Suzuki GSF1200S User Manual

5C-4 Clutch:
Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
B649G15304003
Repair Instructions
Clutch Lever Position Switch Inspection
B649G15306007
Inspect the clutch lever position switch in the following
procedures:
1) Disconnect the clutch lever position switch lead
wires.
2) Inspect the switch for continuity with a tester.
If any abnormality is found, replace the switch with a
new one.
Special tool
: 09900–25008 (Multi-circuit tester set)
Tester knob indication
Continuity ( )
Clutch lever position switch
3) Connect the clutch lever position switch lead wires.
Clutch Fluid Level Check
B649G15306008
Refer to “Clutch System Inspection: in Section 0B”.
Clutch Hose Inspection
B649G15306009
Refer to “Clutch System Inspection: in Section 0B”.
Air Bleeding from Clutch Fluid Circuit
B649G15306010
CAUTION
!
Handle brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber
materials, etc.
The clutch fluid circuit may be purged of air in the
following manner:
1) Keep the motorcycle upright and place the
handlebars straight.
2) Fill up the master cylinder reservoir to the upper end
of the inspection window. Replace the reservoir cap
to prevent entry of dirt.
Condition Possible cause Correction / Reference Item
Engine is noisy (Noise
seems to come from the
clutch).
Worn countershaft spline. Replace countershaft.
Worn clutch hub spline. Replace clutch hub.
Worn clutch plate teeth. Replace clutch plate.
Distorted clutch plate. Replace.
Worn clutch release bearing. Replace.
Weak clutch damper. Replace primary driven gear.
Clutch slips. Weak or broken clutch spring. Replace.
Worn or distorted clutch pressure plate. Replace.
Distorted clutch plate. Replace.
Clutch drags. Leakage of clutch fluid. Repair or replace.
Worn or damaged clutch cylinder/
release cylinder.
Replace.
Some clutch springs are weak, while
others are not.
Replace.
Worn or distorted clutch pressure plate. Replace.
Distorted clutch plate. Replace.
I649G1530003-01
Terminal (B/Y) Terminal (B/W)
FREE
Color
Position
I649G1530004-02

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