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Suzuki GSX650F, Supplementary Service Manual

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Suzuki GSX650F Supplementary Service Manual Download Page 26

9-ii Table of Contents

Horn Inspection ................................................... 9C-*
Horn Removal and Installation ............................ 9C-*

Combination Meter Components 

(GSX650FK8) ...................................................9C-2

Combination Meter Removal and Installation 

(GSX650FK8) ...................................................9C-2

Combination Meter Disassembly and 

Assembly (GSX650FK8) ...................................9C-3

Combination Meter Inspection (GSX650FK8).....9C-3
Engine Coolant Temperature Indicator Light 

Inspection (GSX650FK8) ..................................9C-4

Oil Pressure Indicator Inspection 

(GSX650FK8) ...................................................9C-5

Horn Inspection (GSX650FK8) ...........................9C-5
Horn Removal and Installation (GSX650FK8) ....9C-5

Specifications.......................................................9C-6

Service Data........................................................ 9C-*

Service Data (GSX650FK8) ................................9C-6

Tightening Torque Specifications........................ 9C-*

Special Tools and Equipment ............................. 9C-*

Special Tool ........................................................ 9C-*

Exterior Parts........................................... 9D-1

Schematic and Routing Diagram........................ 9D-*

Seat Lock Cable Routing Diagram...................... 9D-*

Repair Instructions ..............................................9D-1

Exterior Parts Construction ................................. 9D-*
Frame head cover construction........................... 9D-*
Front Fender Construction .................................. 9D-*
Frame Cover Cushion Construction.................... 9D-*
Engine Sprocket Outer Cover Cushion ............... 9D-*
Fastener Removal and Installation...................... 9D-*

Exterior Parts Removal and Installation .............. 9D-*
Seat Height Adjustment ...................................... 9D-*

Cowling Construction (GSX650FK8)...................9D-1
Under Cowl Construction (GSX650FK8).............9D-2
Under Cowl Bracket Cushion Attachment 

(GSX650FK8)....................................................9D-2

Under Cowl Protector Cushion Attachment 

(GSX650FK8)....................................................9D-3

Upper Panel Cushion Attachment 

(GSX650FK8)....................................................9D-3

Windscreen Cushion Attachment 

(GSX650FK8)....................................................9D-4

Intake Net Cover Construction Attachment 

(GSX650FK8)....................................................9D-4

Exterior Parts Removal and Installation 

(GSX650FK8)....................................................9D-5

Body Structure.......................................... 9E-*

Repair Instructions .............................................. 9E-*

Body Frame Construction ................................... 9E-*
Engine Mounting Bracket Bushing 

Replacement ..................................................... 9E-*

Engine Mount Bushing Replacement.................. 9E-*
Front Footrest Bracket Construction ................... 9E-*
Side-stand Construction...................................... 9E-*
Side-stand Removal and Installation................... 9E-*
Center Stand Construction.................................. 9E-*
Center Stand Removal and Installation............... 9E-*

Specifications ....................................................... 9E-*

Tightening Torque Specifications........................ 9E-*

Special Tools and Equipment ............................. 9E-*

Recommended Service Material ......................... 9E-*

Summary of Contents for GSX650F

Page 1: ...GSX650F USE THIS MANUAL WITH GSF650 S SERVICE MANUAL 99500 36170 01E 9 9 5 0 1 3 6 1 8 0 0 1 E ...

Page 2: ...tomers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2007 Manual Name Manual No GSF650 S SERVICE MANUAL 99500 36170 01E This manual has been prepared on the basis of the latest specifications at the time of publication If modifi cations have been made since then differences may exist between the content of this manual and the actual motorcycle Illustrations in this manual are use...

Page 3: ...ension 2B Rear Suspension 2C Wheels and Tires 2D Driveline Axle 3 Precautions 3 Drive Chain Drive Train Drive Shaft 3A Brake 4 Precautions 4 Brake Control System and Diagnosis 4A Front Brakes 4B Rear Brakes 4C ABS 4E Transmission Transaxle 5 Precautions 5 Manual Transmission 5B Clutch 5C Steering 6 i Precautions 6 Steering General Diagnosis 6A Steering Handlebar 6B 1 Body and Accessories 9 i Preca...

Page 4: ......

