Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Suzuki Manuals
Motorcycle
GSX600F
Service manual
Table Of Contents - Suzuki GSX600F Service Manual
Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
Table Of Contents
374
page
of
374
Go
/
374
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Advertisement
Table of Contents
Group Index
3
Symbol
4
Component Parts And Work To Be Done
5
General Information
6
Warning/Caution/Note
7
General Precautions
7
Suzuki Gsx600Fw ('98 Model) Right Side
9
Suzuki Gsx600Fw ('98 Model) Left Side
9
Serial Number Location
9
Fuel And Oil Recommendation
9
Engine Oil
10
Brake Fluid
10
Front Fork Oil
10
Break-In Procedures
10
Cylinder Identification
11
Information Labels
12
Specifications
13
Country And Area Codes
15
Periodic Maintenance
16
Periodic Maintenance Schedule
17
Periodic Maintenance Chart
17
Lubrication Points
18
Maintenance And Tune-Up Procedures
19
Valve Clearance
19
Spark Plugs
20
Carbon Deposits
21
Spark Plug Gap
21
Electrode's Condition
21
Spark Plug Installation
21
Exhaust Pipe Bolts And Muffler Bolts And Nut
22
Air Cleaner
22
Engine Oil Replacement
24
Fuel Hose
25
Engine Oil Filter Replacement
25
Necessary Amount Of Engine Oil
25
Fuel Filter
26
Engine Idle Speed
26
Throttle Cable Play
26
Carburetor Synchronization
27
Evaporative Emission Control System (E-33 Only)
27
Secondary Air Supply (Pair) System (E-33 Only)
28
Clutch Cable Play
28
Drive Chain
29
Drive Chain Adjusting
30
Drive Chain Cleaning And Lubricating
30
Brake Fluid Level
31
Brake Pads
32
Brake Pedal Height
32
Brake Light Switch
33
Air Bleeding The Brake Fluid Circuit
33
Tire Tread Condition
35
Tire Pressure
35
Steering
36
Front Fork
36
Rear Suspension
36
Chassis Bolts And Nuts
37
Compression Pressure Check
39
Compression Test Procedure
39
Oil Pressure Check
40
Oil Pressure Test Procedure
40
Low Oil Pressure
40
High Oil Pressure
40
Engine
41
Engine Components Removable With Engine In Place
42
Engine Removal
43
Engine Installation
47
Engine Disassembly
51
Engine Reassembly
65
Cylinder Block Stud Bolt Location
77
Camshaft/Cylinder Head
88
Camshaft Removal
89
Cylinder Head Removal
90
Camshaft/Cylinder Head Inspection And Service
92
Cam Wear
93
Camshaft Journal Wear
93
Camshaft Runout
94
Camshaft Sprockets
94
Cam Chain Tensioner
95
Cam Chain Guide
95
Cam Chain Tensioner Guide
95
Cylinder Head Disassembly
95
Cylinder Head Distortion
97
Valve Stem Runout
97
Valve Head Radial Runout
97
Valve Face Wear
98
Valve Stem Deflection
98
Valve Stem Wear
98
Valve Guide Servicing
99
Valve Seat Width
100
Valve Seat Servicing
100
Valve Stem End Condition
102
Valve Springs
102
Cylinder Head Reassembly
103
Intake Pipes
104
Cylinder Head Installation
105
Camshaft Installation
108
Cylinder Block/Pistons
110
Cylinder Block/Piston Removal
111
Cylinder Block/Piston Inspection
112
Cylinder Block Distortion
112
Cylinder Bore
112
Piston Diameter
112
Piston-To-Cylinder Clearance
113
Piston-Ring-To-Groove Clearance
113
Piston/Cylinder Block Installation
114
Piston Pins And Pin Bore
114
Oversize Piston Ring
114
Oversize Oil Ring
114
Piston/Cylinder Block
116
Clutch
117
Clutch Removal
118
Clutch Release Assembly Removal
120
Clutch/Clutch Release Assembly Inspection
120
Clutch Drive Plates
120
Clutch Driven Plates
121
Clutch Spring Free Length
121
Clutch Release Bearing
121
Clutch Release Assembly Installation
122
Clutch Installation
123
Starter System/Signal Generator
125
Starter Clutch Removal
126
Signal Generator Removal
127
Starter Clutch/Signal Generator Inspection
127
Signal Generator Installation
128
Starter Driven Gear Bearing Inspection
128
Signal Generator Inspection
128
Starter Clutch Installation
129
Starter Motor Removal
130
Starter Motor Inspection
130
Starter Motor Installation
130
Gearshift Linkage
131
Gearshift Linkage Removal
132
Gearshift Linkage Inspection
133
Gearshift Shaft/Gearshift Arm Inspection
133
Oil Seal Inspection
133
Oil Seal Replacement
133
Gearshift Shaft Hole Inspection
134
Gearshift Shaft Reassembly
134
Gearshift Linkage Installation
135
Crankcase/Transmission/Crankshaft/Conrods
137
Transmission/Crankshaft/Conrod Removal
139
Transmission Inspection And Service
139
Gearshift-Fork-To-Gearshift-Fork-Groove Clearance
139
Countershaft Assembly
140
Driveshaft Assembly
141
Conrod/Crankshaft Inspection
146
Conrod-Crank Pin Bearing Inspection And Service
146
Conrod Small End I.d.
