Suzuki GSX 650 f Service Repair Manual
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GSX650F
USE THIS MANUAL WITH:
GSF650/S SERVICE MANUAL (99500-36170-01E)
99501-36180-01E
FOREWORD
This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI GSF650/S SERVICE MANUAL.
It has been prepared exclusively for the following applicable model.
Applicable model:
GSX650FK8
This supplementary service manual describes only service information which differ from that of the main man-
ual. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any sec-
tion, item or description not found in this supplement, refer to the main manual below.
Main Manual:
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize 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 better so that you can assure your customers of fast and reliable
service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2007
Manual Name Manual No.
GSF650/S SERVICE MANUAL 99500-36170-01E
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content 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.
WARNING !
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the
rider and passenger.
00
0
1
2
3
4
5
6
9
Precautions............................................................... 00-*
Precautions ............................................................. 00-*
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Service Data........................................................... 0C-1
Engine ......................................................................... 1-i
Precautions ............................................................... 1-*
Engine General Information and Diagnosis ........... 1A-1
Emission Control Devices .......................................1B-*
Engine Electrical Devices....................................... 1C-*
Engine Mechanical ................................................. 1D-1
Engine Lubrication System .....................................1E-*
Engine Cooling System........................................... 1F-*
Fuel System ........................................................... 1G-*
Ignition System....................................................... 1H-*
Starting System........................................................ 1I-*
Charging System..................................................... 1J-*
Exhaust System ......................................................1K-*
Suspension ................................................................. 2-*
Precautions ............................................................... 2-*
Suspension General Diagnosis ...............................2A-*
Front Suspension ....................................................2B-*
Rear Suspension.................................................... 2C-*
Wheels and Tires ................................................... 2D-*
Driveline / Axle ........................................................... 3-*
Precautions ............................................................... 3-*
Drive Chain / Drive Train / Drive Shaft ....................3A-*
Brake ........................................................................... 4-*
Precautions ............................................................... 4-*
Brake Control System and Diagnosis .....................4A-*
Front Brakes............................................................4B-*
Rear Brakes ........................................................... 4C-*
ABS .........................................................................4E-*
Transmission / Transaxle .......................................... 5-*
Precautions ............................................................... 5-*
Manual Transmission ..............................................5B-*
Clutch ..................................................................... 5C-*
Steering ....................................................................... 6-i
Precautions ............................................................... 6-*
Steering General Diagnosis ....................................6A-*
Steering / Handlebar .............................................. 6B-1
Body and Accessories............................................... 9-i
Precautions ............................................................... 9-*
Wiring Systems ...................................................... 9A-1
Lighting Systems .................................................... 9B-1
Combination Meter / Fuel Meter / Horn .................. 9C-1
Exterior Parts ......................................................... 9D-1
Body Structure ........................................................9E-*
TABLE OF CONTENTS
NOTE
For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same
sections of the service manual mentioned in the “FOREWORD” of this manual.
Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description ............................................. 0A-1
Symbols ...............................................................0A-*
Abbreviations .......................................................0A-*
SAE-to-Former SUZUKI Term .............................0A-*
Vehicle Side View ................................................0A-*
Vehicle Identification Number ..............................0A-*
Fuel and Oil Recommendation ............................0A-*
Engine Coolant Recommendation .......................0A-*
BREAK-IN Procedures .........................................0A-*
Cylinder Identification...........................................0A-*
Country and Area Codes .....................................0A-*
Wire Color Symbols .............................................0A-*
Warning, Caution and Information Labels
Location .............................................................0A-*
Abbreviations (GSF650A/UA/SA/ASUK7)............0A-*
Vehicle Side View (GSF650A/UA/SA/ASUK7) .....0A-*
Country and Area Codes (GSF650A/UA/SA/
ASUK7) ..............................................................0A-*
Vehicle Side View (GSX650FK8) ........................ 0A-1
Country and Area Codes (GSX650FK8) ............. 0A-1
Warning, Caution and Information Labels
Location (GSX650FK8) ..................................... 0A-2
Component Location ........................................... 0A-*
Electrical Components Location ..........................0A-*
Specifications ....................................................... 0A-3
Specifications .......................................................0A-*
Specifications (GSF650A/UA/SA/ASUK7) ...........0A-*
Specifications (GSF650/S/U/SUK8) .....................0A-*
Specifications (GSF650A/UA/SA/ASUK8) ...........0A-*
Specifications (GSX650FK8) .............................. 0A-3
Special Tools and Equipment ............................. 0A-4
Special Tool ........................................................ 0A-4
Maintenance and Lubrication ................. 0B-1
Precautions........................................................... 0B-*
Precautions for Maintenance ...............................0B-*
General Description ............................................. 0B-*
Recommended Fluids and Lubricants..................0B-*
Scheduled Maintenance ...................................... 0B-1
Periodic Maintenance Schedule Chart .................0B-*
Lubrication Points ................................................0B-*
Periodic Maintenance Schedule Chart
(GSX650FK8) ................................................... 0B-1
Lubrication Points (GSX650FK8) ........................ 0B-2
Repair Instructions .............................................. 0B-*
Air Cleaner Element Replacement ...................... 0B-*
Air Cleaner Element Inspection and Cleaning .... 0B-*
Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-*
Spark Plug Replacement .................................... 0B-*
Spark Plug Inspection and Cleaning ................... 0B-*
Valve Clearance Inspection and Adjustment ...... 0B-*
Fuel Line Inspection ............................................ 0B-*
Engine Oil and Filter Replacement ..................... 0B-*
Throttle Cable Play Inspection and
Adjustment ........................................................ 0B-*
Throttle Valve Synchronization ........................... 0B-*
PAIR System Inspection ..................................... 0B-*
Cooling System Inspection.................................. 0B-*
Clutch System Inspection.................................... 0B-*
Clutch Hose Replacement .................................. 0B-*
Clutch Fluid Replacement ................................... 0B-*
Drive Chain Inspection and Adjustment .............. 0B-*
Drive Chain Cleaning and Lubricating................. 0B-*
Brake System Inspection .................................... 0B-*
Tire Inspection..................................................... 0B-*
Steering System Inspection ................................ 0B-*
Front Fork Inspection .......................................... 0B-*
Rear Suspension Inspection ............................... 0B-*
Chassis Bolt and Nut Inspection ......................... 0B-*
Compression Pressure Check ............................ 0B-*
Oil Pressure Check ............................................. 0B-*
SDS Check.......................................................... 0B-*
Specifications ....................................................... 0B-*
Tightening Torque Specifications ........................ 0B-*
Special Tools and Equipment ............................. 0B-2
Recommended Service Material ......................... 0B-2
Service Data ............................................. 0C-1
Specifications ....................................................... 0C-1
Service Data........................................................ 0C-*
Tightening Torque List ........................................ 0C-*
Service Data (GSF650A/UA/SA/ASUK7) ............ 0C-*
Tightening Torque Specifications (GSF650A/
UA/SA/ASUK7) ................................................. 0C-*
Service Data (GSF650/S/U/SUK8) ..................... 0C-*
Service Data (GSF650A/UA/SA/ASUK8) ............ 0C-*
Service Data (GSX650FK8) ................................ 0C-1
NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.
0A-1 General Information:
General Information
General Information
General Description
Vehicle Side View (GSX650FK8)
B817H20101016
NOTE
Difference between illustration and actual motorcycles may exist depending on the markets.
Right Side
Left Side
Country and Area Codes (GSX650FK8)
B817H20101017
The following codes stand for the applicable country(-ies) and area(-s).
Code Country or Area Effective Frame No.
GSX650F K8 (E-02) U.K. JS1CJ135200100001 –
GSX650F K8 (E-03) U.S.A (Except for California) JS1GP74A 82100001 –
GSX650F K8 (E-19) E.U. JS1CJ135100100001 –
GSX650F K8 (E-24) Australia JS1CJ135300100001 –
GSX650F K8 (E-28) Canada JS1GP74A 82100001 –
GSX650F K8 (E-33) California (U.S.A) JS1GP74A 82100001 –
GSX650F K8 (P-37) Brazil XXXXXXXXXXXXXXXXX –
GSX650FU K8 (E-19) E.U. JS1CJ225100100001 –
I817H2010001-01
I817H2010002-01
General Information: 0A-2
Warning, Caution and Information Labels Location (GSX650FK8)
B817H20101018
[A]
[B] [C]
[D]
[E]
1, 11
12, 13
7
2
3
5
4
10
8
9
6
I817H2010003-03
GSX650F GSX650FU
1. Noise label For E-03, 24, 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. Screen label For E-02, 03, 19, 24, 28, 33 For E-19
7. Screen label For E-28 —
8. Warning steering label For E-02, 03, 19, 24, 28, 33 For E-19
9. Tire information label For E-02, 03, 19, 24, 28, 33 For E-19
10. General warning label For E-02, 03, 19, 24, 28, 33 For E-19
11. ICES Canada label For E-28 —
12. I.D. plate For E-02, 19, 24 For E-19
13. Safety plate For E-03, 28, 33 —
[A]: Frame head (Left side)
[B]: Swingarm
[C]: Frame side tube (Right side)
[D]: Cowling body
[E]: Rear fender
0A-3 General Information:
Specifications
Specifications (GSX650FK8)
B817H20107005
NOTE
• These specifications are subject to change without notice.
