Suzuki GSF 600 & 1200 Bandit Fours Service and Repair Manual: 1995 - 2001 (Haynes Manuals)

HAYNES SERVICE & REPAIR MANUAL

GSF600 & It '95 to '01

Suzuki GSF600 & 1200 Bandit Fours Service and Repair Manual by Matthew Coombs & Phil Mather

Models eoverKi GSFSOO (Bandit N 600). 599cc. UK 1995-on GSF600S (Bandit S 600). 599cc. UK and US 1996-00 GSFt200 (BancIt N 1200), 1157cc. UK 1996-00 GSFI200S (Bandit 5 1200). 1157cc. UK 1996-on, US 1997-00

-0_'" ....... - _"''''\ISo' ~-'" ... ------ --""" '=~ __ 5>ol27JJ,~ --_ ...

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LIVING WITH YOUR SUZUKI BANDIT

Introduction

Daily (pre-ride) checks &9 ....... ' "0 ... 01 ...... '''' ~" CIutdl __ II200m ''J "" ~" a....1Iuid_ "" ~" ~. Sl..mg If'Id drIw en.;., "" ~" ,- eo,. 0-18 leg&Iaod u 1ety c:I'IeC:b ' ''' 0-18

MAINTENANCE

Routine maintenance and servicing S;>aJIi

REPAIRS AND OVERHAUL

Engine, transmission and associated systems ErogiM, ckJ!Ch and traosrrisaion F ..... arod _. ha,IOU .yatem&

Chassis components

""--. ''''' Fairing and bodywor\< Electrical system

Wiring diagrams

REFERENCE

Index

Page 4"

'- 5"! '- ,., '- 8'14 '''' ... , '- ,., '''' ~,

'- ~~

Page REF_52

,

0. 4 Introduction

Suzuki Every Which Way From Textile Machinery to Motorcycles

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In lac! SuzUO ""'" _ In _ ....,. ...... _ 0..:.0. or "'" ~ury __ SunJ

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IJOing ..... ___ 01)'10 01 &..uO.I', GSFCIl_ ..::I ........., ................ GSlWXI. Iho _ GSFeoG N _ "' ... _ In FOIIIIW)' .t86. CoIoo.n_ ...,""'_. t model vew ('-' n.._eoo_S_ ... loa' , In No _ tor ..... ,_ __ . ~ ""'" _. NII.iMlno. .-.- ...... __ ... 10. .... ..._ , .... 1J'1II> _ CGI00 _"' ____ _

~~--"" .... -. _ 0 101IIoIlOON_S __ 00I00n __ __ ..... Tho,2OCIN_S __ _ _~00I00n ___ _ -.,... .. _ .... _.Oor'Igo 10 ..... _ eoo

rnodeIO c __ Iho Y """ sv ..- of :!OIXI. On".eoo S _ ..... moot , ...... .. ......... from pr-.o..- _ .... "-IfIIIing "';t~ l'Mn ~" . Boa> 600"-

19 bnp (5U:W) 0 ~ rpm 1 011 bI>p (7t kWI SOQO rpm IMI.' IJ/I (H kWI 8&10 'I)Ift 1011 bnp 181 kWI

.5.8 III II fII2 ,...... ~ rpm 7U til fll\I7 ""'.8.00 rpm IIILIIIIII ft 111 ,..,... ..wo rpm u l1li ft (100 ~

li: =-~~= .. ::.::::: ., _ 10.3 ...... &.0 Vloo .... Q_U ...... &.1Vloo .... 1t_1'I.18~_

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11010 1110_121.103011 .... 11010 '1IO_121.1O~ ....

Perlormancl 411& IOUfCld from MotOt Cy __

diI" ...... '""" _ . __ "" _

-.g __ '~.on .. S_.8oIh 1200_tooo ' ' ___ b_ _1oAIr __ . oo .. ___ lED IIst*"Q. 0.. _ ..... _....-.goo __ _~l __ ....,.._

D" Bike spec

Weights and di ....... .;on. _ uof.irfil 600 model. ~ .. . ... .. . 0v0n0II1ongtt1 , . ... , ... . o-oIIl'lOIgM . , , .... , ... . 0-0II_ (1I'Ioigt1t , , , ~,~

Orywey,t

Q5HOOStoX 100....., (56.3 In) 20M ......, (II;! t In) 1100....., (43.3 In) 745 mm 129.3inj 805 "... 131 .7 In) 125"..., (4.9 "'1 I~ to 198 i

-.-~-1200 moooI ._

Coo ,,,,, ' IO'...,.-tic 6OOmodoI . . 1200_. ,~-

GSf600SlSS 10 X/SX .- GSFIiOOYISY _onwards . GSF'2OOTIST,o l lST"'-GSF12O(1KlIS1(1_""",_ .

~..,..t~ ... , CkJtd1 ... , ... T""""""-'

~,~Fr.oIdrM ---1200 mo6' . , 00 ITWI1 25.~. 98....., 25.&'. 107.,.." 25.3". It).< ITWI1 2.8 m (11.2 II)

" .,.." ,, ',, :: pIe-,~~ -43....., ",,,,.,.,...-. ,~~ -121 .....,

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125 ....., _ (toioo...,......" ~ IrQm XISX onwarn.) _ ....., rg

OSFtiOOSISS to )(IS)( .- , , , , , , ,,(1171).17 SOH 1frn'). 15(V7o-, 1 ~ (r-l GSoF\IOOY/SY ..- onwwds ... , , .... , .... , . . 12016O-ZA11 ~W ~'O6_ 0< !nO IW ~ __ '"' f/'It.~ 10< 0Wf0'I'fKI1)ft-' ,~-

GSf600SlSS 10)(lS)('- . . GSFeooV/SY _onwards _ GSFl 2OOT1ST1O llSY"'-GSF12OO1\1ISK' _onw_.,

_ 2pIa\on -.g CfIIipn. 290 ....., diocs TokicC 2-p;stoo 0Iiding eoIipeo:'a. 290 ....., diocs _ ~.piston ~ CfIIipn. 310 .,.." diocs ToId (l.pi$loo "I'P'-' eoIipeo:'a. 310 .,.." iO'oo "I'P'-' coIipeo-. 2~O ITWI1 dioc 10I

0' " Safety first! p" "',,_oico __ il_

wor1out gooIllng on ""'" ,,,. jab a! _ ,..,. tho ..... 'Q""'" Iho! your o.o! ..... 10 "'" pUt .. -. A _'. _ ol_ e ... .- in on _1000" ........ , .... to ~--Thef .... _..,.. ........ woyt of MWog ....-_ ....... "'" _'II It "'" compo __ 101 col .. "."g ... ; ~ 10 ... __ 10_ ...... _01""' .... _IO_"_oppoCOloGfoIO"_ ...... corry CUI on _ biIWog ",..,.0

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,.,. Daily (pre ride) checks

Tyres The correct pressures: The ~ ....... r,. ct>od1_.,..10111 .... e Plcl< OUI _ 01_ or ...... w!KII may -_ .. ,_ ..... ..,..._ .. loll, they ... _...,. 1* oeIIMO tr'ougn IN CMing ...., _. pu'ICI\n.

w..,... ~ io --"" Of ~ IoN 01 pr..-. II 1"1**0*1, _ l1li _ of ..,... &ling .. : _.-,..

2 _ ...... """'" !he '*'" of "'" 1\"'1 "",",,, _ """"'_

Legal and safety checks Lighting arw:t s+gnatling: r ___ 10 _ 11>01 IN ""-IIigI_",-". ....... .".., IiogI'o, --....-1gnIlo ..... tum oIgnooIsoi _~_

o..co. 'hi" "'" """" ooundo _ , ... _ io __ . . ... ..-;"g', ._ it I ItltlAo 0Cff0CI ....,..,. 01 "'-'"'I (Moo CNpI

Chapter 1 Routine maintenance and servicing Contents ",_ .. ;' F._ -,.-o - oiI-.. eNd< ., ....... : $ , 311 &91" __ _ " ,- ... ~ ..... .. _ ............ II r. ......... _., : ,-001 _,..-, ~eoo5ISS "" I(IS)Q .... ! 20

Degrees of difficulty

_ ... tcmII ..........

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.. 20 1 . .. . $

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" .... 22 ..... ~

" ~ . " ! ~ . 5 . 11

_. _...... .. 15 ..... _ ... __ 301

,

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,., Specifications

Engine ,-,_ . "._-"'"'--..- ............... ......... ... .............. . e-_ ....... ........... _ .............. .

s.-t< pkIgiI-_..-

"" - ........ . ...... . .... ... .. . ... . ..... .. . For COld _. (boIow S-q . . , .... . .. . . for .,1011..- fIIgfo ~ -.g --....... ... ... .

s.>n ....,. - 1201)_ ,~ - ........ .. ... ..... ......... .. ............. .. .

For COld ..... f>oIow S'Cj . For .... _.~-.g ," --

.. . .. . . . ......... . .......... , _ .. .... . GSR!NISY 00 "" .... ...... . .... . . .. . . ............ .

CyIndoor .... "" II ' .-IIOD_ _ ... ...... . , -_ ...,. ...... bob ... , cyIincIoto CyIndoor co..... ' ,. 1200..-

0.10 .. 0.15 """ D.l ... 0.T,l .....

_ CA8EM or NIppco.II .... ., U2TETl1 NGI( CReEK or ~_..., U2_e-m

NGI< ~IDEK or NjppOo".. .. U31 ETA 0.&100.7mm

~~_"IfO ,otI 0.e lOO,7 ...... '200.,00rpm

101210 2 13 po; (10 10 15 e.r 11' PIlI (S BIrJ" 28 po; (2 8.)'

Sowdood ............ .. ..... ..... l1t1po1 C'Ua-r ........, .... . ___ . . . . ..... ... ..... . 124po1",75o.!" ~_ ..,.bot ooncyll_. .... ..... . ....... . 28pe1C'lB"r

01 ____ (willi ongIno -.n) . . . . . . . . . . . . . . . . . . . . . . . . . . 03 klie .... 13.0 10 8.0 Bot) 01 XUI """ cI .UIOC ./Ior.: 11111 c,-~ _ "..., !tII.~ psi i90rJ. -..." '" ~ _ fut.I. ,,~ ... ~,..",... _ tIWn .",_d filii (8or:I, ilion !til *"""" '" ~ .. """'. _ ~ '" ""'_lI>e-"" pol iSorl_lI>e_ .... "."'_..,.. ...... qIndot"s "'_ "'"" 211 psi (1 Booj.

--0ulCI\ __ Il00 _ 10 II> 1$ ""'" _.--,-~ II> XIS)( ..., GSI"2OOT/sHo Y/sV _ . . . . . . 0.$ II> 1.0".." GSRIOaV!SYoo ds_GSI'I2I)(Io;1ISKI..-dO ~.Oll> . Omm 0..:-__ .. -- .... .. .. .. ......... .... . GSFI2OOTIST .. V/SV_ . . ... . GSl'I2OOK!1SK' __ .. .. .. .... ...... ... . . . .. . . . . --"--- ... .... ............... . . ........... . 12!lO_ .. . . ............ . ...............

_ - 12 ' IIiIp '""011> - _ *

Torque wrench settings c...-"-I 10 rrrn _ ,..,.. Cjtndor _ 6 mm boll

~~...,., - ...... . E'"*'>I ~ 0-,,-,00_ ~,,-

Specifications 1' 3

f'-Y _'" 01 (~ '" 5O-...igt'II) AF'III

,., Component locations

, ___ , 010

2Air_ .! 1M>IIJo'-_...

Coo'OPOO"~_ on rIght ___ - .. _ .I'fOfIf __ , _ 701 __ potIt

,-~ '6v"o""-cop , __ -"~ PEnpnool __

10 __ ,,-,..., -11 """' ___

Ceo, ....... $I . .... .... _----1CUc1> __ -2$-""V_ 0MttIga !RIfI< .. _ --... .". .. ' " ,~ ,,... ............. . -,--,EtIQIno 01_ pNg .~--._;" ..... _ .. _. -II EtIQIno 01_

Ceo"POO_~ ICc 11a". on Ioft __ -,--I Cll.oIcIo _ "" ..... t~_r i ... !RIfI< .. _ --......... [ 1.

Component locations 1-'

1

1.' Maintenance schedule

N_ n..dIM1 ~ ~_ ..-.,,,,. r ' (''''lUd JtI/o "... _____ O'i_OOd"".~_ ""'"'"'" por/orm ... ___ ..... 110, ., -r ., .......... _ .. _ ..... ~..,....1ho ____ ... lin....... w>w" b)' 1M __ /01 _ ~ , .o " _ "'" '*'0 to 'tit ;I" ~ 111 __ QO' "..,.......

Every 600 miles (1000 kin) ., o CiewlWld lubricaIe lI)e ~ cIlain (Sectia1 t). D Check and adJust d~~e chain lraII~y ~hon 2).

Every 7500 miles (12,000 km) c.rr"'" ~",. __ ... 3700 _ /IlOOO ~-.~ ... .., ; ;g'

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Every 11 ,000 miles

RepIace ,the air filter (Sectlon 25). ~ the engine 011 tlHer- aSF600V/SY 0f1V0'Wtb and all 1200 modele ~ :le~

Every two years a Ct\aJ:lge!he brakelluld (Sec1iOn 27), P CtI;v\ga the ckJIch nWd - 1200 models (S:tlon 28).

