Suzuki GSX1200 1999 User manual

GROUP INDEX
1
FOREWORD
This manual contains an introductory description
on the SUZUKI GSX1200 and procedures for its
inspection/service and overhaul of its main com-
ponents.
Other information considered as generally known
is not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its
maintenance. 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.
!
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.
2
3
4
5
6
7
GENERAL INFORMATION
* This manual has been prepared on the basis
of the latest specifications at the time of pub-
lication. If modifications have been made
since then, differences may exist between the
content of this manual and the actual motor-
cycle.
* Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures. They may not represent the actual
motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, includ-
ing special tools, for servicing SUZUKI mo-
torcycles. If you do not have the proper knowl-
edge and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Motorcycle Service Department
cCOPYRIGHT SUZUKI MOTOR CORPORATION 1999
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION

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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
ITEM N.m kgf-m
A100 10.0
B23 2.3
C23 2.3
1Spacer
2Collar
3Brake disc (R)
4Bearing
5Spacer
6Front wheel
7Brake disc (L)
8Speedometer gearbox
AFront axle
BFront axle pinch bolt
CBrake disc bolt
#

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 oil. Use engine oil unless
otherwise specified.
Apply SUZUKI SUPER GREASE “A”.
99000-25010
Apply THREAD LOCK “1322”.
99000-32110
Apply THREAD LOCK SUPER
“1360”.
99000-32130
Apply or use brake fluid.
Apply SUZUKI MOLY PASTE.
99000-25140
Apply SUZUKI BOND “1207B”.
99000-31140
Apply THREAD LOCK SUPER
“1303”.
99000-32030
Measure in voltage range.
Measure in resistance range.
Measure in current range.
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Use fork oil.
99000-99001-SS8
or
99000-99044-10G
Indication of service data.
Apply molybdenum oil solution (mixture
of engine oil and SUZUKI MOLY
PASTE in a ratio of 1:1).

GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
WARNING/CAUTION/NOTE ............................................................. 1- 2
GENERAL PRECAUTIONS ............................................................. 1- 2
SUZUKI GSX1200X (’99-MODEL) ................................................... 1- 4
SERIAL NUMBER LOCATION ........................................................ 1- 4
FUEL AND OIL RECOMMENDATION ............................................. 1- 4
FUEL ............................................................................................. 1- 4
ENGINE OIL .................................................................................. 1- 5
BRAKE FLUID .............................................................................. 1- 5
FRONT FORK OIL ........................................................................ 1- 5
BREAK-IN PROCEDURES ............................................................. 1- 5
CYLINDER IDENTIFICATION .......................................................... 1- 5
INFORMATION LABELS.................................................................. 1- 6
SPECIFICATIONS ............................................................................ 1- 7
COUNTRY OR AREA CODES ......................................................... 1- 9
CONTENTS

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 speci-
fied 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 and other fluids:
batteries, and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION
SUZUKI GSX1200X (’99-MODEL)
* Difference between photograph and actual motorcycle depends 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. The engine serial number 2is located on the right side of the crankcase. These num-
bers are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is
recommended.
LEFT RIGHT

GENERAL INFORMATION 1-5
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification.
The recommended viscosity is SAE 10W-40. If an SAE 10W-40
motor oil is not available, select an alternative according to the
right chart.
BRAKE FLUID
Specification and classification: DOT 4
!
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.
MULTIGRADE
TEMP.
FRONT FORK OIL
Use fork oil SS-08, #10 or equivalent fork oil.
BREAK-IN 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 re-
straint exercised during its early life. The general rules are as follows.
• Keep to these break-in engine speed limits:
Initial 800 km: Below 5 000 r/min.
Up to 1 600 km: Below 8 000 r/min.
Over 1 600 km: Below 10 500 r/min.
• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation.
However, do not exceed 10 500 r/min. at any time.
CYLINDER IDENTIFICATION
The four cylinders of this engine are identified as No.1, No.2, No.3 and No.4 cylinder, as counted from left to
right (as viewed by the rider on the seat).

