Suzuki GSF1200SK2 2002 Service Repair Manual

Name: Suzuki GSF1200SK2 2002 Service Repair Manual
Brand: Suzuki
SKU: 89186
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Taper: Motorcycle

Distributeur:

Suzuki

UGS: 89186

Mots clés: 2002 GSF1200SK2 Misc Motorcycle Motorcycles Suzuki

Variantes de produits

Description

This document provides comprehensive service and repair information for the 2002 Suzuki GSF1200SK2. Known for its powerful inline-four engine derived from the GSX-R lineage, the GSF1200SK2 was a versatile naked sport-touring motorcycle appreciated for its substantial torque, comfortable riding posture, and overall reliability. It offered a compelling blend of performance and practicality, competing effectively in its segment. The engineering quality of the Suzuki Bandit series is well-regarded, making it a popular choice for riders seeking a robust and capable machine for various riding applications, from daily commuting to longer journeys. This Factory Service Manual (FSM) covers all essential aspects of the Suzuki GSF1200SK2, offering detailed guidance for maintenance, repair, and troubleshooting. Within its extensive pages, you will find complete coverage of the engine, transmission, electrical system, chassis, braking system, and fuel system, including detailed procedures, diagnostic steps, and technical specifications. The manual is designed to assist owners, mechanics, and technicians in performing routine maintenance, complex repairs, and in-depth diagnostics, ensuring the continued optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSF1200SK2

Year:

2002

Product Type:

Service Repair Manual

Product Format:

PDF Download

👋 Introduction

Market Position

Positioning:

The Suzuki GSF1200SK2 (Bandit) was positioned as a large-displacement, naked sport-touring motorcycle, known for its strong torque, comfortable riding position, and versatility for both commuting and longer journeys. It appealed to riders seeking power without the full fairing of dedicated sportbikes or the touring-specific features of dedicated tourers.

Competitive Analysis

Competitors:

Competed with motorcycles like the Yamaha FZS1000 Fazer, Honda CB1000R (though later), Kawasaki ZRX1100/1200, and Triumph Speed Triple.

Key Features

Features:

Characterized by its torquey inline-four engine derived from the GSX-R lineage, robust chassis, upright riding posture, and a blend of performance and practicality.

📋 Manual Details

Coverage Areas

Engine Repair:

Complete

Transmission Repair:

Complete

Electrical System:

Complete

Chassis Suspension:

Complete

Braking System:

Complete

Fuel System:

Complete

Cooling System:

Complete

Exhaust System:

Complete

Bodywork And Fairings:

Complete

Troubleshooting:

Comprehensive

Maintenance Schedules:

Detailed

Page Count

Estimated Pages:

500+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full overhaul procedures, component inspection, torque specifications, valve clearance adjustment.

Engine Management:

Ignition system, fuel injection system (EFI), sensor diagnostics, ECU operations.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly and reassembly, chain and sprocket maintenance.

Suspension And Steering:

Front fork (telescopic, cartridge type) disassembly, fork oil changes, rear shock absorber adjustments, steering head bearing service.

Braking System:

Front and rear disc brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures.

Electrical System:

Wiring diagrams, battery service, charging system (stator, regulator/rectifier), starter motor, lighting circuits, ignition coil testing.

Fuel And Emission Controls:

Fuel pump, fuel filter replacement, evaporative emission control system (EVAP).

Cooling System:

Radiator, coolant, thermostat, fan operation.

Wheels And Tires:

Tire pressure, wear inspection, wheel bearing maintenance.

Body And Frame:

Fairing removal and installation, seat maintenance, fuel tank service.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication, brake pad inspection.

Diagnostic Troubleshooting:

Step-by-step guides for identifying and resolving common and uncommon issues.

Component Rebuilds:

Detailed instructions for overhauling engine components, carburetors (if applicable to specific sub-models or variations, though GSF1200SK2 is EFI), and transmission elements.

Electrical Testing:

Methods for testing circuits, components, and sensors using multimeters.

Special Tool Usage:

Identification and application of Suzuki-specific tools required for certain procedures.

