Suzuki GSF600SK2 2002 Manuals

Manuals and User Guides for Suzuki GSF600SK2 2002. We have 1 Suzuki GSF600SK2 2002 manual available for free PDF download: Service Manual

Suzuki GSF600SK2 2002 Service Manual

Suzuki GSF600SK2 2002 Service Manual (380 pages)

Brand: Suzuki | Category: Motorcycle | Size: 19.25 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- How to Use this Manual
  3
- General Information
  6
  - Suzuki Gsf600Sy (2000-Model)
    8
  - Serial Number Location
    8
  - Fuel and Oil Recommendation
    8
    
    Fuel
    8
    
    Engine Oil
    9
    
    Brake Fluid
    9
    
    Front Fork Oil
    9
  - Break-In Procedures
    9
  - Cylinder Identification
    9
  - Information Labels
    10
  - Specifications
    11
  - Country or Area Codes
    13
- General Precautions
  6
- Warning/Caution/Note
  6
Periodic Maintenance

14
- Periodic Maintenance Schedule
  15
  - Periodic Maintenance Chart
    15
  - Lubrication Points
    16
- Maintenance and Tune-Up Procedures
  17
  - Valve Clearance
    17
  - Engine
    17
  - Spark Plugs
    18
  - Exhaust Pipe Bolts and Muffler Bolts
    20
  - Air Cleaner
    20
  - Engine Oil and Oil Filter
    22
  - Fuel Hose
    23
  - Fuel Filter
    24
  - Engine Idle Speed
    24
  - Throttle Cable Play
    24
  - Carburetor Synchronization
    25
  - Evaporative Emission Control System (E-33 Only)
    25
  - Pair (Air Supply) System
    26
  - Clutch Cable Play
    26
  - Drive Chain
    27
  - Brakes
    29
  - Tires
    32
  - Steering
    33
  - Front Fork
    34
  - Rear Suspension
    34
  - Chassis Bolts and Nuts
    35
- Compression Pressure Check
  37
- Oil Pressure Check
  38
Engine

39
- Engine Components Removable with Engine in Place
  40
- Engine Removal and Installation
  41
  - Engine Removal
    41
  - Engine Reinstallation
    46
- Engine Disassembly and Reassembly
  50
  - Engine Reassembly
    64
- Engine Components Inspection and Service
  87
  - Camshaft/Cylinder Head
    87
  - Cam Chain Tensioner
    89
  - Valve
    91
  - Valve Guide
    93
  - Valve Seat
    94
  - Valve Spring
    98
  - Cylinder
    102
  - Piston Ring Groove Width
    103
  - Piston Ring Thickness
    103
  - Piston Ring End Gap
    103
  - Piston Pin
    104
  - Clutch
    106
  - Starter Clutch Inspection
    107
  - Gearshift Linkage Inspection
    108
  - Transmission Inspection and Service
    110
  - Conrod
    119
  - Crankshaft
    121
    
    Crankshaft Thrust Clearance Adjustment
    123
    
    Crankshaft Runout
    124
- Engine Lubrication System
  125
  - Oil Filter
    130
  - Oil Pressure
    130
  - Oil Jet
    130
  - Cylinder Head Cover
    134
  - Oil Pan
    134
- Pair (Air Supply) System
  136
Fuel System

139
- Fuel System
  140
- Fuel Tank
  141
  - Removal
    141
  - Remounting
    141
- Fuel Valve
  142
  - Removal
    143
  - Inspection and Cleaning
    143
  - Remounting
    143
  - Fuel Filter Removal
    144
  - Inspection
    144
  - Fuel Filter Remounting
    144
- Carburetor
  145
  - Construction
    145
  - Specifications
    146
  - I.D. No. Location
    147
  - Diaphragm and Piston Operation
    148
  - Slow System
    149
  - Main System
    150
  - Starter (Enricher) System
    151
  - Float System
    151
  - Removal
    152
  - Disassembly
    153
  - Carburetor Cleaning
    157
  - Carburetor Heater Inspection
    157
  - Thermo-Switch Inspection
    157
  - Carburetor Inspection
    158
  - Reassembly
    159
  - Remounting
    160
  - Carburetor Synchronization
    161
Chassis

