suzuki GSF1200, GSF1200S Service Manual

GSF1200/GSF1200S

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99500-39280-01E

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.

TABLE OF CONTENTS

......................................................................

Engine

Mechanical.................................................1D-1

Fuel

System

...........................................................1G-1

Charging

System.....................................................1J-1

......................................................................

Rear

Suspension....................................................2C-1

......................................................................

Steering

General

Diagnosis

...................................

6A-1

......................................................................

Wiring

Systems

......................................................

9A-1

Lighting

Systems....................................................

9B-1

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

Engine General Information and Diagnosis........... 1A-1

Emission Control Devices ...................................... 1B-1

1-1

Engine Lubrication System .................................... 1E-1

Engine Cooling System.......................................... 1F-1

Ignition System.......................................................1H-1

Starting System....................................................... 1I-1

Exhaust System.....................................................1K-1

Suspension

Precautions

Suspension General Diagnosis.............................. 2A-1

Front Suspension ...................................................2B-1

Wheels and Tires ...................................................2D-1

Driveline / Axle

Precautions

Drive Chain / Drive Train / Drive Shaft ................... 3A-1

Brake................................................................................. .. 4-i

Precautions

Brake Control System and Diagnosis .................... 4A-1

Front Brakes........................................................... 4B-1

Rear Brakes ...........................................................4C-1

Transmission / Transaxle............................................ .. 5-i

Precautions

Manual Transmission............................................. 5B-1

Clutch .....................................................................5C-1

......................................................................

................................................................

......................................................................

.. 2-i

2-1

.. 3-i

3-1

4-1

5-1

Steering............................................................................ .. 6-i

Precautions

Steering / Handlebar ..............................................6B-1

Body and Accessories.................................................... 9-i

Precautions

Combination Meter / Fuel Meter / Horn..................9C-1

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

Body Structure....................................................... 9E-1

......................................................................

6-1

9-1

Section 00

Precautions

CONTENTS

Table of Contents 00- i

Precautions.................................................... 00-1

Precautions

Warning / Caution / Note

.............................................

.....................

00-1

General Precautions

Precautions for Electrical Circuit Service.............. 00-2

.................................................

00-1

Precautions:

Precautions

Warning

Caution

Note

B649G10000001

General

Precautions

B649G10000002

•

Never

use

gasoline

asacleaning

solvent.

Precautions

Please read this manual and follow its instructions carefully. To emphasize 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

•

To avoid 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 and fittings related to the system for leaks.

CAUTION

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.

WARNING

•

Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle.

•

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

•

When it is necessary to run the engine indoors, make sure that exhaust gas is 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 material manufacturer’s instructions.

•

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

•

When removing parts that 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 tools when instructed.

•

Make sure that all parts used in reassembly are clean. Lubricate them 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 tightening torque.

•

Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, selflocking nuts, cotter pins, circlips and certain other parts as specified, be sure to 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 is completely seated in its groove and securely fitted.

•

Precautions

for

Electrical

Circuit

Service

B649G10000003

Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.

•

After reassembling, check partsfor tightness and proper operation.

•

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

•

To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

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.

Precautions:

•

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.

00-2

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/coupler for looseness or bending.

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.

I649G1000013-01

1. Coupler

•

When connecting meter probe from the terminal side

2. Probe

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.

00-3 Precautions:

4“A”3

•

When

fuse

blows,

always

investigate

the

cause,

•

Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc.

•

Be careful not to touch the electrical terminals of the Ignitor unit and ABS control unit/HU. The static electricity from your body may damage this part.

I649G1000030-01

3. Coupler 4. Probe “A”: Where male terminal fits

Fuse

correct it and then replace the fuse.

•

Do not use a fuse of a different capacity.

•

Do not use wire or any other substitute for the fuse.

I649G1000001-01

Ignitor unit / Various sensors / ABS control 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.

I310G1000008-01

•

When disconnecting and connecting the Ignitor unit and ABS control unit/HU couplers, make sure to turn OFF the ignition switch, or electronic parts may get damaged.

I649G1000031-01

1. Ignition S/W

•

Never allow dust or water to contact the ABScontrol unit/HU.

I649G1000004-01

I649G1000003-01

•

The ABS control unit/HU cannot be disassembled. 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.

Precautions:

•

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 not be obtained and personal injury may result.

00-4

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

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.