Every four years o psptxe the brake hosM (Section 29). a FIepIoott the IueI m- and EJlAP ~ (CIIit\)j ,lie

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,., Every 600 mi les ....-.Ii' _ 1M ...- oIlrooop1oy __ ~ 1M ~ ... ", '" 1M CIItI*t" III _ 01 1M ........ of 1M bottom MI 01Il10 "...." t_ IIluII. lOIionl. Following """'" odjuatment, _ k "'.t tho CUI...,.., "" t .... lO!> cI MCIo CNoIn ..:IjuOtW io In "'" ...... poMioIo In .. lion \(I .... __ .... 1M ''''''-''' t-eo t .. I i,""" .... __ ...-.... _ .... _IMA;~ ...... IM _ _ ... .,."",0/ " .... _ ... .... 7 On 1200 -. liKl

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~= ... I I " I -A w ..... liI--I .......... IM ... __ , ~_"""",, __ aiI -"...---, ConoIoI ... """ino oil""" _ ............ III oingie MOl' ''''IIOnarU rnaIn' __ _ ,.... con potiotI'n ... a " ...... e ...... , ltIo 01 "'" Il to !+II IU'I'II' ..... 1IgI1*' _ to tho _ Mt' lno _"14I0I0''''''11 of 'M Choopo", ,o.,_ .............. "' .. ~ '0 !+II......,,,,-*, ' __ ~10"" __

""""" IN ,_",._ typo _..-

1 14 Every 3700 miles

1 TM idle spoI ohouId ~ en.elo,.., .tId adjusted ~ one! _II>I~'" .yr1 rnotorcyclo on Ito c.n" osUolltt 0 ~ is n nfIUI"". 3 WIll> h ongino dng ...... ' Iho 1dIe_ by turning ,he thronle stOP te""" In 0/ .,." until the Idle _ "-'..:l In 11m. eMptor'o Sp.:ihcationt "0/)'_. The throttle . too ""'_ II iOom (_ Stocbon :1-1). 1 ... ,oM 'hO cabl .. , malting our. tt....,. ar. cornctly roolood. 'I tN, fa il. ' 0 im ... .,.... ' hO --.'ion 01 , .... ,IYot,~, 11>00 ~ ....... , W repWIoecI. _ tN, itI "*y"" CUM 11>00 1_

, ClbIot (8), lOCknut tel

00UI11>00 c_ I_ -.tionJ _ ~ tho omouot '0 "'"' IIootood In ,n. ChIopt .... Spoocillea'iono. W ~', ~ a

&.. W...w.g:Tumlllool>at ... ~ ..... _w~~ __ _ -~1cHIt>p. -.-__ ",,-"H_

1IIe"-....,. 0.0 "",led _II), c-t __ ".""..-.g!he -ChoIre ClIbJ. 13 K , .... 0/l0i;:0 '''''' "'" OI*"-'O_hI)' tIio II prI:>abIy _ to. 0 __ . ~ tie _ (_ Chapt .. 3) a'ld ~. ~ (_ SooIion 3-n) . R~_ the --.

11.8 eour-__ tho ......... _ tighWning tho IOCtutut

'16 Every 3700 miles

12.3 _1hocht.nceboot AW i._ , .. and 21 .. pIno to ____ chain

~

e ~ up Iho ~ ~ 00 "'*'",. on h top lI>O """"""'" CCW1f t- .... ,_ t 1.4), ttlI loosen the k>ckrlUt and turn tho odjust.- ...... Iho~ _ 01 ~ .. _ 011 Iho ~ __ end. Tlgmon ,n. Iocl0.,...... 1"""'11\' 1M! t" tho '*".,. t>IHd Iho oMen I. cIesc~~ In CllaptOf 2.

1 CMe~ !he on'" length 01 the c hain for 00 nut,1I>IIn "" oiI...- -.n"" 0>00 rut. On " 1200'-, ~ tho odjuSI" k>cknu" 1 0ng the _ ""' ' he Iw>gI!> 01 21 pIno IfrtM11 , he C1tr. of tho 1. 1 poIn to the cont .. of In. 210' pinl and ~ 11>0 ........ ,.iu> 1M .........,. ..... , spocjIIed at tho boginniny '" "'" Ohaptor (_

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13.'O'j ........ to.~. IT tho paolor. tho _ 00oty is

~. 2 CIHo~. _ . and OIM< d _ _ I\epIace """I ~ part. wn h no .. ...,.. 1_~iS)

Every 3700 miles ,."

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Maintenance and servicing "21

Every 11,000 miles (18,000 km)

""'" OUI MI ,n. Items ...- //No !rOO ",. ...... -1 _ ,M Old ... _ .. dMeo1t>od in -'3 ___ .-_.

Every two years

r TN ___ be S 'm"'" .. _II $"""".01 _ ........... ~ Of.ap. _ 10 ......., 0l'f _(IIoo'.' all'. -~-, The 1uoI-..., _. __ _ PAIR __ twt-- ftntd) ........ be ,,~' ' rov '" __ oclilkn On C" , .. -. __ "",.,-"".,.... .,.-)1"1'_ 2 ~, ..... 1M l\.o0oi t_ (_ Chap,. 3). O',co'_ tile ILIe! _ IfOm 1ho IuOoI tap _ ,r"", "'" ~'"'tOl'l, not.... ,"" fOUling 01 -" ____ ~ ...,.......,,.

.... "'-"3~~~._ .... 10

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,." Non-scheduled maintenance

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Chapter 2 Engine, clutch and transmission

Contents __ ...-.Iond .. " ; ' " ; _ .......... _~e c.._ondcom_IIO ___ -_.

I-=Iioo , ond .. _, ............... , ..... , ...... r. 10

:~~.~-;'~'.~~~~*~~~~-~ ,-~. ijUdo --_Ii. I .. . .. . ......... V ... ~~.~~: ...... 11 ................ ; ......... 22

, ' : I

" ,

... _~1 , .............. ,'8

.. Ie

.. ~ , . 21

' ; .. ' . 31 ___ ........... .. . v ... ;; ......... 2tI

. ............ 15 ............. 12

, ..... \.

,

.................. 23 ... " ........... 1

............. ;._~1

of difficulty

bb\9 ...." - ......... ...... 1Ced DI'I' "oed.it:

2"

" ... _,",-4 , ... ~ . ... ~

.H

, 2!5 . . . . . . . . . . . . . 2

. . . . . 3 II ....... _ ...... 11

;;,,, 11

.. :Ie 2 . ~ "'-'

, ...... , ....... , .... 24 , ...... _cn.pwe

.r. 33 : _ .......... 32

. .. ;;.-a-' " ..... ; I

. . . . . . . . . . . .. ; 13

--

2-2 Engine, clutch and transmission

Specifications - 600 models _ _ ~ __ "'''IIod!IJI_''''_-_IO_' "'._M __ "'''*_ibo_ Generel r",. .... .. .... .. ... . ............... . .... ... . . . ClIo :', -. -Coo ... -~

....., , ........................ .. .... .. ,

- kIt>Ol\oIigtII ~ ... ........................... .... . s.Moolmlllrnin) , ......... . ----- . s.Moo_~ --.... ........... _dioo.

Jco.moI 01 elMo .,. SIa_ ., .. s-.a _ tnuI . , --_ .... _10 _ ..... _00

Cylinder head W_tmuI ......... .

V."'e .. Il"ides and spring. _ ....... ----. --.- ................................... , .. , .. GoJdo __ . ." ... , .... , ............. , SWoo--II>1Jtii

CylInder block -~ .............. . &oMco IImiIl/I'>Ul .. . ---...., ... o,...s.- ... ,.. ! , . Engine, clutch and transmission 2-3

62.IIOOIOQ.815mm 62.11111) mm

=--"-' .. ,-

_ ;_;., __ ,~ 15.0 mm "" 1rom0kirt . ., go' to '"""" p01 axi&l ~ . . ...... ..... . .......... 62 .MOto~.5T(l,..." kYioo limit tM>I . . . . . . . . . . . .. ...... . 62.~ mm !,._. ......... .0.5,..."

