TOP

DIC216
GSF1200/S
GSF1200/S

Printed in Japan 99500-39135-03E

T V W X Y K4

BOTTOM
No.5232 GSF1200/S 99500-39135-03E Cover14 for DOCCU (12mm) 2004.7.24 DIC216
DIC216
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GSF1200/SK4 (’04-MODEL)

This chapter describes specifications, service data and servicing procedures which differ from
those of the GSF1200SAW/SAX (’98/’99-MODEL).

NOTE:
Please refer to the chapters 1 through 11 for details which are not given in this chapter.

CONTENTS
SPECIFICATIONS ..........................................................................................12- 2
SERVICE DATA (GSF1200S) ........................................................................12- 3
SERVICE DATA (GSF1200)...........................................................................12-12
PERIODIC MAINTENANCE CHART..............................................................12-21
EXHAUST PIPE/MUFFLER INSTALLATION ................................................12-22
WIRE HARNESS ROUTING...........................................................................12-23
WIRING DIAGRAM (GSF1200S) For E-03, 24, 28, 33 ..................................12-24 6
WIRING DIAGRAM (GSF1200) For E-03 ......................................................12-25

12
12-2 GSF1200/SK4 (’04-MODEL)

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................................................... 2 070 mm (81.5 in)...............GSF1200S
2 140 mm (84.3 in)............... GSF1200
Overall width ....................................................................................... 765 mm (30.1 in)
Overall height ...................................................................................... 1 220 mm (48.0 in)...............GSF1200S
1 100 mm (43.3 in)............... GSF1200
Wheelbase .......................................................................................... 1 430 mm (56.3 in)
Ground clearance ............................................................................... 130 mm (5.1 in)
Seat height .......................................................................................... 790 mm (31.1 in)
Dry mass .............................................................................................* 221 kg (487 lbs) ............... GSF1200S
* 215 kg (473 lbs) ............... GSF1200
ENGINE
Type .................................................................................................... 4-stroke, air-cooled, DOHC
Number of cylinders ............................................................................ 4
Bore .................................................................................................... 79.0 mm (3.110 in)
Stroke.................................................................................................. 59.0 mm (2.323 in)
Displacement ...................................................................................... 1 157 cm3 (70.6 cu. in)
Compression ratio ............................................................................... 9.5 : 1
Carburetor ........................................................................................... MIKUNI BSR36
Air cleaner ........................................................................................... Non-woven fabric element
Starter system ..................................................................................... Electric
Lubrication system .............................................................................. Wet sump
Idle speed ........................................................................................... 1 300 ± 100 r/min.................E-03, 28, 33
1 200 ± 100 r/min................. Others
DRIVE TRAIN
Clutch .................................................................................................. Wet multi-plate type
Transmission....................................................................................... 5-speed constant mesh
Gearshift pattern ................................................................................. 1-down, 4-up
Primary reduction ratio ........................................................................ 1.565 (72/46)
Gear ratios, Low ................................................................................. 2.384 (31/13)
2nd.................................................................................. 1.631 (31/19)
3rd .................................................................................. 1.250 (25/20)
4th................................................................................... 1.045 (23/22)
Top ................................................................................. 0.913 (21/23)
Final reduction ratio ............................................................................ 3.000 (45/15)
Drive chain .......................................................................................... RK GB50GSVZ3, 110 links
CHASSIS
Front suspension ................................................................................ Telescopic, coil spring, oil damped
Rear suspension ................................................................................. Link type, coil spring, oil damped
Front fork stroke .................................................................................. 130 mm (5.1 in)
Rear wheel travel ................................................................................ 125 mm (4.9 in)
Steering angle ..................................................................................... 35° (right & left)
Caster ................................................................................................. 25° 20’
Trail ..................................................................................................... 104 mm (4.10 in)
Turning radius ..................................................................................... 2.8 m (9.2 ft)
Front brake.......................................................................................... Disc brake, twin
Rear brake .......................................................................................... Disc brake
Front tire size ...................................................................................... 120/70ZR17M/C (58W), tubeless
Rear tire size....................................................................................... 180/55ZR17M/C (73W), tubeless
ELECTRICAL
Ignition type......................................................................................... Electronic ignition (Transistorized)
Ignition timing ...................................................................................... 7° B.T.D.C. at 1 200 r/min
Spark plug ........................................................................................... NGK JR9B
Battery.................................................................................................
12 V 36 kC (10 Ah)/10 HR
Generator ............................................................................................ Three-phase A.C. generator
Main fuse ............................................................................................ 30 A
Fuse ....................................................................................................
10/10/10/15/10 A
Headlight .............................................................................................12 V 60 W (HB3) + 12 V 51 W (HB4) ..... GSF1200S
12 V 60/55 W (H4) ..................................GSF1200
Position light........................................................................................ 12 V 5 W ................................................. Except E-03, 24, 28, 33
Turn signal light................................................................................... 12 V 21 W × 4
Brake light/Taillight.............................................................................. 12 V 21/5 W × 2
License plate light ............................................................................... 12 V 5 W
Speedometer light ............................................................................... LED
Tachometer light ................................................................................. LED
Neutral indicator light .......................................................................... LED
High beam indicator light .................................................................... LED
Turn signal indicator light .................................................................... LED
Oil pressure indicator light .................................................................. LED
CAPACITIES
Fuel tank, including reserve ............................................................... 19.0 L (5.0/4.2 US/Imp gal) .................. E-33
20.0 L (5.3/4.4 US/Imp gal) .................. Others
Reserve ............................................................................. 4.4 L (1.2/1.0 US/Imp gal)
Engine oil, oil change .......................................................................... 3 300 ml (3.4/2.9 US/Imp qt)
with filter change ............................................................... 3 500 ml (3.6/3.0 US/Imp qt)
overhaul............................................................................. 4 600 ml (4.9/4.0 US/Imp qt)
 GSF1200/SK4 (’04-MODEL) 12-3