165
- Exterior Parts
  166
  - Construction
    166
  - Removal
    167
  - Remounting
    170
- Front Wheel
  171
  - Construction
    171
  - Removal
    173
  - Inspection and Disassembly
    173
  - Reassembly
    174
  - Remounting
    175
- Front Fork
  176
  - Construction
    176
  - Removal and Disassembly
    177
  - Inspection
    179
  - Reassembly and Remounting
    180
- Steering
  184
  - Construction
    184
  - Removal and Disassembly
    184
  - Inspection and Disassembly
    186
  - Reassembly and Remounting
    186
  - Steering Tension Adjustment
    189
- Rear Wheel
  190
  - Construction
    190
  - Removal
    192
  - Inspection and Disassembly
    193
  - Reassembly
    194
  - Remounting
    195
- Rear Suspension
  196
  - Construction
    196
  - Removal
    198
  - Inspection and Disassembly
    199
  - Reassembly
    201
  - Rear Shock Absorber Disposal
    202
  - Remounting
    203
  - Final Inspection and Adjustment
    204
  - Suspension Setting
    204
- Front Brake
  205
  - Construction
    205
  - Brake Pad Replacement
    206
  - Brake Fluid Replacement
    206
  - Brake Caliper Removal and Disassembly
    207
  - Brake Caliper Inspection
    208
  - Brake Caliper Reassembly and Remounting
    209
  - Brake Disc Inspection
    210
  - Brake Disc Removal and Remounting
    210
  - Master Cylinder Removal and Disassembly
    211
  - Master Cylinder Inspection
    212
  - Master Cylinder Reassembly and Remounting
    213
- Rear Brake
  215
  - Construction
    215
  - Brake Pad Replacement
    216
  - Brake Fluid Replacement
    216
  - Brake Caliper Removal and Disassembly
    217
  - Brake Caliper Inspection
    218
  - Brake Caliper Reassembly and Remounting
    218
  - Master Cylinder Removal and Disassembly
    219
  - Master Cylinder Inspection
    220
  - Master Cylinder Reassembly and Remounting
    221
  - Tire and Wheel
    222
  - Tire Removal
    222
  - Inspection
    222
  - Tire Tread Depth
    222
  - Tire Installation
    223
Electrical System

225
- Cautions in Servicing
  226
  - Connecting the Battery
    227
  - Using the Multi Circuit Tester
    228
  - Location of Electrical Components
    229
- Charging System
  231
  - Description (Generator with IC Regulator)
    231
  - Troubleshooting
    232
  - Inspection
    233
- Generator
  234
  - Removal and Disassembly
    235
  - Inspection
    237
  - Generator Reassembly and Remounting
    240
- Starter System and Side-Stand Ignition Interlock System
  242
- Ignition System (Digital Ignitor)
  251
  - Description
    251
  - Troubleshooting
    252
  - Inspection
    253
- Combination Meter
  257
  - Removal
    257
  - Disassembly
    257
  - Inspection
    257
- Lamps
  261
  - Headlight
    261
  - Brake Light/Taillight and License Plate Light
    262
  - Turn Signal Lights
    262
- Relays
  263
  - Starter Relay
    263
  - Turn Signal/Side-Stand Relay
    263
- Switches
  264
- Battery
  265
  - Specifications
    265
  - Removal
    265
  - Remounting
    265
  - Initial Charging
    266
  - Servicing
    267
  - Recharging Operation
    268
Servicing Information

269
- Troubleshooting
  270
  - Engine
    270
  - Carburetor
    274
  - Chassis
    274
  - Brakes
    275
  - Electrical
    276
  - Battery
    277
- Wiring Diagram
  278
- Wire Harness, Cable and Hose Routing
  280
  - Wire Harness Routing
    280
  - Cable Routing
    283
  - Pair (Air Supply) System Hose Routing
    284
  - Front Brake Hose Routing
    285
  - Rear Brake Hose Routing
    286
  - Front Footrest Bracket Set-Up
    287
  - Fuel Tank Set-Up
    288
  - High-Tension Cord Routing
    289
  - Muffler Mounting
    289
  - Center Stand Springs
    290
  - Cowling and Cowling Brace Set-Up
    291
  - Frame Cover and Side Frame Cover Set-Up
    292
  - Cowling Cushion and Tape
    293
  - Front Fender Cushion
    294
  - Seat Lock Cable Routing
    294
- Special Tools
  297
- Tightening Torque
  300
  - Engine
    300
  - Chassis
    301
  - Tightening Torque Chart
    302
- Service Data
  303
Gsf600Y (2000-Model)

312
- Country and Area Codes
  312
- Specifications
  313
  - Dimensions and Dry Mass
    313
- Combination Meter
  315
- Headlight
  318
  - Bulb Replacement
    318
- Headlight Beam Adjustment
  319
- Wiring Diagram
  320
- Wire Harness Routing
  321
- Front Brake Hose Routing
  323
- Service Data
  324
- Gsf600Sk1/Gsf600Suk1
  332
- Gsf600K2/Gsf600Sk2
  352
  - Service Data (Gsf600S)
    354
  - Service Data (Gsf600)
    363
  - Fuel Level Gauge
    371
  - Fuel Level Meter
    372
  - Wiring Diagram Gsf600S
    373
  - Wiring Diagram Gsf600
    375
  - Wire Harness Routing (Gsf600S)
    376
  - Wire Harness Routing (Gsf600)
    377

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