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Suzuki Manuals
Motorcycle
Intruder VS600GL
Service manual
Suzuki Intruder VS600GL Service Manual
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Table Of Contents
278
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of
278
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Group Index
How to Use this Manual
Component Parts and Work to be Done
Symbols
General Information
General Precautions
Serial Number Location
Fuel, Oil and Engine Coolant Recommendation
Fuel
Engine Oil
Anti-Freeze/Engine Coolant
Liquid Amount of Water/Engine Coolant
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Dimensions and Dry Mass
Engine Specifications
Transmission Specifications
Chassis Specifications
Electrical Specifications
Capacities
Country or Area
Periodic Maintenance
Periodic Maintenance Shedule
Lubrication Points
Maintenance and Tune-Up Procedures
Battery
Air Cleaner
Front Side Air Cleaner
Rear Side Air Cleaner
Valve Clearance
Spark Plug
Engine Oil and Oil Filter
Fuel Hose
Fuel Valve Strainer
Carburetor
Throttle Cable Play
Cooling System
Final Gear Oil
Clutch
Clutch Fluid Level
Bleeding Air from the Clutch Fluid Circuit
Brake
Front Brake
Brake Fluid Level
Brake Pad
Air Bleeding the Brake Fluid Circuit
Rear Brake
Tire
Tire Pressure
Brake Light Switch
Brake Shoe Wear
Steering
Front Fork
Rear Suspension
Exhaust Pipe Bolts
Chassis Bolts and Nuts
Compression Pressure Check
Compression Pressure Specification
Compression Test Procedure
Oil Pressure Check
Low Oil Pressure
High Oil Pressure
Engine
Engine Components Removable with the Engine in Place
Engine Removal
Engine Reinstallation
Engine Disassembly
Transmission Disassembly
Transmision: Lubrication Related Parts
Crankcase Bearing and Oil Seal
Cooling System Related Parts
Engine Components Inspection and Servicing
Cylinder Head Cover Disassembly
Cylinder Head Cover Distortion
Rocker Arm I.D.
Camshaft
Camshaft Cam Wear
Camshaft Journal Wear
Cylinder Head Cover Bolts Tightening Torque
Camshaft Runout
Cam Chain Tensioner
Cam Chain Guide
Valve and Valve Spring Disassembly
Cylinder Head Distortion
Valve Face Wear
Valve Stem Runout
Valve Head Radial Runout
Valve Stem Deflection
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width
Valve Seat Servicing
Valve Stem End Condition
Valve Spring
Valve and Valve Spring Reassembly
Cylinder Distortion
Valve Spring Tension Table
Cylinder Bore
Piston Diameter
Piston to Cylinder Clearance
Piston Ring Free End Gap and End Gap
Piston Ring to Groove Clearance Table
Piston Ring Groove Width Table
Piston Pin and Pin Bore
Oversize Oil Ring
Oversize Side Rail
Conrod Small End I.D.
