Suzuki B King Workshop Manual
Gsx1300 B-king k8 service manual. 1. GSX1300BK 0-01E. FOREWORDThis manual contains an introductory description on the SUZUKI GSX1300BK and procedures for its inspection/service and overhaul of its main components.Other information considered as generally known is not included.Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Usethis 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.
Suzuki b-king 1300 gsx1300bk 2007-2012 bike workshop service repair manual parts catalog and owners manual also included with this manual engin.
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 the actual motorcycle.
Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.! WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. © COPYRIGHT SUZUKI MOTOR CORPORATION 2007.
00 TABLE OF CONTENTS 0Precautions. 00-i Precautions. 00-1 1General Information.
0-i General Information. 0A-1 Maintenance and Lubrication.
0B-1 Service Data.0C-1 2Engine. 1-i Precautions. 1-1 Engine General Information and Diagnosis. 1A-1 Emission Control Devices. 1B-1 3 Engine Electrical Devices.1C-1 Engine Mechanical.1D-1 Engine Lubrication System. 1E-1 Engine Cooling System. 1F-1 Fuel System.1G-1 4 Ignition System.1H-1 Starting System.
1I-1 Charging System.1J-1 Exhaust System. 1K-1 5Suspension.
2-i Precautions. 2-1 Suspension General Diagnosis. 2A-1 Front Suspension.
2B-1 Rear Suspension.2C-1 6 Wheels and Tires.2D-1Driveline / Axle. 3-i Precautions. 3-1 Drive Chain / Drive Train / Drive Shaft. 4-i Precautions. 4-1 Brake Control System and Diagnosis. 4A-1 Front Brakes. 4B-1 Rear Brakes.4C-1Transmission / Transaxle.
5-i Precautions. 5-1 Manual Transmission. 5B-1 9 Clutch.5C-1Steering. 6-i Precautions. 6-1 Steering General Diagnosis.
6A-1 Steering / Handlebar. 6B-1Body and Accessories. 9-i Precautions. 9-1 Wiring Systems. 9A-1 Lighting Systems.
9B-1 Combination Meter / Fuel Meter / Horn.9C-1 Exterior Parts.9D-1 Body Structure. 9E-1. GSX1300BK 0-01E. FOREWORDThis manual contains an introductory description on the SUZUKI GSX1300BK and procedures for its inspection/service and overhaul of its main components.Other information considered as generally known is not included.Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.
Usethis 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. 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 the actual motorcycle. Illustrations in this manual are used to show the basic principles of operation and work procedures.
They may not represent the actual motorcycle exactly in detail. This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.! WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. © COPYRIGHT SUZUKI MOTOR CORPORATION 2007.
00 TABLE OF CONTENTS 0Precautions. 00-i Precautions. 00-1 1General Information.
0-i General Information. 0A-1 Maintenance and Lubrication. 0B-1 Service Data.0C-1 2Engine. 1-i Precautions. 1-1 Engine General Information and Diagnosis.
1A-1 Emission Control Devices. 1B-1 3 Engine Electrical Devices.1C-1 Engine Mechanical.1D-1 Engine Lubrication System. 1E-1 Engine Cooling System. 1F-1 Fuel System.1G-1 4 Ignition System.1H-1 Starting System. 1I-1 Charging System.1J-1 Exhaust System. 1K-1 5Suspension. 2-i Precautions.
2-1 Suspension General Diagnosis. 2A-1 Front Suspension. 2B-1 Rear Suspension.2C-1 6 Wheels and Tires.2D-1Driveline / Axle. 3-i Precautions. 3-1 Drive Chain / Drive Train / Drive Shaft. 4-i Precautions. 4-1 Brake Control System and Diagnosis.
4A-1 Front Brakes. 4B-1 Rear Brakes.4C-1Transmission / Transaxle. 5-i Precautions. 5-1 Manual Transmission.
5B-1 9 Clutch.5C-1Steering. 6-i Precautions. 6-1 Steering General Diagnosis. 6A-1 Steering / Handlebar.
