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Suzuki GSF1200 Bandit

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Для Suzuki GSF 1200 Bandit

  • Сервисный мануал (Service Manual) для Suzuki GSF1200/S Bandit K6
  • Сервисный мануал (Service Manual) для Suzuki GSF1200/S Bandit (1996-1997)
  • Руководство по ремонту и обслуживанию (Haynes Service & Repair Manual) для Suzuki GSF600/1200 Bandit (1995-2001)
  • Руководство пользователя (Owners Manual) для Suzuki GSF1200S (на русском)

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  • Suzuki GSF 1200 Bandit

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ЛенМото

4-я Красноармейская, 2А
Санкт-Петербург, 190005
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Телефон: +7 (921) 930-81-18
Телефон: +7 (911) 928-08-06

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GSF1200/GSF1200S

9 9 5 0 0 — 3 9 2 8 0 — 0 1 E

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FOREWORD

This manual contains an introductory description on the SUZUKI GSF1200/GSF1200S and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service.

This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service.

*This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle.

*Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail.

*This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

!WARNING

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2005

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TABLE OF CONTENTS

Precautions………………………………………………………….

.. 00-i

Precautions…………………………………………………………..

00-1

General Information………………………………………………

..0-i

General Information………………………………………..

0A-1

Maintenance and Lubrication……………………………

0B-1

Service

Data…………………………………………………..

0C-1

Engine…………………………………………………………………….

..1-i

Precautions…………………………………………………………….

1-1

Engine General Information and Diagnosis………..

1A-1

Emission Control Devices………………………………..

1B-1

Engine Mechanical………………………………………….

1D-1

Engine Lubrication System ………………………………

1E-1

Engine Cooling System……………………………………

1F-1

FuelSystem…………………………………………………..

1G-1

Ignition

System……………………………………………….

1H-1

Starting System……………………………………………….

1I-1

Charging

System……………………………………………..

1J-1

ExhaustSystem……………………………………………..

1K-1

Suspension…………………………………………………………….

..2-i

Precautions…………………………………………………………….

2-1

Suspension General Diagnosis…………………………

2A-1

Front Suspension……………………………………………

2B-1

RearSuspension…………………………………………….

2C-1

Wheels and Tires……………………………………………

2D-1

Driveline / Axle……………………………………………………….

.. 3-i

Precautions…………………………………………………………….

3-1

Drive Chain / Drive Train / Drive Shaft……………….

3A-1

Brake………………………………………………………………………

..4-i

Precautions…………………………………………………………….

4-1

Brake Control System and Diagnosis………………..

4A-1

Front Brakes…………………………………………………..

4B-1

RearBrakes…………………………………………………..

4C-1

Transmission / Transaxle……………………………………..

.. 5-i

Precautions…………………………………………………………….

5-1

Manual Transmission………………………………………

5B-1

Clutch ……………………………………………………………

5C-1

Steering………………………………………………………………….

.. 6-i

Precautions…………………………………………………………….

6-1

Steering General Diagnosis……………………………..

6A-1

Steering / Handlebar……………………………………….

6B-1

Body and Accessories…………………………………………..

.. 9-i

Precautions…………………………………………………………….

9-1

Wiring Systems………………………………………………

9A-1

Lighting Systems…………………………………………….

9B-1

Combination Meter / Fuel Meter / Horn………………

9C-1

Exterior Parts…………………………………………………

9D-1

BodyStructure……………………………………………….

9E-1

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Table of Contents 00- i

Section 00

Precautions

00

CONTENTS

Precautions…………………………………………….

00-1

General Precautions………………………………………….

00-1

Precautions

00-1

Precautions for Electrical Circuit Service…………..

00-2

Warning / Caution / Note…………………

00-1

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00-1 Precautions:

Precautions

Precautions

Warning / Caution / Note

B649G10000001

Please read this manual and follow its instructions carefully. Toemphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

! WARNING

Indicates a potential hazard that could result in death or injury.

! CAUTION

Indicates a potential hazard that could result in motorcycle damage.

NOTE

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must 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

B649G10000002

!WARNING

Proper service and repair proceduresare important for the safety of the service mechanic and the safety and reliabilityof the motorcycle.

When 2 or more persons work together, pay attention to the safety of eachother.

When it is necessary to run the engine indoors, make sure that exhaust gasis forced outdoors.

When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all of the materialmanufacturer’s instructions.

Never use gasoline as a cleaning solvent.

Toavoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have cooled.

After servicing the fuel, oil, exhaust or brake systems, check all lines andfittings related to the system for leaks.

!CAUTION

If parts replacement is necessary,replace the parts with Suzuki Genuine Parts or their equivalent.

When removing partsthat are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

Be sure to use special toolswhen instructed.

Make sure that all parts used in reassembly are clean. Lubricatethem when specified.

Use the specified lubricant, bond,or sealant.

When removing the battery, disconnect the negative (–) cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative (–) cable, and replace the terminal cover on the positive terminal.

When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative (–) cable the battery.

When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside working out and to the specified tighteningtorque.

Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sureto replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it iscompletely seated in its groove and securely fitted.

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Precautions: 00-2

Use a torque wrench to tightenfasteners to the specified torque. Wipe off grease and oil if a thread is smeared withthem.

After reassembling, check partsfor tightness and proper operation.

Toprotect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids:batteries, and tires.

Toprotect Earth’s natural resources, properly dispose of used motorcycleand parts.

Precautions for Electrical Circuit Service

B649G10000003

When handling the electrical parts or servicing the ABS system, observe the following points for the safety of the system.

Electrical Parts

Connector / Coupler

When connecting a connector, be sure to push it in until a click is felt.

I310G1000001-01

With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully till the lock works when connecting it.

When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires.

Inspect each terminal on the connector/couplerfor looseness or bending.

Inspect each terminal for corrosion and contamination. The terminals must be clean andfree of any foreign material which could impede proper terminal contact.

I310G1000002-01

Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace.

I310G1000003-01

When taking measurements at electrical connectors using a tester probe, be sure to insert the probefrom the wire harness side (backside) of the connector/ coupler.

2

1

I649G1000013-01

When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.

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00-3 Precautions:

• Check the male connector for bend and female

• Be careful not to touch the electrical terminals of the

connector for excessive opening. Also check the

Ignitor unit and ABS control unit/HU. The static

coupler for locking (looseness), corrosion, dust,etc.

electricity from your body may damage this part.

4

“A”

3

4

I649G1000030-01

I310G1000008-01

3. Coupler

4. Probe

“A”: Where male terminal fits

• When disconnecting and connecting the Ignitor unit

Fuse

and ABS control unit/HU couplers, make sure toturn

OFF the ignition switch, or electronic parts mayget

• When a fuse blows, always investigate thecause,

damaged.

correct it and then replace the fuse.

• Do not use a fuse of a different capacity.

1

• Do not use wire or any other substitute for thefuse.

I649G1000031-01

1. Ignition S/W

I649G1000001-01

• Never allow dust or water to contact the ABScontrol

Ignitor unit / Various sensors / ABS control unit / HU

unit/HU.

• Since each component is a high-precision part,great

care should be taken not to apply any sharp impacts

during removal and installation.

I649G1000004-01

I649G1000003-01

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Precautions: 00-4

The ABS control unit/HU cannot bedisassembled. Replace the whole unit with a new one.

I649G1000005-01

Battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the ABS control unit/HU instantly when reverse power is applied.

I649G1000006-01

Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the Ignition unit and ABS control unit/HU which may result in serious damage.

I310G1000011-01

Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check at low battery voltage will lead to erroneous diagnosis.

I310G1000012-01

Never connect any tester (voltmeter, ohmmeter, or whatever) to the Ignition and ABS control unit/HU when its coupler is disconnected. Otherwise, damage to Ignitor and ABS control unit/HU may result.

Never connect an ohmmeter to the Ignitor and ABS control unit/HU with its coupler connected. If attempted, damage to Ignitor and ABS control unit/HU or sensors may result.

Be sure to use a specifiedvoltmeter/ohmmeter. Otherwise, accurate measurements may notbe obtained and personal injury may result.

Electrical Circuit Inspection Procedure

While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter.

Open circuit check

Possible causes for the open circuit are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.

Loose connection of connector/coupler

Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.)

Wire harness being open.

Poor terminal-to-wire connection.

When checking system circuits including an electronic control unit such as ignitor, ABS control unit/HU, etc., it is important to perform careful check, starting with items which are easier to check.

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00-5 Precautions:

1)Disconnect the negative (–) cable from the battery.

2)Check each connector/coupler at both ends of the circuit being checked for loose connection. Also check for condition of the coupler lock ifequipped.

“A”

“A”

Ignitor

1

I649G1000026-01

1. Sensor

“A”: Check for loose connection

3)Using a test male terminal, check the female terminals of the circuit being checked for contact tension.

Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust, entry of foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the coupler and locked.

If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be clean and free of any foreign material which could impede proper terminal contact.

“B”

“C”

I649G1000027-01

“B”: Check contact tension by inserting and removing.

“C”: Check each terminal for bend and proper alignment.

4)Using continuity inspect or voltage check procedure as described below, inspect the wire harness terminals for open circuit and poor connection. Locate abnormality, if any.

“D” “F”

“E”

I649G1000028-01

”D”: Looseness of crimping

“E”: Open

“F”: Thin wire (A few strands left)

Continuity check

1)Measure resistance across coupler “B” (between “A” and “C” in figure).

If no continuity is indicated (infinity or over limit), the circuit is open between terminals “A” and “C”.