Page 5: ...rt GSX650FK8 0B 1 Lubrication Points GSX650FK8 0B 2 Repair Instructions 0B Air Cleaner Element Replacement 0B Air Cleaner Element Inspection and Cleaning 0B Exhaust Pipe Bolt and Muffler Bolt Inspection 0B Spark Plug Replacement 0B Spark Plug Inspection and Cleaning 0B Valve Clearance Inspection and Adjustment 0B Fuel Line Inspection 0B Engine Oil and Filter Replacement 0B Throttle Cable Play Insp...

Page 6: ...he following codes stand for the applicable country ies and area s Code Country or Area Effective Frame No GSX650F K8 E 02 U K JS1CJ135200100001 GSX650F K8 E 03 U S A Except for California JS1GP74A 82100001 GSX650F K8 E 19 E U JS1CJ135100100001 GSX650F K8 E 24 Australia JS1CJ135300100001 GSX650F K8 E 28 Canada JS1GP74A 82100001 GSX650F K8 E 33 California U S A JS1GP74A 82100001 GSX650F K8 P 37 Bra...

Page 7: ...label For E 02 24 5 Manual notice label For E 03 33 6 Screen label For E 02 03 19 24 28 33 For E 19 7 Screen label For E 28 8 Warning steering label For E 02 03 19 24 28 33 For E 19 9 Tire information label For E 02 03 19 24 28 33 For E 19 10 General warning label For E 02 03 19 24 28 33 For E 19 11 ICES Canada label For E 28 12 I D plate For E 02 19 24 For E 19 13 Safety plate For E 03 28 33 A Fr...

Page 8: ...128 mm 5 0 in Steering angle 32 right left Caster 26 Trail 108 mm 4 25 in Turning radius 3 0 m 9 8 ft Front brake Disc brake twin Rear brake Disc brake Front tire size 120 70ZR17M C 58W tubeless Rear tire size 160 60ZR17M C 69W tubeless Item Specification Remark Ignition type Electronic ignition Transistorized Ignition timing 2 B T D C at 1 200 r min Spark plug NGK CR8E or DENSO U24ESR N Battery 1...

Page 9: ...General Information 0A 4 Special Tools and Equipment Special Tool B817H20108001 09930 82720 Mode select switch ...

Page 10: ...e I Spark plugs I R I R Fuel line I I I I Evaporative emission control system E 33 only I I Engine oil R R R R R Engine oil filter R R Throttle cable play I I I I I Throttle valve synchronization I E 33 only I I PAIR air supply system I I Engine coolant Replace every 2 years Radiator hose I I I I Clutch hose I I I I Replace every 4 years Clutch fluid I I I I Replace every 2 years Drive chain I I I...

Page 11: ... exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions Special Tools and Equipment Recommended Service Material B817H20208001 NOTE Required service material is also described in the following Lubrication Points GSX650FK8 Page 0B 2 6 7 5 3 2 1 4 I817H2020001 01 1 Clutch lever holder 6 Brake lever holder 2 Gears...

Page 12: ... 7 0 8 0 028 0 031 Spark performance Over 8 0 3 at 1 atm CKP sensor resistance 90 150 Ω CKP sensor peak voltage 2 0 V and more When cranking Ignition coil resistance Primary 1 1 1 9 Ω Terminal Terminal Secondary 10 8 16 2 kΩ Plug cap Terminal Ignition coil primary peak voltage 80 V and more When cranking Generator coil resistance 0 2 0 8 Ω Generator maximum output Approx 400 W at 5 000 r min Gener...

Page 13: ...t 250 kPa 2 50 kgf cm2 36 psi Rear 290 kPa 2 90 kgf cm2 42 psi Tire size Front 120 70 ZR17 M C 58 W Rear 160 60 ZR17 M C 69 W Tire type Front BRIDGESTON BT011F N Rear BRIDGESTON BT020R G Tire tread depth Recommended depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in Item Standard Limit Front fork stroke 130 5 1 Front fork inner tube O D 41 1 61 Front fork spring free length 375 5 14 78 368 14 5 Front ...

Page 14: ...0C 3 Service Data ...

Page 15: ...ary Throttle Valve Actuator STVA Malfunction 1A DTC C29 P1654 H L Secondary Throttle Position Sensor STPS Circuit Malfunction 1A DTC C31 P0705 GP Switch Circuit Malfunction 1A DTC C32 P0201 C33 P0202 C34 P0203 or C35 P0204 Fuel Injector Circuit Malfunction 1A DTC C40 P0505 P0506 or P0507 ISC Valve Circuit Malfunction 1A DTC C41 P0230 H L FP Relay Circuit Malfunction 1A DTC C41 P2505 ECM Power Inpu...