6B-1Body and Accessories. 9-i Precautions. 9-1 Wiring Systems. 9A-1 Lighting Systems. 9B-1 Combination Meter / Fuel Meter / Horn.9C-1 Exterior Parts.9D-1 Body Structure. 9E-1.
Table of Contents 00- i Section 00 00 Precautions CONTENTSPrecautions.00-1 General Precautions. 00-1 Precautions. 00-1 Precautions for Electrical Circuit Service.
00-2 Warning / Caution / Note. 00-1.
00-1 Precautions:PrecautionsPrecautions PrecautionsWarning / Caution / Note. To avoid getting burned, do not touch the B81 engine, engine oil, radiator and exhaustPlease read this manual and follow its instructions system until they have cooled.carefully.
To emphasize special information, the symboland the words WARNING, CAUTION and NOTE have. After servicing the fuel, oil, water, exhaustspecial meanings.
Pay special attention to the messages or brake systems, check all lines andhighlighted by these signal words. Fittings related to the system for leaks.! CAUTION Indicates a potential hazard that could result. If parts replacement is necessary, replace in death or injury. The parts with Suzuki Genuine Parts or their equivalent.! CAUTION.
When removing parts that are to be reused, Indicates a potential hazard that could result keep them arranged in an orderly manner in motorcycle damage. So that they may be reinstalled in the proper order and orientation.
NOTE. Be sure to use special tools when instructed.
Indicates special information to make maintenance easier or instructions clearer. Make sure that all parts used in reassembly are clean. Lubricate themPlease note, however, that the warnings and cautions when specified.contained in this manual cannot possibly cover all.
Use the specified lubricant, bond orpotential hazards relating to the servicing, or lack of sealant.servicing, of the motorcycle. In addition to the. When removing the battery, disconnect theWARNINGS and CAUTIONS stated, you must use good negative (–) cable first and then thejudgement and basic mechanical safety principles. If you positive (+) cable.are unsure about how to perform a particular service. When reconnecting the battery, connectoperation, ask a more experienced mechanic for advice. The positive (+) cable first and then the negative (–) cable, and replace the terminalGeneral Precautions cover on the positive (+) terminal.
WARNING. When performing service to electrical parts, if the service procedures do not.
Proper service and repair procedures are require use of battery power, disconnect important for the safety of the service the negative (–) cable the battery. Mechanic and the safety and reliability of. When tightening the cylinder head or case the motorcycle. Bolts and nuts, tighten the larger sizes. When 2 or more persons work together, first. Always tighten the bolts and nuts pay attention to the safety of each other.
Diagonally from the inside toward outside. When it is necessary to run the engine and to the specified tightening torque. Indoors, make sure that exhaust gas is. Whenever you remove oil seals, gaskets, forced outdoors.
Packing, O-rings, locking washers, self-. When working with toxic or flammable locking nuts, cotter pins, circlips and materials, make sure that the area you certain other parts as specified, be sure to work in is well ventilated and that you replace them with new ones. Also, before follow all of the material manufacturer’s installing these new parts, be sure to instructions. Remove any left over material from the mating surfaces. Never use gasoline as a cleaning solvent.
Precautions: 00-2. Never reuse a circlip.
When installing a. Before refitting the sealed coupler, make sure its seal new circlip, take care not to expand the rubber is positioned properly. The seal rubber may end gap larger than required to slip the possibly come off the position during disconnecting circlip over the shaft. After installing a work and if the coupler is refitted with the seal rubber circlip, always ensure that it is completely improperly positioned, it may result in poor water seated in its groove and securely fitted. Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.
After reassembling, check parts for tightness and proper operation. To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids: batteries, and tires. To protect Earth’s natural resources, properly dispose of used motorcycle and I3-01 parts. Inspect each lead wire circuit for poor connection by shaking it by hand lightly.