“D”

“F”

00-5

Precautions:

“A”

Ignitor

“B”

“C”

“B”

Ignitor

“C”

“

B-2”Ignitor

“

B-1

”

“C”

Disconnect the negative (–) cable from the battery.

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

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.

Continuity check

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”

I649G1000019-03

Disconnect the coupler “B” and measure resistance 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”

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.

“E”

I649G1000028-01

”D”: Looseness of crimping

“E”: Open

“F”: Thin wire (A few strands left)

“B”

I649G1000029-02

Voltage check

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

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

If measurements were taken as shown in figure at 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. 5 V “B” and body ground: Approx. 5 V “C” and body ground: 0 V

“C”

and

body

ground:

3V–2V

voltage

drop

“A”

Ignitor

“B”

“C”

5V5V0V

5V“A”“B”“C

”

“D”“B”Ignitor

“C”

“E”

5V“A”“C”

“D”

Ignitor

“B”“C

”

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

Precautions:

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”

00-6

I649G1000021-02

Short circuit check (Wire harness to ground)

Disconnect the negative (–) cable from the battery.

Disconnect the connectors/couplers at both ends of 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.

I649G1000022-02

“D”: To other parts

Disconnect the connector/coupler included in circuit

“E”: Other parts

(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”

I649G1000023-02

“D”: To other parts

00-7 Precautions:

(A)

Using The Multi-Circuit Testers

•

Use the Suzuki multi-circuit tester set.

•

Use well-charged batteries in the tester.

•

Be sure to set the tester to the correct testing range.

Special tool

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

I649G1000024-02

Using the testers

•

Incorrectly connecting the (+) and (–) probes may cause the inside of the tester to burnout.

•

If the voltage and current are not known, make measurements using the highest range.

•

When measuring the resistance with themulti-circuit tester (1),  will be shown as 10.00 M and “1” flashes in the display.

•

Check that no voltage is applied before making the measurement. If voltage is applied the tester may be damaged.

•

After using the tester, turn the power off.

Special tool

: 09900–25008 (Multi-circuit tester set)

NOTE

•

When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them.

•

Use the needle pointed probe to prevent the rubber of the water proof coupler from damage.

Special tool

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

I649G1000002-01

I649G1000025-02

Section 0

0A-1

0A-2

Specifications.......................................................0A-9

0A-9

Precautions...........................................................0B-1

General Information

CONTENTS

Table of Contents 0- i

General Information.....................................0A-1

General Description.............................................0A-1

Symbols ..............................................................

Abbreviations ......................................................

Vehicle Side View ............................................... 0A-3

Vehicle Identification Number ............................. 0A-4

Fuel and Oil Recommendation ........................... 0A-4

BREAK-IN Procedures........................................ 0A-4

Cylinder Identification..........................................0A-5

Country and Area Codes ....................................0A-5

Wire Color Symbols ............................................0A-5

Warning, Caution and Information

Labels Location ................................................. 0A-6

Component Location ...........................................0A-7

Electrical Components Location ......................... 0A-7

Specifications ......................................................

Special Tools and Equipment ...........................0A-11

Special Tools .................................................... 0A-11

Maintenance and Lubrication................. 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 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

Special Tool ......................................................0B-19

........................

0B-9

Service Data ............................................. 0C-1

Specifications.......................................................0C-1

Service Data........................................................0C-1

Tightening Torque Specifications........................0C-7

0A-1 General Information:

B649G10101001

Symbol

Definition

General Information

General Description

Symbols

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.

AC:

General Information: 0A-2

JASO:

Japanese

Automobile

Standards

Organization

Abbreviations

B649G10101002

A: ABDC: After Bottom Dead Center ABS: Anti-lock Brake System

Alternating Current

ACL: Air Cleaner, Air Cleaner Box API: American Petroleum Institute ATDC: After Top Dead Center A/F:

Air Fuel Mixture

B: BBDC: Before Bottom Dead Center BTDC: Before Top Dead Center B+:

Battery Positive Voltage

C: CKP Sensor: Crankshaft Position Sensor (CKPS) CKT: Circuit CLP Switch: Clutch Lever Position Switch (Clutch

Switch)

CO: Carbon Monoxide CPU: Central Processing Unit D: DC: Direct Current DMC: Dealer Mode Coupler DOHC: Double Over Head Camshaft DRL: Daytime Running Light F: FTPC Valve: Fuel Tank Pressure Control Valve G: GEN: Generator GND: Ground GP Switch: Gear Position Switch

