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.

10
LICENSE PLATE
A: Washer OD:13.0 mm ID:6.5 mm
B: Rear fender
OWNER’S MANUAL
Remove the rear seat using the key.
A: Key
B: Rear seat
Store the owner’s manual in place.
A: Owner’s manual
B: Document tray
Reinstall the rear seat.
Insert the seat hook into the seat hook retainer.
Push the rear seat down to lock it.
A: Rear seat
B: Seat hook
C: Seat hook retainer
NOTE:
When installing the license plate, use the wash-
ers as shown in the photograph.

11
SEAT TAIL COVER
When installing the seat tail cover to the motorcycle,
follow the procedures below.
1. Remove the rear seat using the key.
2. Remove the bolts to take off the pillion handle
assembly.
A: Pillion handle
B: Allen bolt
3. Attach the spacer to the rear frame cover.
Retighten the bolts.
A: Spacer OD:26.0 mm ID:8.5 mm T:10.0 mm
B: Rear frame cover
C: Allen bolt
D: Cushion
4. Insert the seat tail cover hook into the seat hook
retainer.
5. Push the seat tail cover down to lock it.
A: Seat tail cover
B: Seat tail cover hook
C: Seat hook retainer

12
SERVICING
BATTERY
Filling electrolyte
Remove the aluminium tape sealing the battery elec-
trolyte filler holes.
A: Aluminium tape
B: Electrolyte filler hole
Remove the caps from the electrolyte container.
A: Caps
B: Sealed area
With just enough force to break the nozzle seal of elec-
trolyte container, push each nozzle of the electrolyte
container into the battery’s electrolyte filler ports and
hold the container firmly so that it does not fall.
Take precaution not to allow any of the fluid to spill.
A: Electrolyte containers
NOTE:
Use the removed caps as the sealing cap of
battery filler holes.
Do not remove or pierce the sealed areas of the
electrolyte container.

13
Make sure air bubbles are coming up in each electro-
lyte container, and leave in this position for about 20
minutes.
A: Air bubbles
After confirming that the electrolyte has entered the
battery completely, remove the electrolyte containers
from the battery.
Wait for around 20 minutes.
Insert the caps into the filler holes, pressing in firmly so
that the top of the each caps does not protrude above
the upper surface of the battery’s top cover.
A: Caps

NOTE:
If no air bubbles are coming up from a filler
port, tap the bottom of the container two or
three times.
Never remove the container from the battery.
Never use anything except the specified battery
electrolyte.
Once the sealing cap has been installed in the
battery, do not remove the sealing cap.

14
Charge the battery with a battery charger.

After charging the battery, install the battery in the
motorcycle as follows.

Remove the bolts to take off the front seat.
A: Front seat
B: Pin bolt
For charging the battery, make sure to use the
charger specially designed for MF battery.
Otherwise, the battery may be overcharged
resulting in shortened service life.
Do not remove the cap during charging.
Position the battery with the cap facing upward
during charging.
Turn off the ignition switch when connecting or
disconnecting the battery lead wires.
When attaching the wiring harness battery
leads to the battery terminals, observe the cor-
rect polarity.
NOTE:
The terminal bolts and nuts are attached to the
battery.

15

A: Rubber cushion
B: Battery box
1. Install the battery in the motorcycle.
2. First connect the +lead to the +positive terminal
of the battery.
3. Cover +terminal with rubber boot.
4. Connect the -lead to the -negative terminal of
the battery.
A: +lead
B: -lead
C: Rubber boot
Reinstall the front seat.
Insert the seat hook into the seat hook retainer.
A: Front seat
B: Seat hook
C: Seat hook retainer
Tighten the bolts.
A: Front seat
B: Pin bolt
Check the rubber cushions are installed in the
correct position before installing the battery.

