GSX650F

USE THIS MANUAL WITH:GSF650/S SERVICE MANUAL (99500-36170-01E)

9 9 5 0 1 - 3 6 1 8 0 - 0 1 E

FOREWORDThis SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI GSF650/S SERVICE MANUAL.It has been prepared exclusively for the following applicable model.

Applicable model:GSX650FK8

This supplementary service manual describes only service information which differ from that of the main man-ual. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any sec-tion, item or description not found in this supplement, refer to the main manual below.

Main Manual:

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 better so that you can assure your customers of fast and reliableservice.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2007

Manual Name Manual No.GSF650/S SERVICE MANUAL 99500-36170-01E

* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-cations have been made since then, differences may exist between the content of this manual and theactual motorcycle.

* Illustrations in this manual are used to show the basic principles of operation and work procedures. Theymay not represent the actual motorcycle exactly in detail.

* This manual is written for persons who have enough knowledge, skills and tools, including special tools, forservicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorizedSUZUKI motorcycle dealer to help you.

WARNING!

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able toproperly perform the services described in this manual.Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for therider and passenger.

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3

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9

Precautions...............................................................00-*Precautions .............................................................00-*

General Information ................................................... 0-iGeneral Information ...............................................0A-1Maintenance and Lubrication .................................0B-1Service Data...........................................................0C-1

Engine ......................................................................... 1-iPrecautions ...............................................................1-*Engine General Information and Diagnosis ...........1A-1Emission Control Devices .......................................1B-*Engine Electrical Devices....................................... 1C-*Engine Mechanical.................................................1D-1Engine Lubrication System .....................................1E-*Engine Cooling System...........................................1F-*Fuel System ........................................................... 1G-*Ignition System....................................................... 1H-*Starting System........................................................1I-*Charging System..................................................... 1J-*Exhaust System ......................................................1K-*

Suspension.................................................................2-*Precautions ...............................................................2-*Suspension General Diagnosis...............................2A-*Front Suspension ....................................................2B-*Rear Suspension.................................................... 2C-*Wheels and Tires ................................................... 2D-*

Driveline / Axle ...........................................................3-*Precautions ...............................................................3-*Drive Chain / Drive Train / Drive Shaft ....................3A-*

Brake ...........................................................................4-*Precautions ...............................................................4-*Brake Control System and Diagnosis .....................4A-*Front Brakes............................................................4B-*Rear Brakes ........................................................... 4C-*ABS.........................................................................4E-*

Transmission / Transaxle ..........................................5-*Precautions ...............................................................5-*Manual Transmission ..............................................5B-*Clutch ..................................................................... 5C-*

Steering....................................................................... 6-iPrecautions ...............................................................6-*Steering General Diagnosis ....................................6A-*Steering / Handlebar ..............................................6B-1

Body and Accessories............................................... 9-iPrecautions ...............................................................9-*Wiring Systems ......................................................9A-1Lighting Systems....................................................9B-1Combination Meter / Fuel Meter / Horn..................9C-1Exterior Parts .........................................................9D-1Body Structure ........................................................9E-*

TABLE OF CONTENTSNOTEFor the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual.

Table of Contents 0- i

0

Section 0

CONTENTS

General Information

General Information ................................ 0A-1General Description .............................................0A-1

Symbols ...............................................................0A-*Abbreviations .......................................................0A-*SAE-to-Former SUZUKI Term .............................0A-*Vehicle Side View ................................................0A-*Vehicle Identification Number ..............................0A-*Fuel and Oil Recommendation ............................0A-*Engine Coolant Recommendation .......................0A-*BREAK-IN Procedures.........................................0A-*Cylinder Identification...........................................0A-*Country and Area Codes .....................................0A-*Wire Color Symbols .............................................0A-*Warning, Caution and Information Labels

Location .............................................................0A-*Abbreviations (GSF650A/UA/SA/ASUK7)............0A-*Vehicle Side View (GSF650A/UA/SA/ASUK7) .....0A-*Country and Area Codes (GSF650A/UA/SA/

ASUK7) ..............................................................0A-*Vehicle Side View (GSX650FK8)........................0A-1Country and Area Codes (GSX650FK8).............0A-1Warning, Caution and Information Labels

Location (GSX650FK8).....................................0A-2Component Location ........................................... 0A-*

Electrical Components Location ..........................0A-*Specifications.......................................................0A-3

Specifications.......................................................0A-*Specifications (GSF650A/UA/SA/ASUK7) ...........0A-*Specifications (GSF650/S/U/SUK8).....................0A-*Specifications (GSF650A/UA/SA/ASUK8) ...........0A-*Specifications (GSX650FK8) ..............................0A-3

Special Tools and Equipment .............................0A-4Special Tool ........................................................0A-4

Maintenance and Lubrication................. 0B-1Precautions........................................................... 0B-*

Precautions for Maintenance ...............................0B-*General Description ............................................. 0B-*

Recommended Fluids and Lubricants..................0B-*Scheduled Maintenance ......................................0B-1

Periodic Maintenance Schedule Chart.................0B-*Lubrication Points ................................................0B-*Periodic Maintenance Schedule Chart

(GSX650FK8) ...................................................0B-1

Lubrication Points (GSX650FK8) ........................0B-2Repair Instructions .............................................. 0B-*

Air Cleaner Element Replacement...................... 0B-*Air Cleaner Element Inspection and Cleaning .... 0B-*Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-*Spark Plug Replacement .................................... 0B-*Spark Plug Inspection and Cleaning ................... 0B-*Valve Clearance Inspection and Adjustment ...... 0B-*Fuel Line Inspection ............................................ 0B-*Engine Oil and Filter Replacement ..................... 0B-*Throttle Cable Play Inspection and

Adjustment ........................................................ 0B-*Throttle Valve Synchronization ........................... 0B-*PAIR System Inspection ..................................... 0B-*Cooling System Inspection.................................. 0B-*Clutch System Inspection.................................... 0B-*Clutch Hose Replacement .................................. 0B-*Clutch Fluid Replacement ................................... 0B-*Drive Chain Inspection and Adjustment .............. 0B-*Drive Chain Cleaning and Lubricating................. 0B-*Brake System Inspection .................................... 0B-*Tire Inspection..................................................... 0B-*Steering System Inspection ................................ 0B-*Front Fork Inspection .......................................... 0B-*Rear Suspension Inspection ............................... 0B-*Chassis Bolt and Nut Inspection ......................... 0B-*Compression Pressure Check ............................ 0B-*Oil Pressure Check ............................................. 0B-*SDS Check.......................................................... 0B-*

Specifications....................................................... 0B-*Tightening Torque Specifications........................ 0B-*

Special Tools and Equipment .............................0B-2Recommended Service Material .........................0B-2

Service Data ............................................. 0C-1Specifications.......................................................0C-1

Service Data........................................................ 0C-*Tightening Torque List ........................................ 0C-*Service Data (GSF650A/UA/SA/ASUK7)............ 0C-*Tightening Torque Specifications (GSF650A/

UA/SA/ASUK7) ................................................. 0C-*Service Data (GSF650/S/U/SUK8) ..................... 0C-*Service Data (GSF650A/UA/SA/ASUK8)............ 0C-*Service Data (GSX650FK8) ................................0C-1

NOTEFor the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual.

0A-1 General Information:

General InformationGeneral InformationGeneral Description

Vehicle Side View (GSX650FK8)B817H20101016

NOTEDifference between illustration and actual motorcycles may exist depending on the markets.

Right Side

Left Side

Country and Area Codes (GSX650FK8)B817H20101017

The following codes stand for the applicable country(-ies) and area(-s).Code Country or Area Effective Frame No.

GSX650F K8 (E-02) U.K. JS1CJ135200100001 –GSX650F K8 (E-03) U.S.A (Except for California) JS1GP74A 82100001 –GSX650F K8 (E-19) E.U. JS1CJ135100100001 –GSX650F K8 (E-24) Australia JS1CJ135300100001 –GSX650F K8 (E-28) Canada JS1GP74A 82100001 –GSX650F K8 (E-33) California (U.S.A) JS1GP74A 82100001 –GSX650F K8 (P-37) Brazil XXXXXXXXXXXXXXXXX –GSX650FU K8 (E-19) E.U. JS1CJ225100100001 –

I817H2010001-01

I817H2010002-01

General Information: 0A-2

Warning, Caution and Information Labels Location (GSX650FK8)B817H20101018

[A] [B] [C]

[D] [E]

1, 11

12, 13

7

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3

54

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8

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6

I817H2010003-03

GSX650F GSX650FU1. Noise label For E-03, 24, 33 —2. Information label For E-03, 28, 33 —3. Vacuum hose routing label For E-33 —4. Fuel caution label For E-02, 24 —5. Manual notice label For E-03, 33 —6. Screen label For E-02, 03, 19, 24, 28, 33 For E-197. Screen label For E-28 —8. Warning steering label For E-02, 03, 19, 24, 28, 33 For E-199. Tire information label For E-02, 03, 19, 24, 28, 33 For E-19

10. General warning label For E-02, 03, 19, 24, 28, 33 For E-1911. ICES Canada label For E-28 —12. I.D. plate For E-02, 19, 24 For E-1913. Safety plate For E-03, 28, 33 —[A]: Frame head (Left side)[B]: Swingarm[C]: Frame side tube (Right side)[D]: Cowling body[E]: Rear fender

0A-3 General Information:

SpecificationsSpecifications (GSX650FK8)

B817H20107005NOTE

• These specifications are subject to change without notice.• Any differences between the GSF650/SK7 (’07-model) and GSX650FK8 (’08-model) in specifications

are indicated an asterisk mark (*).