H: HC: Hydrocarbons I: IG: Ignition J:

L: LCD: Liquid Crystal Display LED: Light Emitting Diode (Malfunction Indicator Lamp) LH: Left Hand M: Max: Maximum MIL: Malfunction Indicator Lamp (LED) Min: Minimum N: NOx: Nitrogen Oxides O: OHC: Over Head Camshaft OPS: Oil Pressure Switch P: PCV: Positive Crankcase Ventilation (Crankcase

Breather)

R: RH: Right Hand ROM: Read Only Memory S: SAE: Society of Automotive Engineers T: TP Sensor: Throttle Position Sensor (TPS)

0A-3 General Information:

Right

Side

Vehicle Side View

NOTE

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

SUZUKI GSF1200 (2006-model)

Right Side

B649G10101003

SUZUKI GSF1200S (2006-model)

I649G1010005-06

Left Side

I649G1010008-01

I649G1010006-05

I649G1010009-01

Vehicle

Identification

Number

B649G10101004

The frame serial number or V.I.N. (Vehicle Identification

Front

Fork

Oil

BREAK-IN

Procedures

B649G10101007

“A”

“B”

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.

I649G1010001-02

I649G1010002-03

Fuel and Oil Recommendation

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.

General Information: 0A-4

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.

Use fork oil SS8 or an equivalent fork oil.

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 as follows.

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

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.

#1#2#3

0A-5 General Information:

B649G10101008

B649G10101009

Country

Symbol

Wire

Color

Symbol

Wire

Color

Black

Bl/B

Blue

with

Black

tracer

Dbr

Dark

brown

G/Bl

Green

with

Blue

tracer

Green

O/G

Orange

with

Green

tracer

B/Br

Black

with

Brown

tracer

R/B

Red

with

Black

tracer

B/O

Black

with

Orange

tracer

W/B

White

with

Black

tracer

B/Y

Black

with

Yellow

tracer

Cylinder Identification

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

Wire Color Symbols

Bl Blue Br/B Brown with Black tracer

Br Brown G/B Green with Black tracer

Country and Area Codes

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

Code

GSF1200 K6

(E-02)

GSF1200 K6

(E-19)

GSF1200S K6

(E-02)

GSF1200S K6

(E-19)

GSF1200S K6

(E-24)

GSF1200S K6

(E-28)

or Area

U.K. JS1CB112200100001 –

E.U. JS1CB112100100001 –

U.K. JS1CB111200100001 –

E.U. JS1CB111100100001 –

Australia JS1CB121300100001 –

Canada JS1GV79A 62100001 –

Effective Frame No.

B649G10101010

Dg Dark green G/Y Green with Yellow tracer

Lg Light green O/R Orange with Red tracer W

White O/W Orange with White tracer Yellow O/Y Orange with Yellow tracer

B/Bl Black with Blue tracer P/B Pink with Black tracer

B/G Black with Green tracer R/W Red with White 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

354

[B]

[D]109

General Information: 0A-6

I649G1 010011 -04

128

Warning, Caution and Information Labels Location

[A]

B649G10101011

[C]

GSF1200 GSF1200S

1. Noise label

2. Information label

3. Fuel caution label For E-02 For E-02, 24

4. Screen label

5. Warning steering label

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

9. I.D. plate For E-02, 19 For E-02, 19, 24

10. Safety plate

[A]: Frame head (Left side)

[B]: Cowling body

[C]: Chain cover

[D]: Frame side tube (Right side)

—

For E-24

For E-28

For E-02, 19, 24, 28

For E-28

0A-7 General Information:

321

I649G1010003-05

Component Location

Electrical Components Location

B649G10103001

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

21201917182322

General Information:

I649G1010004-04

0A-8

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

0A-9 General Information:

Item

Specification

Remark

Overall

length

130mm(83.9

in)

Overall

width

790mm(31.1

in)

095mm(43.1

in)

GSF1200

235mm(48.6

in)

GSF1200S

Wheelbase

1480

(58.3

in)

Ground

clearance

135mm(5.3

in)

Seat

height

785/805

(30.9/31.7

in)

Low/High

212kg(467

lbs)

GSF1200

215kg(474

lbs)

GSF1200S

Item

Specification

Remark

Type

4-stroke,

air-cooled,

DOHC

Number

cylinders

Bore

79.0mm(3.110

in)

Stroke

59.0mm(2.323

in)

Displacement

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

300100

r/min

E-28

200100

r/min

Others

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)

3rd

1.250

(25/20)

4th

1.045

(23/22)

Top

0.913

(21/23)

Final

reduction

ratio

3.000

(45/15)

Drive

chain

GB50GSVZ3,

116

links

Specifications

NOTE

These specifications are subject to change without notice.

