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Suzuki GSX650F User Manual
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9D-14
Exterior Pa
rts:
Int
ake Net Cover Construction Att
achment (GSX650FK8)
B817H29406017
Exterior Part
s Removal and Inst
allation
(GSX650FK8)
B817H29406010
Under Cowling
Refer to “Exterior Part
s
Removal and Installation
(GSF650/S/A/SAK7) (Pa
ge
9D-6)”.
Removal
1)
Remove the fasteners (1).
2)
Disconnect the turn signal light cou
plers (2), left
and
right.
1
I817H294002
0-01
1.
Cover cushion
1
I817H29400
01-01
2
2
I817H29400
02-01
687
689
Table of Contents
Section 1 Engine
71
Default Chapter
13
General Information
13
Vehicle Identification Number
16
Fuel and Oil Recommendation
16
Cylinder Identification
17
Maintenance and Lubrication
34
Scheduled Maintenance
34
Fuel Line Inspection
45
Table of Contents
71
Table of Contents
72
Precautions
75
Precautions for Engine
75
Section
75
Engine General Information and Diagnosis
76
General Description
76
Injection Timing Description
76
Self-Diagnosis Function (GSF650/S/A/SAK7)
77
Self-Diagnosis Function (GSX650FK8)
79
Schematic and Routing Diagram
81
FI System Wiring Diagram
81
Terminal Alignment of ECM Coupler
82
FI System Parts Location
83
Diagnostic Information and Procedures
84
Engine Symptom Diagnosis
84
Self-Diagnostic Procedures (GSF650/S/A/SAK7)
88
Use of SDS Diagnosis Reset Procedures
90
Show Data When Trouble (DTC)
90
SDS Check
92
DTC Table
96
Fail-Safe Function Table
97
FI System Troubleshooting
98
Malfunction Code and Defective Condition Table
99
DTC "C12" (P0335): CKP Sensor Circuit Malfunction
102
DTC "C13" (P0105-H/L): IAP Sensor (#1) Circuit Malfunction
105
DTC "C14" (P0120-H/L): TP Sensor Circuit Malfunction
114
DTC "C15" (P0115-H/L): ECT Sensor Circuit Malfunction
122
DTC "C17" (P1750-H/L): IAP Sensor (#2) Circuit Malfunction
129
DTC "C21" (P0110-H/L): IAT Sensor Circuit Malfunction
137
DTC "C23" (P1651-H/L): to Sensor Circuit Malfunction
144
DTC "C24" (P0351), "C25" (P0352), "C26" (P0353) or "C27" (P0354): Ignition System Malfunction
150
DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
150
DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction
154
DTC "C31" (P0705): GP Switch Circuit Malfunction
162
DTC "C32" (P0201), "C33" (P0202), "C34" (P0203) or "C35" (P0204): Fuel Injector Circuit Malfunction
164
DTC "C40" (P0505, P0506 or P0507): ISC Valve Circuit Malfunction
168
DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction
174
DTC "C41" (P2505): ECM Power Input Signal Malfunction
177
DTC "C42" (P1650): IG Switch Circuit Malfunction
179
DTC "C44" (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction
179
DTC "C49" (P1656): PAIR Solenoid Valve Circuit Malfunction
185
DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction
189
Self-Diagnostic Procedures (GSX650FK8)
192
Specifications
193
Service Data
193
Special Tools and Equipment
194
Special Tool
194
Emission Control Devices
195
Precautions
195
Precautions for Emission Control Devices
195
General Description
195
Fuel Injection System Description
195
Crankcase Emission Control System Description
196
Exhaust Emission Control System Description
197
Noise Emission Control System Description
197
Schematic and Routing Diagram
198
PAIR System Hose Routing Diagram
198
Repair Instructions
199
Heated Oxygen Sensor (HO2S) Removal and Installation
199
Heated Oxygen Sensor (HO2S) Inspection
200
PAIR Reed Valve Removal and Installation
200
PAIR Control Solenoid Valve Removal and Installation
200
PAIR System Inspection
201
Crankcase Breather (PCV) Hose Inspection
202
Crankcase Breather (PCV) Hose / Cover Removal and Installation
