Suzuki GSF1200SK6 User guide

K6
December ’05 Printed in Japan (TK) 19
99505-01066-01E
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-
egories could lead to serious problems. #and areas are
denoted to emphasize certain areas and carry the following meanings:
#
Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.

1
PREPARATION
WORKSHOP
#
A: Packed motorcycle
B: Working space
SELF PROTECTION
#
UNCRATING THE MOTORCYCLE
Remove the carton.
#
A: Crate
Remove the bolts of the bracket.
A: Bolt
The workshop where the machine is assembled
should be clean, spacious, and have a level
floor.
The technician should wear protective clothing
such as leather gloves, a long sleeve shirt, eye
protection and safety shoes as shown in the
illustration when handling metal crates.
Metal crates may have sharp edges and may
cause injury.

2
Remove the bolts from the crate.
A: Bolt
Lift the steel frame to separate it from the base of the
crate.
Carefully remove the various component parts pack-
aged around the motorcycle.
#

A: Steel frame
B: Crate base
Handling crates requires two operators.
Be careful not to scratch the motorcycle.

3
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Windscreen 1
Stepped Allen screw 4 5 × 18 mm
Rubber cushion (with nut) 4 L:14.0
B
Handlebars assembly 1
Clamp 2
Allen bolt 4 8 × 30 mm
Burring washer 4 OD:13.0 ID:8.5
Plastic cap 4
OD:11.0
For handlebar
clamp bolt
Screw 1 5 × 44 mm
For left switch
Screw 1 5 × 25 mm
For left switch
Screw 1
5 × 29 mm
For throttle
assembly
Choke lever 1
Strap 2 L:140
CHolder 2 For master cylinder
Flange bolt 4 6 × 22 mm
DCable guide 1
Flange bolt 1 6 × 12 mm
Item Part Name Q’ty Remarks
E
Handlebar balancer
weight 2 Right and Left
Screw 2 6 × 105 mm
Flange rubber cushion 2
Spacer 2 L:50.0
Washer 2 OD:16.0 ID:6.5
T:4.0
Rubber cushion 2
Spacer nut 2 6 mm
F
Rear view mirror 2 Right and Left
Allen bolt 4 6 × 16 mm
Plastic cap 4 OD:10.0
G Warning label set 7 For
E-19 CC selection
H Warning label set 4 For
E-19 CD selection
IBattery electrolyte
container 1
J Owner’s manual 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
The parts shown as Item G and H in the above table are supplied for limited markets.
BEG,H
AFDCEC F
G,H

4
RIGHT LEFT
The photographs shown indicates the parts dis-
mounted from the motorcycle in addition to the items
shown in the preceding page.
A: Front brake master cylinder
B: Throttle assembly
C: Left switch
Choke cable
D: Clutch master cylinder
AA
BB
FF
GG
HH
JJ
II
D
C
EE
C
D

5
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 32.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
ASSEMBLY
LEFT RIGHT
REMOVING THE BRACKET
Remove the bolts to take off the front brake and clutch
master cylinder from the bracket.

A: Front brake master cylinder
B: Clutch master cylinder
C: Bolt
D: Bracket
Remove the bracket from the handlebar mounting
position.

A: Bracket
B: Bolt
Keep the position of front brake and clutch
master cylinder with its cap facing upwards
until it is installed.
NOTE:
The bolts are no longer needed and these may
be discarded.
Be careful not to scratch the fuel tank.
NOTE:
The bracket and bolts are no longer needed
and these may be discarded.

6
HANDLEBARS
Loosen the throttle housing retaining screws.
Insert the throttle assembly onto the handlebars.
A: Throttle assembly
B: Handlebars
Install the handlebars assembly using the two clamps,
four Allen bolts and washers.
A: Clamp
B: 8 × 30 mm Allen bolt
C: Burring washer OD:13.0 mm ID:8.5 mm
D: Punch mark
E: Dot mark
F: Plastic cap OD:11.0 mm
Tighten the handlebar clamp bolts to the specified
torque.
"Handlebar clamp bolt: 23 N·m (2.3 kgf-m)

After installing the handlebars, fit the plastic cap on the
head of each bolt.
A: 8 × 30 mm Allen bolt
B: 8 × 30 mm Allen bolt
C: Plastic cap OD:11.0 mm
D: Punch mark
NOTE:
Install the burring washer in the direction as
shown in the illustration.
The punch mark on the clamps shows front
side.
Align the dot mark on the handlebars with the
mating surface of the front side of left clamp.
NOTE:
To install the handlebars correctly, first tighten
the bolt

Aof the front side with specified
torque and then tighten the bolt

Bof the rear
side.
Make sure that the clamp has no clearance at
the front side as shown in the illustration.
FORWARD

7
#
A: Front brake hose
B: Throttle cables
C: Right switch wiring harness
D: Clutch hose
E: Left switch wiring harness
F: Choke cable
THROTTLE
Insert the boss of the throttle lower housing into the
hole on the handlebars.
Tighten the throttle assembly with two screws.
#
A: Boss
B: Hole
C: 5 × 29 mm screw
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting surface.
Tighten the master cylinder mounting bolts to the
specified torque.
"Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: Holder
B: Front brake master cylinder
C: 6 × 22 mm flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
The line drawings on page 29, 30 and 31 show
the proper routing of the control cables, hose
and wirings.
Refer to them in addition to following the
instructions carefully.
Check to ensure that the throttle operates
freely and closes automatically.
NOTE:
To install the holder correctly, first tighten the
bolt

Cof the upper side with specified torque
and then tighten the bolt

Dof the lower side.

8

A: Bolt
B: Holder
C: Front brake master cylinder
D: Handlebars
Connect the front brake light switch lead wires coupler
to the brake light switch.
A: Front brake light switch
B: Lead wire coupler
FRONT BRAKE HOSE
Install the brake hose to the brake hose guide.
A: Front brake hose
B: Front brake hose guide
LEFT SWITCH
A: Choke cable
B: Holder
NOTE:
Install the holder in position according to the
mark “UP”.
Make sure that the holder has no clearance at
the upper side as shown.
Check for brake fluid leakage.
NOTE:
Check the choke cable is fitted into the recess
of holder.

9
Insert the choke cable into the hole of lower housing.
Insert the choke cable end into the recess in the choke
lever.
A: Choke cable end
B: Hole
C: Lower housing
D: Choke lever
Insert the boss of lower housing into the hole on the
handlebars.
Install the left switch upper housing and tighten the left
switch assembly with the two screws.
Fasten the choke cable holder on the front screw.
A: Boss
B: Hole
C: 5 × 44 mm screw
D: 5 × 25 mm screw
E: Cable holder
CLUTCH MASTER CYLINDER
Install the clutch master cylinder onto the handlebars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting surface.
Tighten the master cylinder mounting bolts to the
specified torque.
"Clutch master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: Holder
B: Clutch master cylinder
C: 6 × 22 mm flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
NOTE:
Before installing the cable, grease its cable
end.
NOTE:
To install the holder correctly, first tighten the
bolt

Cof the upper side with specified torque
and then tighten the bolt

Dof the lower side.