Page 16: ...le Cable Routing Diagram 1D Throttle Cable Routing Diagram GSX650FK8 1D 1 Diagnostic Information and Procedures 1D Engine Mechanical Symptom Diagnosis 1D Compression Pressure Check 1D Repair Instructions 1D Engine Components Removable with the Engine in Place 1D Air Cleaner Element Removal and Installation 1D Air Cleaner Element Inspection and Cleaning 1D Air Cleaner Box Removal and Installation 1...

Page 17: ...sor Removal and Installation 1F ECT Sensor Inspection 1F Thermostat Connector Thermostat Removal and Installation 1F Thermostat Inspection 1F Water pump Components 1F Water Pump Construction 1F Water Pump Removal and Installation 1F Water Pump Disassembly and Assembly 1F Water Pump Related Parts Inspection 1F Specifications 1F Service Data 1F Tightening Torque Specifications 1F Special Tools and E...

Page 18: ... Inspection 1I Starter Clutch Removal and Installation 1I Starter Clutch Inspection 1I Starter Button Inspection 1I Specifications 1I Service Data 1I Tightening Torque Specifications 1I Special Tools and Equipment 1I Recommended Service Material 1I Special Tool 1I Charging System 1J Schematic and Routing Diagram 1J Charging System Diagram 1J Component Location 1J Charging System Components Locatio...

Page 19: ... not sent to ECM In this case FI is indicated in the LCD panel Motorcycle does not run CHEC The LCD panel indicates CHEC when no communication signal from the ECM is received for 5 seconds and more For Example The ignition switch is turned ON and the engine stop switch is turned OFF In this case the speedometer does not receive any signal from the ECM and the panel indicates CHEC If CHEC is indica...

Page 20: ...firming DTC Diagnostic Trouble Code stored in memory Such disconnection will erase memorized information in ECM memory DTC stored in ECM memory can be checked by the special tool Before checking DTC read self diagnosis function User mode and dealer mode Refer to Self Diagnosis Function GSX650FK8 Page 1A 1 carefully to have good understanding as to what functions are available and how to use it Be ...

Page 21: ...malfunction history DTC still remains stored in the ECM Therefore erase the history DTC memorized in the ECM using SDS DTC is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefor when a wire coupler has been disconnected at the time of diagnosis erase the stored history DTC using SDS Refer to Use of SDS Diagnosis Reset Procedures in related manual 7 Turn the ignit...

Page 22: ...am GSX650FK8 B817H21402003 A 2 3 4 2 1 5 6 7 3 4 a a I817H2140001 01 1 Wiring harness 4 Throttle cable No 2 7 Ignition switch lead wire 2 Cable guide 5 Handlebar switch lead wire L a 0 mm 0 in 3 Throttle cable No 1 6 Handlebar switch lead wire R A Don t contact the tip of cable guide with the upper bracket ...

Page 23: ...tion 6B Handlebar Height Adjustment 6B Steering Components 6B Steering Removal and Installation 6B Steering Related Parts Inspection 6B Steering System Inspection 6B Steering Stem Bearing Removal and Installation 6B Steering Tension Adjustment 6B Handlebar Construction GSX650FK8 6B 1 Specifications 6B Tightening Torque Specifications 6B Special Tools and Equipment 6B 1 Special Tool 6B Recommended ...

Page 24: ...6012 Special Tools and Equipment Recommended Service Material B817H26208003 NOTE Required service material is also described in the following Handlebar Construction GSX650FK8 Page 6B 1 1 Handlebar switch LH Apply bond A Apply a small amount of the bond 1207B to inside of the handlebar switchbox A 1 I817H2620001 01 ...

Page 25: ...spection 9B Turn Signal Side stand Relay Removal and Installation 9B Hazard Switch Inspection 9B Turn Signal Switch Inspection 9B Passing Light Switch Inspection 9B Dimmer Switch Inspection 9B Headlight Components GSX650FK8 9B 1 Headlight Removal and Installation GSX650FK8 9B 2 Headlight Bulb Replacement GSX650FK8 9B 2 Headlight Beam Adjustment GSX650FK8 9B 3 Reflex Refractor Construction GSX650FK...