“A”

“B” Ignitor

“C”

I649G1000019-03

2)Disconnect the coupler “B” and measureresistance between couplers “A” and “B-1”.

If no continuity is indicated, the circuit is open between couplers “A” and “B-1”. If continuity is indicated, there is an open circuit between couplers “B-2” and “C” or an abnormality in coupler “B-2” or coupler “C”.

“A”

“B-2”

Ignitor

“B” “C”

“B-1”

I649G1000029-02

Voltage check

If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.

1)With all connectors/couplers connected andvoltage applied to the circuit being checked, measure voltage between each terminal and bodyground.

2)If measurements were taken as shown in figureat the right and results are as listed below, it means that the circuit is open between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5V “B” and body ground: Approx. 5V “C” and body ground: 0 V

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Precautions: 00-6

3)Also, if measured values are as listed below, a resistance (abnormality) exists which causes the voltage drop in the circuit between terminals “A” and “B”.

Voltage between

“A” and body ground: Approx. 5 V

“B” and body ground: Approx. 5 V – 2 V voltage drop

“C” and body ground: 3 V – 2 V voltage drop

“A”

Ignitor

“B”

“C”

5V

5V

0V

5V

“A”

“B” “C”

I649G1000021-02

Short circuit check (Wire harness to ground)

1)Disconnect the negative (–) cable from thebattery.

2)Disconnect the connectors/couplers at both endsof the circuit to be checked.

NOTE

If the circuit to be checked branches to other parts as shown, disconnect all connectors/ couplers of those parts. Otherwise, diagnosis will be misled.

3)Measure resistance between terminal at one endof circuit (“A” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “A” and “C”.

“A”

“D”

“B” Ignitor

“C”

“E”

5V

“A” “C”

I649G1000022-02

“D”: To other parts

“E”: Other parts

4)Disconnect the connector/coupler included incircuit (coupler “B”) and measure resistance between terminal “A” and body ground. If continuity is indicated, the circuit is shorted to the ground between terminals “A” and “B”.

“A”

“D”

Ignitor

“B” “C”

I649G1000023-02

“D”: To other parts

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00-7 Precautions:

Using The Multi-Circuit Testers

• After using the tester, turn the power off.

Use the Suzuki multi-circuit tester set.

Special tool

Use well-charged batteries in the tester.

: 09900–25008 (Multi-circuit tester set)

Be sure to set the tester to the correct testingrange.

Special tool

(A): 09900–25008 (Multi-circuit tester set)

(A)

I649G1000002-01

I649G1000024-02

NOTE

Using the testers

• When connecting the multi-circuit tester,

• Incorrectly connecting the (+) and (–) probesmay

use the needle pointed probe to the back

cause the inside of the tester to burnout.

side of the lead wire coupler andconnect

• If the voltage and current are not known,make

the probes of tester to them.

• Use the needle pointed probe to prevent

measurements using the highest range.

• When measuring the resistance with themulti-circuit

the rubber of the water proof couplerfrom

damage.

tester (1), will be shown as 10.00 M and “1”

flashes in the display.

Special tool

• Check that no voltage is applied before making the

(A): 09900–25009 (Needle pointed probe set)

measurement. If voltage is applied the tester maybe

damaged.

(A)

I649G1000025-02

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Table of Contents 0- i

Section 0

General Information

0

CONTENTS

General Information……………………………….

0A-1

General Description………………………………………

0A-1

Symbols ……………………………………………………..

0A-1

Abbreviations ………………………………………………

0A-2

Vehicle Side View ………………………………………..

0A-3

Vehicle Identification Number ………………………..

0A-4

Fuel and Oil Recommendation ………………………

0A-4

BREAK-IN Procedures………………………………….

0A-4

CylinderIdentification……………………………………

0A-5

Country and Area Codes ………………………………

0A-5

Wire Color Symbols ……………………………………..

0A-5

Warning, Caution and Information

Labels Location………………………………………….

0A-6

ComponentLocation…………………………………….

0A-7

Electrical Components Location …………………….

0A-7

Specifications……………………………………………….

0A-9

Specifications ………………………………………………

0A-9

Special Tools and Equipment………………………

0A-11

Special Tools …………………………………………….

0A-11

Maintenance and Lubrication……………..

0B-1

Precautions…………………………………………………..

0B-1

Precautions for Maintenance …………………………

0B-1

General Description………………………………………

0B-1

Recommended Fluids and Lubricants……………..

0B-1

Scheduled Maintenance………………………………..

0B-2

Periodic Maintenance Schedule Chart…………….

0B-2

Lubrication Points ………………………………………..

0B-3

Repair Instructions……………………………………….

0B-4

Air Cleaner Element Removal and Installation….

0B-4

Air Cleaner Element Inspection and Cleaning ….

0B-4

Spark Plug Removal and Installation………………

0B-5

Spark Plug Inspection and Cleaning……………….

0B-6

Exhaust Pipe Bolt and Muffler Mounting Bolt

Inspection………………………………………………….

0B-6

Valve Clearance Inspection and Adjustment ……

0B-7

Fuel Line Inspection……………………………………..

0B-8

Engine Oil and Filter Replacement……………………

0B-9

Throttle Cable Play Inspection

and Adjustment ………………………………………..

0B-10

Engine Idle Speed Inspection

and Adjustment………………………………………..

0B-11

Throttle Valve Synchronization…………………….

0B-11

PAIR System Inspection ……………………………..

0B-11

Clutch System Inspection…………………………….

0B-11

Clutch Hose Replacement …………………………..

0B-12

Air Bleeding from Clutch Fluid Circuit ……………

0B-12

Clutch Fluid Replacement ……………………………

0B-12

Drive Chain Inspection and Adjustment…………

0B-12

Drive Chain Cleaning and Lubricating……………

0B-13

Brake System Inspection …………………………….

0B-13

Rear Brake Light Switch Adjustment……………..

0B-15

Brake Hose Replacement……………………………

0B-15

Air Bleeding from Brake Fluid Circuit …………….

0B-15

Brake Fluid Replacement…………………………….

0B-15

Tire Inspection……………………………………………

0B-15

Steering System Inspection…………………………

0B-16

Front Fork Inspection ………………………………….

0B-16

Rear Suspension Inspection………………………..

0B-16

Chassis Bolt and Nut Inspection …………………..

0B-17

Compression Pressure Check ……………………..

0B-18

Oil Pressure Check…………………………………….

0B-18

Specifications……………………………………………..

0B-19

Tightening Torque Specifications………………….

0B-19

Special Tools and Equipment………………………

0B-19

Recommended Service Material…………………..

0B-19

SpecialTool………………………………………………

0B-19

Service Data………………………………………

0C-1

Specifications……………………………………………….

0C-1

Service Data………………………………………………..

0C-1

Tightening Torque Specifications……………………

0C-7

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0A-1 General Information:

General Information

General Description

Symbols

B649G10101001

Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

Torque control required.

Data beside it indicates specified torque. Apply oil.

Use engine oil unless otherwise specified. Apply molybdenum oil solution

(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent.

99000-25010

Apply SUZUKI MOLY PASTE or equivalent. 99000-25140

Apply SUZUKI SILICONE GREASE or equivalent. 99000-25100

Apply THERMO-GREASE or equivalent. 99000-59029

Apply SUZUKI BOND “1207B” or equivalent. 99000-31140

Apply SUZUKI BOND “1215” or equivalent. 99000-31110

Apply THREAD LOCK SUPER “1303” or equivalent. 99000-32030

Apply THREAD LOCK SUPER “1322” or equivalent. 99000-32110

Apply THREAD LOCK “1342” or equivalent. 99000-32050

Apply THREAD LOCK SUPER “1360” or equivalent. 99000-32130

Use fork oil or equivalent. 99000-99001-SS8

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

Do not reuse.

Note on reassembly.

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General Information: 0A-2

Abbreviations

H:

B649G10101002

HC: Hydrocarbons

A:

I:

ABDC: After Bottom Dead Center

IG: Ignition

ABS: Anti-lock Brake System AC

J:

Alternating Current

ACL: Air Cleaner, Air Cleaner Box

L:

API: American Petroleum Institute

LCD: Liquid Crystal Display

ATDC: After Top Dead Center A/F:

LED: Light Emitting Diode (Malfunction Indicator Lamp)

Air Fuel Mixture

LH: Left Hand

B:

M:

BBDC: Before Bottom Dead Center

Max: Maximum

BTDC: Before Top Dead Center B+:

MIL: Malfunction Indicator Lamp (LED)

Battery Positive Voltage

Min: Minimum

C:

N:

CKP Sensor: Crankshaft Position Sensor (CKPS)

NOx: Nitrogen Oxides

CKT: Circuit

O:

CLP Switch: Clutch Lever Position Switch (Clutch

OHC: Over Head Camshaft

Switch)

OPS: Oil Pressure Switch P:

CO: Carbon Monoxide

PCV: Positive Crankcase Ventilation (Crankcase

CPU: Central Processing Unit

Breather)

D:

R:

DC: Direct Current

RH: Right Hand

DMC: Dealer Mode Coupler

ROM: Read Only Memory

DOHC: Double Over Head Camshaft

S:

DRL: Daytime Running Light

SAE: Society of Automotive Engineers

F:

T:

FTPC Valve: Fuel Tank Pressure Control Valve

TP Sensor: Throttle Position Sensor (TPS)

G:

GEN: Generator

GND: Ground

GP Switch: Gear Position Switch

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suzuki GSF1200, GSF1200S Service Manual

0A-3 General Information:

Vehicle Side View

B649G10101003

NOTE

Difference between photographs and actual motorcycles may exist depending on the markets.

