198: ...Starter relay 3 Ignition coil 4 Front brake light switch 5 Handlebar switch R 6 Ignition switch 7 Ignitor 8 Rear brake light switch 9 Throttle position sensor 0 Signal generator A Oil pressure switch...

Page 199: ...M 6 5 B Clutch lever position switch C Handlebar switch L D Fuel level gauge E Ignition coil F Battery G Horn H Starter motor I Generator J Neutral switch K Side stand switch L Fuse box M Turn signal...

Page 200: ...through the two slip rings to the rotor coil which is mounted on the rotor The stator windings are assembled on the inside of a laminated core that forms part of the generator housing A rectifier bri...

Page 201: ...terminals Correct Faulty battery 6 8 Abnormal driving condition Incorrect Measure the continuity of the stator coil and rotor coil No continuity Faulty stator coil or 6 12 disconnected lead wires Cont...

Page 202: ...itch to the ON position 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 t...

Page 203: ...e clamps Disconnect the starter motor lead wire 1 Disconnect the generator lead wire 2 and coupler 3 Remove the generator by removing the mounting bolts Hold the generator driven gear using a vise 4 a...

Page 204: ...earing remover Remove the generator end cover Remove the brush holder 2 and IC regulator 3 Remove the stator coil lead wire s mounting screws Remove the rectifier 4 NOTE Straighten the stator coil lea...

Page 205: ...generator end housing 2 using a hand press 4 as shown Remove the bearing retainer 5 Remove the bearing 6 washer 7 and spacer 8 Remove the oil seal 9 GENERTOR INSPECTION ROTOR BEARINGS Inspect the roto...

Page 206: ...to the damper surface 99000 25140 SUZUKI MOLY PASTE STATER COIL CONTINUITY CHECK Measure the continuity between the lead wires of the stator coil using a tester If there is no continuity replace the...

Page 207: ...nd the other termi nals P1 P2 P3 and P4 Put the tester lead on the terminal 1 and the other lead to P1 P2 P3 and P4 terminals Observe the reading and then switch the leads Perform other side tests amo...

Page 208: ...aced with a new one Apply grease to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A Apply a small quantity of THREAD LOCK 1342 to the bearing retainer screws and tighten them to the specifie...

Page 209: ...n gear nut to the specified torque Generator driven gear nut 60 N m 6 0 kgf m NOTE After tightening the generator driven gear nut to the specified torque stake the nut using a punch When installing th...

Page 210: ...d 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 housing F Rectifier G IC regulator H Brush holder I Generator end cover A Ge...

Page 211: ...ay causing the contact points to close thus completing the circuit from the starter motor to the battery The starter motor draws about 80 amperes to start the engine SIDE STAND IGNITION INTERLOCK SYST...

Page 212: ...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 213: ...re starter relay connectors between B Y No voltage Faulty ignition switch and B W _ when the starter button is Faulty engine stop switch pushed Faulty clutch lever position switch Faulty neutral switc...

Page 214: ...move the generator 6 9 Disconnect the starter motor lead wire and remove the starter motor by removing the mounting bolts Disassemble the starter motor as shown in the illustration STARTER MOTOR INSPE...

Page 215: ...each segment and the armature shaft If there is no continuity between the segments or there is continu ity between the segments and shaft replace the armature with a new one OIL SEAL INSPECTION Check...

Page 216: ...small quantity of THREAD LOCK 1342 to the starter motor housing bolts 99000 32050 THREAD LOCK 1342 STARTER RELAY INSPECTION Remove the seat 5 2 Remove the document tray 1 Remove right frame cover 5 3...

Page 217: ...INSPECTION If the interlock system does not operate properly check each component If any abnormality is found replace the component with a new one NEUTRAL SWITCH The neutral position indicator switch...

Page 218: ...o not connecting the tester probes TURN SIGNAL SIDE STAND RELAY The turn signal relay is corporated with the side stand relay and diode to form the one component part which is called the turn signal s...