146
Conrod Big End Side Clearance
146
Conrod-Crank Pin Bearing Selection
147
Bearing Selection Table
148
Conrod I.d. Specification
148
Crank Pin O.d. Specification
148
Bearing Thickness Specification
148
Crankcase-Crankshaft Bearing Inspection And Service
149
Bearing Assembly
149
Crankcase-Crankshaft Bearing Inspection
149
Crankcase-Crankshaft Bearing Selection
149
Crankshaft Thrust Clearance Adjustment
152
Crankshaft Runout
153
Left-Side Thrust Bearing Selection Table
153
Transmission/Crankshaft/Conrod Installation
154
Engine Lubrication System
155
Oil Pump Removal
156
Oil Pump Inspection
156
Oil Pump Installation
156
Oil Sump Filter/Oil Pressure Regulator Removal
156
Oil Pressure Regulator Inspection
157
Oil Sump Filter Cleaning
157
Oil Pan
157
Oil Sump Filter/Oil Pressure Regulator Installation
158
Oil Pressure Switch/Oil Cooler Removal
159
Oil Pressure Switch Inspection
159
Oil Cooler Hose Inspection
160
Oil Cooler Inspection And Cleaning
160
Oil Jet
161
Oil Jet Removal
162
Oil Jet Inspection
162
Oil Jet Installation
162
Engine Lubrication System Chart
163
Cylinder Head Cooling System Chart
165
Cylinder Head Cooling System
166
Fuel System
167
Fuel Tank Removal
169
Fuel Tank Remounting
169
Vacuum Fuel Valve
170
Vacuum Fuel Valve Removal
170
Vacuum Fuel Valve Inspection And Cleaning
171
Vacuum Fuel Valve Remounting
171
Fuel Level Gauge Removal
171
Fuel Level Gauge Remounting
171
Fuel Filter Removal
172
Fuel Filter Inspection
172
Fuel Filter Remounting
172
Carburetor Construction
173
Carburetor Specifications
174
I.d. No. Location
175
Diaphragm And Piston Operation
176
Lower Position Of The Piston Valve
176
Upper Position Of The Piston Valve
176
Slow System
177
Main System
178
Starter (Enricher) System
179
Float System
179
Pilot Screw Removal
184
Carburetor Cleaning
185
Carburetor Inspection
185
Needle Valve Inspection
186
Float Height Adjustment
186
Throttle Position Sensor Inspection
186
Throttle Valve
187
Pilot Screw
187
Carburetor Engagement
187
Throttle Position Sensor Positioning
188
Carburetor Clamps
188
Calibrating The Carburetor Balancer
189
Chassis
192
Exterior Parts Construction
193
Lower Fairings Removal
194
Upper Fairings Removal
194
Frame Cover Removal
196
Front Wheel Construction
197
Front Wheel Removal
199
Front Wheel Inspection And Disassembly
200
Front Axle
201
Front Wheel Remounting
202
Front Fork Construction
204
Front Fork Removal And Disassembly
205
Front Fork Inspection
207
Inner And Outer Tube
207
Fork Spring
207
Damper Rod Ring
207
Front Fork Reassembly And Remounting
208
Slide Metals And Oil And Dust Seals
208
Damper Rod Bolt
209
Fork Oil
209
Suspension Setting
211
Steering Construction
212
Steering Removal And Disassembly
212
Steering Inspection And Disassembly
214
Steering Reassembly And Remounting
215
Steering Stem Nut
216
Handlebar And Front Fork
216
Steering Tension Adjustment
217
Rear Wheel Construction
218
Rear Wheel Removal
220
Rear Wheel Inspection And Disassembly
221
Rear Sprocket Mounting Drum Bearing
221
Wheel Bearings Reassembly
222
Rear Axle
222
Cushion
222
Rear Sprocket
222
Rear Sprocket Mounting Drum Bearing And Dust Seal
223
Rear Suspension Construction
224
Rear Suspension Removal
226
Rear Suspension Inspection And Disassembly
227
Chain Buffer
227
Swingarm Needle Bearings