1-6 GENERAL INFORMATION
INFORMATION LABELS
1Noise label (For E-34) 2Tire pressure label 3Warning safety label 4ID label
Frame (right side)

GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ............................................................... 2 140 mm
Overall width ................................................................. 780 mm
Overall height ............................................................... 1 100 mm
Wheelbase .................................................................... 1 465 mm
Ground clearance ......................................................... 125 mm
Seat height.................................................................... 795 mm
Dry mass ....................................................................... 210 kg
ENGINE
Type .............................................................................. Four-stroke, air-cooled, with SACS, DOHC, TSCC
Number of cylinders ..................................................... 4
Bore .............................................................................. 79.0 mm
Stroke............................................................................ 59.0 mm
Compression ratio ........................................................ 9.5 : 1
Piston diplacement ....................................................... 1 157 cm3
Carburetor .................................................................... KEIHIN CVK32, four
Air cleaner ..................................................................... Non-woven fabric element
Starter system .............................................................. Electric starter
Lubrication system ....................................................... Wet sump
TRANSMISSION
Clutch ............................................................................ Wet multi-plate type
Transmission ................................................................. 5-speed constant mesh
Gearshift pattern .......................................................... 1-down, 4-up
Primary reduction ratio ................................................. 1.565 (72/46)
Final reduction ratio...................................................... 2.933 (44/15)
Gear ratios, Low ........................................................... 2.384 (31/13)
2nd ........................................................... 1.631 (31/19)
3rd ............................................................ 1.250 (25/20)
4th ............................................................ 1.045 (23/22)
Top ............................................................ 0.913 (21/23)
Drive chain .................................................................... RK50GSVZ1, 112 links

1-8 GENERAL INFORMATION
CHASSIS
Front suspension .......................................................... Telescopic, coil spring, oil damped
Rear suspension .......................................................... Swingarm type, gas/oil damped, coil spring, spring
pre-load 5-way adjustable, compression damping
force 4-way adjustable
Steering angle .............................................................. 34° (right & left)
Caster ........................................................................... 25° 50’
Trail ............................................................................... 102 mm
Turning radius ............................................................... 2.7 m
Front brake ................................................................... Disc brake, twin
Rear brake .................................................................... Disc brake
Front tire size ................................................................ 120/70 ZR17 (58W)
Rear tire size ................................................................ 170/60 ZR17 (72W)
Front fork stroke ........................................................... 130 mm
Rear wheel travel ......................................................... 120 mm
ELECTRICAL
Ignition type .................................................................. Electronic ignition (Fully Transistorized)
Ignition timing ............................................................... 7° B.T.D.C. at 1 200 r/min.
Spark plug ..................................................................... NGK JR8B
Battery........................................................................... 12V 36 kC(10 Ah)/10HR
Generator ..................................................................... Three-phase A.C. Generator
Main fuse ...................................................................... 30A
Fuse .............................................................................. 15/15/15/10/10A
Headlight ....................................................................... 12V 60/55W
Position light .................................................................. 12V 5W
Turn signal light ............................................................. 12V 21W
Brake light/Taillight ........................................................ 12V 21/5W
Speedometer light ........................................................ 12V 1.7W
Fuel meter light............................................................ 12V 1.7W
Tachometer light ........................................................... 12V 1.7W
Neutral indicator light ................................................... 12V 1.7W
High beam indicator light.............................................. 12V 1.7W
Turn signal indicator light.............................................. 12V 1.7W
Oil pressure indicator light ........................................... 12V 1.7W
CAPACITIES
Fuel tank, including reserve ......................................... 18.0 L
reserve ........................................ 3.7 L
Engine oil, oil change ................................................... 3 300 ml
with filter change ........................................ 3 500 ml
overhaul ...................................................... 4 600 ml
Front fork oil (each leg) ................................................ 582 ml
These specifications are subject to change without notice.

GENERAL INFORMATION 1-9
CODE COUNTRY or AREA
E-04 France
E-22 Germany
E-25 Netherlands
E-34 Italy, Belgium (E-21), Spain (E-53)
COUNTRY OR AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).

