Wheel bearings removal inspection and installation J

Note Always replace the wheel bearings in pairs. Never replace the bearings individually. Avoid using a high pressure cleaner on the wheel bearing area. 1 Remove the wheel (see Section 14) (see illustration). 2 Set the wheel on blocks so as not to allow the weight of the wheel to rest on the brake 3 Using a metal rod (preferably a brass drift punch) inserted through the centre of the upper bearing, tap evenly around the Inner race of the lower bearing to drive it from the hub (see...

Info

Spring retainer Inner spring Outer spring Spring seat Outer spring seat (where fitted) Stem seal Metal plate Exhaust valve Spring seat Intake valve formed on the valve, then use a motorised wire brush to remove deposits from the valve heads and stems. Again, make sure the valves do not get mixed up. 12 Inspect the head very carefully for cracks and other damage. If cracks are found, a new head will be required. Check the cam bearing surfaces for wear and evidence of seizure. Check the camshafts...

Qec

30.4a Remove the bearing shells from the lower case half - they can be identified by their oil holes 30.4b and from the upper case half Note To remove the crankshaft the engine must be removed from the frame and the crankcases separated. 1 Separate the crankcase halves (see Section 26). 2 Before removing the crankshaft check the thrust bearing clearance. The thrust bearings are located between the crank webs and the main bearing housing between cylinder nos. 1 and 2. Push the crankshaft as far...

Ref52

Motorcycle Repair Tools

A toolkit is a fundamental requirement for servicing and repairing a motorcycle. Although there will be an initial expense in building up enough tools for servicing, this will soon be offset by the savings made by doing the job yourself. As experience and confidence grow, additional tools can be added to enable the repair and overhaul of the motorcycle Man of the specialist tools are expensive and not oien used so it may be preferable to hire them, or for a group of friends or motorcycle club...

S

14.30 A small dab of grease will help to keep the collets in place on the valve while the spring is released into the crankcase - secure it with a piece of wire or metal bar to prevent it from doing so. If the block is stuck, tap around the joint faces of the block with a soft-faced mallet to free II i from the crankcase. Don't attempt to free the block by inserting a screwdriver between it and the crankcase - you'll damage the sealing surfaces. When the block Is removed, stuff clean rags...

Removal and installation

Note To remove the transmission shafts the engine must be removed from the frame and the crankcases separated. Note Referrals to the right and left-hand ends of the transmission shafts are made as though the engine is the correct way up, even though throughout this procedure it is upside down. Therefore the right-hand end of a shaft will actually be on your left as you look down onto the underside of the upper crankcase assembly. 32.5b and the needle bearing dowel pins 32.6 Slide a new oil seal...

Haynes

Drain the carburettors) otherwise there is a risk of jets becoming blocked by gum deposits from the fuel (see illustration 4). If the bike is going into long-term storage, consider adding a fuel stabiliser to the fuel in the tank. If the tank is drained completely, corrosion of its Internal surfaces may occur if left unprotected for a long period. The tank can be treated with a rust preventative capociolly for thi3 purpo30. Alternatively, remove the tank and pour half a litre of motor oil Into...

H312w

4.3a The minimum disc thickness is marked on the disc 4.5 The disc is secured by five bolts (arrows) 43b Using a micrometer to measure disc thickness 5.4 Slacken the reservoir cover screws 5.5 Disconnect the brake light switch 5.7 Remove the brake hose banjo bolt (arrows) electrical connectors (arrow) - removal, overhaul and Jt installation 5.4 Slacken the reservoir cover screws 5.5 Disconnect the brake light switch 5.7 Remove the brake hose banjo bolt (arrows) electrical connectors (arrow)...

Hzt

Suitable for expert DIY a or professional Note Where applicable, models are identified by their suffix letter - refer to Identification numbers' at the front of this manual for details. General cc mm multi-plate constant mesh Final to 33.17 mm to 32.89 mm Journal holder dometer to 22.025 mm to 0.066 mm Service limit Rocker arm shaft OD -973 to 11.984 mm Stem-to-guide clearance 020 to 0.047 mm Stem-to-guide clearance to 0.057 mm Stem length above collet groove (min) mm Valve springs (intake and...