202
Crankcase Breather (PCV) Cover Inspection
203
Service Data
204
Tightening Torque Specifications
204
Special Tools and Equipment
204
Recommended Service Material
204
Special Tool
204
Engine Electrical Devices
205
Precautions
205
Precautions for Engine Electrical Device
205
Engine Electrical Components Location
205
Diagnostic Information and Procedures
205
Engine Symptom Diagnosis
205
Repair Instructions
205
ECM Removal and Installation
205
CKP Sensor Inspection
205
CKP Sensor Removal and Installation
205
IAP Sensor (#1) Removal and Installation
206
IAP / TP / IAT Sensor Inspection
206
IAP / TP / IAT Sensor Removal and Installation
206
ECT Sensor Removal and Installation
206
ECT Sensor Inspection
207
TO Sensor Removal and Installation
207
TO Sensor Inspection
207
STP Sensor Inspection
207
STP Sensor Adjustment
208
STP Sensor Removal and Installation
208
STV Actuator Inspection
209
STV Actuator Removal and Installation
209
ISC Valve Inspection
209
ISC Valve Removal and Installation
209
ISC Valve Preset and Opening Initialization
209
HO2 Sensor Inspection
210
HO2 Sensor Removal and Installation
210
GP Switch Inspection
210
GP Switch Removal and Installation
210
Service Data
211
Tightening Torque Specifications
211
Special Tools and Equipment
212
Recommended Service Material
212
Special Tool
212
Engine Mechanical
213
Schematic and Routing Diagram
213
Camshaft and Sprocket Assembly Diagram
213
Throttle Cable Routing Diagram (GSF650/S/A/SAK7)
214
Throttle Cable Routing Diagram (GSX650FK8)
215
Diagnostic Information and Procedures
216
Engine Mechanical Symptom Diagnosis
216
Compression Pressure Check
216
Repair Instructions
217
Engine Components Removable with the Engine in Place
217
Air Cleaner Element Removal and Installation
219
Air Cleaner Element Inspection and Cleaning
219
Air Cleaner Box Removal and Installation
219
Throttle Cable Removal and Installation
219
Throttle Cable Inspection
220
Adjustment
220
Throttle Body Components
220
Throttle Body Construction
221
Throttle Body Removal and Installation
222
Throttle Body Disassembly and Assembly
223
Throttle Body Inspection and Cleaning
227
Throttle Valve Synchronization
228
Engine Assembly Removal
230
Engine Assembly Installation
233
Engine Top Side Disassembly
236
Engine Top Side Assembly
238
Valve Clearance Inspection and Adjustment
245
Cylinder Head Cover Inspection
246
Camshaft Inspection
246
Camshaft Sprocket Inspection
248
Camshaft Sprocket Removal and Installation
248
Cam Chain Tension Adjuster Inspection
248
Cam Chain Guide Removal and Installation
249
Cam Chain Guide Inspection
249
Cam Chain Tensioner Inspection
249
Cylinder Head Disassembly and Assembly
250
Cylinder Head Related Parts Inspection
253
Valve Guide Replacement
256
Valve Seat Repair
257
Cylinder Disassembly and Assembly
258
Cylinder Inspection
259
Piston Ring Removal and Installation
260
Piston and Piston Ring Inspection
261
Engine Bottom Side Disassembly
263
Engine Bottom Side Assembly
270
Conrod Removal and Installation
279
Conrod and Crankshaft Inspection
281
Conrod Crank Pin Bearing Inspection and Selection
282
Crankshaft Journal Bearing Inspection and Selection
283
Crankshaft Thrust Clearance Inspection and Selection
285
Service Data
288
Tightening Torque Specifications
290
Special Tools and Equipment
291
Recommended Service Material
291
Special Tool
291
Engine Lubrication System
294
Precautions
294
Precautions for Engine Oil
294
Schematic and Routing Diagram
295
Engine Lubrication System Chart Diagram
295
Oil Pan
295
Diagnostic Information and Procedures
296
Engine Lubrication Symptom Diagnosis
