Suzuki GSF1200SK6 Setup Manual

Brand: Suzuki

Model: GSF1200SK6

Category: Motorcycle Accessories

Type: Setup Manual

December ’05 Printed in Japan (TK) 19

99505-01066-01E

FOREWORD

This motorcycle has been designed and produced utilizing Suzuki’s most modern

technology. The finest product, however, cannot perform properly unless it is cor-

rectly assembled and serviced. This set-up manual has been produced to aid you in

properly assembling and servicing this motorcycle.

Please review this set-up manual carefully before performing any work. Take spe-

cial care to properly perform the required assembly and servicing marked by either

a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-

egories could lead to serious problems. # and  areas are

denoted to emphasize certain areas and carry the following meanings:

Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

This set-up manual is based on a motorcycle of standard specification. Some minor

differences from this manual may be found in other specifications.

PREPARATION

WORKSHOP

A: Packed motorcycle

B: Working space

SELF PROTECTION

UNCRATING THE MOTORCYCLE

Remove the carton.

A: Crate

Remove the bolts of the bracket.

A: Bolt

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

The technician should wear protective clothing

such as leather gloves, a long sleeve shirt, eye

protection and safety shoes as shown in the

illustration when handling metal crates.

Metal crates may have sharp edges and may

cause injury.

Remove the bolts from the crate.

A: Bolt

Lift the steel frame to separate it from the base of the

crate.

Carefully remove the various component parts pack-

aged around the motorcycle.



A: Steel frame

B: Crate base

Handling crates requires two operators.

Be careful not to scratch the motorcycle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

Windscreen 1

Stepped Allen screw 4 5 × 18 mm

Rubber cushion (with nut) 4 L:14.0

Handlebars assembly 1

Clamp 2

Allen bolt 4 8 × 30 mm

Burring washer 4 OD:13.0 ID:8.5

Plastic cap 4

OD:11.0

For handlebar

clamp bolt

Screw 1

5 × 44 mm

For left switch

Screw 1

5 × 25 mm

For left switch

Screw 1

5 × 29 mm

For throttle

assembly

Choke lever 1

Strap 2 L:140

Holder 2 For master cylinder

Flange bolt 4 6 × 22 mm

Cable guide 1

Flange bolt 1 6 × 12 mm

Item Part Name Q’ty Remarks

Handlebar balancer

weight

2 Right and Left

Screw 2 6 × 105 mm

Flange rubber cushion 2

Spacer 2 L:50.0

Washer 2

OD:16.0 ID:6.5

T:4.0

Rubber cushion 2

Spacer nut 2 6 mm

Rear view mirror 2 Right and Left

Allen bolt 4 6 × 16 mm

Plastic cap 4 OD:10.0

G Warning label set 7

For

E-19 CC selection

H Warning label set 4

For

E-19 CD selection

Battery electrolyte

container

J Owner’s manual 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item G and H in the above table are supplied for limited markets.

G,H

RIGHT LEFT

The photographs shown indicates the parts dis-

mounted from the motorcycle in addition to the items

shown in the preceding page.

A: Front brake master cylinder

B: Throttle assembly

C: Left switch

Choke cable

D: Clutch master cylinder

Before assembling the motorcycle, thoroughly

understand the “Safety Check Out” described on

page 32.

After completion of assembly, carefully check the

motorcycle referring to the “Safety Check Out”,

then deliver the motorcycle to the customer.

ASSEMBLY

LEFT RIGHT

REMOVING THE BRACKET

Remove the bolts to take off the front brake and clutch

master cylinder from the bracket.



A: Front brake master cylinder

B: Clutch master cylinder

C: Bolt

D: Bracket

Remove the bracket from the handlebar mounting

position.



A: Bracket

B: Bolt

Keep the position of front brake and clutch

master cylinder with its cap facing upwards

until it is installed.

NOTE:

The bolts are no longer needed and these may

be discarded.

Be careful not to scratch the fuel tank.

NOTE:

The bracket and bolts are no longer needed

and these may be discarded.

HANDLEBARS

Loosen the throttle housing retaining screws.

Insert the throttle assembly onto the handlebars.

A: Throttle assembly

B: Handlebars

Install the handlebars assembly using the two clamps,

four Allen bolts and washers.

A: Clamp

B: 8 × 30 mm Allen bolt

C: Burring washer OD:13.0 mm ID:8.5 mm

D: Punch mark

E: Dot mark

F: Plastic cap OD:11.0 mm

Tighten the handlebar clamp bolts to the specified

torque.

" Handlebar clamp bolt: 23 N·m (2.3 kgf-m)



After installing the handlebars, fit the plastic cap on the

head of each bolt.