SERVICE DATA (GSF1200S)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diameter IN. 28.5 —
(1.12)
EX. 25 —
(1.0)
Valve clearance (when cold) IN. 0.10 – 0.15 —
(0.004 – 0.006)
EX. 0.18 – 0.23 —
(0.007 – 0.009)
Valve-guide to valve-stem IN. 0.020 – 0.047 —
clearance (0.0008 – 0.0019)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve guide I.D. IN. & EX. 5.000 – 5.012 —
(0.1969 – 0.1973)
Valve stem O.D. IN. 4.965 – 4.980 —
(0.1955 – 0.1961)
EX. 4.945 – 4.960 —
(0.1947 – 0.1953)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve face thickness IN. & EX. — 0.5
(0.02)
Valve stem end length IN. & EX. — 2.5
(0.10)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length INNER — 35.0
(IN. & EX.) (1.38)
OUTER — 37.8
(1.49)
Valve spring tension 53 – 65 N
(IN. & EX.) INNER (5.3 – 6.5 kgf, 11.7 – 14.3 lbs) —
at length 28 mm (1.10 in)
131 – 151 N
OUTER (13.1 – 15.1 kgf, 28.9 – 33.3) —
at length 31.5 mm (1.24 in)
12-4 GSF1200/SK4 (’04-MODEL)

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 33.58 – 33.62 33.28
(1.3220 – 1.3236) (1.3102)
EX. 32.65 – 32.69 32.35
(1.2854 – 1.2870) (1.2736)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —
(0.8645 – 0.8654)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 24th pin —
Rocker arm I.D. IN. & EX. 12.000 – 12.018 —
(0.4724 – 0.4731)
Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —
(0.4714 – 0.4718)
Cylinder head distortion — 0.20
(0.008)

CYLINDER + PISTON + PISTON RING Unit: mm(in)

ITEM STANDARD LIMIT
Compression pressure 1 250 kPa 875 kPa
(12.5 kgf/cm2, 178 psi) (8.75 kgf/cm2, 124 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm2, 28 psi)
Piston-to-cylinder clearance 0.040 – 0.070 0.120
(0.0016 – 0.0028) (0.0047)
Cylinder bore 79.000 – 79.015 79.080
(3.1102 – 3.1108) (3.1134)
Piston diameter 78.945 – 78.960 78.880
(3.1081 – 3.1087) (3.1055)
Measure 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.20
(0.008)
Piston ring free end gap 1st R Approx. 10 (0.39) 8.0
(0.31)
2nd RN Approx. 12 (0.47) 9.6
(0.38)
Piston ring end gap 1st 0.20 – 0.35 0.5
(0.008 – 0.014) (0.02)
2nd 0.35 – 0.50 1.0
(0.014 – 0.020) (0.04)
 GSF1200/SK4 (’04-MODEL) 12-5

ITEM STANDARD LIMIT

Piston-ring to piston-ring-groove 1st — 0.180
clearance (0.007)
2nd — 0.150
(0.006)
Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
Piston ring thickness 1st 0.975 – 0.990 —
(0.0384 – 0.0390)
2nd 0.970 – 0.990 —
(0.038 – 0.039)
Piston pin bore 20.002 – 20.008 20.030
(0.7875 – 0.7877) (0.7886)
Piston pin O.D. 19.996 – 20.000 19.980
(0.7872 – 0.7874) (0.7866)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018 20.040
(0.7878 – 0.7881) (0.7890)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.01)
Conrod big end width 20.95 – 21.00 —
(0.825 – 0.827)
Crank pin width 21.10 – 21.15 —
(0.831 – 0.833)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000 —
(1.4951 – 1.4961)
Crankshaft journal oil clearance 0.020 – 0.044 0.080
(0.0008 – 0.0017) (0.0031)
Crankshaft journal O.D. 35.976 – 36.000 —
(1.4164 – 1.4173)
Crankshaft thrust clearance 0.04 – 0.08 —
(0.0016 – 0.0031)
Crankshaft thrust bearing Left side 2.360 – 2.520 —
thickness (0.0929 – 0.0992)
Right side 2.420 – 2.440 —
(0.0953 – 0.0961)
Crankshaft runout — 0.05
(0.002)
12-6 GSF1200/SK4 (’04-MODEL)

OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1.703 (72/46 × 37/34) —
Oil pressure (at 60 °C,140 °F) Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Clutch drive plate claw width — 13.0
(0.51)
Clutch driven plate distortion — 0.10
(0.004)
Clutch spring free height — 3.1
(0.12)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5511 – 0.5529)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5506)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 1.565 (72/46) —
Final reduction ratio 3.000 (45/15) —
Gear ratios 1st (low) 2.384 (31/13) —
2nd 1.631 (31/19) —
3rd 1.250 (25/20) —
4th 1.045 (23/22) —
5th (top) 0.913 (21/23) —
Gearshift-fork to gearshift-fork- No.1, No.2 0.1 – 0.3 0.50
groove clearance & No.3 (0.004 – 0.012) (0.020)
Gearshift fork groove width No.1, No.2 5.0 – 5.1 —
 & No.3 (0.197 – 0.201)
Gearshift fork thickness No.1, No.2 4.8 – 4.9 —
& No.3 (0.189 – 0.193)
Drive chain Type RK GB50GSVZ3 —
Links 110 links —
20-pitch length — 319.4
(12.57)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 55 —
(2.2)
 GSF1200/SK4 (’04-MODEL) 12-7