Dimensions and dry mass

Overall height

Dry mass

Engine

B649G10107001

Idle speed

Drive train

Gear ratios

Chassis

Item

Specification

Remark

Front

suspension

Telescopic,

coil

spring,

oil

damped

Rear

suspension

Link

type,

coil

spring,

oil

damped

Front

suspension

stroke

130mm(5.1

in)

Rear

wheel

travel

136mm(5.4

in)

Caster

35(right

left)

Trail

2520

’

Steering

angle

104mm(4.10

in)

Turning

radius

2.8m(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

Item

Specification

Remark

lgnition

type

Electronic

ignition

(Transistorized)

7B.T.D.C.

at1300

r/min

E-28

7B.T.D.C.

at1200

r/min

Others

Spark

plug

NGK

JR9B

Battery

12V36kC(10

Ah)/10

Generator

Three-phase

A.C.

generator

Main

fuse

30AFuse

10/10/15/15/10

12V60/55

(H4)

GSF1200

12V55W(H7)+12V55W(H7)

GSF1200S

12V5WGSF1200

12V5Wx2

GSF1200S

Turn

signal

light

12V21Wx

Brake

light/Taillight

12V21/5

License

plate

light

12V5WSpeedometer

light

LED

Tachometer

light

LED

Neutral

indicator

light

LED

High

beam

indicator

light

LED

Turn

signal

indicator

light

LED

Oil

pressure

indicator

light

LED

Item

Specification

Remark

Fuel

tank

Including

reserve

20.0L(5.3/4.4

US/lmp

gal)

Reserve

4.4L(1.2/1.0

US/lmp

gal)

Oil

change

300ml(3.4/2.9

US/lmp

qt)

With

filter

change

500ml(3.6/3.0

US/lmp

qt)

Overhaul

600ml(4.9/4.0

US/lmp

qt)

Electrical

lgnition timing

General Information:

0A-10

Headlight

Position light

Capacities

Engine oil

0A-11 General Information:

09900-20803

09900-20805

09900-21304

09900-22301

09900-22302

Thickness

gauge

Tire

depth

gauge

V-block

set

Plastigauge

Special Tools and Equipment

Special Tools

TT09900-06106-01

09900-06106

Snap ring pliers

TT09900-20202-01

09900-20202

Micrometer (1/100 mm, 25 – 50 mm)

TT09900-06107-02

09900-06107

Snap ring pliers

TT09900-20204-01

09900-20204

Micrometer (1/100 mm, 75 – 100 mm)

TT09900-06108-02

09900-06108

Snap ring pliers

TT09900-20205-01

09900-20205

Micrometer (1/1 000 mm, 0 – 25 mm)

B649G10108001

TT09900-2010 2-01

09900-20102

Vernier calipers (1/20 mm, 200 mm)

TT09900-2050 8-01

09900-20508

Cylinder gauge set (1/100 mm, 40 – 80 mm)

09900-20602

Dial gauge (1/1 000 mm)

09900-22403

Small bore gauge (18 – 35 mm)

TT09900-20602-01

TT09900-20803-01

TT09900-22403-01

TT09900-20605-01

09900-20605

Dial calipers (1/100 mm, 10 – 34 mm)

TT09900-20805-01 TT09900-21304-01 TT09900-22301-01

TT09900-25008-01

09900-25008

Multi circuit tester set

TT09900-20607-01

09900-20607

Dial gauge (1/100 mm)

(100 mm)

TT09900-25009-01

09900-25009

Needle pointed probe set

TT09900-20701-01

09900-20701

Magnetic stand

TT09910-60611-01

09910-60611

Universal clamp wrench

General Information:

0A-12

TT09913-50121-01

09913-50121

Oil seal remover

TT09915-40610-01

09915-40610

Oil filter wrench

TT09915-74540-01

09915-74540

Oil pressure gauge attachment

TT09913-60910-01

09913-60910

Bearing remover

TT09915-63210-01

09915-63210

Compression gauge adaptor

TT09915-77331-01

09915-77331

Meter (for high pressure)