16
FRONT REAR
BRAKE FLUID
Keep the motorcycle upright and place the handlebars
straight.
Check the brake fluid level in both the front and rear
master cylinder reservoirs.
If the fluid level is below the “LOWER” level indicated in
the figure, add the correct type of brake fluid.
Refer to the chart below for the proper selection.

FRONT
BRAKE AIR BLEEDING
Any air which may have been trapped in the brake fluid
circuit must be bled completely.
If the brake lever or brake pedal feels spongy or weak,
then most likely there is air in the hydraulic circuit.
To bleed the air from the front brake, use the following
procedure:
1. Connect a clear hose to the air bleeder valve and
run the hose into a suitable clear container.
2. Pour approximately 1/2 in of brake fluid into the con-
tainer so that the end of the clear hose is sub-
merged and cannot draw any additional air back into
the circuit during the air bleeding servicing.
3. Close the valve, pump and squeeze the lever, and
open the valve while squeezing brake lever.
4. Repeat this process until the fluid flowing into the
receptacle no longer contains air bubbles.
5. After bleeding the brake circuit, tighten the bleeder
valve to the specified torque.
Reinstall the rubber protective cap.
6. Be sure to check the brake fluid level in the reservoir
tank.
Specification and Classification
DOT 4
Be careful not to spill any brake fluid on the
paint or plastic components as they will be
damaged.
LOWER
LOWER
UPPER
UPPER
LOWER
LOWER
NOTE:
Do not drop brake fluid level below lower level
line while bleeding air.

17
RIGHT LEFT
Bleed the air from the front brake caliper.
Front brake caliper air bleeder valve:
7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
A: Bleeder valve
REAR
Bleed the air from the rear brake caliper.
Rear brake caliper air bleeder valve:
7.5 N·m (0.75 kgf-m, 5.5 lb-ft)
B: Bleeder valve
CLUTCH FLUID
Keep the motorcycle upright and place the handlebars
straight.
Check the clutch fluid level in the master cylinder res-
ervoir.
If the fluid level is below the “LOWER” level, add the
correct type of fluid.
Refer to the chart below for the proper selection.

Specification and Classification
DOT 4
Be careful not to spill any clutch fluid on the
paint or plastic components as they will be
damaged.
LOWER
LOWER

18
CLUTCH AIR BLEEDING
Any air which may have been trapped in the clutch fluid
circuit must be bled completely.
If the clutch lever feels spongy or weak, then most
likely there is air in the hydraulic circuit.
To bleed the air from the clutch fluid, use the following
procedure:
Remove the meter lower panel.
A: Meter lower panel
B: Stepped Allen screw
C: Fastener
Remove the meter upper panel.
A: Meter upper panel
B: Fastener (Large)
C: Fastener (Small)
D: Guide
Remove the upper panel (Left).
A: Upper panel (Left)
B: Tapping screw
C: Stepped Allen screw
D: Hook
NOTE:
To remove the fastener, pull the center pin and
pull out the fastener.
NOTE:
To remove the fastener, push in the center pin
and pull out the fastener.

19
Remove the side cowling (Left).
A: Side cowling (Left)
B: 6 × 20 mm stepped Allen screw
C: 5 × 18 mm stepped Allen screw
D: Fastener
E: Boss
Bleed the clutch fluid circuit in the same manner as the
brake air bleeding procedure.
After bleeding the clutch fluid circuit, tighten the
bleeder valve to the specified torque.
Reinstall the rubber protective cap.
Be sure to check the fluid level in the reservoir tank.
Clutch air bleeder valve:
6.0 N·m (0.60 kgf-m, 4.5 lb-ft)
Reinstall the side cowling (Left).
Reinstall the upper panel (Left).
Reinstall the meter upper panel and meter lower panel.
A: Bleeder valve
FRONT BRAKE LEVER
Make sure the front brake lever position is correct.
The standard setting for this motorcycle is as indicated
in the table below.
A: Adjuster
NOTE:
Do not drop clutch fluid level below lower level
line while bleeding air.
Standard setting Position 3