227
Cushion Lever Needle Bearings
228
Cushion Lever And Cushion Lever Rods
228
Pivot Shaft
229
Rear Shock Absorber
229
Rear Suspension Final Inspection And Adjustment
231
Rear Suspension Setting
231
Front Brake Construction
232
Brake Pad Replacement
233
Brake Fluid Replacement
234
Brake Caliper Removal And Disassembly
234
Brake Caliper Inspection
235
Brake Caliper Reassembly And Remounting
236
Rubber Parts
236
Brake Caliper Holder
236
Brake Disc Inspection
237
Master Cylinder Removal And Disassembly
238
Master Cylinder Inspection
239
Master Cylinder Reassembly And Remounting
240
Rear Brake Construction
242
Tire Removal
249
Wheels Inspection
251
Tires Inspection
251
Valve Inspection
251
Tire Installation
252
Valve Installation
252
Electrical System
254
Cautions In Servicing
255
Connectors
255
Couplers
255
Clamps
255
Connecting The Battery
256
Battery Wiring Procedure
256
Using The Multi Circuit Tester
257
Location Of Electrical Components
258
Charging System Description (Generator With Ic Regulator)
260
Trouble Shooting
261
Battery Runs Down Quickly
261
Battery Current Leak Inspection
262
Charging Output Inspection
262
Generator
263
Generator Removal And Disassembly
264
Rotor Bearings Inspection
266
Generator Driven Gear Dampers
267
Stator Coil Continuity Check
267
Rotor Coil Continuity Check
267
Slip Rings
267
Carbon Brushes
268
Rectifier
268
Ic Regulator
268
Generator Reassembly And Remounting
269
Starter System Description
271
Side-Stand/Ignition Interlock System Description
271
Starter Motor Will Not Run
273
Starter Motor Removal And Disassembly
274
Starter Motor Reassembly And Remounting
275
Commutator
275
Armature Coil Inspection
275
Starter Relay Inspection
276
Side-Stand/Ignition Interlock System Part Inspection
277
Neutral Switch
278
Side-Stand Switch
278
Turn Signal/Side-Stand Relay
278
Side-Stand Relay Inspection
279
Diode Inspection
279
Ignition System (Digital Ignitor) Description
280
No Spark Or Poor Spark
281
Ignition Coil Primary Peak Voltage Inspection
282
Ignition Coil Resistance
283
Signal Generator Peak Voltage
284
Signal Generator
285
Combination Meter Removal
286
Combination Meter Disassembly
287
Combination Meter Inspection
287
Fuel Meter Inspection
289
Fuel Level Gauge Inspection
289
Speedometer Inspection
290
Speed Sensor Inspection
290
Oil Pressure Indicator Inspection
291
Lamps
292
Headlight Bulb Replacement
292
Brake Light/Taillight And License Plate Light
293
Turn Signal Lights
293
Switches
295
Battery Specifications
296
Battery Removal
296
Battery Remounting
296
Initial Charging
297
Filling Electrolyte
297
Recharging Operation
299
Servicing Information
300
Troubleshooting Engine
301
Carburetor Troubleshooting
305
Chassis Troubleshooting
305
Brakes Troubleshooting
306
Electrical Troubleshooting
307
Battery Troubleshooting
308
Wiring Diagram For E-02
309
Wiring Diagram For E-04, 17, 18, 22, 25, 34
310
Wiring Diagram For E-24
311
Wiring Diagram For E-03, 28, 33
312
Wire Harness Routing
313
Cable Routing
315
Fuel System Hose Routing
316
Oil Hose Routing
317
Front Brake Hose Routing
318
Rear Brake Hose Routing
319
Pair (Air Supply) System Hose Routing (For E-18)
320
Brake Pedal
321
Side-Stand Spring
322
Fairing Set Up
323
Frame Cover Set Up
324
Frame Cover Cushion
324
Heat Shield And Cushion