Page 26: ...uction 9D Frame Cover Cushion Construction 9D Engine Sprocket Outer Cover Cushion 9D Fastener Removal and Installation 9D Exterior Parts Removal and Installation 9D Seat Height Adjustment 9D Cowling Construction GSX650FK8 9D 1 Under Cowl Construction GSX650FK8 9D 2 Under Cowl Bracket Cushion Attachment GSX650FK8 9D 2 Under Cowl Protector Cushion Attachment GSX650FK8 9D 3 Upper Panel Cushion Attach...

Page 27: ...Wiring Systems 9A 1 Body and Accessories Wiring Systems Schematic and Routing Diagram Wiring Diagram GSX650FK8 B817H29102007 Refer to Wire Color Symbols in Section 0A in related manual ...

Page 28: ... W B Lg R B B Bl B R B G B Bl B B O G B B R B W B B R B W P G B W G B W O G W B O W G O W W Bl O W B O W Y O W B G B R B O G B B O B G Br B B Bl B R B G B Bl B B O G B Y R B W B Lg R B Y B W B W B W W R B Y B Bl Bl Bl W Bl B Bl G W Y Lg G W Bl B Gr W Gr B Gr Y Gr R W B B G Y B Bl Y Lbl Dbr B W Y R Gr B R B W B Br Dg W Bl P B G B Y W B Lg G O G R Bl O R B Y Y Bl W G R B Bl G B P B B G P W W B B Br ...

Page 29: ...l B R B G B Bl B B O G B B R B W B B R B W P G B W G B W O G W B O W G O W W Bl O W B O W Y O W B G B R B O G B B O B G Br B B Bl B R B G B Bl B B O G B Y R B W B Lg R B Y B W B W B W W R B Y B Bl Bl Bl W Bl B Bl G W Y Lg G W Bl B Gr W Gr B Gr Y Gr R W B B G Y B Bl Y Lbl Dbr B W Y R Gr B R B W B Br Dg W Bl P B G B Y W B Lg G O G R Bl O R B Y Y Bl W G R B Bl G B P B B G P W W B B Br Bl W Bl B Bl G ...

Page 30: ...08 2 4 C A B 3 3 3 1 I817H2910903 02 1 EVAP purge control valve E 33 only A Pass the EVAP purge control valve lead wire lower the clutch hose E 33 only 2 Wiring harness No 1 B Do not make slacked lead wire 3 Wiring harness No 2 C Left Right are symmetry 4 Front turn signal ...

Page 31: ... Lighting Systems Repair Instructions Headlight Components GSX650FK8 B817H29206024 FWD FWD 1 3 4 4 3 2 I817H2920001 01 1 Headlight low beam bulb 12 V 55 W H7 3 Position light bulb 12 V 5 W x 2 2 Headlight high beam bulb 12 V 60 W HB3 4 Bulb cap ...

Page 32: ...AUTION When 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 Low Beam 1 Remove the combination meter assembly Refer to Combination Meter Removal and Installation GSX650FK8 in Section 9C Page 9C 2 2 Remove the bulb cap 1 by turning it counterclockwise 3 Disconnect the low beam lead wire coupler 2 4 Replace th...

Page 33: ... the position light bulb 2 5 Reinstall the removed parts Headlight Beam Adjustment GSX650FK8 B817H29206027 1 Remove the combination meter assembly Refer to Combination Meter Removal and Installation GSX650FK8 in Section 9C Page 9C 2 2 Insert 8 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally NOTE Adjust the beam horizontally first then vertically Low beam High bea...

Page 34: ...Construction GSX650FK8 Page 9B 4 Reference For the tightening torque of fastener not specified in this section refer to Tightening Torque List in Section 0C in related manual Tightening Torque List in Section 0C in related manual 2 a 1 I817H2920014 01 1 Front reflex refractor For E 03 24 28 33 2 Front fork 2 N m 0 2 kgf m 1 5 lb ft Item Specification Headlight HI 60 LO 55 Parking or position light...

Page 35: ...ce compared to the bulb Engine Revolution Indicator Lamp This speedometer is equipped the engine revolution indicator lamp The engine revolution indicator lamp is adjustable from 6 000 12 500 r min from 6 000 r min to 10 000 r min every 500 r min and 10 000 r min to 12 500 r min every 250 r min Initial setting 11 000 r min FI 1 2 7 14 8 3 4 5 9 15 10 6 13 11 12 14 I817H2930001 02 1 Adjust switch T...