If any abnormal condition is found, repair or replace.Precautions for Electrical Circuit Service B83When handling the electrical parts or servicing the FI andABS systems, observe the following points for the safetyof the systems.Electrical PartsConnector / Coupler. When connecting a connector, be sure to push it in until a click is felt. I3-02.
When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (rear) of the connector/coupler. 2 I8-01. With a lock type coupler, be sure to release the lock when disconnecting, and push it in fully to engage the lock when connecting. When disconnecting the coupler, be sure to hold the 1 coupler body and do not pull the lead wires.
Inspect each terminal on the connector/coupler for I6-02 looseness or bending. Probe. Push in the coupler straightly. An angled or skewed insertion may cause the terminal to be deformed,. When connecting meter probe from the terminal side possibly resulting in poor electrical contact. Of the coupler (where connection from harness side.
Inspect each terminal for corrosion and not being possible), use extra care not to force and contamination. The terminals must be clean and free cause the male terminal to bend or the female of any foreign material which could impede proper terminal to open. Connect the probe as shown to terminal contact. Avoid opening of female terminal. Never push in the probe where male terminal is supposed to fit.
00-3 Precautions:. Check the male connector for bend and female Switch connector for excessive opening. Also check the Never apply grease material to switch contact points to coupler for locking (looseness), corrosion, dust, etc. Prevent damage. ECM / Various sensors.
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Since each component is a high-precision part, great 4 care should be taken not to apply any severe impacts during removal and installation. “A” 3 4 I6-02 3. Probe “A”: Where male terminal fitsClamp.
Clamp the wire harness at such positions as indicated I3-01 in “Wiring Harness Routing Diagram in Section 9A. Be careful not to touch the electrical terminals of the (Page 9A-5)”. Electronic parts (ECM, etc.). The static electricity from.
Bend the clamp properly so that the wire harness is your body may damage them. Clamped securely.
In clamping the wire harness, use care not to allow it to hang down. Do not use wire or any other substitute for the band type clamp. CORRECT INCORRECT I3-01.
When disconnecting and connecting the coupler, make sure to turn OFF the ignition switch, or I7-02 electronic parts may get damaged.Fuse 1. When a fuse is blown, always investigate the cause to correct it and then replace the fuse. Do not use a fuse of different capacity. Do not use wire or any other substitute for the fuse.
Ignition switch I6-02. Precautions: 00-4Battery. Never connect any tester (voltmeter, ohmmeter, or. Battery connection in reverse polarity is strictly whatever) to the electronic unit when its coupler is prohibited. Such a wrong connection will damage the disconnected. Otherwise, damage to electronic unit components of the FI and ABS systems instantly may result.
When reverse power is applied. Never connect an ohmmeter to the electronic unit with its coupler connected. If attempted, damage to ECM or sensors may result. Be sure to use a specified voltmeter/ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.
Electrical Circuit Inspection Procedure While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. I7-01 Open circuit check. Removing any battery terminal of a running engine is Possible causes for the open circuit are as follows. As strictly prohibited.
The moment such removal is made, the cause can exist in the connector/coupler or terminal, damaging counter electromotive force will be applied they need to be checked carefully. To the electronic unit which may result in serious. Loose connection of connector/coupler damage.
Poor contact of terminal (due to dirt, corrosion or rust, poor contact tension, entry of foreign object etc.). Wire harness being open. Poor terminal-to-wire connection. When checking system circuits including an electronic control unit such as ECM, ABS control unit/HU, etc., it is important to perform careful check, starting with items which are easier to check.
1) Disconnect the negative (–) cable from the battery. 2) Check each connector/coupler at both ends of the circuit being checked for loose connection. Also I3-01 check for condition of the coupler lock if equipped. Before measuring voltage at each terminal, check to make sure that battery voltage is 11 V or higher. Terminal voltage check with a low battery voltage will “A” lead to erroneous diagnosis. “A” 1 ECM I7-02 1. Sensor “A”: Check for loose connection I3-02.