CARBURETOR
SPECIFICATION
ITEM
E-02, 19, 24 E-03, 28
Carburetor type MIKUNI BSR36SS ←
Bore size 36 mm ←
I.D. No. 32F0 32F1
Idle r/min 1 200 ± 100 r/min 1 300 ± 100 r/min
Float height 13.0 ± 1.0 mm ←
(0.51 ± 0.04 in)
Main jet (M.J.) # ←
Jet needle (J.N.) 5C70-3rd 5C71-1st
Needle jet (N.J.) ←
Throttle valve (Th. V.) #100 ←
Pilot jet (P.J.) # ←
Pilot screw (P.S.) 3 turns back PRE-SET
Throttle cable play 2.0 – 4.0 mm ←
(pulling cable) (0.08 – 0.16 in)
Starter (enricher) plunger cable 0.5 – 1.0 mm ←
play (0.02 – 0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-33
Carburetor type MIKUNI BSR36SS
Bore size 36 mm
I.D. No. 32F2
Idle r/min 1 300 ± 100 r/min
Float height 13.0 ± 1.0 mm
(0.51 ± 0.04 in)
Main jet (M.J.) #
Jet needle (J.N.) 5C71-1st
Needle jet (N.J.)
Throttle valve (Th. V.) # 100
Pilot jet (P.J.) #
Pilot screw (P.S.) PRE-SET
Throttle cable play 2.0 – 4.0 mm
(pulling cable) (0.08 – 0.16 in)
Starter (enricher) plunger cable 0.5 – 1.0 mm
play (0.02 – 0.04 in)
12-8 GSF1200/SK4 (’04-MODEL)

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 7° B.T.D.C. at 1 200 r/min
Firing order 1·2·4·3
Spark plug Type NGK: JR9B
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Pickup coil resistance Approx. 130 – 200 Ω Tester range:
(× 100 Ω)
Signal generator peak voltage More than 1.0 V
Ignition coil resistance Primary + tap – - tap Tester range:
Approx. 2 – 4 Ω (× 1 Ω)
Secondary Spark plug cap – Spark plug cap Tester range:
Approx. 30 – 40 kΩ (× 1 kΩ)
Ignition coil primary peak More than 140 V
voltage
Generator Slip ring O.D. Limit: 14.0 (0.55)
DENSO
Brush length Limit: 4.5 (0.18)
Generator maximum output More than 550 W at 5 000 r/min
Regulated voltage 13.5 – 15 V at 5 000 r/min
Starter relay resistance 3–5Ω
Battery Type designation YTX12-BS
Capacity 12V 36.0 kC (10 Ah)/10HR
Standard 1.320 at 20 °C (68 °F)
electrolyte S.G.
Fuse size HI 10 A
Headlight
LO 10 A
Turn signal 15 A
Ignition 10 A
Meter 10 A
Main 30 A
 GSF1200/SK4 (’04-MODEL) 12-9

WATTAGE Unit: W
SPECIFICATION
ITEM
E-03, 24, 28, 33 The other countries
Headlight HI 60 + 51 ←
LO 51 ←
Parking or position light 5
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
Speedometer light LED ←
Tachometer light LED ←
Turn signal indicator light LED × 2 ←
High beam indicator light LED ←
Neutral position indicator light LED ←
Oil pressure indicator light LED ←
License plate light 5 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 55 —
(2.2)
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6264)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Leading 24.000 – 24.076 —
(0.9449 – 0.9479)
Front
Trailing 27.000 – 27.076 —
(1.0630 – 1.0660)
Rear 38.180 – 38.256 —
(1.5031 – 1.5061)
Brake caliper piston diameter Leading 23.925 – 23.975 —
(0.9419 – 0.9439)
Front
Trailing 26.920 – 26.970 —
(1.0598 – 1.0618)
Rear 38.098 – 38.148 —
(1.4999 – 1.5019)
12-10 GSF1200/SK4 (’04-MODEL)

ITEM STANDARD LIMIT

Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 17 M/C × MT3.50 —
Rear 17 M/C × MT5.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 130 —
(5.1)
Front fork spring free length — 366 E-03, 28, 33
(14.4)
— 370 The other
(14.6) countries
Front fork oil level 107 — E-03, 28, 33
(4.2)
105 — The other
(4.1) countries
Rear wheel travel 125 —
(4.9)
Swingarm pivot shaft runout — 0.3
(0.01)

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 250 kPa —
(Solo/Dual riding) (2.50 kgf/cm2, 36 psi)
Rear 250 kPa —
(2.50 kgf/cm2, 36 psi)
Tire size Front 120/70ZR17M/C (58W) —
Rear 180/55ZR17M/C (73W) —
Tire type Front MICHELIN MACADAM 100X B —
Rear MICHELIN MACADAM 100X —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
 GSF1200/SK4 (’04-MODEL) 12-11