A: 8 × 30 mm Allen bolt

B: 8 × 30 mm Allen bolt

C: Plastic cap OD:11.0 mm

D: Punch mark

NOTE:

Install the burring washer in the direction as

shown in the illustration.

The punch mark on the clamps shows front

side.

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

NOTE:

To install the handlebars correctly, first tighten

the bolt

A of the front side with specified

torque and then tighten the bolt

B of the rear

side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FORWARD

A: Front brake hose

B: Throttle cables

C: Right switch wiring harness

D: Clutch hose

E: Left switch wiring harness

F: Choke cable

THROTTLE

Insert the boss of the throttle lower housing into the

hole on the handlebars.

Tighten the throttle assembly with two screws.

A: Boss

B: Hole

C: 5 × 29 mm screw

FRONT BRAKE MASTER CYLINDER

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

" Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

The line drawings on page 29, 30 and 31 show

the proper routing of the control cables, hose

and wirings.

Refer to them in addition to following the

instructions carefully.

Check to ensure that the throttle operates

freely and closes automatically.

NOTE:

To install the holder correctly, first tighten the

bolt

C of the upper side with specified torque

and then tighten the bolt

D of the lower side.



A: Bolt

B: Holder

C: Front brake master cylinder

D: Handlebars

Connect the front brake light switch lead wires coupler

to the brake light switch.

A: Front brake light switch

B: Lead wire coupler

FRONT BRAKE HOSE

Install the brake hose to the brake hose guide.

A: Front brake hose

B: Front brake hose guide

LEFT SWITCH

A: Choke cable

B: Holder

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

NOTE:

Check the choke cable is fitted into the recess

of holder.

Insert the choke cable into the hole of lower housing.

Insert the choke cable end into the recess in the choke

lever.

A: Choke cable end

B: Hole

C: Lower housing

D: Choke lever

Insert the boss of lower housing into the hole on the

handlebars.

Install the left switch upper housing and tighten the left

switch assembly with the two screws.

Fasten the choke cable holder on the front screw.

A: Boss

B: Hole

C: 5 × 44 mm screw

D: 5 × 25 mm screw

E: Cable holder

CLUTCH MASTER CYLINDER

Install the clutch master cylinder onto the handlebars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

" Clutch master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Clutch master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

NOTE:

Before installing the cable, grease its cable

end.

NOTE:

To install the holder correctly, first tighten the

bolt

C of the upper side with specified torque

and then tighten the bolt

D of the lower side.



A: Bolt

B: Holder

C: Clutch master cylinder

D: Handlebars

Connect the clutch lever position switch lead wires to

the clutch lever position switch.

A: Clutch lever position switch

B: Lead wire

RIGHT

CLAMP

Clamp the handlebar right switch wiring harness and

front brake hose union with strap.

A: Strap L:140.0 mm

B: Front brake hose union

C: Right switch wiring harness

LEFT

Clamp the handlebar left switch wiring harness and

choke cable with strap.

A: Strap L:140.0 mm

B: Choke cable

C: Left switch wiring harness

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for clutch fluid leakage.

NOTE:

Cut the remaining of the strap as shown in the

photograph.

OUTSIDE

NOTE:

Cut the remaining of the strap as shown in the

photograph.

OUTSIDE

CABLE GUIDE

Pass the clutch hose, choke cable and left switch wir-

ing harness through the cable guide.

Install the cable guide to the front fork upper bracket.

A: Cable guide

B: 6 × 12 mm flange bolt

C: Clutch hose

D: Left switch wiring harness

E: Choke cable

F: Front fork upper bracket

HANDLEBAR BALANCER

(RIGHT AND LEFT)

Assemble the handlebar balancer parts as shown.

A: 6 × 105 mm screw

B: Balancer weight

C: Flange rubber cushion

D: Spacer L:50.0 mm

E: Washer OD:16.0 mm ID:6.5 mm T:4.0 mm

F: Rubber cushion

G: 6 mm spacer nut

With the screw not tightened, insert the balancer sub-

assembly into the handlebar end all the way, then

tighten the screw securely.

A: Balancer assembly

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Pull the crate base forward, then balance the

motorcycle.

Check to ensure that the throttle operates

freely and closes automatically.

Place the motorcycle on the center-stand, then remove

the hoist hook.

WINDSCREEN

Remove the screws.

A: Meter assembly

B: Stepped Allen screw

Remove the boss and hook of meter assembly.

Disconnect the meter assembly coupler to take off the

meter assembly.

A: Meter assembly

B: Boss

C: Hook

D: Meter assembly coupler

While pulling the meter panel, fit the rubber cushion to

the meter brace.

A: Meter panel

B: Meter brace

C: Hole

D: Rubber cushion (with nut)

Set the windscreen between the rubber cushion and

meter panel.

