Suzuki GSF1200SK6 Benutzerhandbuch

December ’05 Printed in Japan (TK) 19

99505-01066-01E

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 set-up manual has been produced to aid you in

properly assembling and servicing this motorcycle.

Please review this set-up manual 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) cat-

egories 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.

This set-up manual is based on a motorcycle of standard specification. Some minor

differences from this manual may be found in other specifications.

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.

Remove the bolts from the crate.

A: Bolt

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

Handling crates requires two operators.

Be careful not to scratch the motorcycle.

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

Windscreen 1

Stepped Allen screw 4 5 × 18 mm

Rubber cushion (with nut) 4 L:14.0

Handlebars assembly 1

Clamp 2

Allen bolt 4 8 × 30 mm

Burring washer 4 OD:13.0 ID:8.5

Plastic cap 4

OD:11.0

For handlebar

clamp bolt

Screw 1 5 × 44 mm

For left switch

Screw 1 5 × 25 mm

For left switch

Screw 1

5 × 29 mm

For throttle

assembly

Choke lever 1

Strap 2 L:140

CHolder 2 For master cylinder

Flange bolt 4 6 × 22 mm

DCable guide 1

Flange bolt 1 6 × 12 mm

Item Part Name Q’ty Remarks

Handlebar balancer

weight 2 Right and Left

Screw 2 6 × 105 mm

Flange rubber cushion 2

Spacer 2 L:50.0

Washer 2 OD:16.0 ID:6.5

T:4.0

Rubber cushion 2

Spacer nut 2 6 mm

Rear view mirror 2 Right and Left

Allen bolt 4 6 × 16 mm

Plastic cap 4 OD:10.0

G Warning label set 7 For

E-19 CC selection

H Warning label set 4 For

E-19 CD selection

IBattery electrolyte

container 1

J Owner’s manual 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item G and H in the above table are supplied for limited markets.

BEG,H

AFDCEC F

G,H

RIGHT LEFT

The photographs shown indicates the parts dis-

mounted from the motorcycle in addition to the items

shown in the preceding page.

A: Front brake master cylinder

B: Throttle assembly

C: Left switch

Choke cable

D: Clutch master cylinder

Before assembling the motorcycle, thoroughly

understand the “Safety Check Out” described on

page 32.

After completion of assembly, carefully check the

motorcycle referring to the “Safety Check Out”,

then deliver the motorcycle to the customer.

ASSEMBLY

LEFT RIGHT

REMOVING THE BRACKET

Remove the bolts to take off the front brake and clutch

master cylinder from the bracket.



A: Front brake master cylinder

B: Clutch master cylinder

C: Bolt

D: Bracket

Remove the bracket from the handlebar mounting

position.



A: Bracket

B: Bolt

Keep the position of front brake and clutch

master cylinder with its cap facing upwards

until it is installed.

NOTE:

The bolts are no longer needed and these may

be discarded.

Be careful not to scratch the fuel tank.

NOTE:

The bracket and bolts are no longer needed

and these may be discarded.

HANDLEBARS

Loosen the throttle housing retaining screws.

Insert the throttle assembly onto the handlebars.

A: Throttle assembly

B: Handlebars

Install the handlebars assembly using the two clamps,

four Allen bolts and washers.

A: Clamp

B: 8 × 30 mm Allen bolt

C: Burring washer OD:13.0 mm ID:8.5 mm

D: Punch mark

E: Dot mark

F: Plastic cap OD:11.0 mm

Tighten the handlebar clamp bolts to the specified

torque.

"Handlebar clamp bolt: 23 N·m (2.3 kgf-m)



After installing the handlebars, fit the plastic cap on the

head of each bolt.

A: 8 × 30 mm Allen bolt

B: 8 × 30 mm Allen bolt

C: Plastic cap OD:11.0 mm

D: Punch mark

NOTE:

Install the burring washer in the direction as

shown in the illustration.

The punch mark on the clamps shows front

side.

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

NOTE:

To install the handlebars correctly, first tighten

the bolt



Aof the front side with specified

torque and then tighten the bolt



Bof the rear

side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FORWARD

A: Front brake hose

B: Throttle cables

C: Right switch wiring harness

D: Clutch hose

E: Left switch wiring harness

F: Choke cable

THROTTLE

Insert the boss of the throttle lower housing into the

hole on the handlebars.

Tighten the throttle assembly with two screws.

A: Boss

B: Hole

C: 5 × 29 mm screw

FRONT BRAKE MASTER CYLINDER

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

The line drawings on page 29, 30 and 31 show

the proper routing of the control cables, hose

and wirings.

Refer to them in addition to following the

instructions carefully.

Check to ensure that the throttle operates

freely and closes automatically.

NOTE:

To install the holder correctly, first tighten the

bolt



Cof the upper side with specified torque

and then tighten the bolt



Dof the lower side.



A: Bolt

B: Holder

C: Front brake master cylinder

D: Handlebars

Connect the front brake light switch lead wires coupler

to the brake light switch.

A: Front brake light switch

B: Lead wire coupler

FRONT BRAKE HOSE

Install the brake hose to the brake hose guide.

A: Front brake hose

B: Front brake hose guide

LEFT SWITCH

A: Choke cable

B: Holder

NOTE:

Install the holder in position according to the

mark “UP”.

Make sure that the holder has no clearance at

the upper side as shown.

Check for brake fluid leakage.

NOTE:

Check the choke cable is fitted into the recess

of holder.

Insert the choke cable into the hole of lower housing.

Insert the choke cable end into the recess in the choke

lever.

A: Choke cable end

B: Hole

C: Lower housing

D: Choke lever

Insert the boss of lower housing into the hole on the

handlebars.

Install the left switch upper housing and tighten the left

switch assembly with the two screws.

Fasten the choke cable holder on the front screw.

A: Boss

B: Hole

C: 5 × 44 mm screw

D: 5 × 25 mm screw

E: Cable holder

CLUTCH MASTER CYLINDER

Install the clutch master cylinder onto the handlebars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the master cylinder mounting bolts to the

specified torque.

"Clutch master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Clutch master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

NOTE:

Before installing the cable, grease its cable

end.

NOTE:

To install the holder correctly, first tighten the

bolt



Cof the upper side with specified torque

and then tighten the bolt



Dof the lower side.

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