Page 219: ...measure the voltage between the termi nals in the following table Unit V 09900 25008 Multi circuit tester set Tester knob indication Diode test NOTE If the tester read under 1 4 V replace the battery...

Page 220: ...the ignition coil output circuit which is connected to the primary windings of the ignition coils which is turned off and on accordingly Thus it induces the secondary current in the ignition coil s s...

Page 221: ...Faulty engine stop switch Correct Broken wire harness or poor connection of related circuit couplers Measure the ignition coil primary peak voltage 6 28 Inspect the spark plugs NOTE The ignition coil...

Page 222: ...terminal Ground Probe _ Probe 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 approp...

Page 223: ...wire Tester knob indication 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 CO...

Page 224: ...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 the s...

Page 225: ...itor coupler is out of specification the wire har ness must be replaced If both peak voltages are out of specifica tion the signal generator must be replaced and re checked SIGNAL GENERATOR Remove the...

Page 226: ...5 16 Disassemble the combination meter as follows INSPECTION Measure the continuity between the lead wires in the diagram on the next page using a tester If there is no continuity replace the respect...

Page 227: ...ER TACHOMETER TURN SIGNAL L NEUTRAL HIGH BEAM TURN SIGNAL R Y HIGH BEAM O G IGNITION NEUTRAL OIL FUEL FUEL METER B R TACHOMETER SIGNAL W FUEL METER Gr ILLUMINATION Bl B NEUTRAL G Y OIL B TURN SIGNAL L...

Page 228: ...lead wires The fuel meter is operating correctly if the needle moves to E empty when the ignition switch is turned on Replace the 90 100 ohm resistor with a 4 10 ohm resistor The fuel meter is operat...

Page 229: ...ad wire from the oil pressure switch Turn the ignition switch on Check if the oil pressure indicator lights up when grounding the Green Yellow lead wire If the oil pressure indicator does not light up...

Page 230: ...ulb failure LAMPS HEADLIGHT BULB REPLACEMENT Remove the headlight 5 16 Disconnect the socket 1 and remove the rubber cap 2 Headlight bulb 12V 60 55W Position light bulb 12V 5W NOTE Adjust the headligh...

Page 231: ...the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure TURN SIGNAL LIGHTS Turn signal light bulb 12V 21W Do not overtighten the lens fitting screws If you touch...

Page 232: ...r Remove the seat 5 2 Remove the left frame cover 5 3 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 light...

Page 233: ...OTE Before inspecting the oil pressure switch check if the engine oil level is at the proper level 2 8 WIRE COLOR B Black Lbl Light blue R Red Br Brown Lg Light green Y Yellow Gr Gray O Orange W White...

Page 234: ...ith electrolyte use the caps 3 from the electrolyte container to seal the battery filler holes Insert the nozzles of the electrolyte container 5 into the battery s electrolyte filler holes Hold the el...

Page 235: ...onventional battery Only use the specified MF battery Do not remove the caps once they are installed in the battery Measure the battery voltage with a tester The tester should indicate more than 12 5...

Page 236: ...reful not to permit the charging 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 the...

Page 237: ...TING 7 16 REAR BRAKE HOSE ROUTING 7 17 CLUTCH HOSE ROUTING 7 18 BRAKE PEDAL 7 19 SIDE STAND SPRING 7 20 CENTER STAND SPRING 7 20 FUEL LEVEL GAUGE WIRE ROUTING FUEL TANK PROTECTION SHEET 7 21 FUEL TANK...

Page 238: ...ap Replace 3 Fouled spark plug Clean or replace 4 Wet spark plug Clean and dry or replace 5 Defective ignition coil Replace 6 Open or short in high tension cord Replace 7 Defective signal generator Re...

Page 239: ...place primary driven gear Noise seems to come from the crankshaft 1 Rattling bearing Replace 2 Worn or burnt crank pin bearing Replace 3 Worn or burnt journal bearing Replace 4 Excessive thrust cleara...