Dimensions and dry mass

Chassis

Electrical

Item Specification RemarkOverall length 2 130 mm (83.9 in)Overall width * 760 mm (31.1 in)Overall height * 1 225 mm (48.2 in)Wheelbase * 1 470 mm (57.9 in)Ground clearance * 125 mm (4.9 in)Seat height * 770 mm (30.3 in)Dry mass * 216 kg (476 lbs)

Item Specification RemarkFront suspension Telescopic, coil spring, oil dampedRear suspension Link type, coil spring, oil dampedFront suspension stroke 130 mm (5.1 in)Rear wheel travel 128 mm (5.0 in)Steering angle * 32° (right & left)Caster 26°Trail 108 mm (4.25 in)Turning radius * 3.0 m (9.8 ft)Front brake Disc brake, twinRear brake Disc brakeFront tire size 120/70ZR17M/C (58W), tubelessRear tire size 160/60ZR17M/C (69W), tubeless

Item Specification RemarkIgnition type Electronic ignition (Transistorized)Ignition timing 2° B.T.D.C. at 1 200 r/minSpark plug * NGK CR8E or DENSO U24ESR-NBattery 12 V 28.8 kC (8 Ah)/10 HRGenerator Three-phase A.C. generatorMain fuse 30 AFuse 10/10/10/15/15/15 A

Headlight * 12 V 60 W (HB3) High* 12 V 55 W (H7) Low

Position light * 12 V 5 W x 2Turn signal light 12 V 21 WBrake light/Taillight 12 V 21/5 WLicense plate light 12 V 5 WSpeedometer light LEDTachometer light LEDNeutral indicator light LEDHigh beam indicator light LEDTurn signal indicator light LED* Oil pressure/Coolant temperature indicator light LED

Fuel injection indicator light LED* Engine R.P.M. indicator light LED

General Information: 0A-4

Special Tools and EquipmentSpecial Tool

B817H20108001

09930–82720Mode select switch

0B-1 Maintenance and Lubrication:

General InformationMaintenance and LubricationScheduled Maintenance

Periodic Maintenance Schedule Chart (GSX650FK8)B817H20205003

NOTEI = Inspect and clean, adjust, replace or lubricate as necessary.R = Replace.T = Tighten.

Item

Intervalkm 1 000 6 000 12 000 18 000 24 000

miles 600 4 000 7 500 11 000 14 500months 2 12 24 36 48

Air cleaner element — I I R IExhaust pipe bolts, muffler bolts and nut T — T — TValve clearance — — — — ISpark plugs — I R I RFuel line — I I I IEvaporative emission control system (E-33 only) — — I — IEngine oil R R R R REngine oil filter R — — R —Throttle cable play I I I I I

Throttle valve synchronization I(E-33 only) — I — I

PAIR (air supply) system — — I — IEngine coolant Replace every 2 years.Radiator hose — I I I I

Clutch hose — I I I IReplace every 4 years.

Clutch fluid — I I I IReplace every 2 years.

Drive chain I I I I IClean and lubricate every 1 000 km (600 miles).

Brakes I I I I I

Brake hose — I I I IReplace every 4 years.

Brake fluid — I I I IReplace every 2 years.

Tires — I I I ISteering I — I — IFront forks — — I — IRear suspension — — I — IChassis bolts and nuts T T T T T

Maintenance and Lubrication: 0B-2

Lubrication Points (GSX650FK8)B817H20205004

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.Major lubrication points are indicated as follows.

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.

Special Tools and EquipmentRecommended Service Material

B817H20208001NOTERequired service material is also described in the following.“Lubrication Points (GSX650FK8) (Page 0B-2)”

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I817H2020001-01

1. Clutch lever holder 6. Brake lever holder2. Gearshift lever pivot 7. Brake pedal pivot and footrest pivot3. Side-stand pivot and spring hook : Apply oil.

4. Footrest pivot : Apply grease.5. Drive chain

0C-1 Service Data:

General InformationService DataSpecifications

Service Data (GSX650FK8)B817H20307007

NOTE

• These specifications are subject to change without notice.• Any differences between the GSF650/SK7 (’07-model) and GS650FK8 (’08-model) in service data are

indicated an asterisk mark (*).

Throttle Body

ElectricalUnit: mm (in)

Item SpecificationBore size 36 mmI.D. No. * 17H2 (For E-33), 17H3 (For the others)Idle r/min 1 200 ± 100 r/minFast idle r/min 1 300 – 1 800 r/min (When cold engine)Throttle cable play 2.0 – 4.0 mm (0.08 – 0.16 in)

Item Specification NoteFiring order 1 ⋅ 2 ⋅ 4 ⋅ 3

Spark plug * Type NGK: CR8EDENSO: U24ESR-N

Gap 0.7 – 0.8 (0.028 – 0.031)Spark performance Over 8 (0.3) at 1 atm.CKP sensor resistance 90 – 150 ΩCKP sensor peak voltage 2.0 V and more When cranking

Ignition coil resistance Primary 1.1 – 1.9 Ω Terminal – TerminalSecondary 10.8 – 16.2 kΩ Plug cap – Terminal

Ignition coil primary peak voltage 80 V and more When crankingGenerator coil resistance 0.2 – 0.8 ΩGenerator maximum output Approx. 400 W at 5 000 r/minGenerator no-load voltage (When engine is cold) 60 V (AC) and more at 5 000 r/min

Regulated voltage 14.0 – 15.5 V at 5 000 r/min

Starter motor brush length Standard 7.0 (0.28)Limit 3.5 (0.14)

Starter relay resistance 3 – 6 Ω

BatteryType designation YTX9-BS

Capacity 12 V 28.8 kC (8 Ah)/10 HRStandard electrolyte S.G. 1.320 at 20 °C (68 °F)

Fuse size

Headlight HI 10 ALO 10 A

Fuel 10 AIgnition 15 ASignal 15 AFan 15 AMain 30 A

Service Data: 0C-2

WattageUnit: W

Tire

SuspensionUnit: mm (in)

Item Specification

Headlight HI * 60LO * 55

Position/Parking light * 5 x 2Brake light/Taillight 21/5Turn signal light 21 x 4License plate light 5Speedometer light LEDTachometer light LEDTurn signal indicator light LED x 2High beam indicator light LEDNeutral position indicator light LED* Oil pressure/Engine coolant temperature indicator light LED

FI indicator light LED* Engine R.P.M. indicator light LED

Item Standard LimitCold inflation tire pressure(Solo riding)

Front 250 kPa (2.50 kgf/cm2, 36 psi) —Rear 250 kPa (2.50 kgf/cm2, 36 psi) —

Cold inflation tire pressure(Dual riding)

Front 250 kPa (2.50 kgf/cm2, 36 psi) —Rear 290 kPa (2.90 kgf/cm2, 42 psi) —

Tire size Front 120/70 ZR17 M/C (58 W) —Rear 160/60 ZR17 M/C (69 W) —

Tire type Front * BRIDGESTON BT011F N —Rear BRIDGESTON BT020R G —

Tire tread depth (Recommended depth)

Front — 1.6 mm (0.06 in)Rear — 2.0 mm (0.08 in)

Item Standard LimitFront fork stroke 130 (5.1) —Front fork inner tube O.D. 41 (1.61) —Front fork spring free length 375.5 (14.78) 368 (14.5)Front fork oil level (Without spring, outer tube fully compressed) * 132 (5.2) —

Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil —Front fork oil capacity (Each leg) * 459 ml (15.5/16.2 US/lmp oz) —Front fork spring adjuster 5th groove from top —Rear shock absorber spring adjuster 3rd positionRear shock absorber damping force adjuster Rebound 1-1/4 turns out from stiffest

position —

Rear wheel travel 128 (5.0) —Swingarm pivot shaft runout — 0.3 (0.01)

0C-3 Service Data:

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

NOTEFor the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual.