PERIODIC MAINTENANCE 2-1
2
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ........................................... 2- 2
PERIODIC MAINTENANCE CHART ............................................... 2- 2
LUBRICATION POINTS .................................................................. 2- 3
MAINTENANCE AND TUNE-UP PROCEDURES .............................. 2- 4
VALVE CLEARANCE ...................................................................... 2- 4
SPARK PLUG .................................................................................. 2- 5
EXHAUST PIPE BOLT AND MUFFLER BOLT ............................... 2- 6
AIR CLEANER ELEMENT .............................................................. 2- 7
ENGINE OIL AND OIL FILTER ....................................................... 2- 8
FUEL HOSE .................................................................................... 2- 9
ENGINE IDLE SPEED ..................................................................... 2-10
THROTTLE CABLE PLAY............................................................... 2-10
CARBURETOR SYNCHRONIZATION ............................................ 2-10
CLUTCH .......................................................................................... 2-11
DRIVE CHAIN.................................................................................. 2-12
BRAKE ............................................................................................ 2-14
TIRE ................................................................................................. 2-17
STEERING....................................................................................... 2-18
FRONT FORK.................................................................................. 2-18
REAR SUSPENSION ...................................................................... 2-18
CHASSIS BOLT AND NUT ............................................................. 2-19
COMPRESSION PRESSURE CHECK ............................................... 2-21
OIL PRESSURE CHECK .................................................................... 2-22

2-2 PERIODIC MAINTENANCE
Interval km 1 000 6 000 12 000 18 000 24 000
Item months 1 6 12 18 24
Valve clearance I – I – I
Spark plug – I R I R
Exhaust pipe bolt and muffler bolt T – T – T
Air cleaner – I I R I
Engine oil R R R R R
Engine oil filter R – – R –
Fuel hose – I I I I
Replace every 4 years.
Engine idle speed I I I I I
Throttle cable play I I I I I
Carburetor synchronization – – I – I
Clutch hose – I I I I
Replace every 4 years.
Clutch fluid – – I – I
Replace every 2 years.
Drive chain I I I I I
Clean and lubricate every 1 000 km.
Brake IIIII
Brake hose – I I I I
Replace every 4 years.
Brake fluid – I I I I
Replace every 2 years.
Tire – I I I I
Steering I – I – I
Front fork – – I – I
Rear suspension – – I – I
Chassis bolt and nut T T T T T
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer
and time for your convenience.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
I=Inspection and adjust, clean, lubricate or replace as necessary
C=Clean R=Replace T=Tighten

PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
!"Clutch lever holder
!"Drive chain
#"Gearshift lever pivot and footrest pivot
#"Center stand pivot and spring hook
#"Side-stand pivot and spring hook
!"Brake lever holder
#"Brake pedal pivot and footrest pivot

2-4 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP
PROCEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
VALVE CLEARANCE
Inspect Initially at 1 000 km (1 month) and Every 12 000
km (12 months).
•Remove the seat and fuel tank. ($4-3)
•Remove all the spark plugs.
•Remove the breather cover and cylinder head cover. ($3-4
and -11)
•Remove the signal generator cover.
The valve clearance specification is different for intake and ex-
haust valves.
Valve clearance adjustment must be checked and adjusted 1) at
the time of periodic inspection, 2) when the valve mechanism is
serviced, and 3) when the camshafts are disturbed by removing
them for servicing.
%%
%%
%Valve clearance (when cold):
IN.: 0.10 – 0.15 mm
EX.: 0.18 – 0.23 mm
NOTE:
* The cam must be at positions,
A or B , in order to check the
valve clearance or to adjust valve clearance. Clearance read-
ings should not be taken with the cam in any other position than
these two positions.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, be sure to use a
19-mm wrench and rotate in the normal running direction. All
spark plugs should be removed.
•Turn crankshaft to bring the “T”mark on the rotor to the center
of pick up coil and also to bring the notches 1in the right ends
of both camshafts (Ex and In) to the positions shown. In this
condition, read the valve clearance at the valves C(In and Ex
of No.1 cylinder, Ex of No.2 and In of No.3).
•Use thickness gauge between adjusting screw and valve stem
end. If clearance is off the specification, bring it into the speci-
fied range by using the special tool.
&&
&&
&09900-20803: Thickness gauge
09917-14920: Valve adjuster driver
IN. EX.