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane or 91 octane (R/2 + M/2) or higher rated by
the Research Method.
Gasoline containing MTBE (MethyI Tertiary ButyI E-03, 28, 33
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corro-
sion inhibitor is permissible.
Gasoline used should be graded 91 octane or The other
higher. An unleaded gasoline is recommended. countries
Fuel tank capacity 19 L E-33
Including (5.0/4.2 US/lmp gal)
reserve 20 L The other
(5.2/4.4 US/lmp gal) countries
Reserve 4.4 L
only (1.2/1.0 US/lmp gal)
Engine oil type SAE 10W-40, API SF or SG
Engine oil capacity Change 3 300 ml
(3.5/2.9 US/lmp qt)
Filter 3 500 ml
change (3.7/3.1 US/lmp qt)
Overhaul 4 600 ml
(4.9/4.0 US/lmp qt)
Front fork oil type Fork oil SS-08 or equivalent fork oil
Front fork oil capacity (each leg) 507 ml E-03, 28, 33
(17.1/17.9 US/lmp oz)
509 ml The other
(17.2/17.9 US/Imp oz) countries
Brake fluid type DOT 4
12-12 GSF1200/SK4 (’04-MODEL)

SERVICE DATA (GSF1200)

VALVE + GUIDE Unit: mm (in)
ITEM STANDARD LIMIT
Valve diameter IN. 28.5 —
(1.12)
EX. 25 —
(1.0)
Valve clearance (when cold) IN. 0.10 – 0.15 —
(0.004 – 0.006)
EX. 0.18 – 0.23 —
(0.007 – 0.009)
Valve-guide to valve-stem clear- IN. 0.020 – 0.047 —
ance (0.0008 – 0.0019)
EX. 0.030 – 0.057 —
(0.0012 – 0.0022)
Valve stem deflection IN. & EX. — 0.35
(0.014)
Valve guide I.D. IN. & EX. 5.000 – 5.012 —
(0.1969 – 0.1973)
Valve stem O.D. IN. 4.965 – 4.980 —
(0.1955 – 0.1961)
EX. 4.945 – 4.960 —
(0.1947 – 0.1953)
Valve stem runout IN. & EX. — 0.05
(0.002)
Valve face thickness IN. & EX. — 0.5
(0.02)
Valve stem end length IN. & EX. — 2.5
(0.10)
Valve seat width IN. & EX. 0.9 – 1.1 —
(0.035 – 0.043)
Valve head radial runout IN. & EX. — 0.03
(0.001)
Valve spring free length INNER — 35.0
(IN. & EX.) (1.38)
OUTER — 37.8
(1.49)
Valve spring tension 53 – 65 N
(IN. & EX.) INNER (5.3 – 6.5 kgf, 11.7 – 14.3 lbs) —
at length 28 mm (1.10 in)
131 – 151 N
OUTER (13.1 – 15.1 kgf, 28.9 – 33.3 lbs) —
at length 31.5 mm (1.24 in)
 GSF1200/SK4 (’04-MODEL) 12-13

CAMSHAFT + CYLINDER HEAD Unit: mm (in)

ITEM STANDARD LIMIT
Cam height IN. 33.58 – 33.62 33.28
(1.3220 – 1.3236) (1.3102)
EX. 32.65 – 32.69 32.35
(1.2854 – 1.2870) (1.2736)
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
(0.0013 – 0.0026) (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
(0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —
(0.8645 – 0.8654)
Camshaft runout IN. & EX. — 0.10
(0.004)
Cam chain pin (at arrow “3”) 24th pin —
Rocker arm I.D. IN. & EX. 12.000 – 12.018 —
(0.4724 – 0.4731)
Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —
(0.4714 – 0.4718)
Cylinder head distortion — 0.20
(0.008)

CYLINDER + PISTON + PISTON RING Unit: mm (in)

ITEM STANDARD LIMIT
Compression pressure 1 250 kPa 875 kPa
(12.5 kgf/cm2, 178 psi) (8.75 kgf/cm2, 124 psi)
Compression pressure difference — 200 kPa
(2 kgf/cm2, 28 psi)
Piston-to-cylinder clearance 0.040 – 0.070 0.120
(0.0016 – 0.0028) (0.0047)
Cylinder bore 79.000 – 79.015 79.080
(3.1102 – 3.1108) (3.1134)
Piston diameter 78.945 – 78.960 78.880
(3.1081 – 3.1087) (3.1055)
Measure 15 mm (0.6 in) from the skirt end.
Cylinder distortion — 0.20
(0.008)
Piston ring free end gap 1st R Approx. 10 (0.39) 8.0
(0.31)
2nd RN Approx. 12 (0.47) 9.6
(0.38)
Piston ring end gap 1st 0.20 – 0.35 0.5
(0.008 – 0.014) (0.02)
2nd 0.35 – 0.50 1.0
(0.014 – 0.020) (0.04)
Piston-ring to piston-ring-groove 1st — 0.180
clearance (0.007)
2nd — 0.150
(0.006)
12-14 GSF1200/SK4 (’04-MODEL)

ITEM STANDARD LIMIT

Piston ring groove width 1st 1.01 – 1.03 —
(0.040 – 0.041)
2nd 1.01 – 1.03 —
(0.040 – 0.041)
Oil 2.01 – 2.03 —
(0.079 – 0.080)
Piston ring thickness 1st 0.975 – 0.990 —
(0.0384 – 0.0390)
2nd 0.970 – 0.990 —
(0.038 – 0.039)
Piston pin bore 20.002 – 20.008 20.030
(0.7875 – 0.7877) (0.7886)
Piston pin O.D. 19.996 – 20.000 19.980
(0.7872 – 0.7874) (0.7866)

