Suzuki GSF650S User manual

GSF650/S

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FUEL SYSTEM 4
CHASSIS 5
ELECTRICAL SYSTEM 6
SERVICING INFORMATION 7
FOREWORD
This manual contains an introductory description on
the SUZUKI GSF650/S and procedures for its
inspection/service and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
!
© COPYRIGHT SUZUKI MOTOR CORPORATION 2004
*This manual has been prepared on the basis of
the latest specifications at the time of publica-
tion. If modifications have been made since
then, differences may exist between the content
of this manual and the actual motorcycle.
*Illustrations in this manual are used to show the
basic principles of operation and work proce-
dures. They may not represent the actual
motorcycle exactly in detail.
*This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI motor-
cycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel

1Front axle

2Dust seal

3Brake disc (RH)

4Bearing (RH)

5Spacer

6Bearing (LH)

7Brake disc (LH)

8Collar

9Front wheel

0Air bleeder valve

ABalancer

AFront axle

BBrake disc bolt
"
ITEM N·m
kgf-m

A65 6.5

B23 2.3

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK “1342”.
99000-32050
Apply oil.
Use engine oil unless otherwise speci-
fied.
Apply THREAD LOCK SUPER “1360”.
99000-32130
Apply molybdenum oil solution (mixture
of engine oil and SUZUKI MOLY PASTE
in a ratio of 1:1).
Use fork oil.
99000-99044-10G
Apply SUZUKI SUPER GREASE “A”.
99000-25010 Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140 Measure in voltage range.
Apply SUZUKI SILICONE GREASE.
99000-25100 Measure in resistance range.
Apply PBC GREASE.
99000-25110 Measure in current range.
Apply THERMO-GREASE.
99000-59029 Measure in diode test range.
Apply SUZUKI BOND “1207B”.
99000-31140 Measure in continuity test range.
Apply SUZUKI BOND “1215”.
99000-31110 Use special tool.
Apply THREAD LOCK SUPER “1303”.
99000-32030 Indication of service data.
Apply THREAD LOCK SUPER “1322”.
99000-32110

1
GENERAL INFORMATION 1-1
GENERAL INFORMATION
CONTENTS
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY OR AREA
E-02
E-19
E-28
England (UK)
European markets
Canada
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
SUZUKI GSF650 (2005-MODEL) ..................................................................1- 4
SUZUKI GSF650S (2005-MODEL) ................................................................1- 4
SERIAL NUMBER LOCATION ......................................................................1- 4
FUEL AND OIL RECOMMENDATION ..........................................................1- 5
FUEL (For Canada) ...............................................................................1- 5
FUEL (For other countries) ..................................................................1- 5
ENGINE OIL ...........................................................................................1- 5
BRAKE FLUID ........................................................................................1- 5
FRONT FORK OIL .................................................................................1- 5
BREAK-lN PROCEDURES ...........................................................................1- 6
CYLINDER IDENTIFICATION .......................................................................1- 6
INFORMATION LABELS ...............................................................................1- 7
SPECIFICATIONS .........................................................................................1- 8

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system
until they have cooled.
* After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to
the system for leaks.

GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures not require use of bat-
tery power, disconnect the negative cable the battery.
* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside working out and to the specified
tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones. Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION
SUZUKI GSF650 (2005-MODEL)
* Difference between photographs and actual motorcycles may exist depending on the markets.
SUZUKI GSF650S (2005-MODEL)
* Difference between photographs and actual motorcycles may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number)

1is stamped on the right side of the
steering head pipe and frame down tube. The engine serial number

2is located on the right side of the
crankcase. These numbers are required especially for registering the machine and ordering spare parts.

GENERAL INFORMATION 1-5
FUEL AND OIL RECOMMENDATION
FUEL (For Canada)
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the
research method.
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible.
FUEL (For other countries)
Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline is recom-
mended.
ENGINE OIL
Oil quality is a major contributor to your engine’s performance
and life. Always select good quality engine oil. Use SF/SG or
SH/SJ with JASO MA in API (American Petroleum Institute)
classification.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE
10W-40 engine oil is not available, select an alternative accord-
ing to the following chart.
BRAKE FLUID
Specification and classification: DOT 4
!
FRONT FORK OIL
Use fork oil #10 or equivalent fork oil.
MULTIGRADE
TEMP.
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-
facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

1-6 GENERAL INFORMATION
BREAK-lN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Initial 800 km : Below 6 000 r/min
Up to 1 600 km : Below 9 000 r/min
Over 1 600 km : Below 12 000 r/min
• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation.
However, do not exceed 12 000 r/min at any time.
CYLINDER IDENTIFICATION
The four cylinders of this engine are identified as No. 1, 2, 3 and No. 4 cylinder, as counted from left to right
(as viewed by the rider on the seat).
#1 #2 #3 #4