Suzuki GSX1300BKA Supplementary Service Manual

Brand: Suzuki

Model: GSX1300BKA

Type: Supplementary Service Manual

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No. 1847 GSX1300BKAK8 S/M 99501-39580-01E Cover14 for PS printing 2008.01.18 (Back: 4 mm) 1/1

SUMI

Printed in Japan

USE THIS MANUAL WITH:

GSX1300BK SERVICE MANUAL (99500-39320-01E)

99501-39580-01E

GSX1300BKA

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI GSX1300BK SERVICE MANUAL.

It has been prepared exclusively for the following applicable model.

Applicable model:

GSX1300BKAK8

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.

Manual Name Manual No.

GSX1300BK8 SERVICE MANUAL 99500-39320-01E

* 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.

Precautions............................................................... 00-i

Precautions ............................................................ 00-1

General Information ................................................... 0-i

General Information ...............................................0A-1

Maintenance and Lubrication ..................................0B-*

Service Data...........................................................0C-1

Engine ......................................................................... 1-i

Precautions ............................................................... 1-*

Engine General Information and Diagnosis ............1A-*

Emission Control Devices ...................................... 1B-1

Engine Electrical Devices....................................... 1C-*

Engine Mechanical................................................. 1D-*

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-i

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ....................................................2B-*

Rear Suspension.................................................... 2C-*

Wheels and Tires ...................................................2D-1

Driveline / Axle ...........................................................3-*

Precautions ............................................................... 3-*

Drive Chain / Drive Train / Drive Shaft ....................3A-*

Brake ........................................................................... 4-i

Precautions ............................................................... 4-*

Brake Control System and Diagnosis .................... 4A-1

Front Brakes............................................................4B-*

Rear Brakes ........................................................... 4C-*

ABS ........................................................................4E-1

Transmission / Transaxle .......................................... 5-*

Precautions ............................................................... 5-*

Manual Transmission ..............................................5B-*

Clutch ..................................................................... 5C-*

Steering.......................................................................6-*

Precautions ............................................................... 6-*

Steering General Diagnosis ....................................6A-*

Steering / Handlebar ...............................................6B-*

Body and Accessories............................................... 9-i

Precautions ............................................................... 9-*

Wiring Systems ......................................................9A-1

Lighting Systems.....................................................9B-*

Combination Meter / Fuel Meter / Horn.................. 9C-*

Exterior Parts ......................................................... 9D-*

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 00- i

Section 00

CONTENTS

Precautions

Precautions ...............................................00-1

Precautions........................................................... 00-1

Warning / Caution / Note......................................00-*

General Precautions ............................................00-*

Precautions for Electrical Circuit Service .............00-*

Precautions for ABS (GSX1300BKAK8) ............. 00-1

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.

00-1 Precautions:

Precauti ons

Precautions

Precautions for ABS (GSX1300BKAK8)

B823H30000004

ABS Wiring

The ABS parts are connected to various lead wires.

The coupler and lead wire connections, as well as the

lead wire and wire harness routings must be done

correctly. Make sure that the proper clamps are used

and positioned correctly.

NOTE

If all the connections are not properly

connected, the ABS may not operate

correctly. For connector and coupler

precautions. Refer to “Precautions for

Electrical Circuit Service in related manual”.

ABS Control Unit/HU

• Never allow dust or water to contact the ABS control

unit/HU.

• Never subject the ABS control unit/HU to strong

impacts or allow them to be dropped.

• The ABS control unit/HU cannot be disassembled.

Replace the whole unit with a new one.

I649G1000004-02

I649G1000003-02

I649G1000005-02

Table of Contents 0- i

Section 0

CONTENTS

General Information

General Information ................................ 0A-1

General Description .............................................0A-1

Symbols ...............................................................0A-*

Abbreviations .......................................................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 (GSX1300BKAK8)........................ 0A-1

Vehicle Side View (GSX1300BKAK8).................0A-1

SUZUKI GSX1300BKA (2008-model)................. 0A-1

Country and Area Codes (GSX1300BKAK8)...... 0A-1

Component Location ........................................... 0A-*

Electrical Components Location ..........................0A-*

Specifications.......................................................0A-2

Specifications .......................................................0A-*

Specifications (GSX1300BKAK8) ....................... 0A-2

Special Tools and Equipment .............................0A-3

Special Tool ........................................................0A-3

Maintenance and Lubrication..................0B-*

Precautions........................................................... 0B-*

Precautions for Maintenance ...............................0B-*

General Description ............................................. 0B-*

Recommended Fluids and Lubricants..................0B-*

Scheduled Maintenance ...................................... 0B-*

Periodic Maintenance Schedule Chart.................0B-*

Lubrication Points ................................................0B-*

Repair Instructions .............................................. 0B-*

Air Cleaner Element Replacement.......................0B-*

Air Cleaner Element Inspection ...........................0B-*

Exhaust Pipe Bolt and Muffler Bolt Inspection .....0B-*

Exhaust Control Valve Inspection ........................0B-*

Valve Clearance Inspection and Adjustment ...... 0B-*

Spark Plug Replacement .................................... 0B-*

Spark Plug Inspection and Cleaning ................... 0B-*

Fuel Line Inspection ............................................ 0B-*

Engine Oil and Filter Replacement ..................... 0B-*

Throttle Cable Play Inspection and

Adjustment ........................................................ 0B-*

Throttle Valve Synchronization ........................... 0B-*

Evaporative Emission Control System

Inspection (E-33 only) ....................................... 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-*

Recommended Service Material ......................... 0B-*

Special Tool ........................................................ 0B-*

Service Data ............................................. 0C-1

Specifications.......................................................0C-1

Service Data........................................................ 0C-*

Tightening Torque List ........................................ 0C-*

Service Data (GSX1300BKAK8) .........................0C-1

Tightening Torque List (GSX1300BKAK8)..........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 Info rmation

General Information

General Description

Abbreviations (GSX1300BKAK8)

B823H30101012

NOTE

Please refer to the GSX1300BK (’08-model) service manual for other abbreviations which are not given

in this manual.

ABS: Anti-lock Brake System

Vehicle Side View (GSX1300BKAK8)

B823H30101013

NOTE

Difference between illustrations and actual

motorcycles may exist depending on the

markets.

SUZUKI GSX1300BKA (2008-model)

B823H30101014

Right Side

Left Side

Country and Area Codes (GSX1300BKAK8)

B823H30101015

The following codes stand for the applicable country(-ies) and area(-s).

I823H3010001-01

I823H3010002-01

Code Country or Area Effective Frame No.

GSX1300BKA K8 (E-02) U.K. JS1CR112100100001 –

GSX1300BKA K8 (E-19) E.U. JS1CR112100100001 –

GSX1300BKUFA K8 (E-19) E.U. JS1CR212100100001 –

GSX1300BKA K8 (E-03) U.S.A (Except for California) JS1GX71B 82100001 –

GSX1300BKA K8 (E-24) Australia JS1CR112200100001 –

GSX1300BKA K8 (E-28) Canada JS1GX71B 82100001 –

GSX1300BKA K8 (E-33) California (U.S.A) JS1GX71B 82100001 –

General Information: 0A-2

Specifications

Specifications (GSX1300BKAK8)

B823H30107002

NOTE

• These specifications are subject to change without notice.

• Any differences between the GSX1300BKK8 (’08-model) and GSX1300BKAK8 (’08-model) in

specifications are indicated an asterisk mark (*).

Dimensions and dry mass

Electrical

Item Specification Remark

Overall length

2 245 mm (88.4 in) E-03, 28, 33

2 220 mm (87.4 in) Others

Overall width 800 mm (31.5 in)

Overall height 1 085 mm (42.7 in)

Wheelbase 1 525 mm (60.0 in)

Ground clearance 120 mm (4.7 in)

Seat height 805 mm (31.7 in)

Dry mass

* 240 kg (529 lbs) E-33

* 239 kg (526 lbs) Others

Item Specification Remark

Ignition type Electronic ignition (Transistorized)

Ignition timing 3° B.T.D.C. at 1 150 r/min

Spark plug NGK CR9EIA-9 or DENSO IU27D

Battery 12 V 36 kC (10 Ah)/10 HR

Generator Three-phase A.C. generator

Main fuse 30 A

Fuse * 15/15/10/10/10/25/10/10/40 A

Headlight 12 V 60/55 W (H4)

Position light 12 V 5 W x 2

Brake light/Taillight LED

License plate light 12 V 5 W

Turn signal light 12 V 21 W

Speedometer light LED

Tachometer light LED

Turn signal indicator light LED

Neutral indicator light LED

High beam indicator light LED

Engine coolant temperature

indicator light

LED

Oil pressure indicator light LED

FI indicator light LED

Immobilizer indicator light LED E-02, 19, 24

* ABS indicator light LED

0A-3 General Information:

Special Tools and Equipment

Special Tool

B823H30108001

09900–20803

Thickness gauge

09900–20806

Thickness gauge

09900–25008

Multi-circuit tester set

09900–25009

Needle pointed probe

set

09904–41010

SDS set

09930–82710

Mode select switch

99565–01010–015

CD-ROM Ver.15

Service Data: 0C-1

General Info rmation

Service Data

Specifications

Service Data (GSX1300BKAK8)

B823H30307004

Electrical

Unit: mm

Wattage

Unit: W

Tightening Torque List (GSX1300BKAK8)

B823H30307005

Chassis

Item Specification Note

Fuse size

ABS motor 40 A

ABS valve 25 A

Item Specification

ABS indicator light LED

Item N⋅mkgf-mlb-ft

Brake pipe flare nut 16 1.6 11.5

0C-2 Service Data:

Table of Contents 1- i

Section 1

CONTENTS

Engine

Precautions ................................................. 1-*

Precautions.............................................................. 1-*

Precautions for Engine...........................................1-*

Engine General Information and

Diagnosis ..................................................1A-*

General Description ............................................. 1A-*

Injection Timing Description .................................1A-*

Self-Diagnosis Function .......................................1A-*

Schematic and Routing Diagram........................ 1A-*

FI System Wiring Diagram ...................................1A-*

Terminal Alignment of ECM Coupler....................1A-*

Component Location ........................................... 1A-*

FI System Parts Location.....................................1A-*

Diagnostic Information and Procedures............ 1A-*

Engine Symptom Diagnosis .................................1A-*

Self-Diagnostic Procedures .................................1A-*

Use of SDS Diagnosis Reset Procedures............1A-*

Show Data When Trouble (Displaying Data at

the Time of DTC) ...............................................1A-*

SDS Check ..........................................................1A-*

DTC Table............................................................1A-*

Fail-Safe Function Table......................................1A-*

FI System Troubleshooting ..................................1A-*

Malfunction Code and Defective Condition

Table ..................................................................1A-*

DTC “C11” (P0340) CMP Sensor Circuit