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GSF650S
Suzuki GSF650S User Manual
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CH
A
S
SI
S
5-
33
REASSEMBLY AND INSTALLATI
ON
Reas
sem
bly a
nd
instal
lation
is in
the r
evers
e ord
er of
remov
al
and di
sass
embl
y. Pa
y at
tentio
n to th
e fo
llow-
ing
point
s:
Clearance
Right
Light
Left
Right
Spacer
Clearance
Bearing
installer
Left
Right
(F
or E-28)
100 N·m
(10.0 kgf-m)
194
196
Table of Contents
General Information 1
5
How to Use this Manual
3
Table of Contents
5
General Information
5
General Precautions
6
Warning/Caution/Note
6
Serial Number Location
8
Suzuki Gsf650 (2005-Model)
8
Suzuki Gsf650S (2005-Model)
8
Fuel and Oil Recommendation
9
FUEL (for Canada)
9
FUEL (for Other Countries)
9
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
BREAK-Ln PROCEDURES
10
Cylinder Identification
10
Information Labels
11
Specifications
12
Dimensions and Dry Mass
12
Drive Train
12
Periodic Maintenance
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Lubrication Points
16
Maintenance and Tune-Up Procedures
17
Valve Clearance
17
Spark Plugs
19
Exhaust Pipe Bolts and Muffler Bolts
20
Air Cleaner
21
Engine Oil and Oil Filter
22
Fuel Line
24
Engine Idle Speed
24
Throttle Cable Play
24
Carburetor Synchronization
25
Pair (Air Supply) System
25
Fuel Filter
25
Clutch Cable Play
25
Drive Chain
26
Brakes
28
Tires
31
Steering
31
Tire Tread Depth
31
Front Forks
32
Rear Suspension
32
Chassis Bolts and Nuts
33
Compression Pressure Check
35
Compression Test Procedure
35
Oil Pressure Check
36
Oil Pressure Test Procedure
36
Engine
37
Engine Components Removable with Engine in Place
38
Engine Removal and Installation
39
Removal
39
Installation
43
Engine Disassembly
48
Engine Components Inspection and Service
62
Camshaft/Cylinder Head Inspection and Service
62
Cylinder Block/Piston Inspection
75
Piston Ring Thickness
77
Clutch/Clutch Release Assembly Inspection
79
Starter Clutch Inspection
81
Gearshift Linkage Inspection
81
Transmission Inspection and Service
83
Conrod/Crankshaft Inspection
91
Conrod-Crank Pin Bearing Inspection and Service
91
Crankcase-Crankshaft Bearing Inspection and Service
94
Crankshaft Thrust Clearance Adjustment
96
Crankshaft Runout
98
Engine Reassembly
99
Engine Lubrication System
122
Oil Pump
122
Oil Sump Filter/Oil Pressure Regulator
122
Oil Pressure Switch
125
Oil Cooler
126
Oil Filter
126
Oil Pressure
126
Oil Jet
127
Engine Lubrication System Chart
129
Engine Lubrication System
130
Cylinder Head Cover
131
Cylinder Head Cooling System Chart
131
Cylinder Head Cooling System
132
Pair (Air Supply) System
133
Removal
133
Inspection
133
Installation
134
Fuel System
136
Fuel System
137
Fuel Tank
138
Removal
138
Remounting
138
Fuel Valve
139
Removal
140
Inspection and Cleaning
140
Installation
140
Fuel Filter
141
Removal
141
Inspection
141
Installation
141
Fuel Level Gauge
142
Removal and Installation
142
Carburetor
143
Construction
143
Specifications
144
I.D. No. Location
145
Diaphragm and Piston Operation
146
Slow System
147
Main System
148
Starter (Enricher) System
149
Float System
149
Removal
150
Disassembly
151
Cleaning
154
Inspection
155
Reassembly
156
Remounting
159
Carburetor Synchronization
160
Chassis
163
Exterior Parts
165
Construction
165
Removal
166
Installation
168
Front Wheel
169
Construction
169
Removal
170
Inspection and Disassembly
170
Reassembly and Installation
172
Front Fork
175
Construction
175
Removal and Disassembly
176
Inspection
178
Reassembly and Installation
179
Handlebars and Steering
183
Construction
183
Handlebars
184
Steering
186
Steering Tension Adjustment
190
Rear Wheel
191
Construction