SUZUKI GSF1200 (2006-model)

Right Side

I649G1010008-01

Left Side

I649G1010009-01

SUZUKI GSF1200S (2006-model)

Right Side

I649G1010005-06

Left Side

I649G1010006-05

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General Information: 0A-4

Vehicle Identification Number

B649G10101004

The frame serial number or V.I.N. (Vehicle Identification Number) “A” is stamped on the right side of the steering head pipe. The engine serial number “B” is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.

“A”

I649G1010001-02

“B”

I649G1010002-03

Fuel and OilRecommendation

B649G10101005

Fuel (For USA)

Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method.

Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

Fuel (For Other Countries)

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.

Engine Oil

Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the chart.

I310G1010005-01

Brake Fluid

Specification and classification: DOT4

! WARNING

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never reuse brake fluid left over from a previous servicing, which has been stored for a long period.

Front Fork Oil

Use fork oil SS8 or an equivalent fork oil.

BREAK-IN Procedures

B649G10101007

During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are asfollows.

1)Keep to these break-in engine speed limits:

Speed limits

Initial 800 km: Below 5 500 r/min Up to 1 600 km: Below 8 000 r/min Over 1 600 km: Below 11 000 r/min

2)Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 11 000r/ min at any time.

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0A-5 General Information:

Cylinder Identification

B649G10101008

The four cylinders of this engine are identified as No.1, 2, 3 and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat).

I649G1010010-01

Country and Area Codes

B649G10101009

The following codes stand for the applicable country(- ies) and area(-s).

Code

Country

Effective Frame No.

or Area

GSF1200 K6

U.K.

JS1CB112200100001 –

(E-02)

GSF1200 K6

E.U.

JS1CB112100100001 –

(E-19)

GSF1200S K6

U.K.

JS1CB111200100001 –

(E-02)

GSF1200S K6

E.U.

JS1CB111100100001 –

(E-19)

GSF1200S K6

Australia

JS1CB121300100001 –

(E-24)

GSF1200S K6

Canada

JS1GV79A 62100001 –

(E-28)

Wire Color Symbols

B649G10101010

Symbol

Wire Color

Symbol

Wire Color

B

Black

Bl/B

Blue with Black tracer

Bl

Blue

Br/B

Brown with Black tracer

Br

Brown

G/B

Green with Black tracer

Dbr

Dark brown

G/Bl

Green with Blue tracer

Dg

Dark green

G/Y

Green with Yellow tracer

G

Green

O/G

Orange with Green tracer

Lg

Light green

O/R

Orange with Red tracer

W

White

O/W

Orange with White tracer

Y

Yellow

O/Y

Orange with Yellow tracer

B/Bl

Black with Blue tracer

P/B

Pink with Black tracer

B/Br

Black with Brown tracer

R/B

Red with Black tracer

B/G

Black with Green tracer

R/W

Red with White tracer

B/O

Black with Orange tracer

W/B

White with Black tracer

B/R

Black with Red tracer

Y/B

Yellow with Black tracer

B/W

Black with White tracer

Y/W

Yellow with White tracer

B/Y

Black with Yellow tracer

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General Information: 0A-6

Warning, Caution and Information Labels Location

B649G10101011

[A]

1

[C]

2

6

8

7

3

5

4

[B]

[D]

10

9

4

I649G1010011-04

GSF1200

GSF1200S

1.

Noise label

For E-24

2.

Information label

For E-28

3.

Fuel caution label

For E-02

For E-02, 24

4.

Screen label

For E-02, 19, 24, 28

5.

Warning steering label

For E-02, 19, 24, 28

6.

Tire information label

For E-02, 19

For E-02, 19, 24, 28

7.

General warning label

For E-02, 19

For E-02, 19, 24, 28

8.

ICES Canada label

For E-28

9.

I.D. plate

For E-02, 19

For E-02, 19, 24

10.

Safety plate

For E-28

[A]:

Frame head (Left side)

[B]:

Cowling body

[C]:

Chain cover

[D]:

Frame side tube (Right side)

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0A-7 General Information:

Component Location

Electrical ComponentsLocation

B649G10103001

3

7

5

6

8

I649G1010003-05

1.

Ignition coil

3.

Handlebar switch (RH)

5.

Rear brake light switch

7.

CKP sensor

2.

Ignition switch

4.

Front brake light switch

6.

Throttle position sensor

8.

Oil pressure switch

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General Information: 0A-8

12

9

13 14

16

15

21

20

19

17

18

23

22

I649G1010004-04

9.

Clutch lever position switch

14.

Main fuse

19.

Generator

10.

Handlebar switch (LH)

15.

Battery

20.

Carburetor heater (For E-02, 19)

11. Fuse box

16. Ignitor

21. Speed sensor

12.

Turn signal/Side-stand relay

17.

Horn

22.

Gear position switch

13.

Starter relay

18.

Starter motor

23.

Side-stand switch

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0A-9 General Information:

Specifications

Specifications

NOTE

B649G10107001

These specifications are subject to change without notice.

Dimensions and dry mass

Item

Specification

Remark

Overall length

2 130 mm (83.9 in)

Overall width

790 mm (31.1 in)

Overall height

1 095 mm (43.1 in)

GSF1200

1 235 mm (48.6 in)

GSF1200S

Wheelbase

1480 mm (58.3 in)

Ground clearance

135 mm (5.3 in)

Seat height

785/805 mm (30.9/31.7 in)

Low/High

Dry mass

212 kg (467 lbs)

GSF1200

215 kg (474 lbs)

GSF1200S

Engine

Item

Specification

Remark

Type

4-stroke, air-cooled, DOHC

Number of cylinders

4

Bore

79.0 mm (3.110 in)

Stroke

59.0 mm (2.323 in)

Displacement

1 157 cm3 (70.6 cu. in)

Compression ratio

9.5 : 1

Carburetor

MIKUNI BSR36

Air cleaner

Non-woven fabric element

Starter system

Electric

Lubrication system

Wet sump

Idle speed

1 300 100 r/min

E-28

1 200 100 r/min

Others

Drive train

Item

Specification

Remark

Clutch

Wet multi-plate type

Transmission

5-speed constant mesh

Gearshift pattern

1-down, 4-up

Primary reduction ratio

1.565 (72/46)

Low

2.384 (31/13)

2nd

1.631 (31/19)

Gear ratios

3rd

1.250 (25/20)

4th

1.045 (23/22)

Top

0.913 (21/23)

Final reduction ratio

3.000 (45/15)

Drive chain

RK GB50GSVZ3, 116 links

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General Information: 0A-10

Chassis

Item

Specification

Remark

Front suspension

Telescopic, coil spring, oil damped

Rear suspension

Link type, coil spring, oil damped

Front suspension stroke

130 mm (5.1 in)

Rear wheel travel

136 mm (5.4 in)

Caster

35 (right & left)

Trail

25 20’

Steering angle

104 mm (4.10 in)

Turning radius

2.8 m (9.2 ft)

Front brake

Disc brake, twin

Rear brake

Disc brake

Front tire size

120/70ZR17M/C (58W), tubeless

Rear tire size

180/55ZR17M/C (73W), tubeless

Electrical

Item

Specification

Remark

lgnition type

Electronic ignition (Transistorized)

lgnition timing

7 B.T.D.C. at 1 300 r/min

E-28

7 B.T.D.C. at 1 200 r/min

Others

Spark plug

NGK JR9B

Battery

12 V 36 kC (10 Ah)/10 HR

Generator

Three-phase A.C. generator

Main fuse

30 A

Fuse

10/10/15/15/10 A

Headlight

12 V 60/55 W (H4)

GSF1200

12 V 55 W (H7) + 12 V 55 W (H7)

GSF1200S

Position light

12 V 5 W

GSF1200

12 V 5W x 2

GSF1200S

Turn signal light

12 V 21 W x 4

Brake light/Taillight

12 V 21/5 W

License plate light

12 V 5 W

Speedometer light

LED

Tachometer light

LED

Neutral indicator light

LED

High beam indicator light

LED

Turn signal indicator light

LED

Oil pressure indicator light

LED

Capacities

Item

Specification

Remark

Fuel tank

Including reserve

20.0 L (5.3/4.4 US/lmp gal)

Reserve

4.4 L (1.2/1.0 US/lmp gal)

Engine oil

Oil change

3 300 ml (3.4/2.9 US/lmp qt)

With filter change

3 500 ml (3.6/3.0 US/lmp qt)

Overhaul

4 600 ml (4.9/4.0 US/lmp qt)

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0A-11 General Information:

Special Tools and Equipment

Special Tools

B649G10108001

TT09900-06106-01

TT09900-06107-02

TT09900-06108-02

TT09900-20102-01

09900-06106

09900-06107

09900-06108

09900-20102

Snap ring pliers

Snap ring pliers

Snap ring pliers

Vernier calipers

(1/20 mm, 200 mm)

TT09900-20202-01

TT09900-20204-01

TT09900-20205-01

TT09900-20508-01

09900-20202

09900-20204

09900-20205

09900-20508

Micrometer

Micrometer

Micrometer

Cylinder gauge set

(1/100 mm, 25 – 50 mm)

(1/100 mm, 75 – 100 mm)

(1/1 000 mm, 0 – 25 mm)

(1/100 mm, 40 – 80 mm)