Page 240: ...ition coil Replace 7 Defective signal generator Replace 8 Defective ignitor Replace 9 Low float chamber fuel level Adjust float height 10 Dirty air cleaner element Clean or replace 11 Clogged fuel hos...

Page 241: ...ter enricher plunger Adjust Idling or low speed 1 Clogged or loose pilot jet Clean or tighten trouble 2 Clogged or loose pilot air jet Clean or tighten 3 Air leaking from carburetor joint vacuum pipe...

Page 242: ...nd add Front suspension 1 Excessively viscous fork oil Replace too stiff 2 Excessive fork oil Check level and drain Front suspension 1 Insuffcient fork oil Check level and add too noisy 2 Loose front...

Page 243: ...Damaged wheel bearing Replace 4 Worn brake pad Replace 5 Foreign material in brake fluid Change brake fluid 6 Clogged return port of master cylinder Disassemble and clean master cylinder 7 Loose fron...

Page 244: ...not 1 Open or short in lead wires or loose lead Repair replace or charge connections connect properly 2 Shorted grounded or open generator coil Replace 3 Shorted or punctured IC regulator or rectifie...

Page 245: ...h of their active Replace battery and material as a result of overcharging correct charging system 3 Internally shorted battery Replace battery 4 Excessively low battery voltage Recharge 5 Battery is...

Page 246: ...7 10 SERVICING INFORMATION WIRING DIAGRAM...

Page 247: ...HOSE ROUTING WIRE HARNESS ROUTING Clamp Clamp Battery Wire mounted clamp Starter relay Clamp Ignition coils Clamp Wire mounted clamp Battery terminal Starter relay To fuel level gauge Clamp TPS Batter...

Page 248: ...h Side stand switch Clamp Pass the side stand switch lead wire between the crankcase and sprocket cover after installing the sprocket cover Clamp Clamp Generator 30 Turn signal side stand relay Fuse b...

Page 249: ...ON 7 13 Side stand switch lead wire Starter motor lead wire Signal generator lead wire Engine oil hose Generator Clamp Neutral switch lead wire Clamp Engine ground wire Generator lead wire Front Breat...

Page 250: ...hose The starter cable must be passed over the throttle cables and clutch hose Throttle cable No 1 Throttle cable No 2 Brake hose The throttle cables must be passed in front of the brake hose The star...

Page 251: ...SERVICING INFORMATION 7 15 FUEL HOSE ROUTING Backward Fuel pump Clamp Fuel valve Topward Downward...

Page 252: ...cables The throttle cables must be passed in front of the brake hose 30 14 Brake hose No 2 RH 21 21 Brake hose No 2 LH Front 5 49 Clamp the brake hose firmly After touching the brake hose union to th...

Page 253: ...de White mark 25 Stopper Master cylinder After touching the brake hose union to the stopper tighten the union bolt to the speci fied torque Brake caliper Stopper After touching the brake hose union to...

Page 254: ...Clamp Wiring harness Wire harness guide Pass through the clutch hose under the wiring harness Clamp Pass through the clutch hose out side of the wiring harness and fas ten the clutch hose along with...

Page 255: ...SERVICING INFORMATION 7 19 BRAKE PEDAL Front Front Front 40 50 mm Align the punch mark on the shaft with the slot on the brake pedal...

Page 256: ...7 20 SERVICING INFORMATION SIDE STAND SPRING CENTER STAND SPRING Inner spring Outer spring 40 155 71 50 65 154 Side stand Spring 1 Spring 2 Unit mm...

Page 257: ...ORMATION 7 21 FUEL LEVEL GAUGE WIRE ROUTING FUEL TANK PROTECTION SHEET Fuel tank protection sheet 40 mm Clamp 40 mm Clamp 40 mm Fuel level gauge 60 mm 50 mm Fuel valve Fuel level gauge lead wire pro t...