Precautions ................................................. 1-*Precautions..............................................................1-*

Precautions for Engine...........................................1-*

Engine General Information and Diagnosis ................................................. 1A-1

General Description .............................................1A-1Injection Timing Description.................................1A-*Self-Diagnosis Function .......................................1A-*Self-Diagnosis Function (GSX650FK8)...............1A-1

Schematic and Routing Diagram........................ 1A-*FI System Wiring Diagram ...................................1A-*Terminal Alignment of ECM Coupler....................1A-*

Component Location ........................................... 1A-*FI System Parts Location.....................................1A-*

Diagnostic Information and Procedures............1A-2Engine Symptom Diagnosis .................................1A-*Self-Diagnostic Procedures .................................1A-*Use of SDS Diagnosis Reset Procedures............1A-*Show Data When Trouble (DTC) .........................1A-*SDS Check ..........................................................1A-*DTC Table............................................................1A-*Fail-Safe Function Table ......................................1A-*FI System Troubleshooting ..................................1A-*Malfunction Code and Defective Condition

Table ..................................................................1A-*DTC “C12” (P0335): CKP Sensor Circuit

Malfunction.........................................................1A-*DTC “C13” (P0105-H/L): IAP Sensor (#1)

Circuit Malfunction .............................................1A-*DTC “C14” (P0120-H/L): TP Sensor Circuit

Malfunction.........................................................1A-*DTC “C15” (P0115-H/L): ECT Sensor Circuit

Malfunction.........................................................1A-*DTC “C17” (P1750-H/L): IAP Sensor (#2)

Circuit Malfunction .............................................1A-*DTC “C21” (P0110-H/L): IAT Sensor Circuit

Malfunction.........................................................1A-*DTC “C23” (P1651-H/L): TO Sensor Circuit

Malfunction.........................................................1A-*DTC “C24” (P0351), “C25” (P0352), “C26”

(P0353) or “C27” (P0354): Ignition System Malfunction.........................................................1A-*

DTC “C28” (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction................... 1A-*

DTC “C29” (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction...... 1A-*

DTC “C31” (P0705): GP Switch Circuit Malfunction........................................................ 1A-*

DTC “C32” (P0201), “C33” (P0202), “C34” (P0203) or “C35” (P0204): Fuel Injector Circuit Malfunction............................................. 1A-*

DTC “C40” (P0505, P0506 or P0507): ISC Valve Circuit Malfunction................................... 1A-*

DTC “C41” (P0230-H/L): FP Relay Circuit Malfunction........................................................ 1A-*

DTC “C41” (P2505): ECM Power Input Signal Malfunction........................................................ 1A-*

DTC “C42” (P1650): IG Switch Circuit Malfunction........................................................ 1A-*

DTC “C44” (P0130/P0135): HO2 Sensor (HO2S) Circuit Malfunction ............................... 1A-*

DTC “C49” (P1656): PAIR Solenoid Valve Circuit Malfunction............................................. 1A-*

DTC “C60” (P0480): Cooling Fan Relay Circuit Malfunction............................................. 1A-*

Self-Diagnostic Procedures (GSX650FK8) .........1A-2Specifications....................................................... 1A-*

Service Data........................................................ 1A-*Special Tools and Equipment .............................1A-3

Special Tool ........................................................1A-3

Emission Control Devices .......................1B-*Precautions........................................................... 1B-*

Precautions for Emission Control Devices .......... 1B-*General Description ............................................. 1B-*

Fuel Injection System Description....................... 1B-*Crankcase Emission Control System

Description ........................................................ 1B-*Exhaust Emission Control System

Description ........................................................ 1B-*Noise Emission Control System Description....... 1B-*

Schematic and Routing Diagram........................ 1B-*PAIR System Hose Routing Diagram ................. 1B-*

Repair Instructions .............................................. 1B-*Heated Oxygen Sensor (HO2S) Removal and

Installation ......................................................... 1B-*Heated Oxygen Sensor (HO2S) Inspection ........ 1B-*

1-ii Table of Contents

PAIR Reed Valve Removal and Installation........ 1B-*PAIR Control Solenoid Valve Removal and

Installation......................................................... 1B-*PAIR System Inspection ..................................... 1B-*Crankcase Breather (PCV) Hose Inspection....... 1B-*Crankcase Breather (PCV) Hose / Cover

Removal and Installation................................... 1B-*Crankcase Breather (PCV) Cover Inspection ..... 1B-*

Specifications....................................................... 1B-*Service Data........................................................ 1B-*Tightening Torque Specifications........................ 1B-*

Special Tools and Equipment ............................. 1B-*Recommended Service Material ......................... 1B-*Special Tool ........................................................ 1B-*

Engine Electrical Devices........................1C-*Precautions........................................................... 1C-*

Precautions for Engine Electrical Device ............ 1C-*Component Location ........................................... 1C-*

Engine Electrical components Location .............. 1C-*Diagnostic Information and Procedures............ 1C-*

Engine Symptom Diagnosis ................................ 1C-*Repair Instructions .............................................. 1C-*

ECM Removal and Installation............................ 1C-*CKP Sensor Inspection ....................................... 1C-*CKP Sensor Removal and Installation ................ 1C-*IAP Sensor (#1) Inspection ................................. 1C-*IAP Sensor (#1) Removal and Installation .......... 1C-*IAP / TP / IAT Sensor Inspection ........................ 1C-*IAP / TP / IAT Sensor Removal and

Installation......................................................... 1C-*ECT Sensor Removal and Installation ................ 1C-*ECT Sensor Inspection ....................................... 1C-*TO Sensor Removal and Installation .................. 1C-*TO Sensor Inspection ......................................... 1C-*STP Sensor Inspection ....................................... 1C-*STP Sensor Adjustment...................................... 1C-*STP Sensor Removal and Installation ................ 1C-*STV Actuator Inspection ..................................... 1C-*STV Actuator Removal and Installation .............. 1C-*ISC Valve Inspection........................................... 1C-*ISC Valve Removal and Installation.................... 1C-*ISC Valve Preset and Opening Initialization ....... 1C-*HO2 Sensor Inspection ....................................... 1C-*HO2 Sensor Removal and Installation ................ 1C-*GP Switch Inspection .......................................... 1C-*GP Switch Removal and Installation ................... 1C-*

Specifications....................................................... 1C-*Service Data........................................................ 1C-*Tightening Torque Specifications........................ 1C-*

Special Tools and Equipment ............................. 1C-*Recommended Service Material ......................... 1C-*Special Tool ........................................................ 1C-*

Engine Mechanical .................................. 1D-1Schematic and Routing Diagram........................1D-1

Camshaft and Sprocket Assembly Diagram ....... 1D-*Throttle Cable Routing Diagram.......................... 1D-*

Throttle Cable Routing Diagram (GSX650FK8)....................................................1D-1

Diagnostic Information and Procedures............ 1D-*Engine Mechanical Symptom Diagnosis............. 1D-*Compression Pressure Check ............................ 1D-*

Repair Instructions .............................................. 1D-*Engine Components Removable with the

Engine in Place ................................................. 1D-*Air Cleaner Element Removal and Installation .... 1D-*Air Cleaner Element Inspection and Cleaning .... 1D-*Air Cleaner Box Removal and Installation........... 1D-*Throttle Cable Removal and Installation ............. 1D-*Throttle Cable Inspection .................................... 1D-*Throttle Cable Play Inspection and

Adjustment ........................................................ 1D-*Throttle Body Components ................................. 1D-*Throttle Body Construction.................................. 1D-*Throttle Body Removal and Installation .............. 1D-*Throttle Body Disassembly and Assembly.......... 1D-*Throttle Body Inspection and Cleaning ............... 1D-*Throttle Valve Synchronization ........................... 1D-*Engine Assembly Removal ................................. 1D-*Engine Assembly Installation .............................. 1D-*Engine Top Side Disassembly ............................ 1D-*Engine Top Side Assembly ................................. 1D-*Valve Clearance Inspection and Adjustment ...... 1D-*Cylinder Head Cover Inspection ......................... 1D-*Camshaft Inspection ........................................... 1D-*Camshaft Sprocket Inspection ............................ 1D-*Camshaft Sprocket Removal and Installation ..... 1D-*Cam Chain Tension Adjuster Inspection............. 1D-*Cam Chain Guide Removal and Installation ....... 1D-*Cam Chain Guide Inspection .............................. 1D-*Cam Chain Tensioner Inspection........................ 1D-*Cylinder Head Disassembly and Assembly ........ 1D-*Cylinder Head Related Parts Inspection ............. 1D-*Valve Guide Replacement .................................. 1D-*Valve Seat Repair ............................................... 1D-*Cylinder Disassembly and Assembly .................. 1D-*Cylinder Inspection.............................................. 1D-*Piston Ring Removal and Installation ................. 1D-*Piston and Piston Ring Inspection ...................... 1D-*Engine Bottom Side Disassembly ....................... 1D-*Engine Bottom Side Assembly............................ 1D-*Conrod Removal and Installation ........................ 1D-*Conrod and Crankshaft Inspection...................... 1D-*Conrod Crank Pin Bearing Inspection and

Selection ........................................................... 1D-*Crankshaft Journal Bearing Inspection and

Selection ........................................................... 1D-*Crankshaft Thrust Clearance Inspection and

Selection ........................................................... 1D-*Specifications....................................................... 1D-*

Service Data........................................................ 1D-*Tightening Torque Specifications........................ 1D-*

Special Tools and Equipment ............................. 1D-*Recommended Service Material ......................... 1D-*Special Tool ........................................................ 1D-*