00-5 Precautions: 3) Using a test male terminal, check the female Continuity check terminals of the circuit being checked for contact 1) Measure resistance across coupler “B” (between “A” tension. And “C” in figure). Check each terminal visually for poor contact If no continuity is indicated (infinity or over limit), the (possibly caused by dirt, corrosion, rust, entry of circuit is open between terminals “A” and “C”. Foreign object, etc.). At the same time, check to make sure that each terminal is fully inserted in the “A” coupler and locked. If contact tension is not enough, rectify the contact to increase tension or replace. The terminals must be “B” ECM clean and free of any foreign material which could impede proper terminal contact.
“C” “B” I7-02 2) Disconnect the coupler “B” and measure resistance between couplers “A” and “B-1”. “C” If no continuity is indicated, the circuit is open between couplers “A” and “B-1”. If continuity is I6-02 indicated, there is an open circuit between couplers “B”: Check contact tension by inserting and removing. “B-2” and “C” or an abnormality in coupler “B-2” or “C”: Check each terminal for bend and proper alignment. 4) Using continuity inspect or voltage check procedure “A” as described below, inspect the wire harness terminals for open circuit and poor connection. “B-2” Locate abnormality, if any.
ECM “B” “C” “B-1” “D” “F” “E” I7-02 I6-02 Voltage check ”D”: Looseness of crimping If voltage is supplied to the circuit being checked, voltage “E”: Open “F”: Thin wire (A few strands left) check can be used as circuit check. 1) With all connectors/couplers connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. 2) If measurements were taken as shown in the figure and results were listed in the following, it means that the circuit is open between terminals “A” and “B”. Voltage between “A” and body ground: Approx. 5 V “B” and body ground: Approx. 5 V “C” and body ground: 0 V. Precautions: 00-63) Also, if measured values are as listed following, a Short circuit check (Wire harness to ground) resistance (abnormality) exists which causes the 1) Disconnect the negative (–) cable from the battery.
Suzuki B-king Repair Manual
Voltage drop in the circuit between terminals “A” and 2) Disconnect the connectors/couplers at both ends of “B”. The circuit to be checked. Voltage between “A” and body ground: Approx. 5 V NOTE “B” and body ground: Approx.
5 V – 2 V voltage If the circuit to be checked branches to other drop parts as shown, disconnect all connectors/ “C” and body ground: 3 V – 2 V voltage drop couplers of those parts. Otherwise, diagnosis will be wrong. “A” 3) Measure resistance between terminal at one end of circuit (“A” terminal in figure) and body ground. If continuity is indicated, there is a short circuit to ground between terminals “A” and “C”. ECM “A” “B” “C” “D” “B” ECM “C” “E” 5V 5V 5V 0V 5V “A” “B” “C” “A” “C” I7-01 I7-01 “D”: To other parts “E”: Other parts. 00-7 Precautions: 4) Disconnect the connector/coupler included in circuit Using the testers (coupler “B”) and measure resistance between. Incorrectly connecting the (+) and (–) probes may terminal “A” and body ground.
If continuity is cause the inside of the tester to be burned. Indicated, the circuit is shorted to the ground. If the voltage and current are not known, make between terminals “A” and “B”.
Suzuki B King Custom
Measurements using the highest range. When measuring the resistance with the multi-circuit “A” tester (1), will be shown as 10.00 M and “1” “D” flashes in the display. Check that no voltage is applied before making the ECM measurement.
If voltage is applied the tester may be damaged. “B”. After using the tester, turn the power off. “C” Special tool: 8 (Multi-circuit tester set) I7-02 “D”: To other partsUsing The Multi-Circuit Testers. Use the Suzuki multi-circuit tester set. Use well-charged batteries in the tester. Be sure to set the tester to the correct testing range.
Special tool (A): 8 (Multi-circuit tester set) I6-02 (A) NOTE. When connecting the multi-circuit tester, use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them.