CONROD + CRANKSHAFT Unit: mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 20.010 – 20.018 20.040
(0.7878 – 0.7881) (0.7890)
Conrod big end side clearance 0.10 – 0.20 0.30
(0.004 – 0.008) (0.01)
Conrod big end width 20.95 – 21.00 —
(0.825 – 0.827)
Crank pin width 21.10 – 21.15 —
(0.831 – 0.833)
Conrod big end oil clearance 0.032 – 0.056 0.080
(0.0013 – 0.0022) (0.0031)
Crank pin O.D. 37.976 – 38.000 —
(1.4951 – 1.4961)
Crankshaft journal oil clearance 0.020 – 0.044 0.080
(0.0008 – 0.0017) (0.0031)
Crankshaft journal O.D. 35.976 – 36.000 —
(1.4164 – 1.4173)
Crankshaft thrust clearance 0.04 – 0.08 —
(0.0016 – 0.0031)
Crankshaft thrust bearing thickness Left side 2.360 – 2.520 —
(0.0929 – 0.0992)
Right side 2.420 – 2.440 —
(0.0953 – 0.0961)
Crankshaft runout — 0.05
(0.002)
 GSF1200/SK4 (’04-MODEL) 12-15

OIL PUMP
ITEM STANDARD LIMIT
Oil pump reduction ratio 1.703 (72/46 × 37/34) —
Oil pressure (at 60 °C,140 °F) Above 300 kPa (3.0 kgf/cm2, 43 psi)
Below 600 kPa (6.0 kgf/cm2, 85 psi) —
at 3 000 r/min

CLUTCH Unit: mm (in)

ITEM STANDARD LIMIT
Clutch drive plate thickness 2.92 – 3.08 2.62
(0.115 – 0.121) (0.103)
Clutch drive plate claw width — 13.0
(0.51)
Clutch driven plate distortion — 0.10
(0.004)
Clutch spring free height — 3.1
(0.12)
Clutch master cylinder bore 14.000 – 14.043 —
(0.5511 – 0.5529)
Clutch master cylinder piston diam. 13.957 – 13.984 —
(0.5495 – 0.5506)
Clutch release cylinder bore 35.700 – 35.762 —
(1.4055 – 1.4079)
Clutch release cylinder piston 35.650 – 35.675 —
diam. (1.4035 – 1.4045)

TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 1.565 (72/46) —
Final reduction ratio 3.000 (45/15) —
Gear ratios 1st (low) 2.384 (31/13) —
2nd 1.631 (31/19) —
3rd 1.250 (25/20) —
4th 1.045 (23/22) —
5th (top) 0.913 (21/23) —
Gearshift-fork to gearshift-fork- No.1, No.2 0.1 – 0.3 0.50
groove clearance & No.3 (0.004 – 0.012) (0.020)
Gearshift fork groove width No.1, No.2 5.0 – 5.1 —
& No.3 (0.197 – 0.201)
Gearshift fork thickness No.1, No.2 4.8 – 4.9 —
& No.3 (0.189 – 0.193)
Drive chain Type RK GB50GSVZ3 —
Links 110 links —
20-pitch — 319.4
length (12.57)
Drive chain slack 20 – 30 —
(0.8 – 1.2)
Gearshift lever height 55 —
(2.2)
12-16 GSF1200/SK4 (’04-MODEL)

CARBURETOR
SPECIFICATION
ITEM
E-02, 19
Carburetor type MIKUNI BSR36SS
Bore size 36 mm
I.D. No. 32F0
Idle r/min 1 200 ± 100 r/min
Float height 13.0 ± 1.0 mm
(0.51 ± 0.04 in)
Main jet (M.J.) #
Jet needle (J.N.) 5C70-3rd
Needle jet (N.J.)
Throttle valve (Th. V.) #100
Pilot jet (P.J.) #
Pilot screw (P.S.) 3 turns back
Throttle cable play 2.0 – 4.0 mm
(pulling cable) (0.08 – 0.16 in)
Starter (enricher) plunger cable 0.5 – 1.0 mm
play (0.02 – 0.04 in)

CARBURETOR
SPECIFICATION
ITEM
E-03
Carburetor type MIKUNI BSR36SS
Bore size 36 mm
I.D. No. 32F1
Idle r/min. 1 300 ± 100 r/min
Float height 13.0 ± 1.0 mm
(0.51 ± 0.04 in)
Main jet (M.J.) #
Jet needle (J.N.) 5C71
Needle jet (N.J.)
Throttle valve (Th. V.) #100
Pilot jet (P.J.) #
Pilot screw (P.S.) PRE-SET
Throttle cable play 2.0 – 4.0 mm
(pulling cable) (0.08 – 0.16 in)
Starter (enricher) plunger cable 0.5 – 1.0 mm
play (0.02 – 0.04 in)
 GSF1200/SK4 (’04-MODEL) 12-17

ELECTRICAL Unit: mm (in)

ITEM SPECIFICATION NOTE
Ignition timing 7° B.T.D.C. at 1 200 r/min
Firing order 1·2·4·3
Spark plug Type NGK: JR9B
Gap 0.6 – 0.7
(0.024 – 0.028)
Spark performance Over 8 (0.3) at 1 atm.
Pickup coil resistance Approx. 130 – 200 Ω Tester range:
(× 100 Ω)
Signal generator peak voltage More than 1.0 V
Ignition coil resistance Primary + tap – - tap Tester range:
Approx. 2 – 4 Ω (× 1 Ω)
Secondary Spark plug cap – Spark plug cap Tester range:
Approx. 30 – 40 kΩ (× 1 kΩ)
Ignition coil primary peak voltage More than 140 V
Generator Slip ring Limit: 14.0 (0.55)
O.D.
DENSO
Brush Limit: 4.5 (0.18)
length
Generator maximum output More than 550 W at 5 000 r/min
Regulated voltage 13.5 – 15 V at 5 000 r/min
Starter relay resistance 3–5Ω
Battery Type YTX12-BS
designation
Capacity 12V 36.0 kC (10 Ah)/10HR
Standard 1.320 at 20 °C (68 °F)
electrolyte S.G.
Fuse size HI 10 A
Headlight
LO 10 A
Turn signal 15 A
Ignition 10 A
Meter 10 A
Main 30 A
12-18 GSF1200/SK4 (’04-MODEL)