Chamfered Edge

2.9 Correct fitting of a stamped circlip Circlips can wear due to the thrust of components and become loose in their grooves, with the subsequent danger of becoming dislodged in operation. For this reason, renewal is advised every time a circlip is disturbed. Wire circlips are commonly used as piston pin retaining clips. If a removal tang is provided, long-nosed pliers can be used to dislodge them, otherwise careful use of a small flat-bladed screwdriver is necessary. Wire circlips should be...

H29003

Check that the exhaust mountings are secure and that the system does not foul any of the rear suspension components. Start the motorcycle. When the revs are increased, check that the exhaust is neither holed nor leaking from any of its joints. On a linked system, check that the collector bo< is not leaking due to corrosion. Note that the exhaust decibel level (loudness of the exhaust) is assessed at the discretion of the tester. If the motorcycle was first used on or after 1st January 1985...

B

ABS (Anti-lock braking system) A system, usually electronically controlled, that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheel which is about to sktd. Aftermarket Components suitable for the motorcycle, but not produced by the motorcycle manufacturer. Allen key A hexagonal wrench which fits into a recessed hexagonal hole. Alternating current (ac) Current produced by an alternator. Requires converting to direct current by a rectifier for charging purposes....

H

Helical gears Gear teeth are slightly curved and produce less gear noise that straight-cut gears. Often used for primary drives. Installing a Helicoil thread insert in a cylinder head Installing a Helicoil thread insert in a cylinder head Helicoil A thread insert repair system. Commonly used as a repair for stripped spark Honing A process used to break down the glaze on a cylinder bore (also called glaze-busting). Can also be carried out to roughen a rebored HT (High Tension) Description of the...

Xsu

Warning Petrol (gasoline) is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light Dulbs near the work area, and dont work tn a garage where a natural gas-type appliance is present. If you spill any fuel on your skin, rinse it off immediately with soap and water. When you perform any kind of work on the fuel system, wear safety glasses and have a fire extinguisher suitable for a Class B type fire (flammable...

A

Warning Brake and clutch hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it and cover surrounding surfaces with rag. Do not use fluid that has been standing open for some time, as it absorbs moisture from the air which can cause a loss of clutch effectiveness. The clutch fluid level is checked via the sightglass in the reservoir - it must be above the LOWER level mark (arrow). 2 If the level is below the LOWER level mark, remove...

How To Remove Suzuki Gsf600s Front

7.3a Remove the two screws (arrows) 7.3b and remove the trim panel 7.4a Remove the three screws (arrows) from each side securing the fairing side panel 7.4b then carefully remove the panel, 7.5 The front panel is secured by two 7.9 Remove the screws each side of the noting how its tabs fit into the front pane' screws (arrows) instrument cluster 7.3a Remove the two screws (arrows) 7.3b and remove the trim panel 7.4a Remove the three screws (arrows) from each side securing the fairing side panel...

T

T3pered-roller bearing Tapered inner race of caged needle rollers and separate tapered outer rece. Examples of taper roller bearings can be fcund on steering heads. Tappet A cylindrical component which transmits rrotion from the cam to the valve stem, either directly or via a pushrod and rocker arm. Also called a cam follower. TCS Traction Control System An electronically-controlled system which senses wheel spin and reduces engine speed accordingly. TDC Top Dead Centre denotes that the piston...

Suzuki Gsf1200 Removing Seized Disc Bolts

Suzuki Gsf 600 Chain Adjuster Washer

14.8 Check the condition of the seal (arrow) 14.9 Make sure the drive gear tabs fit into the slots 14.10a Smear the spacer contact surfaces with grease (600 model spacer shown) 14.10b On 600 models, fit the flat end of 14.12 Butt the speedometer drive housing 14.13 Tighten the axle the spacer Into the wheel against the back of the lug on the fork (arrow) 14.4 Slacken the axle clamp bolts (A), then unscrew the axle (B) 14.5 Withdraw the axle and remove the wheel 14.10b On 600 models, fit the...

