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GSX1200 1999
Suzuki GSX1200 1999 User Manual
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SERVICING INFORMATION 7-11
WIRE HARNESS, CABLE AND HOSE ROUTING
WIRE HARNESS ROUTING
Clamp
Clamp
Battery
Wire-mounted clamp
Starter relay
Clamp
Ignition coils
Clamp
Wire-mounted clamp
Battery
+
terminal
Starter relay
T
o fuel le
vel gauge
Clamp
TPS
Battery
Fuel pump
Brake light switch
Clamp
Engine
ground
246
248
Table of Contents
General Information 1
5
Table of Contents
5
Warning/Caution/Note
6
General Precautions
6
Suzuki Gsx1200X ('99-Model)
8
Serial Number Location
8
Fuel and Oil Recommendation
8
Fuel
8
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
Break-In Procedures
9
Cylinder Identification
9
Information Labels
10
Specifications
11
Country or Area Codes
13
Periodic Maintenance 2
14
Periodic Maintenance Chart
15
Periodic Maintenance Schedule
15
Lubrication Points
16
Maintenance and Tune-Up Procedures
17
Valve Clearance
17
Spark Plug
18
Exhaust Pipe Bolt and Muffler Bolt
19
Air Cleaner Element
20
Engine Oil and Oil Filter
21
Fuel Hose
22
Carburetor Synchronization
23
Engine Idle Speed
23
Throttle Cable Play
23
Clutch
24
Drive Chain
25
Brake
27
Tire
30
Front Fork
31
Rear Suspension
31
Steering
31
Chassis Bolt and Nut
32
Compression Pressure Check
34
Oil Pressure Check
35
Engine
36
Engine Components Removable with Engine in Place
37
Engine Removal
38
Engine Removal and Reinstallation
38
Engine Reinstallation
43
Engine Disassembly
46
Engine Components Inspection and Service
58
Cylinder Head
60
Valve
60
Camshaft
68
Cam Chain Tension Adjuster
70
Piston
72
Piston Ring
73
Piston Pin
74
Conrod
76
Crankshaft
79
Clutch
81
Oil Pump
82
Transmission
83
Engine Reassembly
88
Fuel and Lubrication System
110
Fuel System
111
Fuel Pump
112
Fuel Pump Mechanism
112
Fuel Tank
112
Remounting
112
Removal
112
Inspection
113
Removal
113
Fuel Valve
115
Removal
115
Fuel Level Gauge Removal
116
Inspection and Cleaning
116
Remounting
116
Carburetor
117
Construction
117
I.D. No. Location
118
Specification
118
Diaphragm and Piston Operation
119
Slow System
120
Main System
121
Float System
122
Starter (Enricher) System
122
Removal
123
Disassembly
124
Carburetor Cleaning
127
Carburetor Inspection
128
Reassembly and Installation
129
Carburetor Synchronization
131
Lubrication System
133
Oil Filter
133
Oil Pressure
133
Oil Sump Filter
133
Engine Lubrication System Chart
134
Engine Lubrication System
135
Cylinder Head Cooling System Chart
136
Cylinder Head Cooling System
137
Engine Oil Cooling System
138
Chassis
139
Construction
140
Removal
140
Seat, Frame Cover and Seat Tail Cover
140
Remounting
141
Construction
142
Front Wheel
142
Removal
144
Inspection and Disassembly
145
Reassembly and Remounting
146
Construction
148
Front Fork
148
Removal and Disassembly
149
Inspection
150
Reassembly and Remounting
151
Construction
154
Removal and Disassembly
154
Steering
154
Inspection and Disassembly
158
Reassembly and Remounting
159
Steering Tension Adjustment
162
Construction
163
Rear Wheel
163
Removal
165
Inspection and Disassembly
166
Reassembly and Remounting
167
Construction
169
Rear Suspension
169
Removal
171
Inspection and Disassembly
172
Reassembly and Remounting
173
Final Inspection and Adjustment
174
Suspension Setting
175
Construction
176
Front Brake
176
Brake Fluid Replacement
177
Brake Pad Replacement
177
Brake Caliper Removal and Disassembly
178
Brake Caliper Inspection
179
Brake Caliper Reassembly and Remounting
179
Brake Disc Inspection
180
Master Cylinder Removal and Disassembly
181
Master Cylinder Inspection
182
Master Cylinder Reassembly and Remounting
183
Construction
185
Rear Brake
185
Brake Fluid Replacement
186
Brake Pad Replacement
186
Brake Caliper Removal and Disassembly
187
Brake Caliper Inspection
188
Brake Caliper Reassembly and Remounting
188
Master Cylinder Removal and Disassembly
189
Master Cylinder Inspection
190
Master Cylinder Reassembly and Remounting
190
Clutch Master Cylinder
191
Inspection
192
Tire Removal
192
Tire Installation
193
Electrical System
195
Cautions in Servicing
196
Location of Electrical Components
198
Charging System
200
Description (Generator with IC Regulator)
200
Troubleshooting
201
Inspection
202
Generator Removal and Disassembly
203
Generator Inspection
205
Generator Reassembly and Remounting
208
Generator Reassembly Information
210
Side-Stand/Ignition Interlock System Description
211
Starter System and Side-Stand/Ignition Interlock System
211
Starter System Description
211
Troubleshooting
213
Starter Motor Inspection
214
Starter Motor Removal and Disassembly
214
Starter Motor Reassembly
215
Starter Relay Inspection
216
Side-Stand/Ignition Interlock System Part Inspection
217
Description
220
Ignition System (Digital Ignitor)
220
Troubleshooting
221
Inspection
222
Combination Meter
226
Inspection
226
Removal and Disassembly
226
Headlight
230
Lamps
230
Brake Light/Taillight
231
Turn Signal Lights
231
Relays
232
Starter Relay
232
Turn Signal/Side-Stand Relay
232
Switches
233
Battery
234
Initial Charging
234
Specifications
234
Servicing
235
Recharging Operation
236
Servicing Information
237
Engine
238
Troubleshooting
238
Carburetor
241
Chassis
242
Brakes
243
Electrical
244
Battery
245
Wiring Diagram
246
Wire Harness Routing
247
Wire Harness, Cable and Hose Routing
247
Cable Routing
250
Fuel Hose Routing
251
Front Brake Hose Routing
252
Rear Brake Hose Routing
253
Clutch Hose Routing
254
Brake Pedal
255
Center Stand Spring
256
Side-Stand Spring
256
Fuel Level Gauge Wire Routing/Fuel Tank Protection Sheet
257
Fuel Tank Water Drain Hose/Fuel Tank Air Breather Hose Routing
258
Fuel Tank under Cover
259
Speedometer Cable Routing
259
Engine Mounting Bolt Installation
260
Seat Tail Cover Installation
261
Special Tools
262
Engine
265
Tightening Torque
265
Chassis
266
Tightening Torque Chart
267
Service Data
268
5
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Suzuki GSX1200 1999 Specifications
General
Brand
Suzuki
Model
GSX1200 1999
Category
Motorcycle
Language
English
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