• Any differences between the GSF650/SK7 (’07-model) and GSX650FK8 (’08-model) in specifications
are indicated an asterisk mark (*).
Dimensions and dry mass
Chassis
Electrical
Item Specification Remark
Overall length 2 130 mm (83.9 in)
Overall width * 760 mm (31.1 in)
Overall height * 1 225 mm (48.2 in)
Wheelbase * 1 470 mm (57.9 in)
Ground clearance * 125 mm (4.9 in)
Seat height * 770 mm (30.3 in)
Dry mass * 216 kg (476 lbs)
Item Specification Remark
Front suspension Telescopic, coil spring, oil damped
Rear suspension Link type, coil spring, oil damped
Front suspension stroke 130 mm (5.1 in)
Rear wheel travel 128 mm (5.0 in)
Steering angle * 32° (right & left)
Caster 26°
Trail 108 mm (4.25 in)
Turning radius * 3.0 m (9.8 ft)
Front brake Disc brake, twin
Rear brake Disc brake
Front tire size 120/70ZR17M/C (58W), tubeless
Rear tire size 160/60ZR17M/C (69W), tubeless
Item Specification Remark
Ignition type Electronic ignition (Transistorized)
Ignition timing 2° B.T.D.C. at 1 200 r/min
Spark plug * NGK CR8E or DENSO U24ESR-N
Battery 12 V 28.8 kC (8 Ah)/10 HR
Generator Three-phase A.C. generator
Main fuse 30 A
Fuse 10/10/10/15/15/15 A
Headlight
* 12 V 60 W (HB3) High
* 12 V 55 W (H7) Low
Position light * 12 V 5 W x 2
Turn signal light 12 V 21 W
Brake light/Taillight 12 V 21/5 W
License plate light 12 V 5 W
Speedometer light LED
Tachometer light LED
Neutral indicator light LED
High beam indicator light LED
Turn signal indicator light LED
* Oil pressure/Coolant temperature
indicator light
LED
Fuel injection indicator light LED
* Engine R.P.M. indicator light LED
General Information: 0A-4
Special Tools and Equipment
Special Tool
B817H20108001
09930–82720
Mode select switch
0B-1 Maintenance and Lubrication:
General Information
Maintenance and Lubrication
Scheduled Maintenance
Periodic Maintenance Schedule Chart (GSX650FK8)
B817H20205003
NOTE
I = Inspect and clean, adjust, replace or lubricate as necessary.
R = Replace.
T = Tighten.
Item
Interval
km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 14 500
months 2 12 24 36 48
Air cleaner element — I I R I
Exhaust pipe bolts, muffler bolts and nut T — T — T
Valve clearance — — — — I
Spark plugs — I R I R
Fuel line — I I I I
Evaporative emission control system (E-33 only) — — I — I
Engine oil R R R R R
Engine oil filter R — — R —
Throttle cable play I I I I I
Throttle valve synchronization
I
(E-33 only)
— I — I
PAIR (air supply) system — — I — I
Engine coolant Replace every 2 years.
Radiator hose — I I I I
Clutch hose
— I I I I
Replace every 4 years.
Clutch fluid
— I I I I
Replace every 2 years.
Drive chain
I I I I I
Clean and lubricate every 1 000 km (600 miles).
Brakes I I I I I
Brake hose
— I I I I
Replace every 4 years.
Brake fluid
— I I I I
Replace every 2 years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
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$31.99
This manual for the SUZUKI GSX 650 F is a comprehensive resource for individuals interested in the technical aspects of this brand. It contains all the technical details provided directly by the manufacturer, making it an invaluable tool for both professional mechanics and DIY enthusiasts.
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Whether you are a professional mechanic or a DIY enthusiast, this manual provides step-by-step instructions, accompanied by pictures, diagrams, assembly and disassembly procedures, cleaning and repairing guidance, and maintenance details for the SUZUKI GSX 650 F.