PERIODIC MAINTENANCE 2-5
•Turn the crankshaft 360°(one rotation) to bring the “T”mark on
the rotor to the center of pick up coil and also to bring the notches
1to the positions shown.
•Read the clearance at the remaining valves Dand adjust the
clearance if necessary.
Cam Position Notch 1position
Intake Camshaft Exhaust Camshaft
C
D
•When installing the cylinder head cover, apply SUZUKI BOND
NO.1207B to the head cover groove and cam end caps. ($3-
73)
''
''
'99000-31140: SUZUKI BOND NO. 1207B
•Tighten the cylinder head cover bolts to the specified torque.
((
((
(Cylinder head cover bolt: 14 N.m (1.4 kgf-m)
)
Both the right and left valve clearances should be as
closely as possible.
•Install the signal generator cover. ($3-73)
SPARK PLUG
Inspect at 6 000 km (6 months), 18 000 km (18 months)
and Replace Every 12 000 km (12 months).
•Remove the seat and fuel tank. ($4-3)
•Remove all the spark plugs.
NOTE:
If it is difficult to remove the spark plug cap, pry up it with a screw-
driver.
&&
&&
&09930-10121: Spark plug socket wrench set
Standard Cold type
NGK JR8B JR9B

2-6 PERIODIC MAINTENANCE
CARBON DEPOSIT
Check to see the carbon deposit on the plug.
If the carbon is deposited, remove it with a spark plug cleaner
machine or carefully using a tool with a pointed end.
SPARK PLUG GAP
Measure the plug gap with a thickness gauge if it is correct.
If not, adjust it to the following gap.
%%
%%
%Spark plug gap: 0.6 – 0.7 mm
&&
&&
&09900-20803: Thickness gauge
ELECTRODE’S CONDITION
Check to see the worn or burnt condition of the electrodes. If it is
extremely worn or burnt, replace the plug. And also replace the
plug if it has a broken insulator, damaged thread, etc.
)
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the screw portion of the plug hole and engine damage
may result.
0.6 –0.7 mm
EXHAUST PIPE BOLT AND MUFFLER BOLT
Tighten Initially at 1 000 km (1 month) and Every 12 000
km (12 months).
•Tighten the exhaust pipe clamp bolts and muffler mounting bolts
to the specified torque.
((
((
(Exhaust pipe bolt: 23 N.m (2.3 kgf-m)
Muffler mounting bolt: 29 N.m (2.9 kgf-m)
INSTALLATION
)
Before using a spark plug wrench, carefully turn the spark
plug by finger into the thread of the cylinder head to pre-
vent damage the alminum threads.
((
((
(Spark plug: 12 N.m (1.2 kgf-m)

PERIODIC MAINTENANCE 2-7
•Reinstall the cleaned or new air cleaner element in the reverse
order of removal.
•When installing the air cleaner element in the cleaner case, make
sure that the broad arrow mark comes upward.
)
If driving under dusty condition, clean the air cleaner el-
ement more frequently. The surest way to accelerate en-
gine wear is to use the engine without the element
or to use a ruptured element. Make sure that the air cleaner
is in good condition at all times. Life of the engine de-
pends largely on this component!
NOTE:
When cleaning the air cleaner element, drain water from the air
cleaner drain hose by removing the drain plug.
AIR CLEANER ELEMENT
Inspect Every 6 000 km (6 months) and
Replace Every 18 000 km (18 months).
•Remove the seat and document tray.
•Remove the air cleaner element by removing the screws.
•Carefully use air hose to blow the dust from the cleaner ele-
ment.
)
Always use air pressure on the outside of the air cleaner
element. If air pressure is used on the inside, dirt will be
forced into the pores of the air cleaner element thus re-
stricting air flow through the air cleaner element.