296
Oil Pressure Check
296
Repair Instructions
297
Engine Oil and Filter Replacement
297
Engine Oil Level Inspection
297
Oil Pan / Oil Strainer / Oil Pressure Regulator Removal and Installation
297
Oil Pressure Regulator / Oil Strainer Inspection
299
Oil Pressure Switch Removal and Installation
300
Oil Pressure Switch Inspection
300
Oil Jet Removal and Installation
301
Oil Gallery Jet Removal and Installation
302
Oil Jet / Oil Gallery Jet Inspection
303
Oil Pump Removal and Installation
303
Oil Pump Inspection
305
Specifications
305
Service Data
305
Tightening Torque Specifications
305
Special Tools and Equipment
306
Recommended Service Material
306
Special Tool
306
Engine Cooling System
307
Precautions
307
Engine Cooling System Warning
307
Precautions for Engine Coolant
307
General Description
307
Engine Coolant Description
307
Schematic and Routing Diagram
308
Cooling Circuit Diagram
308
Water Hose Routing Diagram
309
Diagnostic Information and Procedures
310
Engine Cooling Symptom Diagnosis
310
Repair Instructions
310
Cooling Circuit Inspection
310
Radiator Cap Inspection
311
Radiator / Cooling Fan Motor Removal and Installation
311
Radiator Inspection and Cleaning
312
Radiator Hose Removal and Installation
312
Radiator Reservoir Tank Inspection
313
Water Hose Inspection
313
Radiator Reservoir Tank Removal and Installation
313
Cooling Fan Inspection
314
Cooling Fan Relay Inspection
314
ECT Sensor Removal and Installation
315
ECT Sensor Inspection
315
Thermostat Connector / Thermostat Removal and Installation
315
Thermostat Inspection
316
Water Pump Components
317
Water Pump Construction
318
Water Pump Removal and Installation
318
Water Pump Disassembly and Assembly
319
Water Pump Related Parts Inspection
322
Specifications
323
Service Data
323
Tightening Torque Specifications
324
Special Tools and Equipment
324
Recommended Service Material
324
Special Tool
324
Fuel System
325
Precautions
325
Precautions for Fuel System
325
General Description
326
Fuel System Description
326
Schematic and Routing Diagram
327
Fuel Tank Drain Hose and Breather Hose Routing Diagram
327
Diagnostic Information and Procedures
328
Fuel System Diagnosis
328
Repair Instructions
329
Fuel Pressure Inspection
329
Fuel Pump Inspection
329
Fuel Discharge Amount Inspection
330
Fuel Pump Relay Inspection
330
Fuel Hose Leakage Inspection
331
Fuel Level Gauge Inspection
331
Fuel Level Indicator Inspection
331
Fuel Level Indicator Switch (Thermistor) Inspection
331
Fuel Tank Construction
332
Fuel Tank Removal and Installation
333
Fuel Pump Components
334
Fuel Pump Assembly / Fuel Level Gauge Removal and Installation
335
Fuel Level Gauge and Fuel Level Indicator Switch Inspection
336
Fuel Pump Disassembly and Assembly
336
Fuel Mesh Filter Inspection and Cleaning
338
Fuel Hose Inspection
338
Fuel Injector / Fuel Delivery Pipe / T-Joint Removal and Installation
338
Fuel Injector Inspection and Cleaning
339
Specifications
339
Service Data
339
Tightening Torque Specifications
339
Special Tools and Equipment
340
Recommended Service Material
340
Special Tool
340
Ignition System
341
Schematic and Routing Diagram
341
Ignition System Diagram
341
Ignition System Components Location
341
Diagnostic Information and Procedures
341
Ignition System Symptom Diagnosis
341
No Spark or Poor Spark
342
Repair Instructions
343
Ignition Coil / Plug Cap and Spark Plug Removal and Installation
343
Spark Plug Inspection and Cleaning
344
Ignition Coil / Plug Cap Inspection
344
CKP Sensor Inspection
346
CKP Sensor Removal and Installation
347
Engine Stop Switch Inspection
347
Ignition Switch Inspection
347