Technical Depth

Depth Level:

Comprehensive, from basic owner maintenance to advanced engine and electrical diagnostics and repair.

Detail Level:

Highly detailed, including exploded diagrams, torque values, specifications, and step-by-step instructions.

📊 Manual Specifications

File Format

Format Details:

Searchable PDF, allowing for quick navigation and keyword searches.

Print Quality

Quality:

High-resolution scans of original factory documentation, ensuring clear text and diagrams.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air/Oil-cooled, 4-stroke, DOHC, inline-four

Displacement:

1157 cc

Bore X Stroke:

79.0 mm x 58.4 mm

Compression Ratio:

9.1:1

Performance

Horsepower Estimated:

98-100 hp @ 8000 rpm (crank)

Torque Estimated:

100-103 Nm @ 6500 rpm (crank)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Suzuki's digital fuel injection system

Throttle Body Size:

36 mm

Engine Components

Valve Train:

DOHC, 4 valves per cylinder

Lubrication

Oil Type:

API SG, SF or higher, SAE 10W-40 recommended

Oil Capacity W Filter:

Approximately 4.0 Liters

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Final Drive:

Sealed O-ring chain

Features

Clutch Type:

Wet, multi-plate

Fluid Spec

Transmission Oil Type:

API GL-1, SAE 80W-90 hypoid gear oil

Fluid Capacity

Transmission Oil Capacity:

Approximately 2.8 Liters

📐 Dimensions

Exterior

Length:

2,130 mm (83.9 in)

Width:

775 mm (30.5 in)

Height:

1,065 mm (41.9 in)

Wheelbase:

1,485 mm (58.5 in)

Ground Clearance:

135 mm (5.3 in)

Weights

Dry Weight:

Approximately 212 kg (467 lbs)

Curb Weight:

Approximately 230 kg (507 lbs)

Fluids

Fuel Tank Capacity:

20.0 Liters (5.3 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

CE (for European markets), DOT (for US markets applicable regulations)

Active Features

Braking System:

Dual front disc brakes (310 mm), single rear disc brake (240 mm). ABS was not standard or commonly available on this model.

Passive Features

Frame Construction:

Steel diamond frame for rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment System:

Basic analog instrumentation (speedometer, tachometer, fuel gauge, temperature gauge). No integrated infotainment or digital displays common in modern motorcycles.

Driver Assistance

Assistance Features:

None (ABS was not standard, no traction control or rider modes).

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or 6 months.

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or 12 months.

Valve Clearance Check:

Every 12,000 km (7,500 miles) or 12 months.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km (600 miles).

Fluid Specifications

Brake Fluid:

DOT 4

Coolant:

Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with demineralized water, 50:50 mix)

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, fork seals due to high mileage and torque.

Efi System:

While generally robust, occasional issues with fuel pump, injectors, or sensors might arise with age and mileage. The manual provides diagnostic steps.

Part Numbers

Oil Filter Example:

Suzuki P/N 16510-07H00 (or equivalent aftermarket such as HF138)

Air Filter Example:

Suzuki P/N 13780-33E10

📚 Vehicle History

Brand Heritage

Heritage:

Suzuki has a long history of producing powerful and reliable motorcycles, particularly in the sportbike and sport-touring segments, with a lineage tracing back to early GS series bikes.

Model Evolution

Bandit Lineage:

The GSF1200 Bandit series evolved from the earlier GSF1200S (faired) and GSF1200 (naked) models, utilizing a detuned but potent GSX-R engine for accessible torque and horsepower. The 'SK2' designation typically denotes a specific model year or configuration within the Bandit line.

Production

Production Era:

The GSF1200 Bandit was produced from the late 1990s through the mid-2000s, with the 2002 model year being part of this successful generation.

🏆 Awards & Recognition

Recognitions

Motorcycle Press:

The Bandit series consistently received positive reviews from motorcycle publications for its performance, value, and reliability, often praised for its 'muscle bike' character.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to robust mechanicals and strong performance, though some riders noted suspension could be improved for aggressive riding.