Suzuki GSX650F User Manual

1-ii Table of Contents
PAIR Reed Valve Removal and Installation........ 1B-6
PAIR Control Solenoid Valve Removal and
Installation......................................................... 1B-6
PAIR System Inspection ..................................... 1B-7
Crankcase Breather (PCV) Hose Inspection.......1B-8
Crankcase Breather (PCV) Hose / Cover
Removal and Installation................................... 1B-8
Crankcase Breather (PCV) Cover Inspection .....1B-9
Specifications.....................................................1B-10
Service Data......................................................1B-10
Tightening Torque Specifications......................1B-10
Special Tools and Equipment ...........................1B-10
Recommended Service Material ....................... 1B-10
Special Tool ......................................................1B-10
Engine Electrical Devices....................... 1C-1
Precautions...........................................................1C-1
Precautions for Engine Electrical Device ............1C-1
Component Location ...........................................1C-1
Engine Electrical components Location ..............1C-1
Diagnostic Information and Procedures............1C-1
Engine Symptom Diagnosis ................................1C-1
Repair Instructions ..............................................1C-1
ECM Removal and Installation............................1C-1
CKP Sensor Inspection .......................................1C-1
CKP Sensor Removal and Installation ................1C-1
IAP Sensor (#1) Inspection .................................1C-1
IAP Sensor (#1) Removal and Installation ..........1C-2
IAP / TP / IAT Sensor Inspection ........................1C-2
IAP / TP / IAT Sensor Removal and
Installation.........................................................1C-2
ECT Sensor Removal and Installation ................1C-2
ECT Sensor Inspection .......................................1C-3
TO Sensor Removal and Installation ..................1C-3
TO Sensor Inspection .........................................1C-3
STP Sensor Inspection .......................................1C-3
STP Sensor Adjustment......................................1C-4
STP Sensor Removal and Installation ................1C-4
STV Actuator Inspection .....................................1C-5
STV Actuator Removal and Installation ..............1C-5
ISC Valve Inspection...........................................1C-5
ISC Valve Removal and Installation....................1C-5
ISC Valve Preset and Opening Initialization .......1C-5
HO2 Sensor Inspection .......................................1C-6
HO2 Sensor Removal and Installation ................1C-6
GP Switch Inspection..........................................1C-6
GP Switch Removal and Installation ...................1C-6
Specifications.......................................................1C-7
Service Data........................................................1C-7
Tightening Torque Specifications........................1C-7
Special Tools and Equipment .............................1C-8
Recommended Service Material .........................1C-8
Special Tool ........................................................1C-8
Engine Mechanical .................................. 1D-1
Schematic and Routing Diagram........................1D-1
Camshaft and Sprocket Assembly Diagram .......1D-1
Throttle Cable Routing Diagram (GSF650/S/
A/SAK7) ............................................................1D-2
Throttle Cable Routing Diagram
(GSX650FK8)....................................................1D-3
Diagnostic Information and Procedures............1D-4
Engine Mechanical Symptom Diagnosis.............1D-4
Compression Pressure Check ............................1D-4
Repair Instructions ..............................................1D-5
Engine Components Removable with the
Engine in Place .................................................1D-5
Air Cleaner Element Removal and Installation ....1D-7
Air Cleaner Element Inspection and Cleaning ....1D-7
Air Cleaner Box Removal and Installation...........1D-7
Throttle Cable Removal and Installation .............1D-7
Throttle Cable Inspection ....................................1D-8
Throttle Cable Play Inspection and
Adjustment ........................................................1D-8
Throttle Body Components .................................1D-8
Throttle Body Construction..................................1D-9
Throttle Body Removal and Installation ............1D-10
Throttle Body Disassembly and Assembly........1D-11
Throttle Body Inspection and Cleaning .............1D-15
Throttle Valve Synchronization .........................1D-16
Engine Assembly Removal ...............................1D-18
Engine Assembly Installation ............................1D-21
Engine Top Side Disassembly ..........................1D-24
Engine Top Side Assembly ...............................1D-26
Valve Clearance Inspection and Adjustment ....1D-33
Cylinder Head Cover Inspection .......................1D-34
Camshaft Inspection .........................................1D-34
Camshaft Sprocket Inspection ..........................1D-36
Camshaft Sprocket Removal and Installation ...1D-36
Cam Chain Tension Adjuster Inspection...........1D-36
Cam Chain Guide Removal and Installation .....1D-37
Cam Chain Guide Inspection ............................1D-37
Cam Chain Tensioner Inspection......................1D-37
Cylinder Head Disassembly and Assembly ......1D-38
Cylinder Head Related Parts Inspection ...........1D-41
Valve Guide Replacement ................................1D-44
Valve Seat Repair .............................................1D-45
Cylinder Disassembly and Assembly ................1D-46
Cylinder Inspection............................................1D-47
Piston Ring Removal and Installation ...............1D-48
Piston and Piston Ring Inspection ....................1D-49
Engine Bottom Side Disassembly .....................1D-51
Engine Bottom Side Assembly ..........................1D-58
Conrod Removal and Installation ......................1D-67
Conrod and Crankshaft Inspection....................1D-69
Conrod Crank Pin Bearing Inspection and
Selection .........................................................1D-70
Crankshaft Journal Bearing Inspection and
Selection .........................................................1D-71
Crankshaft Thrust Clearance Inspection and
Selection .........................................................1D-73
Specifications.....................................................1D-76
Service Data......................................................1D-76
Tightening Torque Specifications......................1D-78
Special Tools and Equipment ...........................1D-79
Recommended Service Material .......................1D-79
Special Tool ......................................................1D-79

Suzuki GSX650F Specifications

General

Brand	Suzuki
Model	GSX650F
Category	Motorcycle
Language	English