Ignition Switch Removal and Installation
347
Specifications
349
Service Data
349
Tightening Torque Specifications
349
Special Tools and Equipment
349
Special Tool
349
Starting System
350
Schematic and Routing Diagram
350
Starting System Diagram
350
Component Location
350
Starting System Components Location
350
Diagnostic Information and Procedures
350
Starting System Symptom Diagnosis
350
Starter Motor will Not Run
351
Starter Motor Runs but Does Not Crank the Engine
351
Repair Instructions
352
Starter Motor Components
352
Starter Motor Removal and Installation
353
Starter Motor Disassembly and Assembly
353
Starter Motor Inspection
354
Starter Relay Removal and Installation
355
Starter Relay Inspection
356
Turn Signal / Side-Stand Relay Removal and Installation
356
Side-Stand / Ignition Interlock System Parts Inspection
357
Starter Clutch Removal and Installation
359
Starter Clutch Inspection
360
Starter Button Inspection
361
Specifications
361
Service Data
361
Tightening Torque Specifications
361
Special Tools and Equipment
362
Recommended Service Material
362
Special Tool
362
Charging System
363
Schematic and Routing Diagram
363
Charging System Diagram
363
Component Location
363
Charging System Components Location
363
Diagnostic Information and Procedures
363
Charging System Symptom Diagnosis
363
Battery Runs down Quickly
364
Repair Instructions
365
Battery Current Leakage Inspection
365
Regulated Voltage Inspection
365
Generator Inspection
365
Generator Removal and Installation
366
Regulator / Rectifier Construction
370
Regulator / Rectifier Inspection
370
Battery Components
371
Battery Charging
371
Battery Removal and Installation
374
Battery Visual Inspection
374
Specifications
375
Service Data
375
Tightening Torque Specifications
375
Special Tools and Equipment
375
Recommended Service Material
375
Special Tool
376
Exhaust System
377
Precautions
377
Precautions for Exhaust System
377
Repair Instructions
378
Exhaust System Construction
378
Exhaust Pipe / Muffler Removal and Installation
379
Exhaust System Inspection
381
Specifications
382
Tightening Torque Specifications
382
Special Tools and Equipment
382
Recommended Service Material
382
Section 2 Suspension
383
Precautions
385
Precautions for Suspension
385
2A-1 Suspension General Diagnosis
386
Diagnostic Information and Procedures
386
Suspension and Wheel Symptom Diagnosis
386
Repair Instructions
387
Front Fork Components
387
Front Fork Removal and Installation
388
Front Fork Disassembly and Assembly
389
Front Fork Inspection
395
Front Fork Parts Inspection
395
Front Suspension
387
Special Tools and Equipment
396
Recommended Service Material
396
Special Tool
397
Specifications
396
Service Data
396
Tightening Torque Specifications
396
Rear Suspension
398
Repair Instructions
398
Rear Suspension Components
398
Rear Suspension Assembly Construction
399
Rear Shock Absorber Removal and Installation
400
Rear Suspension Inspection
401
Rear Shock Absorber Inspection
401
Rear Suspension Adjustment
401
Rear Shock Absorber Disposal
402
Cushion Lever Removal and Installation
403
Cushion Lever Inspection
404
Cushion Lever Bearing Removal and Installation
404
Swingarm / Cushion Rod Removal and Installation
405
Swingarm Related Parts Inspection
407
Swingarm Bearing Removal and Installation
408
Specifications
410
Service Data
410
Tightening Torque Specifications
410
Special Tools and Equipment
410
Recommended Service Material
410
Special Tool
411
Wheels and Tires
412
Precautions
412
Precautions for Wheel and Tire
412
Repair Instructions
413
Front Wheel Components (GSF650/S/U/SUK7)
413
Front Wheel Assembly Construction (GSF650/S/U/SUK7)