TT09900-20602-01

TT09900-20605-01

TT09900-20607-01

TT09900-20701-01

09900-20602

09900-20605

09900-20607

09900-20701

Dial gauge

Dial calipers

Dial gauge

Magnetic stand

(1/1 000 mm)

(1/100 mm, 10 – 34 mm)

(1/100 mm)

TT09900-20803-01

TT09900-20805-01

TT09900-21304-01

TT09900-22301-01

09900-20803

09900-20805

09900-21304

09900-22301

09900-22302

Thickness gauge

Tire depth gauge

V-block set

Plastigauge

(100 mm)

TT09900-22403-01

TT09900-25008-01

TT09900-25009-01

TT09910-60611-01

09900-22403

09900-25008

09900-25009

09910-60611

Small bore gauge

Multi circuit tester set

Needle pointed probe set

Universal clamp wrench

(18 – 35 mm)

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General Information: 0A-12

TT09913-50121-01

TT09913-60910-01

TT09913-61510-01

TT09913-70210-01

09913-50121

09913-60910

09913-61510

09913-70210

Oil seal remover

Bearing remover

Bearing remover

Bearing installer set

TT09915-40610-01

TT09915-63210-01

TT09915-64510-01

TT09915-74521-01

09915-40610

09915-63210

09915-64510

09915-74521

Oil filter wrench

Compression gauge adaptor

Compression gauge set

Oil pressure gauge hose

TT09915-74540-01

TT09915-77331-01

TT09916-10911-01

TT09916-14510-02

09915-74540

09915-77331

09916-10911

09916-14510

Oil pressure gauge

Meter (for high pressure)

Valve lapper set

Valve spring compressor

attachment

TT09916-14910-01

TT09916-34542-01

TT09916-34570-01

TT09916-34580-01

09916-14910

09916-34542

09916-34570

09916-34580

Valve lifter attachment

Reamer handle

Valve guide reamer

Valve guide reamer

(4.95 mm)

(10.8 mm)

TT09916-44310-01

TT09916-74521-01

TT09916-74550-01

TT09916-84511-01

09916-44310

09916-74521

09916-74550

09916-84511

Valve guide remover/

Holder body

Band (73 – 85 mm)

Tweezers

installer

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0A-13 General Information:

TT09917-14920-01

TT09917-47010-01

TT09920-34820-01

TT09920-34840-01

09917-14920

09917-47010

09920-34820

09920-34840

Valve adjuster driver

Vacuum pump gauge

Clutch pressure plate holder

Starter clutch holder

TT09920-53740-02

TT09921-20240-01

TT09922-22711-01

TT09923-73210-01

09920-53740

09921-20240

09922-22711

09923-73210

Clutch sleeve hub holder

Bearing remover set

Drive chain cutting and

Bearing remover

joining tool

TT09924-84510-01

TT09924-84521-01

TT09930-10121-01

TT09930-11920-01

09924-84510

09924-84521

09930-10121

09930-11920

Bearing installer set

Bearing installer set

Spark plug wrench set

Torx bit (JT 40H)

TT09930-11940-01

TT09930-30102-01

TT09930-30721-01

TT09940-14911-01

09930-11940

09930-30102

09930-30721

09940-14911

Bit holder

Sliding shaft

Rotor remover

Steering stem nut wrench

TT09940-52841-01

TT09940-52861-01

TT09940-92720-01

TT09941-34513-01

09940-52841

09940-52861

09940-92720

09941-34513

Inner rod holder

Front fork oil seal installer

Spring scale

Steering race installer

TT09941-54911-01

TT09941-74911-01

TT09943-74111-01

09941-54911

09941-74911

09943-74111

Bearing outer race remover

Steering bearing installer

Fork oil level gauge

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Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

Precautions

Precautions for Maintenance

B649G10200001

The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience.

NOTE

More frequent servicing may be required on motorcycles that are used under severe conditions.

General Description

Recommended Fluids and Lubricants

B649G10201001

Refer to “Fuel and Oil Recommendation: in Section 0A”.

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0B-2 Maintenance and Lubrication:

Scheduled Maintenance

Periodic Maintenance Schedule Chart

B649G10205001

NOTE

I = Inspect and clean, adjust, replace or lubricate as necessary.

R = Replace

T = Tighten

Interval

Item

km

1 000

6 000

12 000

18 000

24 000

mile

600

4 000

7 500

11 000

14 500

months

2

12

24

36

48

Air cleaner element

I

I

R

I

Exhaust pipe bolts and muffler bolts

T

T

T

Valve clearance

I

I

I

Spark plugs

I

R

I

R

Fuel line

I

I

I

I

Engine oil

R

R

R

R

R

Engine oil filter

R

R

Throttle cable play

I

I

I

I

I

Engine idle speed

I

I

I

I

I

Throttle valve synchronization

I

I

PAIR (air supply) system

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

I

I

Clean and lubricate every 1 000 km (600 mile).

Brakes

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.

Tires

I

I

I

I

Steering

I

I

I

Front forks

I

I

Rear suspension

I

I

Chassis bolts and nuts

T

T

T

T

T

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Maintenance and Lubrication: 0B-3

Lubrication Points

B649G10205002

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated as follows.

NOTE

Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt orgrime.

Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions.

1

2

3

7

4

5

6

I649G1020001-03

1.

Brake lever holder and throttle cables

5.

Gearshift pivot and left footrest pivot

2.

Brake pedal pivot and right footrest pivot

6.

Center stand pivot and spring hook

3.

Clutch lever holder

7.

Drive chain

4.

Side-stand pivot and spring hook

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0B-4 Maintenance and Lubrication:

Repair Instructions

Air Cleaner Element Removal and Installation

B649G10206001

Inspect air cleaner element

Every 6 000 km (4 000 miles, 12 months)

Replace air cleaner element

Every 18 000 km (11 000 miles, 36 months) Removal

1)Remove the fuel tank. Refer to “Carburetor Assembly Removal and Installation: in Section1G”.

2)Remove the two screws and slide the aircleaner cover backward.

I649G1020002-02

3) Remove the air cleaner element(1).

1

I649G1020003-02

Installation

Reinstall the cleaned or new air cleaner element in the reverse order of removal. Pay attention to thefollowing points:

When installing the air cleaner element into the air cleaner box, make sure that the mark points “A”up.

After cleaning or installing the air cleaner element, drain water from the air cleaner by removing the drain plug.

I649G1020005-01

Air Cleaner Element Inspection and Cleaning

B649G10206002

Refer to “Air Cleaner Element Removal and Installation: ”.

Inspect air cleaner element

Every 6 000 km (4 000 miles, 12 months)

Replace air cleaner element

Every 18 000 km (11 000 miles, 36 months)

Inspection

Inspect the air cleaner element for clogging.

! CAUTION

If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component.

“A”

I649G1020006-01

I649G1020004-02

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Maintenance and Lubrication: 0B-5

Cleaning

Carefully use compressed air to clean the aircleaner element.

! CAUTION

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 cleaner element, restricting air flow through the air cleaner element.

I649G1020007-01

Spark Plug Removal and Installation

B649G10206003

Inspect spark plug

Every 6 000 km (4 000 miles, 12 months)

Replace spark plug

Every 12 000 km (7 500 miles, 24months)

Removal

! WARNING

The hot engine can burn you.

Wait until the engine is cool enough to touch.

!

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 the plug hole and enginedamage may result.

1) Remove the spark plug caps.

I649G1020008-02

2)Remove the spark plugs with the spark plug wrench.

Special tool

(A): 09930–10121 (Spark plug wrench set)

(A)

I649G1020009-02

Installation

Install the spark plugs in the reverse order of removal. Pay attention to the following points:

! CAUTION

Before tightening the spark plug to the specified torque,carefully turnthespark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads.

Install the spark plugs to the cylinder heads byfinger tight, and then tighten them to the specifiedtorque.

Tightening torque

Spark plug: 11 N·m (1.1 kgf-m, 8.0 lb-ft)

Install the spark plug caps onto the spark plugs. Make sure that each spark plug cap is installed in the correct location and direction.

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0B-6 Maintenance and Lubrication:

Spark Plug Inspection and Cleaning

B649G10206004

Refer to “Spark Plug Removal and Installation: ”.

Inspect spark plug

Every 6 000 km (4 000 miles, 12 months)

Replace spark plug

Every 12 000 km (7 500 miles, 24 months)

Heat Range

Check spark plug heat range by observing electrode color.

If it is white or glazed appearing, replace the spark plug with colder type one.

Heat range

Standard

Cold type

Hot type

NGK

JR9B

JR10B

JR8B

Carbon Deposits

Check to see if there 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.

I649G1020010-01

Spark Plug Gap

Measure the spark plug gap using a thickness gauge. Adjust the spark plug gap if necessary.

Spark plug gap

0.6 – 0.7 mm (0.024 – 0.028 in)

Special tool

(A): 09900–20803 (Thickness gauge)

Electrodes Condition

Check to see the worn or burnt condition of the electrodes.

If it is extremely worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread.

Exhaust Pipe Bolt and Muffler Mounting Bolt Inspection

B649G10206021

Tighten exhaust pipe bolt and muffler mounting bolt Initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter.

Check the exhaust pipe bolts, muffler mounting bolts and nut to the specified torque.

Tightening torque

Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft) Muffler mounting bolt (b): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

Muffler connecting bolt (c): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

(a)

(a)

(a)

I649G1020054-03

(b)

(b)

(A)

I649G1020053-02

I649G1020011-03

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Maintenance and Lubrication: 0B-7

Valve Clearance Inspection and Adjustment

B649G10206005

Inspect valve clearance

Initially at 1 000 km (600 miles, 2 month) and every 12 000 km (7 500 miles, 24 months) thereafter.