Page 36: ... Remove the screws 1 and pull out the combination meter assembly 2 from the upper panel 2 Disconnect the combination meter coupler 3 and remove the combination meter assembly 4 3 Remove the combination meter 5 FWD FWD 1 2 3 I817H2930002 01 1 Combination meter cover 2 Combination meter unit 3 Combination meter case A Hooked point 2 1 A I817H2930003 01 3 4 I817H2930004 01 5 I817H2930005 01 ...

Page 37: ...e ignition switch is turned to ON Check that other LEDs Neutral indicator light High beam indicator light and Turn signal indicator lights light up go off by operating each switch If abnormal condition is found replace the combination meter unit with a new one after checking its wire harness coupler Refer to Combination Meter Removal and Installation GSX650FK8 Page 9C 2 Stepping Motor Inspection a...

Page 38: ...nder cowling Refer to Exterior Parts Removal and Installation GSX650FK8 in Section 9D Page 9D 5 2 Disconnect the ECT sensor coupler 1 3 Connect the variable resistor 2 between the terminals 4 Turn the ignition switch ON 5 Check the LED 3 and LCD 4 operations when the resistance is adjusted to the specified values If either one or all indications are abnormal replace the combination meter with a ne...

Page 39: ...e indicator LED A and LCD B will light up when grounding the lead wire 1 If the oil pressure indicator does not light up replace the combination meter unit with a new one after checking connection of couplers Horn Inspection GSX650FK8 B817H29306025 Inspect the horn in the following procedures 1 Disconnect the couplers 1 2 Connect a 12 V battery to terminal A and terminal B If the sound is not hear...

Page 40: ...Wattage Unit W Item Specification Speedometer light LED Tachometer light LED Turn signal indicator light LED x 2 High beam indicator light LED Neutral position indicator light LED Oil pressure Engine coolant temperature indicator light LED FI indicator light LED Engine RPM indicator light LED ...

Page 41: ... 1 Body and Accessories Exterior Parts Repair Instructions Cowling Construction GSX650FK8 B817H29406011 1 2 3 4 5 6 I817H2940014 03 1 Under cowling R 3 Cushion 5 Upper panel 2 Body cowling 4 Windscreen 6 Under cowling L ...

Page 42: ...12 Under Cowl Bracket Cushion Attachment GSX650FK8 B817H29406013 c b a a d c 1 1 I817H2940021 01 1 Heat shield a Max 5 mm 0 19 in c 55 mm 2 17 in 2 Cushion b 0 1 mm 0 0 039 in d 3 mm 0 12 in 1 a b I817H2940016 01 1 Under cowl F T G cushion a 15 mm 0 59 in b 0 mm 0 in ...

Page 43: ... 3 Under Cowl Protector Cushion Attachment GSX650FK8 B817H29406014 Upper Panel Cushion Attachment GSX650FK8 B817H29406015 1 a I817H2940017 01 1 Cushion a 85 mm 3 35 in 1 a I817H2940018 01 1 Panel cushion a 5 mm 0 19 in ...

Page 44: ...Exterior Parts Windscreen Cushion Attachment GSX650FK8 B817H29406016 Intake Net Cover Construction Attachment GSX650FK8 B817H29406017 2 2 1 I817H2940019 01 1 Cushion 2 Tape 1 I817H2940020 01 1 Cover cushion ...

Page 45: ... manual Removal 1 Remove the fasteners 1 2 Disconnect the turn signal light couplers 2 left and right 3 Remove the left under cowling 3 and right under cowling 4 Installation Install the under cowlings in the reverse order of removal 1 I817H2940001 01 2 2 I817H2940002 01 A Hooked point I817H2940006 01 3 A I817H2940003 01 I817H2940004 01 A 4 I817H2940005 02 ...

Page 46: ...e the caps and rear view mirror 1 left and right 2 Remove the upper panel 3 Disconnect the high beam light coupler 2 and low beam light coupler 3 4 Remove the screws 4 5 Disconnect the position lights 5 and clamps left and right 6 Remove the screws 7 Remove the body cowling assembly 6 Installation Install the body cowling in the reverse order of removal 1 I817H2940007 01 1 I817H2940008 01 1 I817H2...

Page 47: ...Prepared by September 2007 Part No 99501 36180 01E Printed in Japan 48 ...

Page 48: ...Printed in Japan K8 ...

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