2001-2002 Suzuki Gsf1200 Gsf1200s Bandit Service Manual

99500-39203-03E GSF1200S/GSF1200

GROUP INDEX 1 2 3 4 5 GENERAL INFORMATION c COPYRIGHT SUZUKI MOTOR CORPORATION 2000 PERIODIC MAINTENANCE ENGINE FUEL SYSTEM CHASSIS 6 7 ELECTRICAL SYSTEM 8 EMISSION CONTROL INFORMATION 9 GSF1200K1 (’01-MODEL) 10 GSF1200K2/SK2 (’02-MODEL) 11 GSF1200K3/SK3 (’03-MODEL) FOREWORD This manual contains an introductory description on the SUZUKI GSF1200S and procedures for its inspection/service and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa- miliarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable service. ! Inexperienced mechanics or mechanics with- out the proper tools and equipment may not be able to properly perform the services de- scribed in this manual. Improper repair may result in injury to the mechanic and may ren- der the motorcycle unsafe for the rider and passenger. * This manual has been prepared on the basis of the latest specifications at the time of publica- tion. If modifications have been made since then, differences may exist between the con- tent of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. IMPORTANT All street-legal Suzuki motorcycles with engine dis- placement of 50 cc or greater are subject to Envi- ronmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific imformation required to properly inspect and service GSF1200S in accordance with all EPA regulations. It is strongly recommended that the chapter on Emis- sion Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLE- TIN. 12 GSF1200K4/SK4 (’04-MODEL) SERVICE INFORMATION

Collar Brake disc (R) Bearing (R) Spacer Bearing (L) Brake disc (L) Collar Front wheel Air valve Balancer Axle shaft Brake disc bolt HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1.The text of this manual is divided into sections. 2.The section titles are listed in the GROUP INDEX. 3.Holding the manual as shown at the right will allow you to find the first page of the section easily. 4.The contents are listed on the first page of each section to help find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel ! ITEM N . m kgf . m lb-ft A 100 10.0 72.5 B 23 2.3 16.5

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI SUPER GREASE “A”. 99000-25030 Apply THREAD LOCK “1342”. 99000-32050 Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply or use brake fluid. Apply SUZUKI MOLY PASTE. 99000-25140 Apply SUZUKI BOND “1207B”. 99104-31140 Apply THREAD LOCK SUPER “1303”. 99000-32030 Measure in voltage range. Measure in resistance range. Measure in current range. Measure in diode test range. Measure in continuity test range. Use special tool. Use fork oil. 99000-99001-SS8 or 99000-99044-10G Indication of service data. Apply molybdenum oil solution (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1). Apply SUZUKI SILICONE GREASE. 99000-25100 Apply THERMO-GREASE. 99000-59029

GENERAL INFORMATION 1-1 1 GENERAL INFORMATION WARNING/CAUTION/NOTE ............................................................. 1- 2 GENERAL PRECAUTIONS .............................................................. 1- 2 SUZUKI GSF1200SK1 (2001-MODEL) ............................................ 1- 4 SERIAL NUMBER LOCATION ......................................................... 1- 4 FUEL AND OIL RECOMMENDATION .............................................. 1- 4 FUEL .............................................................................................. 1- 4 ENGINE OIL ................................................................................... 1- 5 BRAKE FLUID ............................................................................... 1- 5 FRONT FORK OIL ......................................................................... 1- 5 BREAK-IN PROCEDURES ............................................................... 1- 5 CYLINDER IDENTIFICATION ........................................................... 1- 5 INFORMATION LABELS .................................................................. 1- 6 SPECIFICATIONS ............................................................................. 1- 7 COUNTRY OR AREA CODES .......................................................... 1- 9 CONTENTS

1-2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. ! Indicates a potential hazard that could result in death or injury. " Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad- vice. GENERAL PRECAUTIONS ! * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. * When working with toxic or flammable materials, make sure that the area you work in is well- ventilated and that you follow all of the material manufacturer’s instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have cooled. * After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks.

GENERAL INFORMATION 1-3 " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery. * When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Al- ways tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and other fluids: batter- ies, and tires. * To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION SUZUKI GSF1200SK1 (2001-MODEL) SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the steering head pipe. The engine serial number 2 is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATION FUEL 1.Use only unleaded gasoline of at least 87 pump octane ( ) method or 91 octane or higher rated by the research method. 2.Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3.Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4.Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5.If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6.Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above. LEFT RIGHT * Difference between photograph and actual motorcycle depends on the markets.

GENERAL INFORMATION 1-5 ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 10W/40 oil is not available, select and alternative according to the right chart. BRAKE FLUID Specification and classification: DOT 4 ! Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. MULTIGRADE TEMP. FRONT FORK OIL Use fork oil #10 or equivalent fork oil. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. • Keep to these break-in engine speed limits: Initial 800 km (500 miles): Below 5 500 r/min. Up to 1 600 km (1 000 miles): Below 8 000 r/min. Over 1 600 km (1 000 miles): Below 11 000 r/min. • Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 11 000 r/min. at any time. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No.1, No.2, No.3 and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat).

1-6 GENERAL INFORMATION INFORMATION LABELS 10 mm (0.4 in) 10 mm (0.4 in) 10 mm (0.4 in) 10 mm (0.4 in) 28 mm (1.1 in) 28 mm (1.1 in) 10 mm (0.4 in) 10 mm (0.4 in) (E-28 Only) (For E-03, 33) 5 mm (0.2 in) Document tray (Except E-28) (Except E-03, 33) (Attached on the left frame pipe) (Attached on the right side of the rear fender) 1 Noise label (For E-03, 33) 2 Information label (For E-03, 28, 33) 3 Vacuum hose routing label (For E-33) 4 Fuel caution label (For E-02, 24) 5 Manual notice label (For E-03, 33) 6 Warning screen label 7 Warning steering label 8 Tire pressure label 9 Warning safety label 0 ICES Canada label (For E-28) A ID plate (Except E-03, 28, 33) B Safety plate (For E-03, 28, 33)

You're Reading a Preview

2001-2002 Suzuki Gsf1200 Gsf1200s Bandit Service Manual

Description

Reviews

Q&A

Recently Viewed