191
Removal
192
Inspection and Disassembly
193
Reassembly and Installation
195
Rear Suspension
198
Construction
198
Removal
199
Inspection and Disassembly
200
Reassembly
202
Rear Shock Absorber Disposal
203
Installation
204
Final Inspection and Adjustment
207
Suspension Setting
207
Front Brake
208
Construction
208
Brake Pad Replacement
209
Brake Fluid Replacement
210
Brake Caliper Removal and Disassembly
211
Brake Caliper Inspection
212
Brake Caliper Reassembly and Installation
213
Brake Disc Inspection
214
Master Cylinder Removal and Disassembly
215
Master Cylinder Inspection
216
Master Cylinder Reassembly and Installation
217
Rear Brake
219
Construction
219
Brake Pad Replacement
220
Brake Fluid Replacement
221
Brake Caliper Removal and Disassembly
222
Brake Caliper Inspection
223
Brake Caliper Reassembly and Installation
223
Master Cylinder Removal and Disassembly
225
Master Cylinder Inspection
226
Master Cylinder Reassembly and Installation
226
Tire and Wheel
228
Tire Removal
228
Inspection
228
Installation
229
Drive Chain
232
Cutting
232
Connecting
233
Riding Position Adjustment
236
Seat Height Adjustment
236
Handlebar Height Adjustment
237
Electrical System
238
Cautions in Servicing
240
Connector
240
Coupler
240
Clamp
240
Fuse
240
Semi-Conductor Equipped Part
241
Battery
241
Connecting the Battery
241
Wiring Procedure
241
Using the Multi-Circuit Tester
242
Location of Electrical Components
243
Charging System
245
Description (Generator with IC Regulator)
245
Troubleshooting
246
Inspection
248
Generator
249
Removal and Disassembly
250
Inspection
252
Generator Reassembly and Remounting
255
Starter System and Side-Stand Ignition Interlock System
257
Starter System Description
257
Side-Stand/Ignition Interlock System Description
257
Troubleshooting
259
Starter Motor Removal and Disassembly
260
Starter Motor Inspection
261
Starter Motor Reassembly and Remounting
261
Starter Relay Inspection
263
Side-Stand/Ignition Interlock System Part Inspection
264
Ignition System (Digital Ignitor)
266
Description
266
Troubleshooting
267
Inspection
269
Combination Meter
273
Removal
273
Disassembly
273
Inspection
275
Lamps
278
Headlight
278
Brake Light/Taillight and License Plate Light
282
Turn Signal Lights
282
Relays
283
Turn Signal/Side-Stand Relay
283
Starter Relay
283
Switches
284
Ignition Switch Removal and Installation
284
Inspection
285
Battery
286
Specifications
286
Initial Charging
286
Servicing
288
Recharging Operation
288
Servicing Information
289
Troubleshooting
290
Engine
290
Carburetor
294
Chassis
294
Front Axle
294
Brakes
295
Electrical
296
Battery (Mf Battery)
297
Wiring Diagram
298
Gsf650
298
Gsf650S
299
Wire Harness, Cable and Hose Routing
300
Wire Harness Routing
300
Cable Routing (Gsf650)
303
Cable Routing (Gsf650S)
304
Carburetor Hose Routing
305
Fuel Tank Drain Hose Routing
306
Pair (Air Supply) System Hose Routing
307
Front Brake Hose Routing
308
Rear Brake Hose Routing
309
Ignition Coil Installation
310
Spark Plug Cap Installation
310
Fuel Tank Set up
311
Front Footrest Bracket Set-Up
312
Muffler Mounting
312
Center Stand Springs
313
Side-Stand Springs
313
Exterior Parts Construction
314
Frame Cover Cushion
315
Seat Lock Cable Routing
315
Reflex Refrector Installation
316
Taillight Installaion
316
Battery Protector Installation
317
Special Tools
318
Tightening Torque
321
Engine
321
Chassis
322
Air Bleeder Valve
322
Tightening Torque Chart
323
Service Data
324
5
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Suzuki GSF650S Specifications
General
Brand
Suzuki
Model
GSF650S
Category
Motorcycle
Language
English
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