Table of Contents 1-iii

Engine Lubrication System ..................... 1E-*Precautions............................................................1E-*

Precautions for Engine Oil ...................................1E-*Schematic and Routing Diagram.........................1E-*

Engine Lubrication System Chart Diagram..........1E-*Diagnostic Information and Procedures.............1E-*

Engine Lubrication Symptom Diagnosis ..............1E-*Oil Pressure Check ..............................................1E-*

Repair Instructions ...............................................1E-*Engine Oil and Filter Replacement ......................1E-*Engine Oil Level Inspection .................................1E-*Oil Pan / Oil Strainer / Oil Pressure Regulator

Removal and Installation....................................1E-*Oil Pressure Regulator / Oil Strainer

Inspection...........................................................1E-*Oil Pressure Switch Removal and Installation .....1E-*Oil Pressure Switch Inspection ............................1E-*Oil Jet Removal and Installation ..........................1E-*Oil Gallery Jet Removal and Installation ..............1E-*Oil Jet / Oil Gallery Jet Inspection........................1E-*Oil Pump Removal and Installation......................1E-*Oil Pump Inspection.............................................1E-*

Specifications........................................................1E-*Service Data ........................................................1E-*Tightening Torque Specifications.........................1E-*

Special Tools and Equipment ..............................1E-*Recommended Service Material ..........................1E-*Special Tool .........................................................1E-*

Engine Cooling System ........................... 1F-*Precautions............................................................1F-*

Engine Cooling System Warning .........................1F-*Precautions for Engine Coolant ...........................1F-*

General Description ..............................................1F-*Engine Coolant Description .................................1F-*

Schematic and Routing Diagram.........................1F-*Cooling Circuit Diagram .......................................1F-*Water Hose Routing Diagram ..............................1F-*

Diagnostic Information and Procedures.............1F-*Engine Cooling Symptom Diagnosis....................1F-*

Repair Instructions ...............................................1F-*Cooling Circuit Inspection ....................................1F-*Radiator Cap Inspection ......................................1F-*Radiator / Cooling Fan Motor Removal and

Installation..........................................................1F-*Radiator Inspection and Cleaning........................1F-*Radiator Hose Removal and Installation..............1F-*Radiator Reservoir Tank Inspection.....................1F-*Water Hose Inspection.........................................1F-*Radiator Reservoir Tank Removal and

Installation..........................................................1F-*Cooling Fan Inspection ........................................1F-*Cooling Fan Relay Inspection ..............................1F-*ECT Sensor Removal and Installation .................1F-*ECT Sensor Inspection ........................................1F-*Thermostat Connector / Thermostat Removal

and Installation...................................................1F-*Thermostat Inspection .........................................1F-*

Water pump Components ....................................1F-*Water Pump Construction ....................................1F-*Water Pump Removal and Installation.................1F-*Water Pump Disassembly and Assembly ............1F-*Water Pump Related Parts Inspection .................1F-*

Specifications........................................................1F-*Service Data.........................................................1F-*Tightening Torque Specifications.........................1F-*

Special Tools and Equipment ..............................1F-*Recommended Service Material ..........................1F-*Special Tool .........................................................1F-*

Fuel System ..............................................1G-*Precautions........................................................... 1G-*

Precautions for Fuel System ............................... 1G-*General Description ............................................. 1G-*

Fuel System Description ..................................... 1G-*Schematic and Routing Diagram........................ 1G-*

Fuel Tank Drain Hose and Breather Hose Routing Diagram ............................................... 1G-*

Diagnostic Information and Procedures............ 1G-*Fuel System Diagnosis ....................................... 1G-*

Repair Instructions .............................................. 1G-*Fuel Pressure Inspection .................................... 1G-*Fuel Pump Inspection ......................................... 1G-*Fuel Discharge Amount Inspection ..................... 1G-*Fuel Pump Relay Inspection ............................... 1G-*Fuel Hose Leakage Inspection............................ 1G-*Fuel Level Gauge Inspection .............................. 1G-*Fuel Level Indicator Inspection ........................... 1G-*Fuel Level Indicator Switch (Thermistor)

Inspection.......................................................... 1G-*Fuel Tank Construction ....................................... 1G-*Fuel Tank Removal and Installation.................... 1G-*Fuel Pump Components ..................................... 1G-*Fuel Pump Assembly / Fuel Level Gauge

Removal and Installation................................... 1G-*Fuel Level Gauge and Fuel Level Indicator

Switch Inspection .............................................. 1G-*Fuel Pump Disassembly and Assembly.............. 1G-*Fuel Mesh Filter Inspection and Cleaning........... 1G-*Fuel Hose Inspection .......................................... 1G-*Fuel Injector / Fuel Delivery Pipe / T-joint

Removal and Installation................................... 1G-*Fuel Injector Inspection and Cleaning................. 1G-*

Specifications....................................................... 1G-*Service Data........................................................ 1G-*Tightening Torque Specifications........................ 1G-*

Special Tools and Equipment ............................. 1G-*Recommended Service Material ......................... 1G-*Special Tool ........................................................ 1G-*

Ignition System.........................................1H-*Schematic and Routing Diagram........................ 1H-*

Ignition System Diagram ..................................... 1H-*Ignition System Components Location................ 1H-*

Diagnostic Information and Procedures............ 1H-*Ignition System Symptom Diagnosis................... 1H-*No Spark or Poor Spark ...................................... 1H-*

1-iv Table of Contents

Repair Instructions .............................................. 1H-*Ignition Coil / Plug Cap and Spark Plug

Removal and Installation................................... 1H-*Spark Plug Inspection and Cleaning ................... 1H-*Ignition Coil / Plug Cap Inspection ...................... 1H-*CKP Sensor Inspection ....................................... 1H-*CKP Sensor Removal and Installation ................ 1H-*Engine Stop Switch Inspection............................ 1H-*Ignition Switch Inspection.................................... 1H-*Ignition Switch Removal and Installation............. 1H-*

Specifications....................................................... 1H-*Service Data........................................................ 1H-*Tightening Torque Specifications........................ 1H-*

Special Tools and Equipment ............................. 1H-*Special Tool ........................................................ 1H-*

Starting System ..........................................1I-*Schematic and Routing Diagram..........................1I-*

Starting System Diagram ......................................1I-*Component Location .............................................1I-*

Starting System Components Location.................1I-*Diagnostic Information and Procedures..............1I-*

Starting System Symptom Diagnosis....................1I-*Starter motor will not run .......................................1I-*Starter Motor Runs but Does not Crank the

Engine.................................................................1I-*Repair Instructions ................................................1I-*

Starter Motor Components....................................1I-*Starter Motor Removal and Installation.................1I-*Starter Motor Disassembly and Assembly ............1I-*Starter Motor Inspection........................................1I-*Starter Relay Removal and Installation.................1I-*Starter Relay Inspection........................................1I-*Turn Signal / Side-stand Relay Removal and

Installation...........................................................1I-*Side-stand / Ignition Interlock System Parts

Inspection............................................................1I-*Starter Clutch Removal and Installation................1I-*Starter Clutch Inspection.......................................1I-*Starter Button Inspection.......................................1I-*

Specifications.........................................................1I-*Service Data..........................................................1I-*Tightening Torque Specifications..........................1I-*

Special Tools and Equipment ...............................1I-*Recommended Service Material ...........................1I-*Special Tool ..........................................................1I-*

Charging System...................................... 1J-*Schematic and Routing Diagram.........................1J-*

Charging System Diagram ................................... 1J-*Component Location ............................................1J-*

Charging System Components Location.............. 1J-*Diagnostic Information and Procedures.............1J-*

Charging System Symptom Diagnosis................. 1J-*Battery Runs Down Quickly ................................. 1J-*

Repair Instructions ...............................................1J-*Battery Current Leakage Inspection..................... 1J-*Regulated Voltage Inspection .............................. 1J-*Generator Inspection............................................ 1J-*Generator Removal and Installation..................... 1J-*Regulator / Rectifier Construction ........................ 1J-*Regulator / Rectifier Inspection ............................ 1J-*Battery Components ............................................ 1J-*Battery Charging .................................................. 1J-*Battery Removal and Installation ......................... 1J-*Battery Visual Inspection...................................... 1J-*

Specifications........................................................1J-*Service Data......................................................... 1J-*Tightening Torque Specifications......................... 1J-*

Special Tools and Equipment ..............................1J-*Recommended Service Material .......................... 1J-*Special Tool ......................................................... 1J-*

Exhaust System........................................1K-*Precautions........................................................... 1K-*

Precautions for Exhaust System ......................... 1K-*Repair Instructions .............................................. 1K-*

Exhaust System Construction ............................. 1K-*Exhaust Pipe / Muffler Removal and

Installation ......................................................... 1K-*Exhaust System Inspection................................. 1K-*

Specifications....................................................... 1K-*Tightening Torque Specifications........................ 1K-*

Special Tools and Equipment ............................. 1K-*Recommended Service Material ......................... 1K-*

Engine General Information and Diagnosis: 1A-1

EngineEngine General Information and DiagnosisGeneral Description

Self-Diagnosis Function (GSX650FK8)B817H21101003

The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code of the malfunction items.

