Suzuki GSX650F Supplementary Service Manual

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.

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.

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

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 Info rmation

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

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 Info rmation

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

months2 12243648

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 —IIII

Evaporative emission control system (E-33 only) — — I — I

Engine oil RRRRR

Engine oil filter R — — R —

Throttle cable play IIIII

Throttle valve synchronization

(E-33 only)

—I—I

PAIR (air supply) system — — I — I

Engine coolant Replace every 2 years.

Radiator hose —IIII

Clutch hose

—IIII

Replace every 4 years.

Clutch fluid

—IIII

Replace every 2 years.

Drive chain

IIIII

Clean and lubricate every 1 000 km (600 miles).

Brakes IIIII

Brake hose

—IIII

Replace every 4 years.

Brake fluid

—IIII

Replace every 2 years.

Tires —IIII

Steering I—I—I

Front forks ——I—I

Rear suspension — — I — I

Chassis bolts and nuts TTTTT

Maintenance and Lubrication: 0B-2

Lubrication Points (GSX650FK8)

B817H20205004

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated as follows.

NOTE

• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

• Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the

motorcycle has been operated under wet or rainy conditions.

Special Tools and Equipment

Recommended Service Material

B817H20208001

NOTE

Required service material is also described in the following.

“Lubrication Points (GSX650FK8) (Page 0B-2)”

I817H2020001-01

1. Clutch lever holder 6. Brake lever holder

2. Gearshift lever pivot 7. Brake pedal pivot and footrest pivot

3. Side-stand pivot and spring hook : Apply oil.

4. Footrest pivot : Apply grease.

5. Drive chain

0C-1 Service Data:

General Info rmation

Service Data

Specifications

Service Data (GSX650FK8)

B817H20307007

NOTE

• These specifications are subject to change without notice.

• Any differences between the GSF650/SK7 (’07-model) and GS650FK8 (’08-model) in service data are

indicated an asterisk mark (*).

Throttle Body

Electrical

Unit: mm (in)

Item Specification

Bore size 36 mm

I.D. No. * 17H2 (For E-33), 17H3 (For the others)

Idle r/min 1 200 ± 100 r/min

Fast idle r/min 1 300 – 1 800 r/min (When cold engine)

Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in)

Item Specification Note

Firing order 1 ⋅ 2 ⋅ 4 ⋅ 3

Spark plug

* Type

NGK: CR8E

DENSO: U24ESR-N

Gap 0.7 – 0.8 (0.028 – 0.031)

Spark performance Over 8 (0.3) at 1 atm.

CKP sensor resistance 90 – 150 Ω

CKP sensor peak voltage 2.0 V and more When cranking

Ignition coil resistance

Primary 1.1 – 1.9 Ω Terminal – Terminal

Secondary 10.8 – 16.2 kΩ Plug cap – Terminal

Ignition coil primary peak voltage 80 V and more When cranking

Generator coil resistance 0.2 – 0.8 Ω

Generator maximum output Approx. 400 W at 5 000 r/min

Generator no-load voltage (When

engine is cold)

60 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/min

Starter motor brush length

Standard 7.0 (0.28)

Limit 3.5 (0.14)

Starter relay resistance 3 – 6 Ω

Battery

Type designation YTX9-BS

Capacity 12 V 28.8 kC (8 Ah)/10 HR

Standard electrolyte S.G. 1.320 at 20 °C (68 °F)

Fuse size

Headlight

HI 10 A

LO 10 A

Fuel 10 A

Ignition 15 A

Signal 15 A

Fan 15 A

Main 30 A

Service Data: 0C-2

Wattage

Unit: W

Tire

Suspension

Unit: mm (in)

Item Specification

Headlight

HI * 60

LO * 55

Position/Parking light * 5 x 2

Brake light/Taillight 21/5

Turn signal light 21 x 4

License plate light 5

Speedometer light LED

Tachometer light LED

Turn signal indicator light LED x 2

High beam indicator light LED

Neutral position indicator light LED

* Oil pressure/Engine coolant

temperature indicator light

LED

FI indicator light LED

* Engine R.P.M. indicator light LED

Item Standard Limit

Cold inflation tire pressure

(Solo riding)

Front 250 kPa (2.50 kgf/cm

, 36 psi) —

Rear 250 kPa (2.50 kgf/cm

, 36 psi) —

Cold inflation tire pressure

(Dual riding)

Front 250 kPa (2.50 kgf/cm

, 36 psi) —

Rear 290 kPa (2.90 kgf/cm

, 42 psi) —

Tire size

Front 120/70 ZR17 M/C (58 W) —

Rear 160/60 ZR17 M/C (69 W) —

Tire type

Front * BRIDGESTON BT011F N —

Rear BRIDGESTON BT020R G —

Tire tread depth

(Recommended depth)

Front — 1.6 mm (0.06 in)

Rear — 2.0 mm (0.08 in)

Item Standard Limit

Front fork stroke 130 (5.1) —

Front fork inner tube O.D. 41 (1.61) —

Front fork spring free length 375.5 (14.78) 368 (14.5)

Front fork oil level (Without spring,

outer tube fully compressed)

* 132 (5.2) —

Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil —

Front fork oil capacity (Each leg) * 459 ml (15.5/16.2 US/lmp oz) —

Front fork spring adjuster 5th groove from top —

Rear shock absorber spring adjuster 3rd position

Rear shock absorber damping force

adjuster

Rebound

1-1/4 turns out from stiffest

position

—

Rear wheel travel 128 (5.0) —

Swingarm pivot shaft runout — 0.3 (0.01)

0C-3 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-1

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

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

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

Self-Diagnosis Function (GSX650FK8)...............1A-1

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-2

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

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

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

Show Data When Trouble (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 “C12” (P0335): CKP Sensor Circuit