A: Windscreen

B: Meter panel

C: Meter brace

D: Rubber cushion (with nut)

Tighten the screws to fix the windscreen to the meter

panel.

A: Windscreen

B: Meter panel

C: Meter brace

D: Rubber cushion (with nut)

E: 5 × 18 mm stepped Allen screw

Connect the meter assembly coupler.

Install the rubber boot.

Install the meter assembly.

A: Meter assembly coupler

B: Rubber boot

C: Meter assembly

D: Boss

E: Hook

Tighten the screws.

A: Meter assembly

B: Stepped Allen screw

C: Hook

REAR VIEW MIRROR

Install the rear view mirror to the front fairing.

Fit the plastic cap on the head of each bolt.

A: Rear view mirror assembly

B: 6 × 16 mm Allen bolt

C: Water drain hole

D: Plastic cap

REMOVING THE TAPE

Remove the tape from the muffler.

A: Muffler

B: Tape

FRONT REAR

BRAKE DISC

To prevent brake squeaking and pad contamination,

carefully clean the front and rear brake disc plates with

alcohol or other non-petroleum based solvent.

This will remove the rust-preventive coating and dirt.

NOTE:

Align the mirror in the position so as to secure

rear view.

WARNING LABEL

(FOR E-19 CC AND E-19 CD SELECTION)

Select the appropriate language label for your country.

A: For E-19 CC selection

B: For E-19 CD selection

Stick the label selected for your country.

C: Warning label (General warning)

D: Warning label (Windscreen)

E: Side fairing

F: Fuel tank

OWNER’S MANUAL

Store the owner’s manual in place.

A: Owner’s manual

B: Document tray

NOTE:

For E-19 CC selection: seven kinds of labels,

English, French, German, Spanish, Portu-

guese, Dutch, and Italian, are supplied together

with M/C.

For E-19 CD selection: four kinds of labels,

Finnish, Norwegian, Danish and Swedish, are

supplied together with M/C.

SERVICING

BATTERY

The battery is located under the seat.

Remove the seat using the key.

A: Seat lock

B: Seat

Remove the rubber band.

Remove the battery from the motorcycle.

A: Rubber band

Filling electrolyte

Remove the aluminium tape sealing the battery elec-

trolyte filler holes.

A: Aluminium tape

B: Electrolyte filler hole

Remove the caps from the electrolyte container.

A: Caps

B: Sealed area

With just enough force to break the nozzle seal of elec-

trolyte container, push each nozzle of the electrolyte

container into the battery’s electrolyte filler ports and

hold the container firmly so that it does not fall.

Take precaution not to allow any of the fluid to spill.

A: Electrolyte containers

Make sure air bubbles are coming up in each electro-

lyte container, and leave in this position for about 20

minutes.

A: Air bubbles

NOTE:

Use the removed caps as the sealed caps of

battery filler holes.

Do not remove or pierce the sealed areas of the

electrolyte container.

NOTE:

If no air bubbles are coming up from a filler

port, tap the bottom of the container two or

three times.

Never remove the container from the battery.

After confirming that the electrolyte has entered the

battery completely, remove the electrolyte containers

from the battery.

Wait for around 20 minutes.

Insert the caps into the filler holes, pressing in firmly so

that the top of the each caps does not protrude above

the upper surface of the battery’s top cover.

A: Caps



Charge the battery with a battery charger.



After charging the battery, install the battery in the

motorcycle as follows.



Never use anything except the specified battery

electrolyte.

Once the sealing cap has been installed in the

battery, do not remove the sealing cap.

For charging the battery, make sure to use the

charger specially designed for MF battery.

Otherwise, the battery may be overcharged

resulting in shortened service life.

Do not remove the cap during charging.

Position the battery with the cap facing upward

during charging.

When attaching the wiring harness battery

leads to the battery terminals, observe the cor-

rect polarity.

NOTE:

The terminal bolts and nuts are attached to the

battery.

Remove the frame covers.

A: Frame cover

B: Stepped Allen screw

C: Boss

1. Reinstall the battery in the motorcycle.

2. First connect the

+ lead to the + positive terminal

of the battery.

3. Cover

+ terminal with rubber boot.

4. Connect the

- lead to the - negative terminal of

the battery.

5. Fix the battery with rubber band.

6. Reinstall the frame cover.

A: + lead

B: - lead

C: Rubber boot

D: Rubber band

Reinstall the seat.

Insert the seat hook into the seat hook retainer and

push the seat down firmly.

A: Seat assembly

B: Seat hook

C: Seat hook retainer

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Suzuki GSF1200SK6 Setup Manual

Brand: Suzuki

Model: GSF1200SK6

Category: Motorcycle Accessories

Type: Setup Manual

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Suzuki GSF1200SK6 Setup Manual

Suzuki GSF1200SK6 Setup Manual

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