User Mode

*1When one of the signals is not received by ECM, the fail-safe circuit works and injection is not stopped. In this case, “FI” and odometer are indicated in the LCD panel and motorcycle can run.*2The injection signal is stopped, when the crankshaft position sensor signal, tip-over sensor signal, ignition signal, #1, #2, #3 and #4 injector signals, fuel pump relay signal or ignition switch signal is not sent to ECM. In this case, “FI” is indicated in the LCD panel. Motorcycle does not run.“CHEC”:The LCD panel indicates “CHEC” when no communication signal from the ECM is received for 5 seconds and more.For Example:The ignition switch is turned ON, and the engine stop switch is turned OFF. In this case, the speedometer does not receive any signal from the ECM, and the panel indicates “CHEC”.If CHEC is indicated, the LCD does not indicate the trouble code. It is necessary to check the wiring harness between ECM and speedometer couplers.The possible cause of this indication is as follows:Engine stop switch is in OFF position. Side-Stand/ignition inter-lock system is not working. Ignition fuse is burnt.

NOTEThe FI light “B” turns ON about 3 seconds after turning the ignition switch is turned ON.

Malfunction LCD (display) indication “A”

FI indicator light indication “B” Indication mode

“NO” Odometer — —

“YES”Engine can start Odometer and “FI” letters

*1 FI indicator light turns ON. Each 2 sec. Odometer or “FI” is indicated.

Engine can not start “FI” letters *2

FI indicator light turns ON and blinks.

“FI” is indicated continuously.

FI “A”

“B”

I817H2110002-01

1A-2 Engine General Information and Diagnosis:

Dealer ModeThe defective function is memorized in the computer. Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel. Malfunction means that the ECM does not receive signal from the devices. These affected devices are indicated in the code form.

CAUTION!

Before checking the malfunction code, do not disconnect the ECM coupler.If the coupler from the ECM is disconnected, the malfunction code memory is erased and the malfunction code can not be checked.

Special tool(A): 09930–82720 (Mode select switch)

Diagnostic Information and ProceduresSelf-Diagnostic Procedures (GSX650FK8)

B817H21104029Use of Mode Select Switch

NOTE

• Do not disconnect coupler from ECM, the battery cable from the battery, ECM ground wire harness from the engine or main fuse before confirming DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase memorized information in ECM memory.

• DTC stored in ECM memory can be checked by the special tool.

• Before checking DTC, read self-diagnosis function “User mode and dealer mode” (Refer to “Self-Diagnosis Function (GSX650FK8) (Page 1A-1)”.) carefully to have good understanding as to what functions are available and how to use it.

• Be sure to read “Precautions for Electrical Circuit Service” (Refer to “Precautions for Electrical Circuit Service in Section 00 in related manual”.) before inspection and observe what is written there.

1) Remove the right frame cover. Refer to “Exterior Parts Removal and Installation in Section 9D in related manual”.

2) Connect the special tool to the mode select switch at the wiring harness.

Special tool(A): 09930–82720 (Mode select switch)

Malfunction LCD (display) indication FI light indication Indication mode“NO” C00

FI indicator light turns OFF.—

“YES” C** code is indicated from small numeral to large one. For each 2 sec., code is indicated.

(A) (A)

I717H1110005-01 I817H2110003-01

(A)

I717H1110006-01

Engine General Information and Diagnosis: 1A-3

3) Start the engine or crank the engine for more than 4 seconds.

4) Turn the special tool’s switch ON.5) Check the DTC to determine the malfunction part.

Refer to “DTC Table in related manual”.

Special tool(A): 09930–82720 (Mode select switch)

6) After repairing the trouble, turn OFF the ignition switch and turn ON again. If DTC is indicated (C00), the malfunction is cleared.

NOTE

• Even though DTC (C00) is indicated, the previous malfunction history DTC still remains stored in the ECM. Therefore, erase the history DTC memorized in the ECM using SDS.

• DTC is memorized in the ECM also when the wire coupler of any sensor is disconnected. Therefor, when a wire coupler has been disconnected at the time of diagnosis, erase the stored history DTC using SDS. Refer to “Use of SDS Diagnosis Reset Procedures in related manual”.

7) Turn the ignition switch OFF and disconnect the special tool from the mode select switch.

8) Reinstall the right frame cover.

Special Tools and EquipmentSpecial Tool

B817H21108001

(A)

I718H1110006-04

I817H2110001-01

09930–82720Mode select switch

(Page 1A-2) / (Page 1A-2) / (Page 1A-3)

1D-1 Engine Mechanical:

EngineEngine MechanicalSchematic and Routing Diagram

Throttle Cable Routing Diagram (GSX650FK8)B817H21402003

“A”

2

3

42

1

5

6

7

3

4

“a”

“a”

I817H2140001-01

1. Wiring harness 4. Throttle cable No. 2 7. Ignition switch lead wire2. Cable guide 5. Handlebar switch lead wire (L) “a”: 0 mm (0 in)3. Throttle cable No. 1 6. Handlebar switch lead wire (R) “A”: Don’t contact the tip of cable guide with the upper bracket.

Table of Contents 6- i

6

Section 6

CONTENTS

Steering

Precautions ................................................. 6-*Precautions..............................................................6-*

Precautions for Steering ........................................6-*

Steering General Diagnosis.....................6A-*Diagnostic Information and Procedures............ 6A-*

Steering Symptom Diagnosis...............................6A-*

Steering / Handlebar................................ 6B-1Repair Instructions ..............................................6B-1

Handlebars Components .....................................6B-*Handlebar Construction .......................................6B-*Handlebars Removal and Installation ..................6B-*Handlebars Inspection .........................................6B-*

Handlebar Height Adjustment ............................. 6B-*Steering Components ......................................... 6B-*Steering Removal and Installation ...................... 6B-*Steering Related Parts Inspection....................... 6B-*Steering System Inspection ................................ 6B-*Steering Stem Bearing Removal and

Installation ......................................................... 6B-*Steering Tension Adjustment .............................. 6B-*Handlebar Construction (GSX650FK8)...............6B-1

Specifications....................................................... 6B-*Tightening Torque Specifications........................ 6B-*

Special Tools and Equipment .............................6B-1Special Tool ........................................................ 6B-*Recommended Service Material .........................6B-1

NOTEFor the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual.

6B-1 Steering / Handlebar:

SteeringSteering / HandlebarRepair Instructions

Handlebar Construction (GSX650FK8)B817H26206012

Special Tools and EquipmentRecommended Service Material

B817H26208003NOTERequired service material is also described in the following.“Handlebar Construction (GSX650FK8) (Page 6B-1)”

1. Handlebar switch (LH) : Apply bond.“A”: Apply a small amount of the bond 1207B to inside of the handlebar switchbox.

“A”

1

I817H2620001-01

Table of Contents 9- i

9

Section 9

CONTENTS

Body and Accessories

NOTEFor the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual.

Precautions ................................................. 9-*Precautions..............................................................9-*

Precautions for Electrical System ..........................9-*Component Location ..............................................9-*

Electrical Components Location ............................9-*

Wiring Systems........................................ 9A-1Schematic and Routing Diagram........................9A-1

Wiring Diagram (GSF650)....................................9A-*Wiring Diagram (GSF650S) .................................9A-*Wiring Harness Routing Diagram.........................9A-*Wiring Diagram (GSF650A/UAK7).......................9A-*Wiring Diagram (GSF650SA/ASUK7) ..................9A-*Wiring Routing Diagram.......................................9A-*Wiring Diagram (GSX650FK8)............................9A-1Wiring Harness Routing Diagram

(GSX650FK8) ...................................................9A-4Specifications....................................................... 9A-*

Service Data ........................................................9A-*Service Data (GSF650A/UA/SA/ASUK7).............9A-*Tightening Torque Specifications.........................9A-*

Lighting Systems..................................... 9B-1Repair Instructions ..............................................9B-1

Headlight Components ........................................9B-*Headlight Components ........................................9B-*Headlight Removal and Installation .....................9B-*Headlight Bulb Replacement ...............................9B-*Headlight Beam Adjustment ................................9B-*Rear Combination Light Components..................9B-*Rear Combination Light Construction ..................9B-*Rear Combination Light Removal and

Installation..........................................................9B-*Brake Light Bulb / Taillight Bulb Replacement .....9B-*License Plate Light Components .........................9B-*License Plate Light Removal and Installation ......9B-*License Plate Light Bulb Replacement ................9B-*Turn Signal Light Components ............................9B-*Front Turn Signal Light Removal and

Installation..........................................................9B-*Rear Turn Signal Light Removal and

Installation..........................................................9B-*Turn Signal Light Bulb Replacement ...................9B-*Reflex Refractor Construction..............................9B-*Turn Signal / Side-stand Relay Inspection...........9B-*

Turn Signal / Side-stand Relay Removal and Installation ......................................................... 9B-*