Tool

Suzuki Gsf 600 Ignition Coil Replacing

A simple spark gap testing tool can be made from a block of wood, a large alligator clip and two nails, one of which is fashioned so that a spark plug cap or bare HT lead end can be connected to Its end. Make sure the gap between the two nail ends is the same as specified. 5 Connect one of the spark plug HT leads from one coil to the protruding electrode on the test tool, and clip the tool to a good earth (ground) on the engine or frame. Check that the kill switch is in the RUN position, turn...

Removal

1 Remove the brake hose banjo bolt, noting its alignment on the caliper and separate the hose from the caliper see illustration . Clamp the brake hose and plug the hose end or wrap a plastic bag tightly around it to minimise fluid loss and prevent dirt entering the system. Discard the sealing washers as new ones must be used on installation. Note If you are planning to overhaul the caliper and don't have a source of compressed air to blow out the pistons, just loosen the banjo bolt at this...

How To Change Headlight Bulb On Gsf600

Gsf1200 Speedo

If the socket contacts are dirty or corroded, scrape them clean and spray with electrical contact cleaner before a new bulb is installed. 11.1a Unscrew the three screws arrows 11.1b and remove the turn signal lens 11.2 To release the bulb gently push it in and twist it anti-clockwise illustrations . Remove the rubber gasket and check it for damage or deterioration see illustration . Replace it if necessary. 2 Push the bulb into the holder and twist It anti-clockwise to remove it see...

Gsf1200 Front Brakes Binding

Engine lubrication system P Electncal system White smoke . Black smoke Handlebar hard to turn Handlebar shakes or vibrates excessively Handlebar pulls to one side Poor shock absorbing qualities Brakes are spongy, don't hold B Brake lever or pedal pulsates Brakes drag . Battery dead or weak Battery overcharged 1 Engine doesn't start or is difficult to start Fuse blown. Check fuse Chapter 8 . Battery voltage low. Check and recharge battery Chapter 8 . Starter motor defective. Make sure the w...

Klr Start But Only If Fuel Is Squirted In Carbu

Screw the compression gauge adapter Into the spark plug hole, then screw the gauge into the adapter 3 On kickstart-equipped motorcycles, make sure the ignition switch is OFF. then open the throttle fully and kick the engine over a couple of times until the gauge reading stabilises. 4 On motorcycles with electric start only, the procedure will differ depending on the nature of the ignition system. Flick the engine kil switch engine stop switch to OFF and turn the ignition switch ON open the...

Starter Clutch Gsf600

Suzuki Gsx1100e Rotor Removal Tool

1 Bleeding the clutch is simply the process of removing all the air bubbles from the clutch fluid reservoir, the hydraulic hose and the release cylinder. Bleeding is necessary whenever a clutch system hydraulic connection is loosened, when a component or hose is replaced, or when the master cylinder or release cylinder is overhauled. Leaks in the system may also allow air to enter, but leaking clutch fluid will reveal their presence and warn you of the need for repair. 2 To bleed the clutch,...

How To Adjust Throttle Gsf600 Y

1 All repairs to the fuel tank should be carried out by a professional who has experience in this critical and potentially dangerous work. Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of the tank. 2 If the fuel tank is removed from the bike, it should not be placed In an area where sparks or open flames could ignite the fumes coming out of the tank. Be especially careful inside garages where a natural gas-type appliance is located,...

Travel Gsf600 Forks

Type DOHC four-stroke in-line four, oil air-cooled 1200 GSF600S SS to X SX x 32 mm Keihin CVK32 carburettors GSF600Y SY models x 32 mm Keihin CVR32SS carburettors GSF1200T ST to Y SY x 36 mm Mikuni BST36SS carburettors GSF1200K1 SK1 models x 36 mm Mikuni BSR36SS carburettors 600 Turning circle - all models m 9.2 ft Adjustments Adjustments Type shock with rising rate linkage Adjustments - 600 also rebound damping from X SX onwards Adjustments - 1200 and rebound damping GSF600S SS to X SX 54H...

Every Which

From Textile Machinery to Motorcycles Suzuki were the second of Japan's Big Four motorcycle manufacturers to enter the business, and like Honda they started by bolting small two-stroke motors to bicycles. Unlike Honda, they had manufactured other products before turning to transportation in the aftermath of World War II. In fact Suzuki has been in business since the first decade of the 20th-century when Michio Suzuki manufactured textile machinery. The desperate need for transport in postwar...

Sfl

Cable lubricated when oil drips from far end 35.3a Lubricating a cable with a pressure lubricator. Make sure the tool seals around the inner cable 35.3b Lubricating a cable with a makeshift funnel and motor oil 1 The oil pressure warning light should come on when the ignition main switch is turned ON and extinguish a few seconds after the engine is started - this serves as a check that the warning light bulb is sound. If the oil pressure light comes on whilst the engine is running, low oil...

Gnz

8.8 The headlight assembly is secured by four screws arrows 8.12 The headlight unit is secured by two nuts arrows on each side 9.11 The licence plate light assembly is secured by two nuts 9.3 Twist the bulbholder anti-clockwise to release it from the tail light 9.4 To release the bulb gently push It in and twist it anti-clockwise. Note that the pins on the bulb are offset 8.7 Disconnect the wiring connectors arrows from the headlight and sidelight bulbs secured. Check the operation of the head...

Gsf1200 Oil In Crankcase

Crengkes Zealing Bango

24.14b Check that the dowel is installed arrow , then fit a new gasket 24.14d making sure the sealing washer is fitted with the front top bolt 24.14d making sure the sealing washer is fitted with the front top bolt 25.3 Unscrew the oil hose banjo bolts arrows 25.4 Sump bolts arrows . A sealing washer is fitted with the bolt A 25.3 Unscrew the oil hose banjo bolts arrows 25.5 The oil pressure regulator threads into the sump 25 Oil sump, oil strainer and oil k pressure regulator - removal, jfc...

Disassembly inspection and S reassembly

Note References to the right- and left-hand ends of the transmission shafts are made as though they are installed in the engine and the engine is the correct way up. 1 Remove the transmission shafts from the upper crankcase half see Section 32 . Always disassemble the transmission shafts separately to avoid mixing up the components. 32.6 Slide a new oil seal onto the output shaft 4 Remove the spacer and oil seal from the lei-hand end of the output shaft, and on 1200 models the O-ring. noting...

Clutch master cylinder 1200 models removal overhaul and installation

1 If the master cylinder is leaking fluid, or if the clutch does not work when the lever is applied, and bleeding the system does not help see Section 22 , and the hydraulic hoses are all in good condition, then master cylinder overhaul is recommended. 2 Before disassembling the master cylinder, read through the entire procedure and make sure that you have the correct rebuild kit. Also, you will need some new DOT 4 hydraulic brake and clutch fluid, some clean rags ard internal circlip pliers....

Installation

5 Install the cable making sure it is correctly routed. The cable must not interfere with any other component and should not be kinked or bent sharply. 6 Lubricate the upper cable nipple with multipurpose grease. Install the cable in the switch choke lever housing and attach the nipple to the choke lever see Illustrations . Fit the two halves of the housing onto the handlebar, making sure the lever fits correctly Into the lower half, and the pin in the upper half locates in the hole in the top...

How To Replace Gsf 600 Disc Brakes Threadlock

Note The original equipment drive chain fitted to all models is an endless chain. Removal requires the removal of the swingarm as 1 Pivot cap 4 Bearing Inner sleeve 7 Pivot bott 2 Pivot nut 5 Needle roller bearing 8 Swingarm 3 Washer 6 Spacer 9 Chain slider 1 Pivot cap 4 Bearing Inner sleeve 7 Pivot bott 2 Pivot nut 5 Needle roller bearing 8 Swingarm 3 Washer 6 Spacer 9 Chain slider 15.2a Make some alignment marks arrows then remove the pinch bolt 15.2a Make some alignment marks arrows then...

Adjust Front Fork Dampers On Gsf1200

Slackening the fork clamp bolts in the top yoke before slackening the fork top bolts releases pressure on the top bolt This makes it much easier to remove and helps to preserve the threads. 6.7 Install the fork up through the yokes 6.8a Tighten the bottom yoke clamp 6.8b and the top yoke clamp bolts to and headlight bracket bolts the specified torque setting 5.11 Clutch lever pivot bolt arrow 10 To remove the lever blade from the pivot assembly, unscrew the span adjuster pivot bolt locknul,...

How To Bleed Front Brakes Gsf 600 Y

Banjo bolt Sealing washers Hose Union 11.6 Brake caliper bleed valve arrow 11.6 Brake caliper bleed valve arrow 6 Flush the old brake fluid from the system, refill with new DOT 4 brake fluid see Daily ore-ride checks and bleed the air from the system see Section 11 . Check the operation of the brakes carefully before riding the motorcycle. 1 Bleeding the brakes Is simply the prccess of removing all the air bubbles from the brake fluid reservoirs, the hoses and the brake calipers. Bleeding is...

Electrical system

Altemator regulator rectifier - removal, inspection and installation . 34 Battery - removal, installation, inspection and maintenance 3 Brake light switches - check and replacement 14 Charging system - leakage and output test 33 Charging system testing - general information and precautions 32 Clutch switch - check and replacement 25 Diode - check and Electrical system - fault finding 2 Fuel level sender 1200 models - check and repacement 27 Handlebar switches - Handlebar switches - removal and...

General information

A Warning The dust created by the brake system may contain asbestos, which is harmful to your health. Never blow it out with compressed air and don t inhale any of it. An approved filtering mask should be worn when working on the brakes. 1 On GSF600S SS to X SX models, unscrew the pad retaining pin plug followed by the pad retaining pin see illustrations . On GSF600Y SY models onwards, remove the R-pin from the end of the pad retaining pin then withdraw the pad retaining pin. Remove the pads,...

Spark Plugs Condition Chart

Electrode gap check - use a wire type gauge for best results. Electrode gap check - use a wire type gauge for best results. Electrode gap adjustment - bend the side electrode using the correct tool. Electrode gap adjustment - bend the side electrode using the correct tool. Normal condition - A brown, tan or grey firing end indicates that the engine is in good condition and that the plug type is correct. Normal condition - A brown, tan or grey firing end indicates that the engine is in good...

Gsf600 Battery Voltage Fully Charged

Digital multimeter can be used for all electrical tests Checking battery specific gravity SG some electrolyte into the hydrometer and note the reading see illustration 5 . Return the electrolyte to the ceil and install the cap. 2 The reading should be in the region of 1.260 to 1.280. If SG is below 1.200 the battery needs charging. Note that SG will vary with temperature It should be measured at 20 C 68CF . Add 0.007 to the reading for every 10 C above 20 C. and subtract 0.007 from the reading...

Test Gsf 400 Rectifier Diode

34.7a Rectifier soldered connections arrows 34.7a Rectifier soldered connections arrows 34.6b Identify the regulator terminals and set up the circuit as shown to test the bulb and connecting wires. Identify the regulator terminals and set up the circuit as shown see illustrations . Set the power source to 12V and turn the switch on. The bulb should light. Increase the voltage to 34.8 Remove the terminal nut and sleeve, then undo the screws arrows to free the cover 34.8 Remove the terminal nut...

Suzuki Gsf600 Vacuum Hose

Dont smoke or allow open flames or bare light bulbs near the work area, and don't work in a garage where a natural gas-type appliance is present If you spill any fuel on your skin, rinse it off immediately with soap and water. When you perform any kind of work on the fuel system, wear safety glasses and have a fire extinguisher suitable for a Class B type fire flammable liquids on hand. Warning Take great care not to burn your hand on the hot engine unit...

Suzuki Bandit Gsf 1200 Carb Heater

Using the name and style of Suzuki's GSF400 Bandit and a retuned engine from the GSX600, the naked GSF600 N Bandit was Introduced in February 1995. Colours were red and green. The faired 600 Bandit S model was introduced in November 1995 for the 1996 model year. Apart from its half-fairing, changes v ere few and amounted to a centrestand and passenger grab rails. Colours were red, green and Teal green blue . The 600 N Bandit continued without significant change apart from an addtional colour...

Plain Nut A Steel Washer

12.18b Tighten the cylinder head nuts to the specified torque setting 12.20a Install the front cylinder head bolt 12.20b and tighten it to the specified torque setting 12.20a Install the front cylinder head bolt 12.20b and tighten it to the specified torque setting torque setting specified at the beginning of the Chapter see illustration 12.18b . 20 When the nuts are correctly torqued, install the bolt in the front of the cylinder head and tighten it to the specified torque setting see...