414
Front Wheel Assembly Removal and Installation (GSF650/S/U/SUK7)
415
Front Wheel Related Parts Inspection
417
Front Wheel Dust Seal / Bearing Removal and Installation
418
Rear Wheel Components (GSF650/S/U/SUK7)
420
Rear Wheel Assembly Construction (GSF650/S/U/SUK7)
421
Rear Wheel Assembly Removal and Installation (GSF650/S/U/SUK7)
422
Rear Wheel Related Parts Inspection
423
Rear Wheel Dust Seal / Bearing Removal and Installation
424
Tire Removal and Installation
426
Wheel / Tire / Air Valve Inspection and Cleaning
427
Air Valve Removal and Installation
428
Wheel Balance Check and Adjustment
428
Front Wheel Components (GSF650A/UA/SA/ASUK7)
429
Front Wheel Assembly Construction (GSF650A/UA/SA/ASUK7)
430
Front Wheel Assembly Removal and Installation (GSF650A/UA/SA/ASUK7)
431
Rear Wheel Components (GSF650A/UA/SA/ASUK7)
434
Rear Wheel Assembly Construction (GSF650A/UA/SA/ASUK7)
435
Rear Wheel Assembly Removal and Installation (GSF650A/UA/SA/ASUK7)
435
Specifications
437
Service Data
437
Tightening Torque Specifications
437
Section 3 Driveline / Axle
439
Precautions
440
Precautions for Driveline / Axle
440
Diagnostic Information and Procedures
441
Drive Chain and Sprocket Symptom Diagnosis
441
Repair Instructions
441
Drive Chain Related Components
441
Engine Sprocket Removal and Installation
442
Rear Sprocket / Rear Sprocket Mounting Drum Removal and Installation
444
Drive Chain Related Parts Inspection
445
Sprocket Mounting Drum Dust Seal / Bearing Removal and Installation
446
Drive Chain Replacement
447
Drive Chain / Drive Train / Drive Shaft
441
Specifications
450
Service Data
450
Tightening Torque Specifications
451
Special Tools and Equipment
451
Recommended Service Material
451
Special Tool
451
Section 4 Brake
453
Precautions
455
Precautions for Brake System
455
Brake Fluid Information
455
Schematic and Routing Diagram
456
Front Brake Hose Routing Diagram (GSF650)
456
Front Brake Hose Routing Diagram (GSF650S)
457
Rear Brake Hose Routing Diagram
458
Brake Control System and Diagnosis
456
Repair Instructions
459
Brake Pedal Height Inspection and Adjustment
459
Front Brake Light Switch Inspection
459
Rear Brake Light Switch Inspection
460
Rear Brake Light Switch Inspection and Adjustment
460
Brake Fluid Level Check
460
Brake Hose Inspection
460
Air Bleeding from Brake Fluid Circuit
460
Brake Fluid Replacement
462
Brake Hose Removal and Installation
463
Front Brake Master Cylinder Components
464
Front Brake Master Cylinder Assembly Removal and Installation
464
Front Brake Master Cylinder / Brake Lever Disassembly and Assembly
465
Front Brake Master Cylinder Parts Inspection
467
Rear Brake Master Cylinder Components
467
Rear Brake Master Cylinder Assembly Removal and Installation
468
Rear Brake Master Cylinder Disassembly and Assembly
469
Rear Brake Master Cylinder Parts Inspection
470
Diagnostic Information and Procedures
459
Brake Symptom Diagnosis
459
Specifications
470
Service Data
470
Tightening Torque Specifications
471
Special Tools and Equipment
471
Recommended Service Material
471
Special Tool
471
Front Brakes
472
Repair Instructions
472
Front Brake Components
472
Front Brake Pad Inspection
472
Front Brake Pad Replacement
473
Front Brake Caliper Removal and Installation
473
Front Brake Caliper Disassembly and Assembly
474
Front Brake Caliper Parts Inspection
476
Front Brake Disc Removal and Installation
477
Front Brake Disc Inspection
477
Specifications
478
Service Data
478
Tightening Torque Specifications
478
Special Tools and Equipment
478
Recommended Service Material
478
Special Tool
479
Rear Brakes
480