:!rIeI_ ... ....... ............. . 1.0,..." _ ,10 boo.' .... ~ ..... . _lImiIlmPl .. ,

_p01-.r ~ ..... __ 1n'*'>I ..

_P"Ibcn_, ! ! Inpooton "" ... d ... --...., ........ .. .

PIlton rings fIoog .... __ 1 r"" ling - GSfi500SlSS to )(IS)( _ --., ..... --....., ... '''''''''II -GSftJtJfNlSY _ ,",_do 51& ... d ... . ........... .

.. .. .

--~ ......................... . :!riel ""II - GSfW:I8!S9 to It/S,!(_ """'d. .. ..... ... .. --1"""1 , ...

ihI>I ling _ GSftJtJfNlSV _ .. , ... do lIta_d ................................... , __ tnrot .. . ......... .

..... __ " !, 0 ,~ .. S."'d ... . ..... . .. ---GSl'i5OOSISS 10 )(fS)(""- .. . GSl'f!Q1f/SV_ .. , do . . h" ..... d .................. . __ tnooI .... ... ....... .. ......

...... 0cI0 __ GSf'!08ISS 1O)(fS)("-l ""oIng ...... ...... ... .. ... , .. ...... . .. 2ndolng ..... . .. ..... , ..... ... .. Fli"II __ GSftlOOV/SV....- ...... _ , ,,,,Mg ... ..... .... .. ........ . :!rIeImg ............... ............ . .. ..... .

... __ In piMofI_ GSfIlllDSlSS '" X/SX..-'...... ...... ............ .. ... .. . :!riel Mg . ..... . . . . .. . 01 ..... ................. . ~ __ In '"""" - GSff'JOOYlSV __ onwordo r"" lIng. .. ... ..... .......... . . 2nd '"'" . .. . . .. . . . . . ....... . OIMg. .. . .......................

..... 111.. ! .... l",Mgtno.l ... :!riel Mg tno.I ..

o...m.Mg_ lop OIl:;I fIngoo I,. ....-1. O~"""I.

2rId .......,. 1. 1.00 >rrnj OIMg~ "'d~ ,._10.-.... ........ :!rIeI __ I,~

11.99610 ' 8 .000""" 11.M ......

MOmm~. ) ,~-.ro_ 5.0\0 mm

6.70 mm 1 __ .) ,M_ 1.00 ..... ,~-

O.'OIOO.lOmm

0.70""" 0.50 ......

o.:lO to 0.50 ...... .ro_ O.n to O.N ...... O.~7100."mm

O~7too.lI9mm

0. n .. 0. N """

0.111 ",0.13""" '1)1 '" U13 ...... 2.01 10 2.03 mm

U Xl kl 1.04 ..... 0.111"'0.13 ...... 1.51'" 1.s3 .....

0.18mm 0.15 """

ro '00 -,-

2 4 Engine, clutch and transmlssloo

c ... '" --o...c.y ...... .... ..................................... . TI'iIdo.- - GSfJCIS./SS 10 XIS)( _ ~ ............ , ......... . SooMceIimil ... . ..... , .

TI'iIdo.- _ GsFeooYiSY __ """ ~ .............. . SooMce_. . .. .

:::::;:;::::; :.:.: .:.:.:: :::::::::::::::::::::

T,-.namlMIon a-_~. aI--o -,.-.c:oon .....

AMI_ '

~-"'-,. __ --~.. -511>_ .... . 8110_ ... .

;;:,;;.;, ........ ........... .

-"""--_,1 ,13 . , ~. 2. er.nk8Mtl and bHrings ..-....,- .................... . -~ .. .-.... - ............................ . SoM

Connecting rod. (contin~ c.or;q,;,,_.,' , """ . .. """ Iig.orIcI


Cam.natu lind nx:ker IKTt\S

""""" ....... -"'"""" ,.. .. d ................. , ...... .. --~ .................... " .... , .. .

E-.oI _ "'"""" _ OSFt2OOf/ST 10 YISY _ ~. . ........................ .. __ .-.J , ........ .

E-.. _ "'9'>I-GSF'2OOKIISII . __ _ ~.......... ..." .. . __ (r'nInI ....... .

-_or, ... ---.JoumoI 01 I O ~ ........ __ I"tI&-'l ' ~~, ... .

_"",bcnlO ... . _"",_00 CylIncMr h .. d

--~ .......

V.IQ, gukIn .nd springs v __ ...... ..... . --_.-,- ... SIem dIor, .. , ... GuIdo_doo,_ .. , S' ''''\01IUkIO .-..-.co

GSF'2OOTIST'o Y/SV..-- ... ,

....... . '

GS/'12OO1-. .1165 10 4.9!IQ ..... 5.000 10 5,012 """"

0.1nO '0 0.(loI7 """" 0.000 10 0.057 mm O.35mm O.Smm o.e 101.1 mm NoI.,'I 000_ O~_ ,,-~-..114510 . 980 """ 5.000105.012 ...... 0.040 to 0.0157 mm

~,,-O.i.o l .l ......

~.O.Wmm O,O!! ...... 2,5mm

211.0 ..... will> 5.3 iO 8.5 ""_ 3UI mm """ 13.1 10 .5.1 ""_

N.om '" 19.015 ...... 79.080 ...... 0,20 ..... -,,",",,'

Engine, clutch and transmission 2. 7 -. _ ... , ""~ ".0 ..... "" 1n>m II! ......... .. .... .. Oo.*e,.._--.., T"'""' t. ~m.oI .................... . ...... (.~ ...... .. . 0II ... ~A.d> .................. . .... . ..... . ..... .

""" --~...... .. ...... . - .. .. ............. . --............................. . IIII_~ .............. .. ................ . --..... "II-~ .. .......... ..... .

_ ' .. " """"'" _ hoigI111""1 ......

1lSF1 2OOTISTto VISV"- . . . . ... . ClSF12OC1(11S1(1 _......... .. . . , _~bOtI_,_ ............ . ...... . - cyIOodor piItm ... , ... .. .. . .. . .. .. ... .. ...... . -.,,----, .................. . -.,..... pioeoo\ "", .

_ _ "'.oI l~ --__ ion ,._. ZroI_ .............................................. . :w"""" ...................................... . ---- ..................................... ..

0.001010 0.010 mm 0.120 .....

2!l.

-2- 8 Engine, clutch and tnlnsmission

Selector drum and fork. _or_" ~_"OC4' - ... , ......... .

s.Moo _ fMII) ......... ............ ' ......... s-:.or ____ .................. . .. .... . s-:to< ___ ........

Crankshaft and bearings JoumoI_ .. . , M ... ~OI---'OO _ ... ,,,. . . ........ .. --~. . ............ .

_ tr-..) ....................... ... ...... --.;' .... ................................... . ---.g- ......... -_ ............ -. Connecting rods ---- ..... --~ . -~- ' .... Stao_CI ....... .. ............. ... ....... .