Valve clearance adjustment must be checked and adjusted, a) at the time of periodic inspection, b) when the valve mechanism is serviced, and c) when the camshafts are removed for servicing.

1)Remove the fuel tank. Refer to “Fuel TankRemoval and Installation: in Section 1G”.

2)Remove the frame head covers. (GSF1200) Refer to “Exterior Parts Removal and Installation: in Section 9D”.

3)Remove the PAIR valve. Refer to “PAIRSystem Removal and Installation: in Section 1B”.

4)Remove all the spark plugs. Refer to “SparkPlug Removal and Installation: ”.

5)Remove the breather cover (1).

1

I649G1020066-01

6)Remove the cylinder head cover. Refer to “Engine Top Side Disassembly: in Section 1D”.

NOTE

The valve clearance specification is different for both intake and exhaust valves.

Valve clearance (When cold)

IN.: 0.10 – 0.15 mm (0.004 – 0.006 in) EX.: 0.18 – 0.23 mm (0.007 – 0.009 in)

NOTE

The camshafts must be at positions “A” or

“B”, in order to check or adjust the valve clearance. Clearance readings should not be taken with the camshafts in any other position than the ones shown.

The valve clearance should onlybe checked when the engine is cold.

I649G1020012-01

7)Remove the CKP sensor cover. Refer to “CKP Sensor Removal and Installation: in Section1H”.

8) Turn the crankshaft clockwise and align the “T” mark on the rotor with the center of the CKP sensor. Also, position the notches “C” on the right end of each camshaft as shown. Then, measure the following valve clearances “D”.

Cylinder #1: Intake and exhaust valve clearances

Cylinder #2: Exhaust valve clearance

Cylinder #3: Intake valve clearance

I649G1020013-02

“C” “C”

I649G1020014-02

“D” “D”

“D”

“D”

I649G1020017-02

Camshaft position

Notch “C” position

faces outside

Measuring position

“D”

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0B-8 Maintenance and Lubrication:

9) Insert the thickness gauge between the valve stem

end and adjusting screw on the rocker arm. If the

Camshaft position

Notch “C” position

clearance is out of specification, hold the lock-nut

faces inside

with a wrench and use the special tools to adjust the

Measuring position

“E”

clearance.

12) Turn the crankshaft and recheck the valve

! CAUTION

clearances.

Both the right and left valve clearances

13) After finishing the valve clearanceadjustment,

should be as closely as possible.

reinstall the following items.

a) CKP sensor cover (Refer to “CKP Sensor

Removal and Installation: in Section1H”.)

(B)

b) Cylinder head cover (Refer to “Engine TopSide

Assembly: in Section 1D”.)

(A)

c)

Breather cover

d) Spark plugs and plug caps (Refer to “SparkPlug

Removal and Installation: ”.)

e) PAIR valve (Refer to “PAIRSystem Removal and

Installation: in Section 1B”.)

f) Frame head covers (for GSF1200) (Referto

“Exterior Parts Removal and Installation: in

I649G1020015-03

Section 9D”.)

Special tool

g)

Fuel tank (Refer to “Fuel Tank Removal and

(A) : 09900–20803 (Thickness gauge) (B):

Installation: in Section 1G”.)

09917–14920 (Valve adjusterdriver)

h)

Seat (Refer to “Exterior Parts Removaland

10) Turn the crankshaft clockwise 360 (one full rotation)

Installation: in Section 9D”.)

and align the “T” mark on the rotor with the center of

Fuel Line Inspection

the CKP sensor. Also, position the notches “C” on

B649G10206006

the right end of each camshaft as shown. Then,

Inspect fuel line

measure the following valve clearances “E”.

• Cylinder #2: Intake valveclearance

Every 6 000 km (4 000 miles, 12 months)

• Cylinder #3: Exhaust valveclearance

Inspect the fuel line in the following procedures:

• Cylinder #4: Intake and exhaust valveclearances

1) Remove the seat. Refer to “Exterior PartsRemoval

11) Measure the valve clearances of theremaining

and Installation: in Section 9D”.

valves “E” and adjust them if necessary.

2) Remove the fuel tank mounting bolts. Refer to “Fuel

Tank Removal and Installation: in Section 1G”.

“C”

“C”

3) Lift up the fuel tank.

4) Inspect the fuel hose for damage and fuel leakage. If

any defects are found, the fuel hose must be

replaced.

I649G1020016-03

“E”

“E”

I649G1020065-01

“E” “E”

I649G1020018-02

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Maintenance and Lubrication: 0B-9

Engine Oil and Filter Replacement

B649G10206007

Replace engine oil

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Replace oil filter

Initially at 1 000 km (600 miles, 2 month) and every 18 000 km (11 000 miles, 36 months) thereafter.

Oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.

Engine Oil Replacement

1)Keep the motorcycle upright.

2)Place an oil pan below the engine, and drainengine oil by removing the oil drain plug (1) and filler cap

(2).

1

I649G1020019-01

2

I649G1020020-01

3)Tighten the oil drain plug (1) to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 3.3 L of oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Tightening torque

Oil drain plug (a): 23 N·m (2.3 kgf-m, 16.5 lb-ft)

1, (a)

I649G1020021-03

4)Start up the engine and allow it to run forseveral minutes at idling speed.

5)Turn off the engine and wait about three minutes, then check the oil level through the inspection window (3). If the level is below the “L” mark, addoil to the “F” mark. If the level is above the “F” mark, drain the oil until the level reaches the “F” mark.

3

I649G1020022-01

Oil Filter Replacement

1)Drain engine oil as described in the engineoil replacement procedure.

2)Remove the oil filter (1) using the special tool.

Special tool

(A): 09915–40610 (Oil filter wrench)

(A)

1

I649G1020023-02

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0B-10 Maintenance and Lubrication:

3) Apply engine oil lightly to the O-ring of new oil filter,

Throttle Cable Play Inspection and Adjustment

before installation.

B649G10206012

! CAUTION

Inspect throttle cable play

Initially at 1 000 km (6 000 miles, 2 month) and every

ONLY USE A GENUINE SUZUKI

6 000 km (4 000 miles, 12 months) thereafter.

MOTORCYCLE OIL FILTER.

Inspect and adjust the throttle cable play “a” as follows.

Other manufacturer’s oil filters may differin

Throttle cable play “a”

thread specifications (thread diameter and

pitch), filtering performance and durability

2.0 – 4.0 mm (0.08 – 0.16 in)

which may lead to engine damage or oil

leaks. Also, do not use a genuine Suzuki

automobile oil filter on this motorcycle.

4)Install a new oil filter. Turn it by hand until you feel that the oil filter O-ring contacts the oil filter mounting

surface. Then, tighten the oil filter two full turns (or to

“a”

specified torque) using the special tool.

NOTE

To properly tighten the oil filter, use the

special tool. Never tighten the oil filter by

I649G1020026-01

hand only.

1) Loosen the lock-nut (1) of the throttle pullingcable

Special tool

(2).

2) Turn the adjuster(3) in or out until the throttle cable

(A): 09915–40610 (Oil filter wrench)

Tightening torque

play “a” (at the throttle grip) is between 2 – 4 mm

(0.08 – 0.16 in).

Oil filter (a): 20 N·m (2.0 kgf-m, 14.5 lb-ft)

3) Tighten the lock-nut (1) while holding theadjuster

1, (a)

(3).

(A)

1

3

2

I649G1020024-03

5) Add new engine oil and check the oil level is as

described in the engine oil replacement procedure.

I649G1020027-01

Necessary amount of engine oil

! WARNING

Oil change: 3.3 L (3.4/2.9 US/lmp qt)

Oil and filter change: 3.5 L (3.6/3.0 US/lmpqt)

After the adjustment is completed, check that

Engine overhaul: 4.6 L (4.9 /4.0 US/lmp qt)

handlebar movement does not raise the

engine idle speed and that the throttle grip

returns smoothly and automatically.

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Maintenance and Lubrication: 0B-11

Engine Idle Speed Inspection and Adjustment

B649G10206011

Inspect engine idle speed

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

NOTE

Make this adjustment when the engine is hot.

Start the engine, turn the throttle stop screw (1) and set the engine idle speed “a”.

Engine idle speed “a”

1300 100 r/min (E-28)

1200 100 r/min (Others)

1

I649G1020025-02

Throttle Valve Synchronization

B649G10206013

Inspect throttle valve synchronization Every 12 000 km (7 500 miles, 24months)

Inspect the throttle valve synchronization periodically. Refer to “Carburetor Synchronization: in Section 1G”.

PAIR System Inspection

B649G10206014

Inspect PAIR system

Every 12 000 km (7 500 miles, 24months)

Inspect the PAIR (air supply) system periodically.Refer to “PAIR System Inspection: ”.

Clutch SystemInspection

B649G10206026

Inspect clutch hose and clutch fluid Every 6 000 km (4 000 miles, 12 months)

Replace clutch hose Every 4 years

Replace clutch fluid Every 2 years

! WARNING

The clutch system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as siliconebased or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for a long period of mine. Check the clutch hose and hose joints for cracks and fluid leakage.

Clutch Fluid Level Check

1)Keep the motorcycle upright and placethe handlebars straight.

2)Check the clutch fluid level by observing thelower limit line on the clutch fluid reservoir.

When the clutch fluid level is below the lowerlimit line, replenish with clutch fluid that meets the following specification.