WATTAGE Unit: W
SPECIFICATION
ITEM
E-03 E-02, 19
Headlight HI 60 ←
LO 55 ←
Parking or position light 5
Brake light/Taillight 21/5 × 2 ←
Turn signal light 21 × 4 ←
Speedometer light LED ←
Tachometer light LED ←
Turn signal indicator light LED × 2 ←
High beam indicator light LED ←
Neutral position indicator light LED ←
Oil pressure indicator light LED ←
License plate light 5 ←

BRAKE + WHEEL Unit: mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 55 —
(2.2)
Brake disc thickness Front 4.5 ± 0.2 4.0
(0.177 ± 0.008) (0.16)
Rear 5.0 ± 0.2 4.5
(0.197 ± 0.008) (0.18)
Brake disc runout — 0.30
(0.012)
Master cylinder bore Front 15.870 – 15.913 —
(0.6248 – 0.6264)
Rear 12.700 – 12.743 —
(0.5000 – 0.5017)
Master cylinder piston diameter Front 15.827 – 15.854 —
(0.6231 – 0.6242)
Rear 12.657 – 12.684 —
(0.4983 – 0.4994)
Brake caliper cylinder bore Leading 24.000 – 24.076 —
(0.9449 – 0.9479)
Front
Trailing 27.000 – 27.076 —
(1.0630 – 1.0660)
Rear 38.180 – 38.256 —
(1.5031 – 1.5061)
Brake caliper piston diameter Leading 23.925 – 23.975 —
(0.9419 – 0.9439)
Front
Trailing 26.920 – 26.970 —
(1.0598 – 1.0618)
Rear 38.098 – 38.148 —
(1.4999 – 1.5019)
Wheel rim runout Axial — 2.0
(0.08)
Radial — 2.0
(0.08)
 GSF1200/SK4 (’04-MODEL) 12-19

ITEM STANDARD LIMIT

Wheel axle runout Front — 0.25
(0.010)
Rear — 0.25
(0.010)
Wheel rim size Front 17 M/C × MT3.50 —
Rear 17 M/C × MT5.50 —

SUSPENSION Unit: mm (in)

ITEM STANDARD LIMIT NOTE
Front fork stroke 130 —
(5.1)
Front fork spring free length — 366
(14.4)
Front fork oil level 107 —
(4.2)
Rear wheel travel 125 —
(4.9)
Swingarm pivot shaft runout — 0.3
(0.01)

TIRE
ITEM STANDARD LIMIT
Cold inflation tire pressure Front 250 kPa —
(Solo/Dual riding) (2.50 kgf/cm2, 36 psi)

Rear 250 kPa —

(2.50 kgf/cm2, 36 psi)
Tire size Front 120/70 ZR17 M/C (58W) —
Rear 180/55 ZR17 M/C (73W) —
Tire type Front MACADAM 90XM —
Rear MACADAM 90XM —
Tire tread depth Front — 1.6 mm
(Recommended depth) (0.06 in)
Rear — 2.0 mm
(0.08 in)
12-20 GSF1200/SK4 (’04-MODEL)

FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method. Gasoline containing MTBE
E-03
(MethyI Tertiary ButyI Ether), less than 10% etha-
nol, or less than 5% methanol with appropriate
cosolvents and corrosion inhibitor is permissible.
Gasoline used should be graded 91 octane or
E-02, 19
higher. An unleaded gasoline is recommended.
Fuel tank capacity Including
20 L (5.3/4.4 US/lmp gal)
reserve
Reserve 4.4 L
only (1.2/1.0 US/lmp gal)
Engine oil type SAE 10W-40, API SF or SG
Engine oil capacity Change 3 300 ml
(3.5/2.9 US/lmp qt)
Filter 3 500 ml
change (3.7/3.1 US/lmp qt)
Overhaul 4 600 ml
(4.9/4.0 US/lmp qt)
Front fork oil type Fork oil SS-08 or equivalent fork oil
Front fork oil capacity (each leg) 507 ml
(17.1/17.9 US/Imp oz)
Brake fluid type DOT 4
 GSF1200/SK4 (’04-MODEL) 12-21

PERIODIC MAINTENANCE CHART

Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 2 12 24 36 48
Valve clearance I — I — I
Spark plugs — I R I R
Exhaust pipe bolts and muffler bolts T — T — T
Air cleaner — I I R I
Engine oil R R R R R
Engine oil filter R — — R —
Fuel hose — I I I I
Replace every four years.
Engine idle speed I I I I I
Throttle cable play I I I I I
Carburetor synchronization I
— I — I
(E-33 only)
Evaporative emission control system — I — I I
(E-33 only) Replace vapor hose every four years.
PAIR (air supply) system — — I — I
Clutch hose — I I I I
Replace every four years.
Clutch fluid — — I — I
Replace every two years.
Drive chain I I I I I
Clean and lubricate every 1 000 km (600 miles)
Brakes I I I I I
Brake hoses — I I I I
Replace every four years.
Brake fluid — I I I I
Replace every two years.
Tires — I I I I
Steering I — I — I
Front forks — — I — I
Rear suspension — — I — I
Chassis bolts and nuts T T T T T
I = Inspect and adjust, clean, lubricate or replace lubricate as necessary
R = Replace
T = Tighten
12-22 GSF1200/SK4 (’04-MODEL)

EXHAUST PIPE/MUFFLER INSTALLATION

29 N.m
(2.9 kgf-m, 21.0 lb-ft)

23 N.m
(2.3 kgf-m, 16.5 lb-ft)

29 N.m
(2.9 kgf-m, 21.0 lb-ft)

Apply the exhaust gas sealer

to both the inside and outside.

