Suzuki GSF1200S User Manual

1D-42 Engine Mechanical:
Piston Pin and Pin Bore
Measure the piston pin bore inside diameter using the
small bore gauge. If either is out of specification or the
difference between these measurement is more than the
limits, replace the piston.
Special tool
(A): 09900–20602 (Dial gauge (1/1000mm,
1mm))
(B): 09900–22403 (Small bore gauge (18-
35mm))
Piston pin bore I.D.
Service limit: 20.030 mm (0.7886 in)
Measure the piston pin outside diameter at three
positions using the micrometer. If any of the
measurements are out of specification, replace the
piston pin.
Special tool
(C): 09900–20205 (Micrometer (0-25mm))
Piston pin O.D.
Service limit: 19.980 mm (0.7866 in)
Engine Bottom Side Disassembly
B649G11406005
NOTE
The crankcase must be separated to service
the crankshaft and conrod.
1) Remove the engine assembly. Refer to “Engine
Assembly Removal: ”.
2) Disassemble the engine top side. Refer to “Engine
Top Side Disassembly: ”.
Starter Motor
Remove the starter motor (1).
Generator
Remove the generator (1).
Oil Filter
Remove the oil filter (1) using the special tool.
Special tool
: 09915–40610 (Oil filter wrench)
(A)
(B)
I649G1140267-02
(C)
I649G1140268-02
1
I649G1140094-01
1
I649G1140095-02
1
I649G1140033-02

Suzuki GSF1200S Specifications

General

Displacement	1157 cc
Bore x Stroke	79.0 mm x 59.0 mm
Compression Ratio	9.5:1
Ignition	Electronic ignition (transistorized)
Transmission	5-speed constant mesh
Front Suspension	Telescopic, coil spring, oil damped
Rear Brakes	Single hydraulic disc
Front Tire	120/70-ZR17
Rear Tire	180/55-ZR17
Overall Width	790 mm (31.1 in)
Seat Height	790 mm (31.1 in)
Lubrication	Wet sump
Final Drive	Chain
Starter	Electric
Engine Type	4-stroke, 4-cylinder, DOHC
Rear Suspension	Link-type, coil spring, oil damped
Front Brakes	Dual disc
Fuel Tank Capacity	20 liters
Rear Suspension Adjustability	Preload adjustable
Ground Clearance	135 mm
Overall Length	2, 130 mm