BF: Brake fluid (DOT 4)

I649G1020028-01

Clutch Hose Inspection

1)Remove the left frame cover. Refer to “Exterior Parts Removal and Installation: in Section 9D”.

2)Remove the fuel tank. Refer to “Fuel TankRemoval and Installation: in Section 1G”.

3)Inspect the clutch hose for crack, damage or clutch fluid leakage. If it is defected, replace the clutch hose with a new one.

I649G1020031-01

4)After finishing the clutch hose inspection,reinstall the removed parts.

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0B-12 Maintenance and Lubrication:

Clutch Hose Replacement

B649G10206031

Refer to “Clutch Hose Removal and Installation: in Section 5C”.

Air Bleeding from Clutch Fluid Circuit

B649G10206032

Refer to “Air Bleeding from Clutch Fluid Circuit: ”.

Clutch Fluid Replacement

B649G10206033

Refer to “Clutch Fluid Replacement: in Section 5C”.

Drive Chain Inspection and Adjustment

B649G10206028

Inspect drive chain

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Drive Chain Visual Check

1)With the transmission in neutral, support the motorcycle using the center-stand and turn therear wheel slowly by hand.

2)Visually check the drive chain for the possible defects listed as follows. If any defects are found, the drive chain must be replaced. Refer to “Drive Chain Replacement: in Section 3A”.

Loose pins

Damaged rollers

Dry or rusted links

Kinked or binding links

Excessive wear

Improper chain adjustment

Missing O-ring seals

NOTE

When replacing the drive chain, replace the drive chain and sprockets as a set.

2

1

I649G1020032-01

Drive Chain Length Inspection

1)Remove the cotter pin. (For E-28)

2)Loosen the axle nut (1).

3)Loosen the chain adjuster lock-nuts (2).

4)Give tension to the drive chain fully by turningboth chain adjuster bolts (3).

2

3

1

2

3

I649G1020033-01

5)Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

Drive chain 20-pitch length Service limit: 319.4 mm (12.57 in)

I649G1020034-01

6)After finishing the drive chain lengthinspection, adjust the drive chain slack.

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Maintenance and Lubrication: 0B-13

Drive Chain Slack Adjustment

1)Place the motorcycle on its side-stand foraccurate adjustment.

2)Loosen the axle nut (1).

3)Loosen the chain adjuster lock-nuts (2).

4)Loosen or tighten both chain adjuster bolts (3) until there is 20 – 30 mm (0.8 – 1.2 in) “a” of slack atthe middle of the chain between the engine and rear sprockets as shown.

! CAUTION

The reference marks “A” on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.

Drive chain slack “a”

Standard 20 – 30 mm (0.8 – 1.2 in)

“A” “A” 1

I649G1020035-02

“a”

I649G1020036-01

5)After adjusting the drive chain, tighten the axle nut

(1) to the specified torque.

6)Tighten both chain adjuster lock-nuts (2) securely.

Tightening torque

Rear axle nut: 100 N·m (10.0 kgf-m, 72.5 lb-ft)

7)Install a new cotter pin. (For E-28)

8) Recheck the drive chain slack after tighteningthe axle nut.

Drive Chain Cleaning and Lubricating

B649G10206029

Clean and lubricate drive chain Every 1 000 km (600 miles)

Clean and lubricate the drive chain in the following procedures:

1)Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

! CAUTION

Do not use trichloroethylene, gasoline or any similar solvent.

These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain.

2)After cleaning and drying the chain, oil it witha heavyweight motor oil.

!CAUTION

Do not use any oil sold commercially as “drive chain oil”. Such oil can damagethe O-rings.

The standard drive chain is a RK GB50GSVZ3. SUZUKI recommends to use this standard drive chain as a replacement.

I649G1020037-01

Brake System Inspection

B649G10206030

Inspect brake system

Initially at 1 000 km (600 miles, 2 month) and every 6

000 km (4 000 miles, 12 months) thereafter.

Inspect brake hose and brake fluid Every 6 000 km (4 000 miles, 12 months)

Replace brake hose Every 4 years

Replace brake fluid Every 2 years

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0B-14 Maintenance and Lubrication:

!WARNING

The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based 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 stored for a long period of time.

Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oilleakage before riding.

Brake Fluid Level Check

1)Keep the motorcycle upright and placethe handlebars straight.

2)Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs. When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.

BF: Brake fluid (DOT 4)

I649G1020038-01

I649G1020039-01

Brake Pads Check

The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad Replacement: in Section 4B” and “Rear Brake Pad Replacement: in Section 4C”.

! CAUTION

Replace the brake pad as a set, otherwise braking performance will be adversely affected.

“A”

I649G1020040-02

“A”

I649G1020041-02

Front Brake Hose Inspection

Inspect the brake hoses and hose joints for crack, damage or oil leakage. If any defects are found, replace the brake hose with a new one.

I649G1020047-01

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Maintenance and Lubrication: 0B-15

Rear Brake Hose Inspection

Inspect the brake hose for crack, damage or brakeoil leakage. If any defects are found, replace the brake hose with a new one.

I649G1020048-01

Brake Pedal Height Inspection and Adjustment

1)Inspect the brake pedal height “a” between the pedal top face and footrest.

Adjust the brake pedal height if necessary.

Brake pedal height “a” Standard: 60 mm (2.4 in)

2)Loosen the lock-nut (1).

3)Turn the push rod (2) until the brake pedal is 60mm (2.4 in) below the top of the footrest.

4)Tighten the lock-nut (1) securely.

Tightening torque

Rear master cylinder rod lock-nut (a): 18 N·m ( 1.8 kgf-m, 13.0 lb-ft)

2

1,

(a)

“a”

I649G1020042-04

Rear Brake Light Switch Adjustment

B649G10206036

Refer to “Rear Brake Light Switch Inspection and Adjustment: in Section 4A”.

Brake Hose Replacement

B649G10206037

Refer to “Front Brake Hose Removal and Installation: in Section 4A” and “Rear Brake Hose Removal and Installation: in Section 4A”.

Air Bleeding from Brake Fluid Circuit

B649G10206034

Refer to “Air Bleeding from Brake Fluid Circuit: in Section 4A”.

Brake Fluid Replacement

B649G10206035

Refer to “Brake Fluid Replacement: in Section 4A”.

Tire Inspection

B649G10206017

Inspect tire

Every 6 000 km (4 000 miles, 12months)

Tire Tread Condition

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification.

Special tool

: 09900–20805 (Tire depth gauge)

Tire tread depth (Service limit) Front: 1.6 mm (0.06 in)

Rear: 2.0 mm (0.08 in)

I310G1020068-01

Tire Pressure

If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows.

Cold inflation tire pressure

Solo riding

Dual riding

kPa

kgf/cm2

psi

kPa

kgf/cm2

psi

Front

250

2.50

36

250

250

36

Rear

250

2.50

36

250

250

36

I310G1020069-01

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0B-16 Maintenance and Lubrication:

! CAUTION

Front Fork Inspection

B649G10206019

The standard tire fitted on this motorcycle is

Inspect front fork

120/70 ZR17 M/C (58W) for front and 180/55

Every 12 000 km (7 500 miles, 24months)

ZR17 M/C (73W) for rear. The use of tires

Inspect the front forks for oil leakage, scoring or

other than those specified may cause

instability. It is highly recommended to use a

scratches on the outer surface of the inner tubes.

SUZUKI Genuine Tire.

Replace any defective parts, if necessary. Refer to

“Front Fork Parts Inspection: in Section 2B”.

Tire type

DUNLOP

Front: D218 FN

Rear: D218 N

Steering System Inspection

B649G10206018

Inspect steering system

Initially at 1 000 km (600 miles, 2 month) and every

12 000 km (7 500 miles, 24 months) thereafter.

Steering should be adjusted properly for smooth turning

I649G1020050-01

of handlebars and safe running. Overtight steering

prevents smooth turning of the handlebars and too loose

Rear Suspension Inspection

steering will cause poor stability.

B649G10206020

1) Check that there is no play in the front fork.

Inspect rear suspension

2) Support the motorcycle so that the front wheel isoff

Every 12 000 km (7 500 miles, 24months)

the ground, with the wheel facing straightahead,

Inspect the rear shock absorbers for oil leakage and

grasp the lower fork tubes near the axle and pull

check that there is no play in the swingarm.

forward.

Replace any defective parts, if necessary. Refer to “Rear

If play is found, readjust the steering. Refer to

Shock Absorber Removal and Installation: in Section

“Steering Tension Adjustment: in Section 6B”.

2C”, “Cushion Lever Removal and Installation: in

Section 2C” and “Swingarm / Cushion Rod Removal and

Installation: in Section 2C”.

I649G1020049-01

I649G1020051-01

I649G1020052-01

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Maintenance and Lubrication: 0B-17

Chassis Bolt and Nut Inspection

B649G10206022

Tighten chassis bolt and nut

Initially at 1 000 km (600 miles, 2 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Check that all chassis bolts and nuts are tightened to their specified torque.

2,

(b)

2,

(b)

1,

(a)

I649G1020055-04

1.

Steering stem head nut

: 65 N m (6.5 kgf-m, 47.0lb-ft)

2.

Front fork cap bolt

: 23 N m (2.3 kgf-m, 16.5lb-ft)

3.

Handlebar holder bolt

5, (c)

4,

(b)

2,

(b)

I649G1020056-05

2. Front fork cap bolt

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

4.

Front fork upper clamp bolt

: 8 N m (0.8 kgf-m, 6.0 lb-ft)

5.