Repair Instructions
480
Rear Brake Components
480
Rear Brake Pad Inspection
481
Rear Brake Pad Replacement
481
Rear Brake Caliper Removal and Installation
482
Rear Brake Caliper Disassembly and Assembly
483
Rear Brake Caliper Parts Inspection
485
Rear Brake Disc Removal and Installation
485
Rear Brake Disc Inspection
486
Specifications
486
Service Data
486
Tightening Torque Specifications
487
Special Tools and Equipment
487
Recommended Service Material
487
Special Tool
487
Precautions
488
Precautions for ABS
488
ABS Information
488
General Description
488
Wheel Speed Sensor Description
488
ABS Control Unit Description
489
Hydraulic Unit (HU) Description
491
Self-Diagnosis Function and ABS Indicator Light Description
492
Fail-Safe Function Description
493
Abs
488
Schematic and Routing Diagram
494
ABS Wiring Diagram
494
ABS Unit Diagram
495
Front Wheel Speed Sensor Routing Diagram
496
Rear Wheel Speed Sensor Routing Diagram
498
Component Location
499
ABS Components Location
499
Diagnostic Information and Procedures
500
ABS Troubleshooting
500
Pre-Diagnosis Inspection
502
ABS Indicator Light Inspection
504
DTC (Diagnostic Trouble Code) Output
510
DTC (Diagnostic Trouble Code) Deleting
513
SDS Check
516
Active Control Inspection
517
DTC Table
520
DTC "13" (C1613): Wheel Speed Sensor Rotor Malfunction
522
DTC "14" (C1614): Wheel Speed Sensor Rotor Malfunction
524
DTC "22" (C1622): ABS Actuator Circuit Malfunction
526
DTC "23" (C1623): ABS Actuator Circuit Malfunction
527
DTC "25" (C1625): Wheel Speed Sensor Related Malfunction
529
DTC "35" (C1635): ABS Motor Malfunction
531
DTC "41" (C1641): Wheel Speed Sensor Signal Malfunction
533
DTC "42" (C1642): Wheel Speed Sensor Circuit Open
534
DTC "43" (C1643): Wheel Speed Sensor Circuit Short
539
DTC "44" (C1644): Wheel Speed Sensor Signal Malfunction
541
DTC "45" (C1645): Wheel Speed Sensor Circuit Open
543
DTC "46" (C1646): Wheel Speed Sensor Circuit Short
547
DTC "47" (C1647): Supply Voltage (Increased)
549
DTC "48" (C1648): Supply Voltage (Decreased)
551
DTC "55" (C1655): ABS Control Unit Malfunction
553
DTC "61" (C1661): ABS Solenoid Malfunction
555
Repair Instructions
556
ABS Control Unit Coupler Disconnect and Connect
556
Front Wheel Speed Sensor Removal and Installation
557
Rear Wheel Speed Sensor Removal and Installation
557
Front Wheel Speed Sensor Rotor Removal and Installation
558
Rear Wheel Speed Sensor Rotor Removal and Installation
559
Wheel Speed Sensor and Sensor Rotor Inspection
560
ABS Control Unit/Hu Removal and Installation
560
Specifications
562
Tightening Torque Specifications
562
Special Tools and Equipment
562
Special Tool
562
Section 5 Transmission / Transaxle
565
Precautions
566
Precautions for Transmission / Transaxle
566
Diagnostic Information and Procedures
567
Manual Transmission Symptom Diagnosis
567
Manual Transmission
567
Repair Instructions
568
Transmission Components
568
Transmission Removal
568
Transmission Installation
571
Transmission Construction
574
Countershaft Gear / Driveshaft Gear Disassembly and Assembly
575
Transmission Related Parts Inspection
577
Gear Position Switch Inspection
578
Gear Position Switch Removal and Installation
578
Gearshift Lever Construction
579
Gearshift Lever Removal and Installation
580
Gearshift Lever Height Inspection and Adjustment
580
Gearshift Shaft / Gearshift Cam Plate Components
580
Gearshift Construction
580
Gearshift Shaft / Gearshift Cam Plate Removal and Installation
581
Gearshift Linkage Inspection
584
Gearshift Shaft Oil Seal / Bearing Removal and Installation
584
Specifications
585
Service Data
585
Tightening Torque Specifications
586