23 N.m
(2.3 kgf-m, 16.5 lb-ft)
 GSF1200/SK4 (’04-MODEL) 12-23

WIRE HARNESS ROUTING

Signal generator
lead wire

Engine oil hose

Engine ground wire must be

faced to the inside.

Engine ground wire

Generator lead wire

Starter motor A
lead wire
45˚ – 60˚
Side-stand switch
lead wire
Clamp
VIEW OF A
Speed sensor
Gear position switch
lead wire

30˚
 12-24

HANDLEBAR SWITCH (R)

ENGINE FRONT BRAKE
SPEEDOMETER STOP SWITCH LIGHT SWITCH
OFF OFF SIDE-STAND REAR BRAKE
SP : SPEEDOMETER LIGHT RUN ON SWITCH LIGHT SWITCH
TA : TACHOMETER LIGHT N HAZARD STARTER
N : NEUTRAL INDICATOR LIGHT ON
H SWITCH SWITCH PUSH
H : HIGH BEAM INDICATOR LIGHT SP TA IGNITION COIL OFF
OFF IGNITION SWITCH FREE
O : OIL PRESSURE WARNING LIGHT O TP
R : TURN SIGNAL INDICATOR LIGHT(R) ON PUSH FUEL SENSOR
ON
L : TURN SIGNAL INDICATOR LIGHT(L) L R OFF GAUGE
LOCK
P
IGNITOR

P
Y

R
B
B

O
Gr

Lg
Lg
Lbl

B/Y
G/Y
R/B
B/R
Y/G

O/B

O/G

B/W
Bl/B
O/W
B/Bl

B/Br
R
O
Br
Gr

O/Y
B/W
Y
B

Bl

G
Y/B

B/W
B/W
GSF1200/SK4 (’04-MODEL)

Y
Y
Y

B
B
R
O
G

W
W
Bl
Bl

Br

Lg
Lg
Lbl

P/B
B/Y
Y/B
B/Y
Y/B
B/Y

G/Y
Y/G
O/Y
R/B
O/Y

O/R
O/B

O/G
O/G
O/G
O/G
O/G
Y/W

R/W
B/W
B/W
W/B
B/W
B/W
B/W
W/B
B/W

Bl/B
O/W
O/W
O/W
O/W
B/Bl

G/Bl
B/Br
B/Br

FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B
B/W B/W B/W B

HEADLIGHT (LO)
BRAKE LIGHT/TAILLIGHT
W W W Br
B/W Gr B/W
Lg Lg W/B
Y Y
Y Br Br
B/W B/W B/W B/W B/W
W/B W/B
HEADLIGHT (HI)
Br
B/W
LICENSE PLATE LIGHT

B B B B
B/W B/W B/W B

FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

WIRE COLORS
B : Black
Bl : Blue
Br : Brown
Dg : Dark green
B/W

G : Green
Gr : Gray
Lbl : Light blue
R
R

B
R

O
O
G

Bl
Bl
Br
B/Y

Lbl

P/B

R/B
R/B
O/Y
O/Y
O/Y
B/W

O/R
B/O
O/B

O/G

B/W
B/W
B/W
Y/Bl
R/W
Bl/B

G/Bl
Lg : Light green
O : Orange

B
O
O

Lg
Lbl
B/Y
Y/G
O/G

B/W
Y/Bl

B/Bl
B/Bl
P : Pink
B/W

R : Red

G/Y

P
Y/W
B/Bl

Bl
R/B
O/G

B/W
B/W
W : White

G/Bl
3 4 5 1 Y : Yellow

B/O
B/W
B/Bl : Black with Blue tracer

B
W

Lg
Lbl
B/Br : Black with Brown tracer

B/Y
B/Y

O/R
Y/W

B/W
B/Bl
HORN NEUTRAL
SPEED 1: MAIN 30 A BATTERY B/O : Black with Orange tracer
SWITCH B/R : Black with Red tracer
SENSOR 1 2 STARTER STARTER
Y
Bl

G/Y

B/W : Black with White tracer

B/W MOTOR RELAY
B/Y : Black with Yellow tracer
B Bl/B : Blue with Black tracer
GENERATOR FUSE BOX 1. HEAD HI 10 A G/Y : Green with Yellow tracer
FREE

B
B
B
B
2. HEAD LO 10 A O/B : Orange with Black tracer

B/W
PUSH PUSH
O/G : Orange with Green tracer
WIRING DIAGRAM (GSF1200S) For E-03, 24, 28, 33