Air bleeder valve (Clutch)

8, (b) 7, (b)

6,

(d)

6,

(d)

I649G1020057-03

6.

Front brake/Clutch master

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

cylinder mounting bolt

7.

Brake hose union bolt (Front

: 10 N m (1.0 kgf-m, 7.0lb-ft)

brake)

8.

Clutch hose union bolt

10, (f)

9,

(e)

I649G1020058-03

9.

Rear shock absorber mounting

: 50 N m (5.0 kgf-m, 36.0lb-ft)

nut (Upper)

10.

Cushion rod mounting nut

: 78 N m (7.8 kgf-m, 56.5lb-ft)

12,

(f)

11,

(e)

13,

(f)

I649G1020059-03

11. Rear shock absorber mounting

: 50 N m (5.0 kgf-m, 36.0 lb-ft)

nut (Lower)

12.

Cushion lever mounting nut

: 78 N m (7.8 kgf-m, 56.5 lb-ft)

13.

Cushion rod mounting nut

14, (b)

I649G1020060-03

14. Front fork lower clamp bolt

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

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0B-18 Maintenance and Lubrication:

21, (o) 17, (h)

16, (b)

19,

15,

(g)

(b)

18,

(i)

20,

(b)

I649G1020061-04

15.

Front axle bolt

21.

Air bleeder valve (Brake)

16.

Front axle pinch bolt

:

23 N m (2.3 kgf-m, 16.5 lb-ft)

17.

Front brake caliper mounting

:

100 N m (10.0 kgf-m, 72.5lb-ft)

bolt

18.

Front brake caliper housing

:

26 N m (2.6 kgf-m, 19.0 lb-ft)

bolt

19.

Brake hose union bolt (Front)

:

21 N m (2.1 kgf-m, 15.0 lb-ft)

20.

Brake disc bolt (Front)

: 7.5 N m (0.75 kgf-m, 5.5 lb-ft)

21, (j)

24, (b)

22, (b)

23, (k)

22, (b)

I649G1020062-03

21. Air bleeder valve (Brake)

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

22. Brake disc bolt (Rear)

: 6 N m (0.6 kgf-m, 4.5 lb-ft)

23. Rear brake caliper mounting bolt

:

22 N m (2.2 kgf-m, 16.0 lb-ft)

24. Brake hose union bolt (Rear)

26,

(b)

29,

(b)

27, (b)

28,

(m) 25,

(l)

I649G1020063-04

25.

Front footrest bolt

29.

Front footrest bracket

mounting bolt

26.

Brake hose union bolt (Rear)

: 23 N m (2.3 kgf-m, 16.5 lb-ft)

27.

Rear brake master cylinder

:

35 N m (3.5 kgf-m, 25.5 lb-ft)

mounting bolt

28.

Rear brake master cylinder rod

:

18 N m (1.8 kgf-m, 13.0 lb-ft)

lock-nut

30,

(n)

31, (g)

30,

(n)

I649G1020064-04

30.

Rear sprocket nut

: 100 N m (10.0 kgf-m, 72.5 lb-ft)

31.

Rear axle nut

: 60 N m (6.0 kgf-m, 43.5 lb-ft)

Refer to “Compression Pressure Check: in Section1D”.

Oil Pressure Check

B649G10206024

Refer to “Oil Pressure Check: in Section 1E”.

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Maintenance and Lubrication: 0B-19

Specifications

Tightening TorqueSpecifications

B649G10207001

Fastening part

Tightening torque

Note

N m

kgf-m

lb-ft

Spark plug

11

1.1

8.0

Exhaust pipe bolt

23

2.3

16.5

Muffler mounting bolt

23

2.3

16.5

Muffler connecting bolt

23

2.3

16.5

Oil drain plug

23

2.3

16.5

Oil filter

20

2.0

14.5

Rear axle nut

100

10.0

72.5

Rear master cylinder rod lock-nut

18

1.8

13.0

NOTE

The specified tightening torque is also described in the following. “Chassis Bolt and Nut Inspection: ”

Reference:

For the tightening torque of fastener not specified in this section, refer to “Tightening Torque Specifications: in Section 0C”.

Special Tools and Equipment

Recommended Service Material

B649G10208001

Material

SUZUKI recommended product or Specification

Note

Brake fluid

DOT 4

/

Special Tool

B649G10208002

09900–20803

09900–20805

Thickness gauge

Tire depth gauge

/

09915–40610

09917–14920

Oil filter wrench

Valve adjuster driver

/

09930–10121

Spark plug wrench set

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0C-1 Service Data:

Service Data

Specifications

Service Data

Valve + Guide

B649G10307003

Unit: mm (in)

Item

Standard

Limit

Valve diameter

IN.

28.5 (1.12)

EX.

25 (1.0)

Valve clearance (when cold)

IN.

0.10 – 0.15 (0.004 – 0.006)

EX.

0.18 – 0.23 (0.007 – 0.009)

Valve guide to valve stem clearance

IN.

0.020 – 0.047 (0.0008 – 0.0019)

EX.

0.040 – 0.067 (0.0016 – 0.0026)

Valve stem deflection

IN. & EX.

0.35

(0.014)

Valve guide I.D.

IN. & EX.

5.000 – 5.012 (0.1969 – 0.1973)

Valve stem O.D.

IN.

4.965 – 4.980 (0.1955 – 0.1961)

EX.

4.945 – 4.960 (0.1947 – 0.1953)

Valve stem runout

IN. & EX.

0.05

(0.002)

Valve face thickness

IN. & EX.

0.5

(0.02)

Valve stem end length

IN. & EX.

2.5

(0.10)

Valve seat width

IN. & EX.

0.9 – 1.1 (0.035 – 0.043)

Valve head radial runout

IN. & EX.

0.03

(0.001)

Valve spring free length (IN. & EX.)

INNER

35.0 (1.38)

OUTER

37.8 (1.49)

INNER

53 – 65 N (5.3 – 6.5 kgf, 11.7 – 14.3 lbs)

at length 28 mm (1.10 in)

Valve spring tension (IN. & EX.)

OUTER

131 – 151 N (13.1 – 15.1 kgf, 28.9 – 33.3 lbs)

at length 31.5 mm (1.24 in)

Camshaft + Cylinder Head

Unit: mm (in)

Item

Standard

Limit

Cam height

IN.

33.58 – 33.62 (1.3220 – 1.3236)

33.28

(1.3102)

EX.

32.65 – 32.69 (1.2854 – 1.2870)

32.35

(1.2736)

Camshaft journal oil clearance

IN. & EX.

0.032 – 0.066 (0.0013 – 0.0026)

0.150

(0.0059)

Camshaft journal holder I.D.

IN. & EX.

22.012 – 22.025 (0.8666 – 0.8671)

Camshaft journal O.D.

IN. & EX.

21.959 – 21.980 (0.8645 – 0.8654)

Camshaft runout

IN. & EX.

0.10

(0.004)

Cam chain pin (at arrow “3”)

24th pin

Rocker arm I.D.

IN. & EX.

12.000 – 12.018 (0.4724 – 0.4731)

Rocker arm shaft O.D.

IN. & EX.

11.973 – 11.984 (0.4714 – 0.4718)

Cylinder head distortion

0.20

(0.008)

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Service Data: 0C-2

Cylinder + Piston + Piston Ring

Unit: mm (in)

Item

Standard

Limit

Compression pressure

1 250 kPa (12.5 kgf/cm2, 178 psi)

875 kPa

(8.75 kgf/cm2, 124 psi)

Compression pressure difference

200 kPa

(2 kgf/cm2, 28 psi)

Piston-to-cylinder clearance

0.050 – 0.060 (0.0020 – 0.0024)

0.120 (0.0047)

Cylinder bore

79.000 – 79.015 (3.1102 – 3.1108)

79.080 (3.1134)

Piston diameter

78.945 – 78.960 (3.1081 – 3.1087)

78.880 (3.1055)

Measure 15 mm (0.6 in) from the skirt end.

Cylinder distortion

0.20 (0.008)

Piston ring free end gap

1st

N

Approx. 10 (0.39)

8.0 (0.31)

2nd

2N

Approx. 9.5 (0.37)

7.6 (0.30)

Piston ring end gap

1st

0.15 – 0.30 (0.006 – 0.012)

0.5 (0.020)

2nd

0.30 – 0.45 (0.012 – 0.018)

0.7 (0.028)

Piston ring-to-groove clearance

1st

0.180 (0.007)

2nd

0.150 (0.006)

1st

1.01 – 1.03 (0.040 – 0.041)

Piston ring groove width

2nd

1.01 – 1.03 (0.040 – 0.041)

Oil

2.01 – 2.03 (0.079 – 0.080)

Piston ring thickness

1st

0.975 – 0.990 (0.0384 – 0.0390)

2nd

0.970 – 0.990 (0.038 – 0.039)

Piston pin bore

20.002 – 20.008 (0.7875 – 0.7877)

20.030 (0.7886)

Piston pin O.D.

19.992 – 20.000 (0.7871 – 0.7874)

19.980 (0.7866)

Conrod + Crankshaft

Unit: mm (in)

Item

Standard

Limit

Conrod small end I.D.

20.010 – 20.018 (0.7878 – 0.7881)

20.040 (0.7890)

Conrod big end side clearance

0.10 – 0.20 (0.004 – 0.008)

0.30 (0.012)

Conrod big end width

20.95 – 21.00 (0.825 – 0.827)

Crank pin width

21.10 – 21.15 (0.831 – 0.833)

Conrod big end oil clearance

0.032 – 0.056 (0.0013 – 0.0022)

0.080 (0.0031)

Crank pin O.D.