Hazard Switch Inspection.................................... 9B-*Turn Signal Switch Inspection............................. 9B-*Passing Light Switch Inspection.......................... 9B-*Dimmer Switch Inspection................................... 9B-*Headlight Components (GSX650FK8) ................9B-1Headlight Removal and Installation

(GSX650FK8)....................................................9B-2Headlight Bulb Replacement (GSX650FK8) .......9B-2Headlight Beam Adjustment (GSX650FK8) ........9B-3Reflex Refractor Construction (GSX650FK8) .....9B-4

Specifications.......................................................9B-4Service Data........................................................ 9B-*Service Data (GSX650FK8) ................................9B-4Tightening Torque Specifications........................9B-4

Special Tools and Equipment ............................. 9B-*Special Tool ........................................................ 9B-*

Combination Meter / Fuel Meter / Horn.. 9C-1General Description .............................................9C-1

Combination Meter System Description.............. 9C-*Combination Meter System Description

(GSX650FK8)....................................................9C-1Repair Instructions ..............................................9C-2

Combination Meter Components ........................ 9C-*Combination Meter Removal and Installation ..... 9C-*Combination Meter Disassembly and

Assembly........................................................... 9C-*Combination Meter Inspection ............................ 9C-*Engine Coolant Temperature Indicator Light

Inspection.......................................................... 9C-*Engine Coolant Temperature Removal and

Installation ......................................................... 9C-*Fuel Level Indicator Inspection ........................... 9C-*Fuel Level Indicator Switch (Thermistor)

Inspection.......................................................... 9C-*Fuel Level Gauge Inspection .............................. 9C-*Speedometer Inspection ..................................... 9C-*Speed Sensor Removal and Installation ............. 9C-*Speed Sensor Inspection .................................... 9C-*Oil Pressure Indicator Inspection ........................ 9C-*Oil Pressure Switch Removal and Installation .... 9C-*Ignition Switch Inspection.................................... 9C-*Ignition Switch Removal and Installation............. 9C-*

9-ii Table of Contents

Horn Inspection ................................................... 9C-*Horn Removal and Installation ............................ 9C-*Combination Meter Components

(GSX650FK8) ...................................................9C-2Combination Meter Removal and Installation

(GSX650FK8) ...................................................9C-2Combination Meter Disassembly and

Assembly (GSX650FK8) ...................................9C-3Combination Meter Inspection (GSX650FK8).....9C-3Engine Coolant Temperature Indicator Light

Inspection (GSX650FK8) ..................................9C-4Oil Pressure Indicator Inspection

(GSX650FK8) ...................................................9C-5Horn Inspection (GSX650FK8) ...........................9C-5Horn Removal and Installation (GSX650FK8) ....9C-5

Specifications.......................................................9C-6Service Data........................................................ 9C-*Service Data (GSX650FK8) ................................9C-6Tightening Torque Specifications........................ 9C-*

Special Tools and Equipment ............................. 9C-*Special Tool ........................................................ 9C-*

Exterior Parts........................................... 9D-1Schematic and Routing Diagram........................ 9D-*

Seat Lock Cable Routing Diagram...................... 9D-*Repair Instructions ..............................................9D-1

Exterior Parts Construction ................................. 9D-*Frame head cover construction........................... 9D-*Front Fender Construction .................................. 9D-*Frame Cover Cushion Construction.................... 9D-*Engine Sprocket Outer Cover Cushion............... 9D-*Fastener Removal and Installation...................... 9D-*

Exterior Parts Removal and Installation .............. 9D-*Seat Height Adjustment ...................................... 9D-*Cowling Construction (GSX650FK8)...................9D-1Under Cowl Construction (GSX650FK8).............9D-2Under Cowl Bracket Cushion Attachment

(GSX650FK8)....................................................9D-2Under Cowl Protector Cushion Attachment

(GSX650FK8)....................................................9D-3Upper Panel Cushion Attachment

(GSX650FK8)....................................................9D-3Windscreen Cushion Attachment

(GSX650FK8)....................................................9D-4Intake Net Cover Construction Attachment

(GSX650FK8)....................................................9D-4Exterior Parts Removal and Installation

(GSX650FK8)....................................................9D-5

Body Structure.......................................... 9E-*Repair Instructions .............................................. 9E-*

Body Frame Construction ................................... 9E-*Engine Mounting Bracket Bushing

Replacement ..................................................... 9E-*Engine Mount Bushing Replacement.................. 9E-*Front Footrest Bracket Construction ................... 9E-*Side-stand Construction...................................... 9E-*Side-stand Removal and Installation................... 9E-*Center Stand Construction.................................. 9E-*Center Stand Removal and Installation............... 9E-*

Specifications....................................................... 9E-*Tightening Torque Specifications........................ 9E-*

Special Tools and Equipment ............................. 9E-*Recommended Service Material ......................... 9E-*

Wiring Systems: 9A-1

Body and AccessoriesWiring SystemsSchematic and Routing Diagram

Wiring Diagram (GSX650FK8)B817H29102007

Refer to “Wire Color Symbols in Section 0A in related manual”.

9A-2 Wiring Systems:

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BlG

B/R B/RB/WB/W

B/YBl/BB/RB/R

RG/BDgYW

R/Bl

O/YB/OB/GR

O/RBl/BBl

GO/Y

B/BlBr/BB/Br

B/BlB/GB/Br

B

G/BDbrDg

B/WB/Y

B/BlB/GB/Br

B

G/B

DgB/WB/Y

G/Y

B/BlO/G

B/R B/RB/WB/W

B/YB/R

B/W B/W

BlP

B/W

O/WB/BrW/GW/B

WGrBW

B/LgP/WG

W/B

EC

M

FR

ON

T T

UR

N

SIG

NA

L L

IGH

T (

R)

FR

ON

T T

UR

N

SIG

NA

L L

IGH

T (

L)

HE

AD

LIG

HT

(L

O)

HE

AD

LIG

HT

(H

I)

PO

SIT

ION

LIG

HT

(R

)

PO

SIT

ION

LIG

HT

(L

)

LIC

EN

SE

LIG

HT

RE

AR

TU

RN

SIG

NA

L L

IGH

T (

R)

RE

AR

C

OM

BN

AT

ION

LIG

HT

RE

AR

TU

RN

SIG

NA

L L

IGH

T (

L)

I817H2910901-01

Wiring Systems: 9A-3

For E-03, 24, 28

M

EN

GIN

E S

TO

PS

WIT

CH

FU

EL

PU

MP

STA

RT

ER

BU

TT

ON

FR

ON

T B

RA

KE

SW

ITC

H

HA

ND

LE

BA

R S

WIT

CH

(R

)

IGN

ITIO

N S

WIT

CH

SP

EE

DS

EN

SO

R

SID

E S

TA

ND

S

WIT

CH

FR

EE

PU

SH

BR

AK

E L

IGH

TS

WIT

CH

IGN

ITIO

NC

OIL

#1

PA

IRS

OL

EN

OID

FA

N R

EL

AY

FA

N M

OTO

RH

O2

SE

NS

OR

EC

TS

EN

SO

RG

PS

WIT

CH

TO

SE

NS

OR

FU

EL

PU

MP

RE

LA

Y

ST

PS

EN

SO

R

IAP

SE

NS

OR

(#1

)

GEN

ERAT

OR

BA

TT

ER

Y

1:

MA

IN 3

0A

STA

RT

ER

M

OTO

RS

TA

RT

ER

R

EL

AY

1

12

3

BB

l4

56

1. H

EA

D H

I

2. H

EA

D L

O

3. F

UE

L

4. IG

NIT

ION

5. S

IGN

AL

6. FA

N

10 A

10 A

10 A

15 A

15 A

15 A

FU

SE

BO

XC

LUTC

HS

WIT

CH

FRE

E

HA

ND

LE

BA

R S

WIT

CH

(L

)