TT09913-61510-01

09913-61510

Bearing remover

TT09915-64510-01

09915-64510

Compression gauge set

TT09916-10911-01

09916-10911

Valve lapper set

TT09913-7021 0-01

09913-70210

Bearing installer set

TT09915-7452 1-01

09915-74521

Oil pressure gauge hose

TT09916-1451 0-02

09916-14510

Valve spring compressor

TT09916-14910-01

09916-14910

Valve lifter attachment

TT09916-44310-01

09916-44310

Valve guide remover/ installer

09916-34542

Reamer handle

09916-74521

Holder body

TT09916-34542-01

TT09916-74521-01

TT09916-34570-01

09916-34570

Valve guide reamer (4.95 mm)

TT09916-74550-01

09916-74550

Band (73 – 85 mm)

TT09916-3458 0-01

09916-34580

Valve guide reamer (10.8 mm)

TT09916-84511-01

09916-84511

Tweezers

0A-13 General Information:

TT09917-14920-01

09917-14920

Valve adjuster driver

TT09920-53740-02

09920-53740

Clutch sleeve hub holder

TT09924-84510-01

09924-84510

Bearing installer

set

TT09917-47010-01

09917-47010

Vacuum pump gauge

TT09921-20240-01

09921-20240

Bearing remover set

TT09924-84521-01

09924-84521

Bearing installer set

TT09920-34820-01

09920-34820

Clutch pressure plate holder

TT09922-22711-01

09922-22711

Drive chain cutting and joining tool

TT09930-10121-01

09930-10121

Spark plug wrench set

TT09920-3484 0-01

09920-34840

Starter clutch holder

TT09923-7321 0-01

09923-73210

Bearing remover

TT09930-11920-01

09930-11920

Torx bit (JT 40H)

TT09930-11940-01

09930-11940

Bit holder

TT09940-52841-01

09940-52841

Inner rod holder

TT09941-54911-01

09941-54911

Bearing outer race remover

TT09930-30102-01

09930-30102

Sliding shaft

TT09940-52861-01

09940-52861

Front fork oil seal installer

TT09941-74911-01

09941-74911

Steering bearing installer

TT09930-30721-01

09930-30721

Rotor remover

TT09940-92720-01

09940-92720

Spring scale

TT09943-74111-01

09943-74111

Fork oil level gauge

TT09940-14911-01

09940-14911

Steering stem nut wrench

TT09941-3451 3-01

09941-34513

Steering race installer

Maintenance and Lubrication: 0B-1

B649G10200001

Maintenance and Lubrication

Precautions

Precautions for Maintenance

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

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

B649G10201001

0B-2 Maintenance and Lubrication:

Interval

km10006000120001800024000

mile

600400075001100014500

months

212243648

Exhaust

pipe

bolts

and

muffler

bolts

T—T—T

Spark

plugs

—IRIR

Engine

idle

speed

IIIII

PAIR

(air

supply)

system

——I—I

—IIII

IIIII

—IIII

Tires

—IIII

Rear

suspension

——I—I

Scheduled Maintenance

Periodic Maintenance Schedule Chart

NOTE

I = Inspect and clean, adjust, replace or lubricate as necessary. R = Replace T = Tighten

Item

Air cleaner element

Valve clearance

Fuel line Engine oil Engine oil filter Throttle cable play

Throttle valve synchronization

Clutch hose

B649G10205001

— I I R I

I — I — I

— I I I I

R R R R R R — — R —

I I I I I

— — I — I

— I I I I

Replace every 4 years.

Clutch fluid

Drive chain

Brakes

Brake hose

Brake fluid

Steering Front forks

Chassis bolts and nuts

Replace every 2 years.

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

I I I I I

— I I I I

Replace every 4 years.

Replace every 2 years.

I — I — I

— — I — I

T T T T T

23745

Maintenance and Lubrication: 0B-3

B649G10205002

I649G1020001-03

Lubrication Points

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 or grime.

•

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. 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

0B-4 Maintenance and Lubrication:

B649G10206001

B649G10206002

“A”

Repair Instructions

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)

Removal

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

Remove the two screws and slide the air cleaner cover backward.

•

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

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

I649G1020002-02

Remove the air cleaner element (1).

I649G1020003-02

Installation

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

•

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

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.

I649G1020006-01

I649G1020004-02

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