Suzuki GSF650 Service Manual

Table of Contents 5- i
5
Section 5
CONTENTS
Transmission / Transaxle
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission.............................. 5B-1
Diagnostic Information and Procedures............5B-1
Manual Transmission Symptom Diagnosis .........5B-1
Repair Instructions ..............................................5B-2
Transmission Components ................................. 5B-2
Transmission Removal........................................5B-2
Transmission Installation .................................... 5B-5
Transmission Construction..................................5B-8
Countershaft Gear / Driveshaft Gear
Disassembly and Assembly .............................. 5B-9
Transmission Related Parts Inspection.............5B-11
Gear Position Switch Inspection .......................5B-12
Gear Position Switch Removal and
Installation....................................................... 5B-12
Gearshift lever Construction ............................. 5B-13
Gearshift lever Removal and Installation ..........5B-14
Gearshift Lever Height Inspection and
Adjustment ......................................................5B-14
Gearshift Shaft / Gearshift Cam Plate
Components.................................................... 5B-14
Gearshift Construction ......................................5B-14
Gearshift Shaft / Gearshift Cam Plate
Removal and Installation................................. 5B-15
Gearshift Linkage Inspection ............................ 5B-18
Gearshift Shaft Oil Seal / Bearing Removal
and Installation................................................5B-18
Specifications.....................................................5B-19
Service Data ..................................................... 5B-19
Tightening Torque Specifications...................... 5B-20
Special Tools and Equipment ...........................5B-20
Recommended Service Material .......................5B-20
Special Tool ......................................................5B-21
Clutch ....................................................... 5C-1
Precautions...........................................................5C-1
Precautions for Clutch System............................5C-1
Clutch Fluid (Brake Fluid) Information.................5C-1
Schematic and Routing Diagram........................5C-2
Clutch Hose Routing Diagram.............................5C-2
Diagnostic Information and Procedures............5C-3
Clutch System Symptom Diagnosis ....................5C-3
Repair Instructions ..............................................5C-3
Clutch Lever Position Switch Inspection .............5C-3
Clutch Fluid Level Check ....................................5C-3
Clutch Hose Inspection .......................................5C-3
Air Bleeding from Clutch Fluid Circuit .................5C-3
Clutch Fluid Replacement ...................................5C-4
Clutch Hose Removal and Installation ................5C-5
Clutch Control System Components ...................5C-6
Clutch Master Cylinder Assembly Removal
and Installation ..................................................5C-6
Clutch Master Cylinder / Clutch Lever
Disassembly and Assembly ..............................5C-8
Clutch Master Cylinder Parts Inspection .............5C-9
Clutch Release Cylinder / Push Rod Removal
and Installation ..................................................5C-9
Clutch Push Rod (Left) Inspection ....................5C-10
Clutch Release Cylinder Disassembly and
Assembly.........................................................5C-10
Clutch Release Cylinder Inspection ..................5C-11
Clutch Components...........................................5C-12
Clutch Removal.................................................5C-12
Clutch Installation..............................................5C-14
Clutch Parts Inspection .....................................5C-17
Specifications.....................................................5C-19
Service Data......................................................5C-19
Tightening Torque Specifications......................5C-19
Special Tools and Equipment ...........................5C-20
Recommended Service Material .......................5C-20
Special Tool ......................................................5C-20

Suzuki GSF650 Specifications

General

Displacement	656 cc
Bore x Stroke	65.5 mm x 48.7 mm
Compression Ratio	11.5:1
Fuel System	Fuel injection
Ignition	Electronic ignition (transistorized)
Starter	Electric
Transmission	6-speed, constant mesh
Final Drive	Chain
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Link type, coil spring, oil damped
Front Tire	120/70ZR17M/C (58W), tubeless
Rear Tire	160/60ZR17M/C (69W), tubeless
Overall Length	2, 130 mm
Rear Brakes	Disc brake
Fuel Tank Capacity	19.0 L
Wheelbase	1, 470 mm
Seat Height	790 mm
Ground Clearance	135 mm
Engine Type	4-stroke, liquid-cooled, DOHC, 4-cylinder