Use the needle pointed probe to prevent I6-03 the rubber of the water proof coupler from damage. When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend.
Special tool (A): 9 (Needle pointed probe set) (A) I6-03. Table of Contents 0- i Section 0 General Information 0 CONTENTSGeneral Information. 0A-1 Spark Plug Replacement.0B-9 General Description.0A-1 Spark Plug Inspection and Cleaning.0B-9 Symbols.
Suzuki B King Review
0A-1 Fuel Line Inspection.0B-10 Abbreviations. 0A-1 Engine Oil and Filter Replacement.0B-10 Vehicle Side View. 0A-2 Throttle Cable Play Inspection and Vehicle Identification Number. 0A-3 Adjustment.0B-12 Fuel and Oil Recommendation.
0A-3 Throttle Valve Synchronization.0B-12 Engine Coolant Recommendation. 0A-4 Evaporative Emission Control System BREAK-IN Procedures. 0A-4 Inspection (E-33 only).0B-13 Cylinder Identification. 0A-4 PAIR System Inspection.0B-13 Country and Area Codes. 0A-5 Cooling System Inspection.0B-13 Wire Color Symbols. 0A-5 Clutch System Inspection.0B-14 Warning, Caution and Information Labels Clutch Hose Replacement.0B-15 Location.
0A-6 Clutch Fluid Replacement.0B-15 Drive Chain Inspection and Adjustment.0B-15 Component Location.0A-7 Drive Chain Cleaning and Lubricating.0B-17 Electrical Components Location. 0A-7 Brake System Inspection.0B-17 Specifications.0A-9 Tire Inspection.0B-19 Specifications.
0A-9 Steering System Inspection.0B-20 Special Tools and Equipment.0A-11 Front Fork Inspection.0B-20 Special Tool. 0A-11 Rear Suspension Inspection.0B-20 Chassis Bolt and Nut Inspection.0B-21Maintenance and Lubrication. 0B-1 Compression Pressure Check.0B-22 Precautions.0B-1 Oil Pressure Check.0B-22 Precautions for Maintenance. 0B-1 SDS check.0B-22 General Description.0B-1 Specifications.0B-23 Recommended Fluids and Lubricants. 0B-1 Tightening Torque Specifications.0B-23 Scheduled Maintenance.0B-1 Special Tools and Equipment.0B-23 Periodic Maintenance Schedule Chart. 0B-1 Recommended Service Material.0B-23 Lubrication Points. 0B-2 Special Tool.0B-23 Repair Instructions.0B-3 Air Cleaner Element Replacement.
0B-3 Service Data. 0C-1 Air Cleaner Element Inspection. 0B-3 Specifications.0C-1 Exhaust Pipe Bolt and Muffler Bolt Inspection. 0B-3 Service Data.0C-1 Exhaust Control Valve Inspection. 0B-4 Tightening Torque List.0C-9 Valve Clearance Inspection and Adjustment. 0B-4.
0A-1 General Information:General InformationGeneral Information General DescriptionSymbols B81Listed in the table below are the symbols indicating instructions and other information necessary for servicing.The meaning of each symbol is also included in the table. Symbol Definition Torque control required. Data beside it indicate specified torque. Use engine oil unless otherwise specified.
Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1). Apply SUZUKI SUPER GREASE “A” or equivalent.
0 Apply SUZUKI MOLY PASTE or equivalent. 0 Apply SUZUKI SILICONE GREASE or equivalent. 0 Apply SUZUKI BOND “1207B” or equivalent. 0 Apply THREAD LOCK SUPER “1303” or equivalent. 0 Apply THREAD LOCK SUPER “1322” or equivalent. 0 Apply THREAD LOCK SUPER “1360” or equivalent.
0 Use engine coolant or equivalent. 2-11X Use fork oil or equivalent. 4-L01 Apply MUFFLER SEAL LOCTITE “5920” (commercially available) or equivalent. Apply or use brake fluid. Use special tool.
Do not reuse.