325
Heat Shield
326
Fuel Tank Molding
326
Special Tools
327
Tightening Torque Engine
330
Tightening Torque Chassis
331
Tightening Torque Chart
332
Service Data Valve + Guide
333
Service Data Camshaft + Cylinder Head
334
Service Data Cylinder + Piston + Piston Ring
334
Service Data Conrod + Crankshaft
335
Service Data Oil Pump
335
Service Data Clutch
336
Service Data Transmission + Drive Chain
336
Service Data Carburetor
337
Service Data Electrical
338
Service Data Wattage
338
Service Data Brake + Wheel
339
Service Data Suspension
340
Service Data Tire Pressure
340
Service Data Fuel + Oil
340
Emission Control Information
341
Emission Control Carburetor Components
342
Evaporative Emission Control System (California Model Only)
343
Canister Hose Routing (California Model Only)
344
Evaporative Emission Control System Inspection
345
Hoses
345
Canister
345
Purge Control Valve
345
Pair (Air Supply) System Diagram
346
Pair (Air Supply) System Hose Routing
347
Pair (Air Supply) System Inspection
348
Hoses And Pipes
348
Pair Cleaner
348
Pair Reed Valve
348
Pair Control Valve
349
Gsx600Fx/Y ('99/'00 Model)
350
Gsx600Fx/Y ('99/'00 Model) Specifications
351
Gsx600Fk1 ('01 Model)
362
Gsx600Fk1 ('01 Model) Specifications
363
Gsx600Fk1 ('01 Model) Service Data
364
Gsx600Fk1 ('01 Model) Change
373
Previous
Page
1
...
373
374
Advertisement
Table of Contents
Troubleshooting
Trouble Shooting
261
Troubleshooting Engine
301
Carburetor Troubleshooting
305
Brakes Troubleshooting
306
Electrical Troubleshooting
307
Battery Troubleshooting
308
Related Manuals for Suzuki GSX600F
Motorcycle Suzuki GSX650FA Service Manual
(66 pages)
Motorcycle Suzuki GSF650A Service Manual
(697 pages)
Motorcycle Suzuki GSX650F Supplementary Service Manual
(48 pages)
Motorcycle Suzuki GSX 600F 2000 Owner's Manual
(83 pages)
Motorcycle Suzuki GSX1300R Owner's Manual
(143 pages)
Motorcycle Suzuki GSX1400K2 Setup Manual
Suzuki motorcycle (25 pages)
Motorcycle Suzuki GSX-R750 Service Manual
(659 pages)
Motorcycle Suzuki 1996 GSX-R750 Service Manual
(557 pages)
Motorcycle Suzuki GSX1300BK Owner's Manual
(204 pages)
Motorcycle Suzuki GSX1400 Owner's Manual
(37 pages)
Motorcycle Suzuki GSX1400 Service Manual
(396 pages)
Motorcycle Suzuki GSX1300BKA Supplementary Service Manual
(108 pages)
Motorcycle Suzuki GSX1250FA Owner's Manual
(135 pages)
Motorcycle Suzuki GSX-S1000 Owner's Manual
(155 pages)
Motorcycle Suzuki GSX-R1000 2007 Service Manual
(549 pages)
Motorcycle Suzuki GSX-R150 Owner's Manual
(188 pages)
Related Content for Suzuki GSX600F
GSF650A Table Of Contents
Suzuki GSF650A
GSF1250 Table Of Contents
Suzuki GSF1250
RM250 Table Of Contents
Suzuki RM250
GS1000G 1980 Table Of Contents
Suzuki GS1000G 1980
SV650 Table Of Contents
Suzuki SV650
125 Table Of Contents
Suzuki 125
GSX R600 2003 Table Of Contents
Suzuki GSX R600 2003
GS850G Table Of Contents
Suzuki GS850G
1982 GS450GA Table Of Contents
Suzuki 1982 GS450GA
GSX-R1000 Table Of Contents
Suzuki GSX-R1000
GSX-R250 Table Of Contents
Suzuki GSX-R250
GS1100E Table Of Contents
Suzuki GS1100E
GZ250 Table Of Contents
Suzuki GZ250
SV650 Table Of Contents
Suzuki SV650
VS1400 Table Of Contents
Suzuki VS1400
GSX1300BK Table Of Contents
Suzuki GSX1300BK
Table of Contents
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL