How To Change Headlight Bulb On Gsf600

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 illustration). Check the socket terminals for corrosion and clean them if necessary. Line up the pins of the new bulb with the slots in the socket, then push the bulb in and turn it clockwise until it locks into place. Note: It is a good Idea to use a paper towel or dry cloth when handling the new bulb to prevent injury if the bulb should break and to increase bulb life.

3 Install the lens back onto the assembly, using a new gasket if required, and tighten the lens retaining screws. Take care not to overtighten the screws as the assembly is easily cracked.

Front - untaired models Removal

1 Remove the two screws securing the headlight rim to the headlight shell, and ease the rim out of the shell, noting how it fits (see illustrations 7.1a and b).

2 Trace the turn signal wiring back from the turn signal and disconnect it at the connectors inside the headlight shell (see illustration). Pull the wiring through to the turn signal mounting, noting its routing.

3 Unscrew the nut securing the turn signal assembly to the support frame and carefully remove the assembly, taking care not to snag the wiring connectors as you draw them through the mounting hole (see illustration).

Installation

4 Installation is the reverse of removal. Make sure the wiring is correctly routed and securely connected. Check the operation of the turn signals.

Front - faired models Removal

5 Trace the turn signal wiring back from the turn signal and disconnect it at the connector

11.1c Replace the gasket if necessary Installation

13 Installation is the reverse of removal. Check the operation of the light.

1 Remove the three screws at the back or one screw at the front securing the lens to the turn signal assembly and remove the lens, noting which way round it fits (see

12.2 The front turn signal wire connectors are inside the 12.3 Front turn signal mounting nut headlight

12.9 The rear turn signal assembly is 13.3a Disconnect the turn signal relay secured to the mudguard by a single nut wiring connector (arrow) and check for (arrow) power at the orange/green terminal - early models

13.3b The turn signal relay is behind the seat lock mechanism - later models

12.6b and remove the turn signal

12.8 Disconnect the tum signal wiring connector

12.9 The rear turn signal assembly is 13.3a Disconnect the turn signal relay secured to the mudguard by a single nut wiring connector (arrow) and check for (arrow) power at the orange/green terminal - early models

13.3b The turn signal relay is behind the seat lock mechanism - later models

Circuit check

1 Before checking any electrical circuit, check the bulb (see Section 9) and fuse (see Section 5).

2 Using a multimeter or test light connected to a good earth (ground), check for voltage at the brake light switch wiring connector (see illustration 14.5 or 14.8). If there's no voltage present, check the wire between the switch and the ignition switch (see the wiring diagrams at the end of this Chapter).

3 If voltage is available, touch the probe of the test light to the other terminal of the switch, then pull the brake lever in or depress the

inside the fairing. Pull the wiring through to the turn signal mounting, noting its routing.

6 Unscrew the nut securing the turn signal assembly to the support frame and carefully withdraw the turn signal from the fairing, taking care not to snag the wiring connectors as you draw them through the mounting hole (see illustrations).

Installation

7 Installation is the reverse of removal. Make sure the wiring is correctly routed and securely connected. Check the operation of the turn signals.

Rear - all models

Removal

8 Remove the seat (see Chapter 7). Trace the turn signal wiring back from the turn signal and disconnect it at the connector (see illustration). Pull the wiring through to the turn signal mounting, releasing it from any clips and noting its routing.

9 Unscrew the nut securing the turn signal assembly to the mudguard and carefully remove the assembly, taking care not to snag the wiring connectors as you draw them through the mounting hole (see illustration). Installation

10 Installation is the reverse of removal. Make sure the wiring is correctly routed and

12.6b and remove the turn signal securely connected. Check the operation of the tum signals.

1 The battery provides power for operation of the turn signal lights, so if they do not operate, a ways check the battery voltage first. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 32 and 33 for charging system tests. Also, check the fuse (see Section 5) and the switch (see Section 20).

2 Most turn signal problems are the result of a burned out bulb or corroded socket. This is especially true when the turn signals function p'operty in one direction, but fail to flash in the other direction. Check the bulbs and the sockets (see Section 11).

3 If the bulbs and sockets are good, check for power at the turn signal relay orange/green wire with the ignition ON. On GSF600S/SS to X'SX and GSF1200T/ST to Y/SY models, the relay is mounted behind the left-hand side panel (see illustration); on GSF600Y/SY and GSF1200K1/SK1 models onwards, the relay is mounted behind the seat lock mechanism

12.8 Disconnect the tum signal wiring connector

(see illustration). Turn the ignition OFF when the check is complete.

4 If no power was present at the relay, check the wiring from the relay to the ignition (main) switch for continuity.

5 If power was present at the relay, using the appropriate wiring diagram at the end of this Chapter, check the wiring between the relay, turn signal switch and turn signal lights for continuity. If the wiring and switch are sound, replace the relay with a new one.

14.5 Disconnect the wiring connectors (A), 14.8 Rear brake light switch wiring 14.9 Unhook the spring from the pedal then remove the switch screw (B) connector (arrow) (arrow)

14.5 Disconnect the wiring connectors (A), 14.8 Rear brake light switch wiring 14.9 Unhook the spring from the pedal then remove the switch screw (B) connector (arrow) (arrow)

15.1a Instrument cluster wiring connector 15.1b On early faired models, the 15.2 Unscrew its knurled ring (arrow) and

- unfaired models connectors are housed inside a cover that detach the speedometer cable sits on top of the headlight brake pedal. If no reading is obtained or the test light doesn't light up, replace the switch.

4 If a reading is obtained or the test light does light up. check the wiring between the switch and the brake light bulb (see the wiring diagrams at the end of this Chapter).

Switch replacement

Front brake lever switch

5 Disconnect the wiring connectors frorr the switch (see illustration).

6 Remove the single screw securing the switch to the bottom of the front brake master cylinder and remove the switch (see illustration 14.5).

7 Installation is the reverse of removal. The switch isn't adjustable.

Rear brake pedal switch

8 The switch is mounted to the back of the right-hand footrest bracket. Pull the terminal cover off the top of the switch and discomect the wiring connector (see illustration).

9 Detach the lower end of the switch spring from the brake pedal, then unscrew the switch (see illustration).

10 Installation is the reverse of removal. Make sure the brake light is activated just before the rear brake pedal takes effect. If adjustment is necessary, hold the switch and turn the adjusting nut on the switch body until the brake light is activated when required.

15 Instrument cluster and speedometer cable - removal ^ and installation ^

Instrument cluster

GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

1 Trace the wiring back from the instrument cluster and disconnect It at the connector (blue). On models without a fairing, the connector is located inside the top of the headlight shell (see illustration). Remove the two screws securing the headlight rim to the headlight shell, and ease the rim out of the shell, noting how it fits (see illustrations 7.1a and b). Release the wiring from any clips or ties. On S models, the connector is in a cover which sits on top of the headlight inside the fairing (see illustration).

2 Unscrew the speedometer cable retaining ring from the back of the speedometer and detach the cable (see illustration).

3 Unscrew the bolts (four on 600 models, two on 1200 models) which secure the instrument cluster bracket to the underside of the top yoke and carefully remove the assembly from the yoke, taking care not to snag the wiring and noting its routing.

4 Installation is the reverse of removal. Make sure that the speedometer cable and wiring connector are correctly routed and secured. GSF600Y-on and GSF1200K1-on

5 Remove the headlight assembly (see Section 8).

6 Remove the two bolts securing the instrument cluster to the top yoke. Lift the instruments away complete with mounting bracket and wiring.

7 Installation is the reverse of removal. Make sure that the wiring and connector are correctly routed and secured. GSF600SY-on and GSF1200SK1-on

8 Refer to the fairing removal procedure in Chapter 7, Section 7.

9 Installation is the reverse of removal. Make sure that the wiring and connector are correctly routed and secured.

Speedometer cable -GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

Removal

10 Unscrew the speedometer cable retaining ring from the rear of the instrument cluster and detach the cable (see illustration 15.2).

11 Unscrew the retaining ring (600 models) or screw (1200 models) securing the lower end of the cable to the drive housing on the left-hand side of the front wheel.

15.1a Instrument cluster wiring connector 15.1b On early faired models, the 15.2 Unscrew its knurled ring (arrow) and

- unfaired models connectors are housed inside a cover that detach the speedometer cable sits on top of the headlight

15.15 ... and the lower end of the speedometer cable

15.14 Install the upper end ...

12 Withdraw the cable from its guides and remove it from the bike, noting its correct routing. Installation

13 Route the cable correctly and install it in its retaining guides.

14 Connect the cable upper end to the Instrument cluster and tighten the retaining ring securely (see illustration).

15 Connect the cable lower end to the drive housing, aligning the slot in the cable end with the drive tab, and tighten the retaining ring (600 models) or screw (1200 models) securely (see illustration).

16 Check that the cable doesn't restrict steering movement or interfere with any other components.

Speedometer

Check - GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

1 Special instruments are required to properly check the operation of this meter. If it is believed to be faulty, take the motorcycle to a Suzuki dealer for assessment.

Check - GSF600Y/SY-on and GSF1200K1/SK1-on

2 Special equipment is needed to check the

15.15 ... and the lower end of the speedometer cable operation of the speedometer and sensor. If the speedometer stops working, take the motorcycle to a Suzuki dealer for checking. Replacement - GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

3 Unscrew the speedometer cable retaining ring from the rear of the instrument cluster and detach the cable (see illustration 15.2).

4 On 600 models, unscrew the two bolts securing the speedometer and lift it off the bracket (see illustration). Note how the holes in the mounting plate locate over the lugs on the bracket. Remove the single screw securing the casing and withdraw the speedometer from the casing, then remove the bulbholders.

5 On 1200 models, remove the single screw securing the speedometer casing and remove the casing, noting how it fits (see illustrations). Remove the bulbholders from the back of the speedometer. Unscrew the two nuts securing the speedometer to the bracket and remove the speedometer (see illustration).

6 Installation is the reverse of removal. Make sure the cable is correctly and securely connected.

Replacement - GSF600Y/SY-on and GSF1200K1/SK1-on

Note: The speedometer is only available as a unit with the other electronic components inside the instrument cluster.

7 On unfaired models, remove the instrument

16.4 Remove the relevant instrument mounting bolts (A), then remove the casing screw (B) and withdraw the instrument cluster as described in Section 15. Remove the two screws to free the lower cover from the instrument cluster, then remove the nuts and washers to free the cluster from its mounting bracket. Remove the screws holding the two halves of the instruments together in order to access the meter assembly and printed circuit. Further dismantling is not advised.

8 On faired models, remove the instrument cluster as described in Chapter 7, Section 7. Remove the two screws to free the front cover from the instrument cluster. Remove the screws holding the two halves of the instruments together in order to access the meter assembly and printed circuit. Further dismantling is not advised.

Tachometer

Check - GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

9 Trace the wiring back from the instrument cluster and disconnect it at the connector (blue). On models without a fairing, the connector is located inside the headlight shell (see illustration 15.1a). Remove the two screws securing the headlight rim to the headlight shell, and ease the rim out of the shell, noting how it fits (see illustrations 7.1a and b). On faired models, the connector is located inside the fairing (see illustration 15.1b).

10 Using a multimeter or continuity tester, check for continuity first between the black/red and black/white terminals on the

16 Instruments-

check and replacement ^

16.5a Remove the screw (arrow)... 16.5b ... and remove the speedometer 16.5c The speedometer is secured by two casing nuts (arrows)

16.5a Remove the screw (arrow)... 16.5b ... and remove the speedometer 16.5c The speedometer is secured by two casing nuts (arrows)

Gsf1200 Speedo

16.19a Remove the screw to free the fuel gauge casing

16.19b The fuel gauge is secured by two nuts (arrows)

17 Instrument and warning light J bulbs - replacement

16.19a Remove the screw to free the fuel gauge casing

16.19b The fuel gauge is secured by two nuts (arrows)

GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

Instrument light bulbs

1 Remove the relevant instrument from the casing (600 models) or the casing from the instrument (1200 models) (see Section 16).

16.12 Disconnect the three tachometer wires (arrows) 16.13 Disconnect the three tachometer wires (A), then remove the two nuts (B)

instrument side of the wiring connector, then between the orange/green and black/white terminals. There should be continuity in both cases. If not, check the wiring between the connector and the tachometer for breakage. If the wiring is good, check for voltage at the orange/green wire connector on the wiring loom side of the connector. If voltage is present, check the black/red wire between the connector and the ignition control module for continuity (see the wiring diagrams at the end of this Chapter). If the wiring is good, then a faulty tachometer is indicated; take the tachometer to a Suzuki dealer for assessment.

Check - GSF600Y/SY-on and GSF1200K1/SK1-on

11 No test details are available for checking the tachometer. If the tachometer stops working, take the motorcycle to a Suzuki dealer for checking.

Replacement - GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

12 On 600 models, unscrew the two bDlts securing the tachometer and lift it off the bracket (see illustration 16.4). Note how the holes in the mounting plate locate over the lugs on the bracket. Remove the single screw securing the casing and withdraw the tachometer from the casing, then remove the bulbholders. Remove the screws securing the three tachometer wires, noting their positions (see illustration).

13 On 1200 models, unscrew the single screw securing the tachometer casing and remove the casing (see illustrations 16.4a and b). Remove the bulbholders from the back of the tachometer followed by the screws securing the three wires, noting their positions (see illustration). Unscrew the two nuts securing the tachometer to the bracket and remove the tachometer.

14 Installation is the reverse of removal. Make sure the wires are correctly and securely connected.

Replacement - GSF600Y/SY-on and GSF1200K1 /SK1 -on

Note: The tachometer is only available as a unit with the other electronic components inside the instrument cluster.

15 Refer to Steps 7 and 8 above. Fuel gauge (1200 models) Check

16 Remove the seat (see Chapter 7). Trace the fuel level sender wiring from the underside of the fuel tank and disconnect it at the connector.

17 Connect a jumper wire between the black/white and yellow/black terminals on the wiring loom side of the connector. With the ignition switched ON, the fuel gauge should read FULL. If it doesn't, check the wiring between the connector and the gauge, and check for voltage at the orange/green wire on the back of the fuel gauge. If the wiring .s good, then the gauge is faulty.

18 If the gauge reads FULL, check the fuel level sender inside the fuel tank (see Section 27).

Replacement - GSF600S/SS to X/SX and GSF1200T/ST to Y/SY

19 Remove the single screw securing the fuel gauge casing and remove the casing (see illustration). Unscrew the two nuts securing the gauge to the bracket and slip the gauge of the bracket (see illustration). Pull the bulbholder out of the gauge and remove the three screws securing the gauge wires; make a note of the wire locations as a guide to installation.

20 Installation Is the reverse of removal. Make sure the wires are correctly and securely connected.

Replacement - GSF1200K1/SK1-on Note: The fuel gauge is only available as a uni with the other electronic components inside the instrument duster.

21 Refer to Steps 7 and 8 above.

17.3b ... and lift the panel off the cluster

17.4a Unscrew the screws (arrows) and remove the cover

17.2a Pull the bulbholder out of the instrument...

17.2b ... and the bulb out of the holder

17.3a Remove the two screws (A) and snip the cable tie (B)...

17.4d ... and replace the bulb

18 Oil pressure switch - check, ^ removal and installation «V

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  • tim propst
    How to change headlight bulb on gsf600?
    12 months ago

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