Sonb_ .... ... , ......... . --er ....... _ , .. . ~-.. ............ , ..... , ......... . IIig-

Torque wrench setting_ (continued) ~6mn'1 _ __ """

GSFI2OOTISTtoY/S't _ .... , GSFl2OOK1/S1

Tho ~1' ond oo ..... bI . JlstO

""'"" ottllfllion .. 11-.. _ timo. '""""""' 01 .. "'IJIno 10 'ocoo" 'iOiodfod. 01 __ c:coIr --c... ___ ".", ct-.~

c.n.notI:I fI>ublO 110m a ,oIluitt ..-.gino. .......-,1hing ....... bo = ,_ with

2' 10 Engine, clutch and tr8nsm1ssioo

I =:~I00'''''ioI ifld ~

"" A

_,w.. n.. ___ ,"~ -,..I'to;, ,_~ ...... _____ IIIOMJ oIM __ -..c: __ ....

~OI ___ """"'"" Il10 ...... _01,",*', I " . I _IM,. .... ___ /IOdHCl_ ""'Irog. bI.cI< IrOn'I , ,,. lOp of Iho Cf_CUO ..... _ .a ~ .' Il1O ccrnec1_ 1_ ... . .. otlono). _ tho -..\rIng ........ ..,

tI.121o """', .... WIne coo. I coo '"'"""' ...

Engine, clutch and transmission 2. 11

1.1211 ___ .....",... _._too ...., .... or a..1"IOIi"liI" JCU1in9. ......... ~ on .. 01 ..... cr....,....,_. __ IIipoodt ___ i.'''' .... 1.1 ......... ..... . ..._...wr.g.,- 01 ............ . lJ u..o.c.- 1M ~ ...... """-.., pInc:t\ !>Oft __ ..... """ ".." t~

-. ft01ing *'f ..... " .... __ on lhe..", .......... 0/I&1t 1_ 11",."._,. II roo man.. WI _ ...... 'fOUl """ _ ~

' .13 _011'.' .. 4_ ........ _ thoo_IwrowI __ ,' _ ......

~-Ihe """..,....., ~ '*' boO.....-.cII)I oIIgnecI .... lhe_onio, L ,. __ lhefronl ... ,. __ '"

fronI 0IIf0CI0* ~ ChoopI.- 51- The 0IIf0CI0* _ ..., boO -..:I out 01 ..... ....,. _ Ihe ckJldl caDIT (eoo """'"'*l or _ ~ - ".,... I''''''' mnop-'.3). ,e _. ,"- .,., c.- __ 1_ -, 17 On ..- hned ""'" P .... R '\'S*" . .,.."._ Ihe PAIR syotom pIJIooo _ .....

"- Ir' 3/. Dirro .. ~ or .. 00CfI00_ jodo ....... tho ongho -.._ of _ boOt" ... , ,,.,. jock ,.,..., mel.....,,, ............ ,"- jodo io C8nIraIy ~_ ..,

,"- ""I)iM ... root IOI>PIr In ...,. _"'" _ ...... ..........cing bOIl . ,_T_ ".. ~ '-'1'

2012 Engine, clutch and transmission

5.200 ~Iho_~_""" ___ ~ ... 5.201> It.n ......... "'" ...... ""'" I>0Il W"'" Iho _ __ (II~ __ 1ho_1t

5.2Oc __ ...... ..-bolt. noting Ita ~ nul . 5.2011 . _ .lado Iho.--rnounting _~

~ "" 11>0 ~ ..-.:;I _ on _ ... pport ~ .. ...... R.....",. Iho ....-naInIng ~ ~ ""I. __ _,....,.,.,. 10. I>tto~~ tn0 .. orIouo nu'". ~ ... brad

-.a. ond ....... _ ... ......,..., or'Iy IIII_-'~"""_ond~ ........ __ on " , --D _ion .. u.._ .................. "'*"II !hi ~... "" 9 __ ._ ... no-._",_

"""""'" ~ WI' ,., .... ,",,*,"_ ... __ I , '" ..... '""*'""

11111Ie '""*'" """"""'" _ .... at _~ _"'II'IOCOt>'I boIIlI_"''''_~ q _Il'10 1Or>g .... ="IJhe ~ _ ""'" Il'1O WI ___ . J1II ""'- _ II """. _ .... ~. _Il'10 _JoIII'IO_ .... ~.

4I.l00 __ Ill _ ......... ""'*'" ~_ DonatU)l~_at

... _-..,.-"'--_ ........ _--.. "'~ .... "".

"' YI;I'>Ien ........... ~ __ .... __ '*' 'N __ ... ..,.---_ ....... --.po ... If.., et Il'10 . .... ", at ... """". Rr_"""'"" __ .... ,'_ .... .. _PItoe ... ...... .. ".""-_ .... ""; --..... -~.",,---.-'" IN.", ""'" ..... ...", _ 1IgIo ...... pirocto boII~.

~- ..... "'..-.---... _fty ___ Md._ __ 1It'..,. .... "'"-

_ ........... -.,. .. CIIepNor I~ , ....., Il'1O __ IwQIey_ """" " ~""""--IwQIey---. _ .... 100_". """'" ......,. ... """*" I).

Di ..... mb/y , __ .... ""mOlinO !lie ~. !lie WI ..... MMl_ I)l ,"- unit 01\0II1lo ~. Q ..... ., .-y Idoo IF ... ......... Sorno __ __ be .... _ ... pwmiI_totoo __ _ ........ _, ...... ~"'",:,il_~.

I s-n ... ,., ..... "'-......, """""",,IN ......... --_ ... _--"' .... ,..., .try ......,..,..... - l1li QM>ed . _ , .. , .... J;oog ... ,_ .. ot. ~ _ be toe, .... ,t>Ot 11'''' _ .. -., __ ..... uoIes. _lii0.:i. In .,.,.~ .-. """""" ... "1 ,eWctInce '0 too _ ...... _ .... .., ..... ,eG1 .. , ~'" r.rHO'I'oI mort~ H In ....... _ .... __ In. -. 4 ko ........ _oc...a..-ffom_ 1eng11-.01 2 ........ __ .... ,~ .... IIOCWIgIO .. I"ooMp _ .... .......

.... . b.IIce . "" .... " 01 .... ......... _ boO juOI tIig -.. to ",_, .... __ ....... lhIongk-._ .... .-, - .... " . -'0 .............. "-. .......,. """0 ,.....,.... '" $ '"'e __ CjPio_ .. 1OieI __ . _'" rode.-' __ ... __ In """-' .... ..,.,_ ctumg ......... _It Ion). ~ mat .... _ ...... , boO _ '" ,..-,..: _ ..,

'otJIr e EnginoII'_""" " ..... -otJ """"" boO _ In ,"- _".>9 _01 0!'

2. 14 Engine. clulch and transmission

(oottowaj

3 u..oc.... ItM two /)OftS _'""'sl the top '" the 000lo< to tflo _. "*' ~ 011 "'" 000lo< out '" ito bottom mou:uing Iug(sl (oM on 000 mooN. two on t200 ~ on Iho 1,..,.. OOwntulle(s) 4_ 1 . ...... Uonol_ h k. ~...,."" 10M It>O U.......,., ~ ~ol !rom It>O lug(o). ond ,~ ~ _ . -" '"

-~. ~ lk>oO two """" ~ 1hI"- """'" """"" to IhI Cfanio ....... co ... ( ... "111","1"""'). I.ON t>atIjo t>on od lhe f>ON """"" t>on. 10 tho

1.51> __ NoIin\I .... -.on_ _ 01_ '**' tIttItIgo

_ MItlng ."..,ifled .. U>o begio. ;' og d It>O ~ c- _Irationj.