37.976 – 38.000 (1.4951 – 1.4961)

Crankshaft journal oil clearance

0.020 – 0.044 (0.0008 – 0.0017)

0.080 (0.0031)

Crankshaft journal O.D.

35.976 – 36.000 (1.4164 – 1.4173)

Crankshaft thrust clearance

0.04 – 0.08 (0.0016 – 0.0031)

Crankshaft thrust bearing thickness

Left side

2.360 – 2.520 (0.0929 – 0.0992)

Right side

2.420 – 2.440 (0.0953 – 0.0961)

Crankshaft runout

0.05 (0.002)

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0C-3 Service Data:

Oil Pump

Item

Standard

Limit

Oil pump reduction ratio

1.703 (72/46 x 37/34)

Oil pressure (at 60 C, 140 F)

Above 300 kPa (3.0 kgf/cm2, 43 psi)

Below 600 kPa (6.0 kgf/cm2, 85psi)

at 3 000 r/min.

Clutch

Unit: mm (in)

Item

Standard

Limit

Clutch drive plate thickness

2.92 – 3.08 (0.115 – 0.121)

2.62 (0.103)

Clutch drive plate claw width

13.0 (0.51)

Clutch driven plate distortion

0.10 (0.004)

Clutch spring free height

3.1 (0.12)

Clutch master cylinder bore

14.000 – 14.043 (0.5511 – 0.5529)

Clutch master cylinder piston diam

13.957 – 13.984 (0.5495 – 0.5506)

Clutch release cylinder bore

38.18 – 38.23 (1.503 – 1.505)

Clutch release cylinder piston diam

38.08 – 38.13 (1.500 – 1.501)

Transmission + Drive Chain

Unit: mm (in) Except ratio

Item

Standard

Limit

Primary reduction ratio

1.565 (72/46)

Final reduction ratio

3.000 (45/15)

1st (Low)

2.384 (31/13)

2nd

1.631 (31/19)

Gear ratios

3rd

1.250 (25/20)

4th

1.045 (23/22)

5th (Top)

0.913 (21/23)

Gearshift-fork to gearshift-fork

No.1, No.2 &

0.1 – 0.3 (0.004 – 0.012)

0.50 (0.020)

groove clearance

No.3

Gearshift fork groove width

No.1, No.2 &

5.0 – 5.1 (0.197 – 0.201)

No.3

Gearshift fork thickness

No.1, No.2 &

4.8 – 4.9 (0.189 – 0.193)

No.3

Type

RK GB50GSVZ3

Drive chain

Links

116 links

20-pitch length

319.4 (12.57)

Drive chain slack

20 – 30 (0.8 – 1.2)

Gearshift lever height

55 (2.2)

Carburetor

Item

E-02, 19, 24

Specification

E-28

Carburetor type

MIKUNI BSR36

Bore size

36 mm (1.42 in)

I.D. No.

49G0

49G1

Idle r/min.

1 200 100 r/min

1 300 100 r/min

Float height

13.0 1.0 mm (0.51 0.04 in)

Main jet (M.J.)

#100

Jet needle (J.N.)

5C70-3rd

5C71

Needle jet (N.J.)

P-0M

Throttle valve (Th. V.)

#100

Pilot jet (P.J.)

#15

Pilot screw (P.S.)

PRE-SET (3-1/2 turns back)

Throttle cable play (pulling cable)

2.0 – 4.0 mm (0.08 – 0.16 in)

Starter (enricher) plunger cable play

0.5 – 1.0 mm (0.02 – 0.04 in)

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Service Data: 0C-4

Electrical

Unit: mm (in)

Item

Specification

Note

Ignition timing

7 B.T.D.C. at 1 300 r/min.

E-28

7 B.T.D.C. at 1 200 r/min.

Others

Firing order

1 2 4 3

Spark plug

Type

NGK: JR9B

Gap

0.6 – 0.7 (0.024 – 0.028)

Spark performance

Over 8 (0.3) at 1 atm.

CKP sensor resistance

Approx. 130 – 200

Tester range: (x 100 )

CKP sensor peak voltage

1.0 V and more

Primary

(+) tap – (–) tap

Tester range: (x 1 )

Approx. 2 – 4

Ignition coil resistance

Secondary

Spark plug cap – Spark plug cap

Tester range: (x 1 k )

Approx. 30 – 40 k

Ignition coil primary peak voltage

140 V and more

Generator

Slip ring O.D.

Limit: 14.0 (0.55)

DENSO

Brush length

Limit: 4.5 (0.18)

Generator maximum output

More than 550 W at 5 000 r/min.

Regulated voltage

13.5 – 15 V at 5 000 r/min.

Starter motor brush length

Standard

12.5 (0.49)

Limit

6.0 (0.24)

Starter relay resistance

3 – 6

Type designation

FT12A-BS

Battery

Capacity

12 V 36.0 kC (10 Ah)/10 HR

Standard electrolyte S.G.

1.320 at 20 C (68 F)

Headlight

HI

10 A

LO

10 A

Fuse size

Ignition

15 A

Signal

15 A

Meter

10 A

Main

30 A

Wattage

Unit: W

Item

GSF1200

Specification

GSF1200S

Headlight

HI

60

55

LO

55

55

Parking or position light

5

5 x 2

Brake light/Taillight

21/5

Turn signal light

21 x 4

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 indicator light

LED

License plate light

5

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0C-5 Service Data:

Brake + Wheel

Unit: mm (in)

Item

Standard

Limit

Rear brake pedal height

60 (2.4)

Brake disc thickness

Front

4.8 – 5.2 (0.189 – 0.205)

4.5 (0.18)

Rear

4.8 – 5.2 (0.189 – 0.205)

4.5 (0.18)

Brake disc runout

0.30 (0.012)

Master cylinder bore

Front

15.870 – 15.913 (0.6248 – 0.6264)

Rear

14.000 – 14.043 (0.5512 – 0.5529)

Master cylinder piston diameter

Front

15.827 – 15.854 (0.6231 – 0.6242)

Rear

13.957 – 13.984 (0.5495 – 0.5506)

Front

Leading

30.230 – 30.306 (1.1902 – 1.1931)

Brake caliper cylinder bore

Trailing

33.960 – 34.036 (1.3370 – 1.3400)

Rear

38.180 – 38.256 (1.5031 – 1.5061)

Front

Leading

30.150 – 30.200 (1.1870 – 1.1890)

Brake caliper piston diameter

Trailing

33.884 – 33.934 (1.3340 – 1.3360)

Rear

38.098 – 38.148 (1.4999 – 1.5019)

Wheel rim runout

Axial

2.0 (0.08)

Radial

2.0 (0.08)

Wheel axle runout

Front

0.25 (0.010)

Rear

0.25 (0.010)

Wheel rim size

Front

17 M/C x MT3.50

Rear

17 M/C x MT5.50

Suspension

Unit: mm (in)

Item

Standard

Limit

Front fork stroke

130 (5.1)

Front fork inner tube O.D.

43 (1.69)

Front fork spring free length

392.8 (15.46)

384 (15.1)

Front fork oil level

107 (4.2)

Front fork spring adjuster

3rd groove from top

Rear shock absorber spring adjuster

4th position

GSF1200

1-1/8 turns out from

Rear shock absorber damping force

stiffest position

Rebound

adjuster

GSF1200S

1-1/4 turns out from

stiffest position

Rear wheel travel

136 (5.4)

Swingarm pivot shaft runout

0.3 (0.01)

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Перевод и редактирование сервис-мануала Suzuki GSF1200 Bandit (2001-2005) закончено.

Мануал поступил в продажу.
Рекомендуем поторопиться с оформлением заказа, первый тираж разлетается как горячие пирожки. Когда будет напечатан второй тираж неизвестно. 
Планируемая дата старта продаж 25.06.2018г.

Сервис Мануал на мотоцикл Suzuki GSF1200 Bandit (2001-2005), на Русском языке. Продаётся в виде напечатанной книги, в формате А4. 

Руководство по ремонту и обслуживанию мотоцикла Suzuki GSF1200 Bandit (2001-2005)  содержит инструкции по разборке и сборке всех узлов мотоцикла, процедуры настройки и поиска неисправностей, 370стр. + электросхемы внутри.

Suzuki GSF1200 Bandit (2001-2005)

Оформи заказ прямо сейчас

Оставь отзыв и получи ПОДАРОК

брелок с логотипом

БЕСПЛАТНАЯ ДОСТАВКА

Переведённые на Русский язык сервис мануалы для мотоциклов. Продаются и высылаются по почте в виде книги. Работа авторская и выполнена вручную. 
В электронном виде мануалы не распространяются! 
Количество переведённых сервис мануалов постепенно увеличивается.

Комментарии:

  • ВКонтакте

Андрей Вдовин

О нашей книге.

vdovin

«Огромное спасибо!!! Мануал просто огонь!!! В нем я нашёл даже больше чем ожидал. Женя, ты сверхчеловек!!!!!»

Сергей Игнатов

О нашей книге.

ignatov

«Женя, спасибо, книга блеск я счастлив как «слон»»

Димыч Дубов

О нашей книге.

dimych

«. . . Особенно понравились плакаты, хорошая шпаргалка в гараже. Рекомендую.«

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Руководство на английском языке по ремонту мотоциклов Suzuki GSF1250/GSF1250A/GSF1250S/GSF1250SA.

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