3. IGNITION 10 A
HORN PASSING CLUTCH 4. SIGNAL 15 A O/R : Orange with Red tracer
Y/W
Y/W

BUTTON LIGHT LEVER 5. METER 10 A O/W : Orange with White tracer

SWITCH HI POSITION OFF ON O/Y : Orange with Yellow tracer
L
LO SWITCH ON OFF P/B : Pink with Black tracer
PUSH SIGNAL
R CARB. R/W : Red with White tracer
DIMMER GENERATOR W/B : White with Black tracer
SWITCH THERMO-
TURN SIGNAL SWITCH Y/B : Yellow with Black tracer
CARB.4 OIL Y/Bl : Yellow with Blue tracer
SWITCH PRESSURE
CARB.3 CARB.2 CARB.1 Y/G : Yellow with Green tracer
SWITCH Y/W : Yellow with White tracer
HANDLEBAR SWITCH (L)
 HANDLEBAR SWITCH (R)
ENGINE FRONT BRAKE
SPEEDOMETER STOP SWITCH LIGHT SWITCH
OFF OFF SIDE-STAND REAR BRAKE
SP : SPEEDOMETER LIGHT RUN ON SWITCH LIGHT SWITCH
TA : TACHOMETER LIGHT N HAZARD STARTER
H : NEUTRAL INDICATOR LIGHT ON
H SWITCH SWITCH PUSH
O : HIGH BEAM INDICATOR LIGHT SP TA IGNITION COIL OFF
OFF IGNITION SWITCH FREE
R : OIL PRESSURE WARNING LIGHT O
L : TURN SIGNAL INDICATOR LIGHT(R) ON PUSH FUEL
ON
: TURN SIGNAL INDICATOR LIGHT(L) L R OFF GAUGE
LOCK
P
TP
IGNITOR SENSOR

P
Y

R
B
B

O
Gr

Lg
Lg
Lbl

B/Y
G/Y
R/B
B/R
Y/G

O/B

O/G

B/W
Bl/B
O/W
B/Bl

B/Br
R
O
Br
Gr

O/Y
B/W
G
Y/B

B/W
B/W

Y
Y
Y

B
B
R
O
G

W
W
Bl
Bl

Br

Lg
Lg
Lbl

P/B
B/Y
Y/B
B/Y
Y/B
B/Y

G/Y
Y/G
O/Y
R/B
O/Y

O/R
O/B

O/G
O/G
O/G
O/G
O/G
Y/W

R/W
B/W
B/W
W/B
B/W
B/W
B/W
W/B
B/W

Bl/B
O/W
O/W
O/W
O/W
B/Bl

G/Bl
B/Br
B/Br

FRONT TURN SIGNAL LIGHT (R) REAR TURN SIGNAL LIGHT (R)
Lg Lg Lg B
B/W B/W B/W B

BRAKE LIGHT/TAILLIGHT
Br
B/W
W/B
HEADLIGHT
Y Br Br
B/W B/W B/W
W W/B W/B

Br
B/W
LICENSE PLATE LIGHT

B B B B
B/W B/W B/W B

FRONT TURN SIGNAL LIGHT (L) REAR TURN SIGNAL LIGHT (L)

WIRE COLORS
WIRING DIAGRAM (GSF1200) For E-03

B : Black
Bl : Blue
Br : Brown
Dg : Dark green
B/W

G : Green
Gr : Gray
Lbl : Light blue
R
R

B
R

O
G

Bl
Bl
Br
B/Y

Lbl

P/B
R/B
O/Y
O/Y
O/Y
B/W

O/R
B/O
O/B

O/G

B/W
B/W
B/W
Y/Bl
R/W
Bl/B

G/Bl
W/Bl

Lg : Light green
O : Orange

B
O
O

Lg
Lbl
B/Y
Y/G
O/G
O/G

B/W
Y/Bl

B/Bl
B/Bl
B/Bl

W/Bl
P : Pink
B/W

R : Red
G/Y

P
Y/W
B/Bl

Bl
R/B

O/G
B/W
B/W
W : White

G/Bl
3 4 5 1 Y : Yellow

B/O
B/W
B/Bl : Black with Blue tracer

B
W

Lg
Lbl
B/Br : Black with Brown tracer

B/Y
B/Y

O/R
Y/W

B/W
B/Bl
HORN L HORN H NEUTRAL
SPEED 1: MAIN 30 A BATTERY B/O : Black with Orange tracer
SWITCH B/R : Black with Red tracer
SENSOR 1 2 STARTER STARTER
Y
Bl

G/Y

B/W : Black with White tracer

B/W MOTOR RELAY
B/Y : Black with Yellow tracer
B Bl/B : Blue with Black tracer
GENERATOR FUSE BOX 1. HEAD HI 10 A G/Y : Green with Yellow tracer
FREE

B
B
B
B
2. HEAD LO 10 A O/B : Orange with Black tracer

B/W
PUSH PUSH
3. IGNITION 10 A O/G : Orange with Green tracer
HORN PASSING CLUTCH 4. SIGNAL 15 A O/R : Orange with Red tracer
Y/W
Y/W

BUTTON LIGHT LEVER 5. METER 10 A O/W : Orange with White tracer

SWITCH HI POSITION OFF ON O/Y : Orange with Yellow tracer
L
LO SWITCH ON OFF P/B : Pink with Black tracer
PUSH SIGNAL
R CARB. R/W : Red with White tracer
DIMMER GENERATOR W/B : White with Black tracer
SWITCH THERMO-
TURN SIGNAL SWITCH Y/B : Yellow with Black tracer
CARB.4 OIL Y/Bl : Yellow with Blue tracer
SWITCH PRESSURE
CARB.3 CARB.2 CARB.1 Y/G : Yellow with Green tracer
SWITCH Y/W : Yellow with White tracer
HANDLEBAR SWITCH (L)
GSF1200/SK4 (’04-MODEL)
12-25
 Prepared by

5th Ed. July, 2004

1st Ed. July, 1996
Part No. 99500-39135-03E
Printed in Japan

406
 TOP

DIC216
GSF1200/S
GSF1200/S

Printed in Japan 99500-39135-03E

T V W X Y K4

BOTTOM
No.5232 GSF1200/S 99500-39135-03E Cover14 for DOCCU (12mm) 2004.7.24 DIC216
DIC216