HI

LO DIM

ME

RS

WIT

CH

OF

F

ON HA

ZAR

D

SW

ITC

H

PU

SH

HO

RN

BU

TTO

N

L

PU

SH

R

TUR

N S

IGN

AL

LIG

HT

SW

ITC

H

ON

OF

FO

IL

PR

ES

SU

RE

SW

ITC

H

HO

RN

ST

VA

ISC

VA

LVE

IAP

/TP

/IA

TS

EN

SO

R

(#2

)IN

JEC

TO

R#4

INJE

CTO

R#2

INJE

CTO

R#3

INJE

CTO

R#1

RE

GU

LA

TO

R/

RE

CT

IFIE

R

SP

EE

DO

ME

TE

R

PU

SH

PAS

SIN

GLI

GH

TS

WIT

CH

OF

F NP

US

H

OF

F

ON

RU

ON

OF

F

LOC

K

P

ON

OF

F

IGN

ITIO

NC

OIL

#2

IGN

ITIO

NC

OIL

#3

IGN

ITIO

NC

OIL

#4

EC

M

Br

B/W

Br

B/W

B

B/W

B

B/W

B

B/W

Br

B/W

Br

B/W

Lg

B/W

W

B/W

W B Lg Y Br

B/W

W B

B/G Y Br

B/W

Y

B/W

B/RY

Bl/BB

LgG/YR/BR/BlO/GB/Lg

PY/BlB/GB/W

Y/RB/WB/LgR/B

B/BlB/RB/GB

Bl/BB/OG/B

B/RB/W

B

B/RB/W

P

GB/W

GB/W

O/GW/B

O/WG

O/WW/Bl

O/WB

O/WY

O/WB/G

B/RB/OG/BB/OB/GBr/B

B/BlB/RB/GB

Bl/BB/OG/B

Y/RB/WB/LgR/B

YB/WB/WB/WW/RB/YB/BlBl

Bl/WBl/BBl/GW/YLgG

W/BlB

Gr/WGr/BGr/YGr/RW/BB/GY/BBl/YLblDbrB/WY/RGrB/RB/WB/Br

DgW/Bl

PB

G/BY/WB/Lg

GO/GR/BlO/RB/YY/BlW/G

RB/BlG/BP/B

B/G

P/WW/B

B/BrBl/WBl/BBl/G

Bl/YR

O/G

W/R

GrB/W

Br

B/W Lg

B/W Br

B/W B

Br

B/W

W/B

BB

/W BB

/WB

B/W

B B

B/WB

BBl

O/RO/WO/RB

B/BlB/Br

BlP

B/W

RB

B/Br

Y/BB/RY/RR/Bl

B/LgP/WG

W/B

Gr/WY/R

Gr/BW/YLbl

Gr/YLgDbrGr/R

Gr/WY/R

Gr/BW/YLbl

Gr/YLgDbrGr/R

W/YLblLgDbr

B/LgP/WG

W/B

Gr/WY/R

Gr/BY/R

Gr/YY/R

Gr/RY/R

DgG/BB/BrP/BR

B/BrW/Bl

B

RY/WB/Br

BBB

BBB

BlG

B/R B/RB/WB/W

B/YBl/BB/RB/R

RG/BDgYW

R/Bl

O/YB/OB/GR

O/RBl/BBl

GO/Y

B/BlBr/BB/Br

B/BlB/GB/Br

B

G/BDbrDg

B/WB/Y

B/BlB/GB/Br

B

G/B

DgB/WB/Y

G/Y

B/BlO/G

B/R B/RB/WB/W

B/YB/R

B/W B/W

BlP

B/W

O/WB/BrW/GW/B

WGrBW

B/LgP/WG

W/B

B/RB/OG/BB/WB/GBr/B

PO

SIT

ION

LIG

HT

(R

)

FR

ON

T T

UR

N

SIG

NA

L L

IGH

T (

R)

FR

ON

T T

UR

N

SIG

NA

L L

IGH

T (

L)

HE

AD

LIG

HT

(L

O)

HE

AD

LIG

HT

(H

I)

PO

SIT

ION

LIG

HT

(L

)

LIC

EN

SE

LIG

HT

RE

AR

TU

RN

SIG

NA

L L

IGH

T (

R)

RE

AR

C

OM

BN

AT

ION

LIG

HT

RE

AR

TU

RN

SIG

NA

L L

IGH

T (

L)

I817H2910902-01

9A-4 Wiring Systems:

Wiring Harness Routing Diagram (GSX650FK8)B817H29102008

2

4

“C”

“A”

“B”

3

33

1

I817H2910903-02

1. EVAP purge control valve (E-33 only) “A”: Pass the EVAP purge control valve lead wire lower the clutch hose (E-33 only).2. Wiring harness No. 1 “B”: Do not make slacked lead wire.3. Wiring harness No. 2 “C”: Left & Right are symmetry.4. Front turn signal

Lighting Systems: 9B-1

Body and AccessoriesLighting SystemsRepair Instructions

Headlight Components (GSX650FK8)B817H29206024

FWDFWD

1

3

4

4

3

2

I817H2920001-01

1. Headlight low beam bulb (12 V 55 W, H7) 3. Position light bulb (12 V 5 W x 2)2. Headlight high beam bulb (12 V 60 W, HB3) 4. Bulb cap

9B-2 Lighting Systems:

Headlight Removal and Installation (GSX650FK8)

B817H29206025Removal1) Remove the body cowling assembly. Refer to

“Exterior Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-5)”.

2) Remove the headlight assembly (1).

InstallationInstallation is in the reverse order of removal. Pay attention to the following point:• After installing, be sure to inspect the headlight beam.

Refer to “Headlight Beam Adjustment (GSX650FK8) (Page 9B-3)”.

Headlight Bulb Replacement (GSX650FK8)B817H29206026

CAUTION!

When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

Low Beam1) Remove the combination meter assembly. Refer to

“Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”.

2) Remove the bulb cap (1) by turning it counterclockwise.

3) Disconnect the low beam lead wire coupler (2).4) Replace the low beam bulb (3) by unhooking the

bulb holder spring (4).

5) Reinstall the removed parts.

High Beam1) Remove the bulb cap (1) by turning it

counterclockwise.

2) Remove the bulb socket (2) by turning it counterclockwise.

1

I817H2920002-01

1

I817H2920003-01

3

42

I817H2920006-02

1

I817H2920007-01

2

I817H2920008-01

Lighting Systems: 9B-3

3) Replace the high beam bulb (3).

4) Reinstall the removed parts.

Position Light1) Remove the combination meter assembly. Refer to

“Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”.

2) Remove the upper panel. Refer to “Exterior Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-5)”.

3) Remove the position light socket (1).

4) Replace the position light bulb (2).

5) Reinstall the removed parts.

Headlight Beam Adjustment (GSX650FK8)B817H29206027

1) Remove the combination meter assembly. Refer to “Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”.

2) Insert 8 mm hexagon wrench as shown and adjust the Low and High headlight beam horizontally.

NOTEAdjust the beam horizontally first, then vertically.

Low beam

High beam

3

I817H2920009-01

1

I817H2920010-01

2

I817H2920011-01

“A”: Horizontal adjuster “B”: Vertical adjuster

“C”: Horizontal adjuster “D”: Vertical adjuster

“A”

“B”

I817H2920012-02

“C”

“D”

I817H2920013-02

9B-4 Lighting Systems:

Reflex Refractor Construction (GSX650FK8)B817H29206028

SpecificationsService Data (GSX650FK8)

B817H29207003WattageUnit: W

Tightening Torque SpecificationsB817H29207004

NOTEThe specified tightening torque is also described in the following.“Reflex Refractor Construction (GSX650FK8) (Page 9B-4)”

Reference:For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List in Section 0C in related manual”“Tightening Torque List in Section 0C in related manual”.

2

(a)1

I817H2920014-01

1. Front reflex refractor (For E-03, 24, 28, 33) 2. Front fork : 2 N⋅m (0.2 kgf-m, 1.5 lb-ft)

Item Specification

Headlight HI 60LO 55

Parking or position light 5 x 2Brake light/Taillight 21/5Turn signal light 21 x 4License plate light 5

Combination Meter / Fuel Meter / Horn: 9C-1

Body and AccessoriesCombination Meter / Fuel Meter / HornGeneral Description

Combination Meter System Description (GSX650FK8)B817H29301002

This combination meter mainly consists of the stepping motor, LCD (Liquid Crystal Display) and LED (Light Emitting Diode).The rpm pointer is driven by the stepping motor.The LCDs indicate Speed, Odo / Trip 1 / Trip 2 / Fuel reserve’s trip / Clock / FI (DTC), Gear position, Engine revolution indicator and Fuel level indicator respectively.

LED (Light Emitting Diode)LED is used for the illumination light and each indicator light.LED is maintenance free. LED is less electric-power consuming and stronger to vibration resistance compared to the bulb.

Engine Revolution Indicator LampThis speedometer is equipped the engine revolution indicator lamp. The engine revolution indicator lamp is adjustable from 6 000 – 12 500 r/min. (from 6 000 r/min to 10 000 r/min, every 500 r/min and 10 000 r/min to 12 500 r/min, every 250 r/min: Initial setting: 11 000 r/min)

FI

1

2 714

8 3

4

5

9

15106

13

11

12

14

I817H2930001-02

1. Adjust switch (Trip / Engine revolution / Clock) 9. LCD (Engine coolant temperature indicator light)2. LED (Tachometer) 10. LCD (Engine revolution)3. LCD (Speedometer) 11. LED (FI indicator light)4. LCD (Odo / Trip 1/ Trip 2 / Clock / FI (DTC)) 12. LED (Neutral indicator light)5. LCD (Fuel level indicator) 13. LED (High-beam indicator light)6. Select switch (Odo / Trip 1 / Trip 2 / Fuel reserve’s trip / Clock) 14. LED (Turn signal indicator light)7. LCD (Gear position) 15. LED (Engine revolution indicator light)8. LCD (Oil pressure indicator light)

9C-2 Combination Meter / Fuel Meter / Horn:

Repair InstructionsCombination Meter Components (GSX650FK8)

B817H29306019

Combination Meter Removal and Installation (GSX650FK8)

B817H29306020Removal1) Remove the screws (1) and pull out the combination

meter assembly (2) from the upper panel.