Special Tools and Equipment
586
Recommended Service Material
586
Special Tool
587
Precautions
588
Precautions for Clutch System
588
Clutch Fluid (Brake Fluid) Information
588
Clutch
588
Schematic and Routing Diagram
589
Clutch Hose Routing Diagram
589
Repair Instructions
590
Clutch Lever Position Switch Inspection
590
Clutch Fluid Level Check
590
Clutch Hose Inspection
590
Air Bleeding from Clutch Fluid Circuit
590
Clutch Fluid Replacement
591
Clutch Hose Removal and Installation
592
Clutch Control System Components
593
Clutch Master Cylinder Assembly Removal and Installation
593
Clutch Master Cylinder / Clutch Lever Disassembly and Assembly
595
Clutch Master Cylinder Parts Inspection
596
Clutch Release Cylinder / Push Rod Removal and Installation
596
Clutch Push Rod (Left) Inspection
597
Clutch Release Cylinder Disassembly and Assembly
597
Clutch Release Cylinder Inspection
598
Clutch Components
599
Clutch Removal
599
Clutch Installation
601
Clutch Parts Inspection
604
Diagnostic Information and Procedures
590
Clutch System Symptom Diagnosis
590
Specifications
606
Service Data
606
Tightening Torque Specifications
606
Special Tools and Equipment
607
Recommended Service Material
607
Special Tool
607
Section 6 Steering
609
Precautions
610
Precautions for Steering
610
Steering General Diagnosis
611
Diagnostic Information and Procedures
611
Steering Symptom Diagnosis
611
Repair Instructions
612
Handlebars Components
612
Handlebar Construction (GSF650/S/A/SAK7)
613
Handlebars Removal and Installation
614
Handlebars Inspection
615
Handlebar Height Adjustment
615
Steering Components
616
Steering Removal and Installation
617
Steering Related Parts Inspection
619
Steering System Inspection
620
Steering Stem Bearing Removal and Installation
620
Steering Tension Adjustment
621
Handlebar Construction (GSX650FK8)
622
Steering / Handlebar
612
Specifications
622
Tightening Torque Specifications
622
Special Tools and Equipment
623
Recommended Service Material
623
Special Tool
623
Section 9 Body and Accessories
625
Precautions
627
Precautions for Electrical System
627
Component Location
627
Electrical Components Location
627
Schematic and Routing Diagram
628
Wiring Diagram (GSF650K7)
628
Wiring Diagram (GSF650SK7)
630
Wiring Diagram (GSF650A/UAK7)
632
Wiring Diagram (GSF650SA/ASUK7)
633
Wiring Harness Routing Diagram (GSF650/S/A/SAK7)
635
Wiring Diagram (GSX650FK8)
638
Wiring Harness Routing Diagram (GSX650FK8)
640
Wiring Systems
628
Specifications
641
Service Data (GSF650/S/U/SUK7)
641
Service Data (GSF650A/UA/SA/ASUK7)
641
Tightening Torque Specifications
641
Repair Instructions
642
Headlight Components (GSF650/AK7)
642
Headlight Components (GSF650S/SAK7)
642
Headlight Removal and Installation (GSF650/ S/A/SAK7)
643
Headlight Bulb Replacement (GSF650/S/A/ SAK7)
643
Headlight Beam Adjustment (GSF650/S/A/ SAK7)
645
Rear Combination Light Components
646
Rear Combination Light Construction
646
Rear Combination Light Removal and Installation
647
Brake Light Bulb / Taillight Bulb Replacement
647
License Plate Light Components
648
License Plate Light Removal and Installation
648
License Plate Light Bulb Replacement
648
Turn Signal Light Components
649
Front Turn Signal Light Removal and Installation
649
Rear Turn Signal Light Removal and Installation
649
Turn Signal Light Bulb Replacement
650
Reflex Refractor Construction (GSF650/S/A/SAK7)
650
Turn Signal / Side-Stand Relay Inspection
651
Turn Signal / Side-Stand Relay Removal and Installation
651
Hazard Switch Inspection
651
Turn Signal Switch Inspection
651
Passing Light Switch Inspection
652
Dimmer Switch Inspection
652