Suzuki Bandit 600 Piston Rings Rn

If a piston pin is a tight fit in the piston bosses, soak a rag in boiling water then wring it out and wrap it around the piston - this will expand the alloy piston sufficiently to release its grip on the pin. If the piston pin is particularly stubborn, extract it using a drawbolt tool, but bo careful to protect the piston's working surfaces. 16.5a Removing the piston rings using a ring removal and 16.5b Note the letter arrow which must face up 16.3a Remove the circlip using a pair of pliers or...

Fuel and exhaust systems

Ajr filter cleaning and replacement see Chapter 1 Air filter housing - removal and installation 12 Air fuel mixture adjustment - general information 4 Carburettor overhaul - general information 5 Carburettor synchronisation see Chapter 1 Carburettors - disassembly, cleaning and inspector 7 Carburettors - reassembly, and float height check 9 Carburettors - removal and installation 6 Carburettors - separation and joining 8 Choke cable - removal and installation 11 EVAP system - general California...

How To Adjust The The Rear Brake Light Activation On A Gsf600n

1 Each brake pad has wear indicator grooves or a line that can be viewed without removing the pads from the caliper. On the front brake caliper, the pad wear indicator grooves are visible by looking up at the bottom of the pads see illustrations . On the rear brake caliper, the pad wear indicator is visible by looking down onto the top of the pads see illustrations 2 If the pads are worn to or beyond the base of the grooves, they must be replaced. If the pads are dirty or if you are in doubt as...

What Is The Length Of A Gsf600 Diaphragm Spring

A clutch centre holding tool can easily bo made using two strips of steel bent over at the ends and bolted together in the middle. Rle o fle d J w lo c amp respocd with prom Of cMch ctrrtr sp'too 18.14 Withdraw the pushrod end piece along with the thrust washer and release bearing 18.14 Withdraw the pushrod end piece along with the thrust washer and release bearing the input shaft see Illustration . If required, withdraw the clutch pushrod right-hand half from the input shaft - it may have to...

Hydraulic Jack To Lift Gsf600

Motorcycle Engine Removal Hoist

1 It is not always easy to determine when or if an engine should be completely overhauled, as a number of factors must be considered. 2 High mileage is not necessarily an indication that an overhaul is needed, while low mileage, on the other hand, does not preclude the need for an overhaul. Frequency of servicing is probably the single most important consideration. An engine that has regular and frequent oil and filter changes, as well as other required maintenance, v ill most likely give many...

Suzuki Gsf 1200 Timing

Suzuki Gsx400f Cam Timing Pins

Before replacing camshafts , or the cylinder head and Hi NT Journal holders because of damage, check with local machine shops specialising In motorcycle engine work. In the case of the camshafts, it may be possible for cam lobes to be welded, reground and hardened, at a cost far lower than that of a new camshaft. If the bearing surfaces in the cylinder head are damaged, it may be possible for them to be bored out to accept bearing Inserts. Due to the cost of a new cylinder head It is...

Gsf 600 Fork Oil Capacity

Note Where applicable, models are identified by their suffix letter - refer to 'Identification numbers' at the front of this manual for details. Front forks 'Oil level is measured from the top of the tube with the fork spring removed and the leg fully compressed. Brake pedal and gearchange lever pivot Nm Clutch master cylinder bolts 1200 Nm Steering head bearing adjuster nut Nm Front sprocket lockbolt GSF600S SS to X SX models 11 Nm All models use a full cradle twin spar steel frame. The...

How To Check The Tps Sensor On A Gsf 1200

Honda Knucklehead

12 Install the pulse generator coil assembly onto the crankcase and tighten the assembly mounting screws securely see illustration 4,10a . 13 Apply a smear of sealant to the rubber wiring seal and fit the grommet in its recess in the crankcase see illustration . Feed the wiring connector through the hole in the crankcase see illustration . 14 Connect the oil pressure switch wire to its terminal on the switch and tighten the screw securely see illustration 4.9 . 15 Install the timing rotor onto...