2) Disconnect the combination meter coupler (3) and remove the combination meter assembly (4).

3) Remove the combination meter (5).

FWDFWD

1

2 3

I817H2930002-01

1. Combination meter cover 2. Combination meter unit 3. Combination meter case

“A”: Hooked point

2

1

“A”

I817H2930003-01

34

I817H2930004-01

5

I817H2930005-01

Combination Meter / Fuel Meter / Horn: 9C-3

InstallationInstall the combination meter in the reverse order of removal.

NOTEFix the boot of the combination meter coupler properly.

Combination Meter Disassembly and Assembly (GSX650FK8)

B817H29306021Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-2)”.

DisassemblyDisassemble the combination meter as shown in the combination meter components. Refer to “Combination Meter Components (GSX650FK8) (Page 9C-2)”.

AssemblyAssemble the combination meter as shown in the combination meter components. Refer to “Combination Meter Components (GSX650FK8) (Page 9C-2)”.

Combination Meter Inspection (GSX650FK8)B817H29306022

LED InspectionCheck that the LEDs (FI indicator light, Engine revolution indicator light and Meter panel illumination) immediately light up when the ignition switch is turned to ON. Check that other LEDs (Neutral indicator light, High-beam indicator light and Turn signal indicator lights) light up/go off by operating each switch.

If abnormal condition is found, replace the combination meter unit with a new one after checking its wire harness/coupler. Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-2)”.

Stepping Motor Inspection and Adjustment1) Check that the pointer calibrates itself immediately

after turning the ignition switch on and stops at zero point.If abnormal condition is found, replace the combination meter unit with a new one after checking its wire harness/coupler.

NOTE

• The pointer may not return to the proper position even turning the ignition switch on under low temperature condition. In that case, you can reset the pointer to the proper position by following the instruction.

• Complete the operation within 10 seconds after the ignition switch has been turned on.

I817H2930006-02

FI

I817H2930007-01

FI

I817H2930008-01

9C-4 Combination Meter / Fuel Meter / Horn:

2) With the adjuster switch (1) pressed, turn the ignition switch on.

3) Release the adjuster switch (1), 3 to 5 seconds after turning the ignition switch on.

4) Press the adjuster switch (1) twice (within 1 second). → Reset

5) Pointer will return to the starting point right after the completion of the operation. In the case of the pointer not returning to the proper position after doing above, replace the combination meter unit. Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-2)”.

Engine Coolant Temperature Indicator Light Inspection (GSX650FK8)

B817H29306023Inspect the engine coolant temperature indicator light in the following procedures:1) Remove the left under cowling. Refer to “Exterior

Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-5)”.

2) Disconnect the ECT sensor coupler (1).

3) Connect the variable resistor (2) between the terminals.

4) Turn the ignition switch ON.5) Check the LED (3) and LCD (4) operations when the

resistance is adjusted to the specified values.If either one or all indications are abnormal, replace the combination meter with a new one. Refer to “Combination Meter Removal and Installation (GSX650FK8) (Page 9C-2)”.

6) Connect the ECT sensor coupler.

FI

1

I817H2930009-01

Time Ignition switch Adjuster switch (1)

PUSH

Release

Push

Push→Reset

OFF

ON0

••

••••

3 sec.•5 sec.

10 sec.I718H1930006-01

Resistance LED (3) LCD (4) Water temperature

2.45 kΩ and over OFF – 19 °C (67 °F) and below

Approx. 0.811 kΩ OFF – Approx. 50 °C (122 °F)

Approx. 0.1 kΩ ON ON 120 – 139 °C (248 – 282 °F)

0 Ω (Jumper wire) ON ON 140 °C (283 °F) and over

1

I718H1930007-03

2

I718H1930009-05

FI

34

I817H2930010-01

Combination Meter / Fuel Meter / Horn: 9C-5

Oil Pressure Indicator Inspection (GSX650FK8)B817H29306024

Inspect the oil pressure indicator in the following procedures:

NOTEBefore inspecting the oil pressure switch, check if the engine oil level is correct. Refer to “Engine Oil and Filter Replacement in Section 0B in related manual”.

1) Remove the right under cowling. Refer to “Exterior Parts Removal and Installation (GSX650FK8) in Section 9D (Page 9D-5)”.

2) Disconnect the oil pressure switch lead wire (1) from the oil pressure switch.

3) Turn the ignition switch to ON.4) Check if the oil pressure indicator (LED) “A” and

(LCD) “B” will light up when grounding the lead wire (1).If the oil pressure indicator does not light up, replace the combination meter unit with a new one after checking connection of couplers.

Horn Inspection (GSX650FK8)B817H29306025

Inspect the horn in the following procedures:1) Disconnect the couplers (1).

2) Connect a 12 V battery to terminal “A” and terminal “B”. If the sound is not heard from the horn, replace the horn with a new one.

3) Connect the horn coupler.

Horn Removal and Installation (GSX650FK8)B817H29306026

Removal1) Disconnect the horn couplers (1).2) Remove the horn (2) by removing the mounting nut.

InstallationInstall the horn in the reverse order of removal.

1

I717H1930013-01

1

“B”“A”

I817H2930011-02

1

I817H2930012-01

“A”

“B”

I817H2930014-02

1

2

I817H2930013-01

9C-6 Combination Meter / Fuel Meter / Horn:

SpecificationsService Data (GSX650FK8)

B817H29307003WattageUnit: W

Item SpecificationSpeedometer light LEDTachometer light LEDTurn signal indicator light LED x 2High beam indicator light LEDNeutral position indicator light LEDOil pressure/Engine coolant temperature indicator light LEDFI indicator light LEDEngine RPM indicator light LED

Exterior Parts: 9D-1

Body and AccessoriesExterior PartsRepair Instructions

Cowling Construction (GSX650FK8)B817H29406011

1

2

3

4

56

I817H2940014-03

1. Under cowling (R) 3. Cushion 5. Upper panel2. Body cowling 4. Windscreen 6. Under cowling (L)

9D-2 Exterior Parts:

Under Cowl Construction (GSX650FK8)B817H29406012

Under Cowl Bracket Cushion Attachment (GSX650FK8)B817H29406013

“c”

“b”

“a” “a”

“d”

“c”

11

I817H2940021-01

1. Heat shield “a”: Max. 5 mm (0.19 in) “c”: 55 mm (2.17 in)2. Cushion “b”: 0 – 1 mm (0 – 0.039 in) “d”: 3 mm (0.12 in)

1

“a”

“b”

I817H2940016-01

1. Under cowl F.T.G. cushion “a”: 15 mm (0.59 in) “b”: 0 mm (0 in)

Exterior Parts: 9D-3

Under Cowl Protector Cushion Attachment (GSX650FK8)B817H29406014

Upper Panel Cushion Attachment (GSX650FK8)B817H29406015

1

“a”

I817H2940017-01

1. Cushion “a”: 85 mm (3.35 in)

1

“a”

I817H2940018-01

1. Panel cushion “a”: 5 mm (0.19 in)

9D-4 Exterior Parts:

Windscreen Cushion Attachment (GSX650FK8)B817H29406016

Intake Net Cover Construction Attachment (GSX650FK8)B817H29406017

2 2

1

I817H2940019-01

1. Cushion 2. Tape

1I817H2940020-01

1. Cover cushion

Exterior Parts: 9D-5

Exterior Parts Removal and Installation (GSX650FK8)

B817H29406010Under CowlingRefer to “Exterior Parts Removal and Installation in related manual”.

Removal1) Remove the fasteners (1).

2) Disconnect the turn signal light couplers (2), left and right.

3) Remove the left under cowling (3) and right under cowling (4).

InstallationInstall the under cowlings in the reverse order of removal.

1

I817H2940001-01

2

2

I817H2940002-01

“A”: Hooked point

I817H2940006-01

3

“A”

I817H2940003-01

I817H2940004-01

“A”

4

I817H2940005-02

9D-6 Exterior Parts:

Upper PanelRemoval1) Remove the combination meter assembly. Refer to

“Combination Meter Removal and Installation (GSX650FK8) in Section 9C (Page 9C-2)”.

2) Remove the upper panel (1).

InstallationInstall the under panel in the reverse order of removal.

Body CowlingRemoval 1) Remove the caps and rear view mirror (1), left and

right.

2) Remove the upper panel.

3) Disconnect the high beam light coupler (2) and low beam light coupler (3).

4) Remove the screws (4).5) Disconnect the position lights (5) and clamps, left

and right.

6) Remove the screws.

7) Remove the body cowling assembly (6).

InstallationInstall the body cowling in the reverse order of removal.

1

I817H2940007-01

1

I817H2940008-01

1

I817H2940009-01

2

3

I817H2940010-01

4

5

4

55

4

I817H2940011-01

I817H2940012-01

6

I817H2940013-02

Prepared by

September, 2007

Part No. 99501-36180-01E

Printed in Japan

48

Printed in JapanK8