Suzuki k8 gsx1300r User manual

Assembly and Pre-Delivery
Service Guide
K8
September ’07 Printed in Japan (TK) 03
99505-01028-03E
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 service guide has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this service guide 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)
categories 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.
Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the
dealer shall be deemed by your Suzuki distributor to be performed at the dealer’s
sole risk and responsibility. The Suzuki distributor disclaims any and all liability,
obligation or responsibility for any defects resulting from said assembly and pre-
delivery set-up, and for any claims, demands or causes of action for damage to
property or for personal injuries resulting from the Dealer’s assembly and pre-
delivery set-up of Suzuki motorcycle.
This Assembly and Pre-Delivery Service Guide may contain photographs of
products sold in other markets. The assembly and pre-delivery service procedures
in this guide, however, apply to this market.

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 Aused to mount the steel frame on
the crate base.

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
Don’t remove the bolt Bof the motorcycle sup-
porting bracket C.
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
Allen screw 2 5 × 14 mm
Washer 2 OD:12.0 ID:5.5
Rubber cushion (with nut) 2 5 mm L:17.0
B Steering stem head nut 1 24 mm
C
Front brake lever 1
Flange stepped bolt 1 6 × 35 mm
Self-lock nut 1 6 mm
D
Clutch lever 1
Flange stepped bolt 1 6 × 35 mm
Flange nut 1 6 mm
Push rod holder 1
ERear view mirror 2 Right and Left
Flange bolt 4 6 × 30 mm
Item Part Name Q’ty Remarks
F
Handlebar balancer
weight 2 Right and Left
Allen bolt 2 6 × 60 mm
Plastic cap 2 OD:10.0
G
Seat tail cover 1
Spacer 2 OD:26.0 ID:8.5
T:10.0
H Washer 2 OD:13.0 ID:6.5
I
Battery set 1
Battery electrolyte
container 1
JOwner’smanualset 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
Use washers of Item H for mounting the license plate.
Please hand over the parts shown as Item G and J in the above table to your customer together with
motorcycle.
D
EGF
FB E A
C

4
The certification of vehicle pre-delivery form must
be filled out in duplicate for every motorcycle.
Use of this form is mandatory and serves as pro-
tection for yourself and your customer, as well as
assuring that all necessary assembly and service
functions have been completed.
AA
BB
CC
DD
EE
GG
IIJJ
FF
HH

5
ASSEMBLY
RIGHT
FRONT BRAKE LEVER
Set the front brake lever to the lever holder and tighten
the flange stepped bolt.
Then tighten the self-lock nut securely.
A: Front brake lever
B: 6 × 35 mm flange stepped bolt
C: 6 mm self-lock nut
LEFT
CLUTCH LEVER
Install the clutch push rod holder to the clutch lever.
A: Clutch lever
B: Push rod holder
Insert the hole of the push rod holder into the push rod
of the clutch master cylinder.
A: Push rod
B: Push rod holder
C: Clutch lever
NOTE:
Before installing the brake lever, grease the
sliding surface.

6
Set the clutch lever to the lever holder and tighten the
flange stepped bolt.
Then tighten the flange nut securely.
A: Clutch lever
B: 6 × 35 mm flange stepped bolt
C: 6 mm flange nut

A: Hoist hook
B: Bracket
RIGHT LEFT
Remove the motorcycle supporting brackets.
A: Bracket
B: Bolt
C: Bolt
D: Rubber cushion
E: Washer
F: Nut
G: Paper
1. Lift the front of motorcycle by using a hoist.
2. Raise the rear of motorcycle.
3. Pull the crate base forward then balance the motor-
cycle.
NOTE:
Before installing the clutch lever, grease the
sliding surface.
Before removing the motorcycle supporting
bracket, lift the motorcycle a little by using a
hoist to prevent the motorcycle from falling
down.
NOTE:
The brackets, bolts, rubber cushion, washers,
nut and paper are no longer needed and may be
discarded.

7
Place the motorcycle on the side-stand, then remove
the hoist hook.
REMOVING THE BRACKET
Remove the bolt and bracket.
Remove the steel nut.

A: Bracket
B: Bolt (with lock washer)
C: Steel nut
Confirm that the washer is placed on the steering stem
head.
Tighten the steering stem head nut to the specified
torque.
Steering stem head nut:
90 N·m (9.0 kgf-m, 65.0 lb-ft)
A: Washer
B: Steering stem head nut
Be careful not to scratch the fuel tank.
NOTE:
The bracket, bolt and steel nut are no longer
needed and may be discarded.

8
WINDSCREEN
Assemble the windscreen fitting parts.
A: Windscreen fitting parts
B: 5 × 14 mm Allen screw
C: Washer OD:12.0 mm ID:5.5 mm
D: Rubber cushion (with nut) 5 mm L:17.0 mm
Set the windscreen to the upper cowling and attach the
fitting parts.
A: Windscreen
B: 5 × 14 mm Allen screw
C: Washer OD:12.0 mm ID:5.5 mm
D: Rubber cushion (with nut) 5 mm L:17.0 mm
E: Upper cowling
F: Plate
Tighten the screws to fix the windscreen to the upper
cowling.

A: Windscreen
B: 5 × 14 mm Allen screw
C: Washer OD:12.0 mm ID:5.5 mm
D: Rubber cushion (with nut) 5 mm L:17.0 mm
E: Upper cowling
F: Plate
REAR VIEW MIRROR
Install the rear view mirror assembly to the upper cowl-
ing.
Install the rubber boot.
A: Rear view mirror assembly
B: 6 × 30 mm flange bolt
C: Rubber boot
D: Water drain hole
NOTE:
Don’t tighten the screw excessively.
Don’t tighten the screw excessively.
NOTE:
Align the mirror in the position so as to secure
rear view.

9
HANDLEBAR BALANCER
Install the right and left handlebar balancers to each of
handlebar end.

After installing the balancer weight, fit the plastic cap
on the head of each bolt.
A: Balancer weight
B: 6 × 60 mm Allen bolt
C: Plastic cap
RIGHT LEFT
REMOVING THE PROTECTION PAD AND
WRAP FILM
Remove the protection pad and wrap film from the
muffler.
A: Muffler
B: Protection pad
C: Wrap film
FRONT REAR
BRAKE DISC
To prevent brake squeaking and pad contamination,
carefully clean the front and rear brake disc plates with
alcohol or other non-petroleum based solvent.
This will remove the rust-preventive coating and dirt.
NOTE:
Apply SUZUKI THREAD LOCK SUPER “1342”
to the attaching screw of handlebar balancer.
Check to ensure that the throttle operates freely
and closes automatically.