8 VIfw_- removal and insla8ation ~

.~ I! HOt., 11>e ._ cov. _ l:>o ~ _

tho"",*," " tho ",..".. ~ ""'...yno"' _ ,_IOd. ~ "'" OMp< wfricfl dO nor fPIlI1.

7.50 Tjghton -" 01 U>o _ "" tho oporciIIed 1

_." , _""_ond""_~1 '- boll. If>d .- ~ Irotll tho _ c..- oIong ";t~ thO ~'Ut I_ , ....... 11.80 _ bl. I C ...... "" ~ poIu; _ Irom "" .. one! NCIH __ 01 ,"'" *'!line.

- IN -" pIUgt. 1 ............ __ ~ .... aI_ .......... _"'-ond ........ _ .. . j , 7A/:11,0i0c:MI ... o-mg._ _ .... _ bot -. ... __ 10 t:>oio'9 t ._ ..... ...-... "'" Iw

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2\1 Tum Iho ongIno ""'Of. Inst" the _ e .,.." _ a-ank0lM Dolts ond tne ~ nul IVhich I. located inside tl>o altomator mounting ftor>go (OIl _ .... tiona :111.7._ b). C...." 1M I ..... " .. " on 'M _ (\lro ""' little " Ii",. Ie 11>0 ."..:ifioo c,ank_n and ,,~ _ rot ... ornooIN)' _ eniIy. CI-'< the 01*11"'" ot 1M ' , .... omloalon ItI Meh guo-(Me Stop 23). ~ ........... _ sigos '" ......... _, tI{tIto.-. ~ruru-. 30 Instal tl>o plug if>1e R, I>0Io ..... '0 tl>o I ttOffll'Of """""ing 1Ia~ u.ing no .. ~ .. _. and ti0 cronk","" I ... Hlu'''otion ~.5b). llgnton tho tdt .-nIy, Ihon bond up tho ~ "" ,1>0 pia,. 10 Ioc~ ,hem "' ~ e_ -~,"",~, 32 Instoltho ' ;;;'.",.o'm ~_ '-'""'.I "'_ plot. ""'0 tho O 001..- cyIiOOor _ ond /rom lho t>oorIng rut_ In tI>O top '" tho _ cnr.keaM ..... C ... 1_" .tIo ... l Check tho condition '"

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~'orm"" u,.. colour cod. of tho bootlr.g ""QUired, For 0lMring _0;"11' in beth CfankCUl -. ,e Press tho booting __ Into ,_ eu' 0010 ......... 1od eomparo yOU! flndi"110 _ thi> Chapt.'. St>t ~ 01. ""- tho ~ ..... Into tl>lir Iooolk>ns. no. _ wit!t !he .. _ Iocat. in tho __ ~ r.orI (_ 1liio_ 30.-48). MaKo sure tho1all 00 ~ _ ._ In ' ho notcl> in tho ea*>g 10M 1I"" 1"~"" 30.1&). MI'" "',. t"" boorIrogo IfI fit ted in tho comoct Ioc.tion. and _ CII'O net to touch ....,. _ boooirog _

-~-:Ie Low .. tho Of __ !Mo poo/Iion In tho ""'"'" _ . --.g tho corn _ down ~ Its tLlmll I ___ 30.31. 29 _thottvust'-"'9>lnto _comct Ioc:.tloo. 100 .-.o! mi. U9 tho ...... with tho

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access, .-:f1 behind t!lo 5th _ pinion wiIfo cIrcIo circIip ..0'-""11 tt>o .th _ pinion. t...., _ tt>o pinion _ ito bush It

~-.1 TM l ot ~ .. pinion it Intogo ...... " Of bush M without Llnduo 1reopIoy, CfluIIO mo .... f,ooIy on tM _ but -.out Llnduo 1rM pity, 7 Tho oha~ is unlikoty to ""'toj" ~""'90 ........ 'M ong.,. h ...... zed , ~ing an ~ hIgI> ~on ".,. ,,~ Of t"- rnactlino I'IaI oo.euo .-bNtIno,l ,,",,0"'" _. _ chocl< ~ fOf

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Output 8heft .... uembI\I 53 During , __ 1>1)'. aw!'I ~ -'" or ..-l(,lir>o 011 to I ... mo1>ng oo.riaca '" m._. ~ _ 000h/t0, _ ~ .... circtipo., do no' pand ,M 0000 11'1' Iurthot I!..-."~. __ Ihom.., that tho ""_..-ed .KIo 1"" .. .... pinion ...,..,.. I .... COffKt "ltjng of otompod dtdfp _ tlon In Toolo _ WotkoIoop ropo 01 tho -.nco ~Ionj. 1501 SlIde 1 ... 2rod ~ pinoon onrI< groovo 1"""" _ from thO 2rod _ ponion, _ by If>o ~ -III! SIIJIII

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Chapter 3 Fuel and exhaust systems

Contents .... _.-...grd, .... , ... , ............ . __ ~1 .... _~ ___ io ' . ................... . 2 __ .. 10 ---"' .... " i ............. . ~ __ ~Io .. " _. .... 5 ~ 1't'0Ch","'1O'I . . . . ... , . . __ Cho!>ttor' ~_-.-roDIy.~_~ ... 7 CortIurtnors _ r i obIy. _ II,_~.'._~,_ .",._d ... _ib

3-2 Fuel and exhaust systems

Carbu",ltors Typo . ... . Bore . ... . I.D.no. ~.

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us rod CaIifomia Aootho9"' . . ldIoopMCl f'IoI)oO: ......... .

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Torque wrench saltlngs

GSFI 2OOTISTIo YISY MIkuni BST.l6SS

~-27E' 27ES ,,~

1 :lI~ lurns O\JI --... 6 " .0.,.." 1200" ' OOrpm J7.5

C-WOl1Of joO>OIg bOI1O - GSHnNIS'f-n _ GSf.2OOK.1SK'-oo .

~~"''''''''-~-~ ~-~ ~ro= GSFSOOYIS'f 0fIWIIrds ..... 200 mooI_ 0Q00flI'-" by. ,... - - ""',....,.

Air II "' ...... Into "'" CIort>uo'OI1Ot1 via on .. firt ... """"" it hOuHd LJndof IhIIItMO t.lk.

Tho. GIl ... ., oyslem Is two pjeca '01>"_ ~-Mw!)' 01 "'" "* .yolom _ ~ .,. eon_"" :>utif'Io mainton.""" il"",. _ "" 1hat rMSOO ... inclu

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ouch unbumt hydrOcarbonS. carbon mono.ido etc. """ con t>. omItled b'y _ macl>inoo . .... voohicloo o"ored lor ... ...... oO' _

u " _ "'- _from "'- _ 01 "'-UI> _fon'ow1 __ -_

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Fuel and exhaust systems 3-3

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33 To check ,1>0 lloa' hoigh' . hold t!oe cartoJTecl""""_ be M gi-. In "'" Spoci6caIic:oro .. l1'li t>Igir.;, og 01"," C/oapIor. ~ ~ io inco 'our ..,..... ond tig/lton tI>om .......ty In diagooaI uqueoce. AtUoch tIHI IdIo opood aoJUsl .. tnekII ' 0 tIHI no. I """""""" _ ~. 35 ~ removed. inlll~ 'M Edp Into t"" opoo:i!"" """'" In .... iII_. thon_tho nylon ring ..-odornooth iI. Frt tIHI __ onto tho .- oItIHI ill _ (~ tIHI E-dp). __ bot ' ''" I!'wI is In II-.. _ Q/ tfle oprio>g

_to U--.bIy Into t"" piston, ~ I, In,o pIOca 31 eor. , LlIIy Install tIHI pIs,oroIdl.p'ngm .....,."., Into II-.. carto

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Chapter 4 Ignition system

Contents _ ir'lI

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4- 4 Ignition system

,~ Oi_ 1M oil pr.-. ..... ch IAJ 811

__ iho ,_ on "'" pUIH _~or coil _ 01 tho ""',...,..". 3 Compare 1110 rH"ablo _1ItnOO) 01 an opor> oi'o.rit IW_. or ......" r.igfo -tanooj. 4 11 1110 pojM 11""""''"" coli is ~ '0 Do faully. Nt .. Ol>OCk tha' WI II no1 d .... to ~ 01 ~ ... wire !rom 1110 coil ' 0 tho """"""'or, pirK:hod '"" brobn witH can LlSUaIty Do 'opoIt..:j. Note "'"' tho _ 10 no1 IV"",," .. If>di'l"""-Ily tM "omo. as on .. e ,Ib[, wi1t11ho fIlOU"Iting ptat. _ wIrIoV. Removal 5 ~. tho _,. OOCUmO' tray __ ! iltO

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Ignition s ystem 4 ' 5

' .101> FMd "'" """inII __ ._' 01 1hrough __ In_ .--

.. ,,. R1.""'" .... w ... 'InIo ...... _ . .. ..U1> ... __ "'" -. "'"""'" ""'_ 11*~""' H' .~~ __ "~atef""'piro "' '''''_at''''' Ii> II-.. eYW (_ ..... "-'Ionf, e1 C/>8pW 1_ IIIU" _ . I'*' ,_tho coW ".'-otJ. _4.111. "'*'G __ IIII t-.=.tIiur~. ,. _ ..... ~ ..... _ I ..... , __ 11 E.- "'" .... Of I", signa 01..... uoinII' _ ~ _ ".,..., ita bolls .., ........ , .. "Y---II _ ..... ""'"' ..... . too.... .iIiII' ....... ...... , _ ..... IVftn ... I .... , --.0 __ """"My 1_ ..... "._ .. ,Got. Il ~ ......... of .... "'" 10 I". _ ~ _ ..... lit !toe .......... "' ~._'" 1'10 ............ (_ ''''''''01I00>I. FMd ' ''' ..mg COIIt*CIOf Ihigh tho ,..,.. In 1M Ira _ '"" _.Iioi~. M eo:n- ....... _.- _lOiII _ an tho __ .... .,... ""' ...... -..,..... .4.111. II _ ... '"'*111 ........ '" _ 01 ... _ . moki'>g .... tho ...,. In tho ""'"

......-OIy. moki'>g ..... tho 0NIinIJ .. _ 50 _ ,."" "'" lOP bo/I I_ ~_

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4-6 Ignition system

Ii.3 111. "rulOCliho two wiring 001._ ~ . ..

.*kill _II ... unit - chIeIo;, ...... ""-1 W __ 11flans I>avo _ 10 -.. tho .,... of on iIJniIIoo lauI1, K .. ..,.,. I~" II-.. 19rNlion oonlrQI unit KHII .. faulty. ~ !ell ollail' .... ,~.~_ __ ,I-.. .... , c.on Doo ,.0,..:1 on I>Oo'N _ ohop ~ T_ tho ~ 10 . Suzoo deale< kl< t.lling on ,I-.. O~",1c

'. '. -"-mo,,,-, .nd In.,./II1f/OII

OSfMOSlSS to XlSX end GSF1200TfST to YISY ~ fWnow tho _ I 10 ace-. tho control

Note: Tho _ pOriIjon _io _ to III 1200 m

IL2t Tf'I. ] t __

boI.=, __ ...,tooo: ~"'-..,

~ __ ",-,'.'o"" -------: ' I~. "'7. 5 lM .......... _ 10 _ on "'" ".,.... "' .... rigM_ (flo. 41-.no.. On 1200 ..-. ." ""'..- ......... ..., -....ooel N ~ -'orfn:>m tho top 01 Iho _ 1 __ ".1Ion 1.2.01. On !IOO _ , 1OIIt*I 110 p

Chapter 5 Frame, suspension and final drive Contents ~_-_ondno'''_kwl ''''''''''''' _ .. . . 1 ~ Dr!

_ . __ 10 ' ......... e """_10 : __ __ .... . .......... . 2 0r00r0I i"",,-... .. .. .. . _ ... " .... _ . _ .. .. . 1 1._. __ -___ '*' ............. 5 ~_ I_-CI\Od< ............. , ..... , .-CI'>optw8 ~ ____ ond_1on , ..... , ... ~a ___ -...nec.lonond_tion _.'0

Degrees of difficulty

~ -...p ...

Specifications

5'

..... , ..... , .. -~ , " 11

.,' 11 .. '8

.......... __ ~1

___ ~1

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! .... .................. .

....... . ..... , .... 12 .... _ CI>oc>t 1 ... . , ~

. , ... 13

0'

_ __ .... _. ~ ... __ l>jI _____ '" __ .......o.oro .c rntlrMloJlIIio_ tor_

Front fork' fork"~ . ~..a_

i.'(_ ........ _........... ...... . ____ . ..... . US_ ," __ ........ ........... .

OSI"2OOTISTIOV/SV ..-1.1("- ......................... .. ... ........ .... . L8..- ..................... .

G$F12(10I

5- 2 Frame, suspension and final drive

FronllorQ leonti~ Fotk IP"'II"" '->gIll tr*'I

.... 800..- ........................ . GSf12OtT1IST 10 'lISt ..-UK_ .. .. .... . .... . ........ .

"'-GSfl2OOKlf5I(I _ UK_ ........... ........ 370 ..... us _ ..................... . :JIIlII ......

Fotk U>e nroout _ ......... . . . . . . . . . . . . 0.2 ...... '01'_ _1Ium N .... Of NUll ... N _ ..-*'V ' __ N "'" Illy .... , .. Rur.uspenslon Sdoga-m p;.ut Ildt nroout ~ ......

