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.
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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.
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Indicates a potential hazard that could result in death or injury.
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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
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* 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
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* 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
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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)