Headlight Components (GSX650FK8)
653
Headlight Removal and Installation (GSX650FK8)
654
Headlight Bulb Replacement (GSX650FK8)
654
Headlight Beam Adjustment (GSX650FK8)
655
Reflex Refractor Construction (GSX650FK8)
656
Lighting Systems
642
Specifications
656
Service Data (GSF650/S/A/SAK7)
656
Service Data (GSX650FK8)
656
Tightening Torque Specifications
657
Special Tools and Equipment
657
Special Tool
657
Combination Meter / Fuel Meter / Horn
658
General Description
658
Combination Meter System Description (GSF650/S/A/SAK7)
658
Combination Meter System Description (GSX650FK8)
659
Repair Instructions
660
Combination Meter Components (GSF650/S/A/SAK7)
660
Combination Meter Removal and Installation (GSF650/S/A/SAK7)
662
Combination Meter Disassembly and Assembly (GSF650/S/A/SAK7)
662
Combination Meter Inspection (GSF650/S/A/ SAK7)
663
Engine Coolant Temperature Indicator Light Inspection (GSF650/S/A/SAK7)
664
Engine Coolant Temperature Removal and Installation
664
Fuel Level Indicator Inspection
664
Fuel Level Indicator Switch (Thermistor) Inspection
665
Fuel Level Gauge Inspection
666
Speedometer Inspection
666
Speed Sensor Removal and Installation
666
Speed Sensor Inspection
667
Oil Pressure Indicator Inspection (GSF650/S/ A/SAK7)
667
Oil Pressure Switch Removal and Installation
668
Ignition Switch Inspection
668
Ignition Switch Removal and Installation
668
Horn Inspection (GSF650/S/A/SAK7)
668
Horn Removal and Installation (GSF650/S/A/ SAK7)
669
Combination Meter Components (GSX650FK8)
670
Combination Meter Removal and Installation (GSX650FK8)
670
Combination Meter Disassembly and Assembly (GSX650FK8)
671
Combination Meter Inspection (GSX650FK8)
671
Engine Coolant Temperature Indicator Light Inspection (GSX650FK8)
672
Oil Pressure Indicator Inspection (GSX650FK8)
673
Horn Inspection (GSX650FK8)
673
Horn Removal and Installation (GSX650FK8)
673
Special Tools and Equipment
674
Special Tool
674
Specifications
674
Service Data (GSF650/S/A/SAK7)
674
Service Data (GSX650FK8)
674
Tightening Torque Specifications
674
Exterior Parts
675
Schematic and Routing Diagram
675
Seat Lock Cable Routing Diagram
675
Repair Instructions
676
Exterior Parts Construction (GSF650S/SAK7)
676
Frame Head Cover Construction (GSF650/AK7)
677
Front Fender Construction
678
Frame Cover Cushion Construction
678
Engine Sprocket Outer Cover Cushion
679
Fastener Removal and Installation
679
Exterior Parts Removal and Installation (GSF650/S/A/SAK7)
680
Seat Height Adjustment
682
Cowling Construction (GSX650FK8)
684
Under Cowl Construction (GSX650FK8)
685
Under Cowl Bracket Cushion Attachment (GSX650FK8)
686
Under Cowl Protector Cushion Attachment (GSX650FK8)
686
Upper Panel Cushion Attachment (GSX650FK8)
687
Windscreen Cushion Attachment (GSX650FK8)
687
Intake Net Cover Construction Attachment (GSX650FK8)
688
Exterior Parts Removal and Installation (GSX650FK8)
688
Body Structure
691
Repair Instructions
691
Body Frame Construction
691
Engine Mounting Bracket Bushing Replacement
692
Engine Mount Bushing Replacement
692
Front Footrest Bracket Construction
692
Side-Stand Construction
693
Side-Stand Removal and Installation
693
Center Stand Construction
694
Center Stand Removal and Installation
694
Specifications
695
Tightening Torque Specifications
695
Special Tools and Equipment
695
Recommended Service Material
695
Other manuals for Suzuki GSX650F
Supplementary Service Manual
48 pages
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Suzuki GSX650F Specifications
General
Brand
Suzuki
Model
GSX650F
Category
Motorcycle
Language
English
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