TorqutI wr-enc:h Mtling. _pedII_; 0190 __ _ F~_U"'c""_ .... ......... . _tnI ' I_".,. __ ~ .... '" -. l1li __ be _ oIOootII"

........ "" cro

1

Foot,. .... ~. ,_ ..... ___ ..... _01 ... _ phGI pori. _ 001II0 ..... phooI t:-I "",,_1Il00_.-_ botl ..... On ..... IrOtII ,..' . ""'0 1IlOo IIItJn; 011Il00 """"'""""" _ oncI..- _ . On ... ____ lNofitWlllol ..... _ .... 1M """"" _ lake".,. _ tM1 ooI_........,_ : ........ wt __

Frame. suspeosion and final drive 5-3

1.1' ... _."''''' ........ W_ ... loop. __ ......... .,..,....._181 --br-..t ( __ tr._ l.51 . hpat.,O \Iloo _ ,bIy_~"";>eGII. (notJoU..t1on 7 __ is Iho _ d..........al. QIOdI "" .......... ,d ... __ iI[tot __ Iho PIIIgroI d IN _ """"' ... ~ ,).

a..rcMnge ,.~ ......... ................ U d ..... _ ...... """ phtI--_ ..... """ ....... .,..-. ~"':oIY" _ ,",,"=i ~. Kno_ .. _. ____ _ ~ tI>O ....., 00 tne! ~ COlI be COl ........ 01!1'*1 with Iho ohofI. on .... ,-. Unoco.... ,ho piYOI _ _urinQ tho _Mi>go _ _ _, o;aono.

:u _ .......... W _ .iII""o. ... -......... -~-... ....,... __ 1IlOo cof>ooI _ tel

1.10 ___ Ion-t_ _ ... toCIM .......

'-" ~ ... - podol"""""", w ___ ...... _.,..,.....181 ~ to ..... 100" __ t t_ _tr.lIonj. s.-o ....... _ n. ,otII. __ tho_rd~ ..... '0 II ,*,,,"00

5- 4 Frame, suspension and final drive

4.1 Unhook _ spring ends !AI and __ ,*,"'_(1:1)

Centre.tand (whare flttad) , Tho oontrMtarv:llo ...,.,..0 ... II>t ~_ Dy _~_. _!II ____ "' 11>0 ,w'" pk. DO ~. _ ,and &rOd ""_ II>t """' " ,,_ OJ>ringoo, !hen ..-..crtIW ,he bolt. _ rIlOv. 11>0 . ,.,., t_ 11l""."tlo~), W~l>CIr .... lhe __ from..:l1 ~.

2 I_, , he ".,." .".., ... &rOd t>ol" lor "'IJno 01 _ ond r.pIaot _ l ..." ">'Y-~ ...-- 01_ to 11>0 00_ 01 ,he opaca ond ' he 1>0lIo ond !II ' he ttarv:I boocI< "" ~ t>iI01, (_ 1111,1""11",,1).

5.'" 0i0c0tw000cI "'" _ .... "" _ch .. .

4.6a tIMooII .... opring _. (arI'O'onj ..

_It-.. pivOt boll to _ ,he otond from ~. brackoI. On Ins~ awl\' grease to Iho ~ Dot! ..,..,.. _ IIgnIoro 11'11 Dot! ooco.nty Reconr-.:t ,he _ ,_ spriotj. _ oheClo.

' '''' ' tho ,","'" opmg hok!o Iho ttarv:I..:urolj' "P ....... oot In __ - .., occ;oor" 10 atmo., certain to ocwr rt Ihoo _ " .,,,",," _ ,he mochIno io In """Ion_ 7 For check orod rept"""""'"' Of I"" _'...-.d .... it _ ChopI .. 8_

I

5 l\andlebars IItId ,--* -removal and jn$laUa.!icon

Handlebars Removal

Not. , /I ~I.-.d. u.. ~ ""n be ditpIacedtl>ocMcfo_'matoor --, o;oeomoc' '''" Do".~. ilgnl IwllOh wlrlrog """"""''''' !rom the ~ Of Ihoo mas' " 0)'1ind0r 00'>

... 1roe .. _ ... "'h r ondWiIha . 0l0i, _ .... !No~ .. 2.~.

n.. It no.- '" dIoooo._ Iha _ ..,." "_~.~IN .ti). .. .. ur>ri9M position _ 00 1111' no sir ... it piIcj on Iha_. I PriM OUI IfIO e.poo from 1111 _ --.mg .... _ o:Iaonp iOPO. "*' ....."... Iha _ _ ........ 1111 o:Iaonp 'OlIO _ IN __ 1 __ .tIoMI. NOlo _

_ ....... ""-_01 ..... -_ .... _ ... moIing_oI ... --- M .., ...,.. iJflOCNW Iha "" __ ... ' 'tlOOining _'. "*' ........ 1111 .. ~". from 'he ond 01 tIM -. 1_ _lo'alloo>I. K roopII ".. ... ', ~ -....wr;:ot ........ -. /I .-vP_ trooing ~ ...... !'-_, __ oj,a.

d) COo 1200_1f ,_1iI;o'IIo+:r IN *", __ IOIIto __ -"'--- To.......,.. lIMo...."".... fron1 ....... _ iti). from 1III"-1.~. """""

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Frame, suspension and final drive 5- 7

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5 10 Frame, suspension and final drive

!lie oil ..... 111 aI>oukI .ftc ~ _ and aodjuslment maOo I:')' 1!dOing ... 1Icting 01 FuI!), compr". !lie 1"", Iubo into tile .-. ...., ~ "'" fork 01 _ !rom Iflo top 01 tho t~ r_ lIIu. t rati""l. Add ... 1Ubtr.ct fork oiIl.O'ltiI tho 01 .. .t "'" _ opooci1ied in h ~_ Section 01 tM Ch.pter. 2>1> C I.rT\9 I .... _ "' I ""'. "'. "'" "'"k, caIIpor mounting lugs, takinV ""'" not to """'9/>1"'''''' d~ thorn. PIA t .... r"", lubo out of t .... __ I.,. _ poMObioo U,.,

....... the oping """ ill oIoMr-"""'" ooiII at "'" top, _ .. .., tI)' "'" 0!>rinII ... , and lho _ r __ Obc>oosj. XI F~ I ...... O-ring 10 tho lorI< 101> t>OIt ...., I"""",, t .... boll inlo , .... lop oj Iflo 1"", tube r_"'_1-

womr..g; " will "- n .. 1 ..,. 10

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_~.,.."..,.,..,. ___ 11M and _ "-".,,,,,,--.,.... ~ ... _'lfnle "')I. ~"" __ oil I>efjob """"""I. CouUy prIM out tho dull .... from tho lOP of 'he _ to gain acOMO to tho oil _ retaining eIp. 0I0e0fd tr.o dust _ ......... 001 muot ~-.

721 FlO . _ o-- boIt _ __ boIt inlo _ _ _

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rod in """ """ '" "'" CIImpOf II.- rod """" ,..,. ........ III'IOOthIy in !he ~ ~ """'"' t ....-R"_bIy ~ tnMr1 , "'" ~ rod in.o t". To

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Frame, suspension and final drive 5. 15

10.& l\ghtMl __ to_~ --Installation ..... ~ 10 11-.. ~ Of _. rooting h_ ~ Ap{)Iy ~ ~ ___ to lI>I two<

""""" .,., to 11>1 _ '90 ~ lI>Ili>II~..,.... .... -..pundo _"'h""IIs_~_ -C/ hstalll>l_ "",,",Mg _ Int. tout "'" not tigIo ..... ~ 0JfI1j/ .... _ """",,Mg _""~fOd_ ... _.

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Documents

Suzuki GSF 600 & 1200 Bandit Fours Service and Repair Manual: 1995 - 2001 (Haynes Manuals)