Page 258: ...REATHER HOSE ROUTING Do not bend the hoses Wiring harness Clamp Wiring harness Battery lead wire 10 20 mm Clamp Do not bend the hose with a clamp Water drain hose 3 way connector Battery lead wire Fue...

Page 259: ...TANK UNDER COVER Fuel tank under cover Speedometer cable Clamp Horn Clamp Frame center Frame Fuel tank under cover Clamp SPEEDOMETER CABLE ROUTING Pass through the speedometer cable behind of the bra...

Page 260: ...OLT INSTALLATION Washer Rear top Washer Spacer 27 mm 85 N m 8 5 kgf m Bushing Front top 5 N m 5 5 kgf m 55 N m 5 5 kgf m Bushing Center bottom Nut Bushing 55 N m 5 5 kgf m Nut Bushing Rear bottom Wash...

Page 261: ...SERVICING INFORMATION 7 25 SEAT TAIL COVER INSTALLATION...

Page 262: ...08 Cylinder gauge set 1 100 mm 40 80 mm 09900 20202 Micrometer 1 100 mm 25 50 mm 09900 20606 Dial gauge 1 100 mm 10 mm 09900 20803 Thickness gauge 09900 20701 Magnetic stand 09900 20602 Dial gauge 1 1...

Page 263: ...5 64510 Compression gauge 09915 63210 Adapor See page 3 26 Valve seat cutter head N 121 122 09913 60910 Bearing remover 09913 61510 Bearing remover 09914 24510 T handle 09916 34580 Valve guide reamer...

Page 264: ...seal installer 09943 74111 Fork oil level gauge 09924 84510 Bearing installer set 09930 11920 Torx bit 09930 11940 Bit holder 09940 14911 Steering stem nut wrench 09941 34513 Steering outer race inst...

Page 265: ...g bolt 7 0 7 Cam chain tensioner spring holder bolt 35 3 5 Conrod cap nut 51 5 1 Starter clutch mounting bolt 150 15 0 Sigal generator rotor bolt 25 2 5 Crankcase bolt nut M 6 11 1 1 M 8 23 2 3 Main o...

Page 266: ...ster cylinder mounting bolt 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 7 5 0 75 Brake disc bolt front rear 23 2 3 Front footre...

Page 267: ...o this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt A A A A A mm 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...

Page 268: ...2 35 IN EX 0 032 0 066 0 150 IN EX 22 012 22 025 IN 0 10 0 15 Camshaft journal oil clearance Camshaft journal holder I D Valve head thickness IN EX Valve guide I D 5 000 5 012 0 35 IN EX Valve stem de...

Page 269: ...de Right side CLUTCH Unit mm 1st 2nd 0 20 0 35 0 35 0 50 Piston ring end gap 1 0 0 5 1st 2nd Piston ring to groove clearance 0 180 0 150 1st 2nd 1 01 1 03 1 01 1 03 Piston ring groove width Oil 1st 2...

Page 270: ...o 3 5 0 5 1 4 8 4 9 ITEM SPECIFICATION Carburetor type I D No Idle r min Float height Main jet M J Bore size Jet needle J N Needle jet N J Throttle valve Th V Pilot jet P J Pilot screw P S Throttle ca...

Page 271: ...light Tachometer light Turn signal indicator light High beam indicator light Neutral indicator light Oil pressure indicator light Fuel meter light Speedometer light 55 5 21 5 21 4 1 7 1 7 1 7 1 7 2 1...

Page 272: ...ngine oil capacity 3 300 ml Change 3 500 ml Filter change 4 600 ml Overhaul Front fork oil type Fork oil SS8 10 or equivalent Front fork oil capacity each leg 582 ml Brake fluid type DOT 4 reserve SUS...

Page 273: ...SERVICING INFORMATION 7 37...

Page 274: ......

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Suzuki GSX1200 1999, Service Manual

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