Conrod Big End Thrust Clearance
Conrod-Crank Pin Bearing Selection
Crank Pin Bearing Oil Clearance
Bearing Selection Table
Conrod I.D. Specification Table
Crank Pin O.D. Specification Table
Bearing Thickness Table
Conrod-Crank Pin Bearing Assembly
Crankcase-Crankshaft Bearing Selection
Crankshaft Thrust Clearance
Clutch Drive Plate and Driven Plate
Clutch Spring Free Length
Clutch Bearing
Generator and Signal Generator Servicing
Starter Clutch Servicing
Oil Pump
Transmission
Transmission Gears and Related Parts
Gear-Shifting Fork Clearance
Countershaft and Driveshaft
Top Drive Gear Bushing
Low and 3Rd Driven Gear Bushings
3Rd Driven Gear Lock Washers
Engine Reassembly
Secondary Bevel Gear Case Bolt
Secondary Driven Bevel Gear Housing Bolt
Secondary Driven Bevel Gear Shaft Nut
Geafshift Arm Stopper
Oil Pump Bolt
Cam Chain Guide Set Bolt
Primary Drive Gear Bolt
Oil Filter Wrench
Snap Ring Pliers
Clutch Sleeve Hub Nut
Clutch Spring Mounting Bolt
Cylinder Head Bolts and Nuts
Camshaft Timing
(Rear) Engine
(Front) Engine
Cam Shaft Timing
Location of Cylinder Head Bolt
Location of Cylinder Head Cover Bolt
Valve Inspection Cap and Cam Timing Inspection Cap
Intake Pipe
Shaft Drive
Shaft Drive Diagram
Secondary Bevel Gears Construction
Secondary Bevel Gear Removal and Disassembly
Secondary Drive Bevel Gear Inspection
Secondary Drive Bevel Gear Reassembly
Secondary Gears Shim Adjustment
Backlash
Tooth Contact
Reassembly Information
Final Bevel Gears Construction
Final Gear Case Breather Circuit
Air and Gear Oil Flow in Final Gear Case Breather Circuit
Air Passage
Oil Passage
Final Bevel Gear Removal and Disassembly
Final Gear Case
Propeller Shaft
Driven Bevel Gear
Drive Bevel Gear
Final Bevel Gears Inspection
Final Bevel Gears Reassembly
Final Gear Case and Bearing Case
Final Gear Shim Adjustment
Final Gear Bearing Case Shim Clearance
Backlash too Large
Backlash too Small
Tooth Contact
Final Assembly and Remounting
Shaft Drive Reassembly Information
Fuel and Lubrication System
Fuel System Overview
Fuel Pump Description
Fuel Pump Removal
Fuel Pump Inspection
Fuel Tank and Fuel Valve
Fuel Valve Mechanism
Fuel Tank Removal
Fuel Valve Removal
Carburetor Consruction
(Rear) Carburetor Exploded View
Carburetor Specifications
I.D. NO. Location
Diaphragm and Piston Operation
Slow System
Transient Enrichment System
Main System
Starter System
Float System
Carburetor Removal
Carburetor Disassembly
Carburetor Inspection and Adjustment
Needle Valve Inspection
Carburetor Reassembly and Remounting
Balance of Carburetors
In Case of Changing the Synchronizing Cable
In Case of Changing the Throttle Cable
Lubrication System
Oil Sump Filter
In Case of Changing the Carburetors
Engine Lubrication System Chart
Engine Lubrication System View
Cooling System - Contents
Cooling System Overview
Cooling System Construction
Cooling System Exploded View
Engine Coolant
Cooling System Removal and Disassembly
Radiator and Water Hoses
Cooling Fan
Cooling Fan Thermo-Switch
Engine Coolant Temperature Gauge
Water Pump
Thermostat
Radiator Inspection
Radiator Removal
Radiator Installation
Cooling Fan Inspection
Cooling Fan Installation
Engine Coolant Temperature Gauge Inspection
Temperature Gauge Specification
Engine Coolant Temperature Gauge Reassembly
Cooling Fan Thermo-Switch Inspection
Thermo-Switch Specification
Cooling Fan Thermo-Switch Reassembly
Water Pump Removal and Disassembly
Water Pump Inspection
Water Pump Bearing
Water Pump Reassembly
Thermostat Inspection
Thermostat Valve Opening Temperature
Thermostat Reassembly
Chassis
Chassis Exterior Parts
Frame Cover Removal
Seat Removal
Rear Cushion Removal
Fuel Tank Mounting Bracket Removal
Frame Head Cover Removal
Chassis Exterior Parts Remounting
Front Wheel Exploded View
Front Wheel Removal
Speedometer Gearbox Inspection
Front Wheel Inspection
Wheel Bearings Inspection
Brake Disc
Speedometer Gearbox
Front Axle
Front Brake Exloded View
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Front Fork Exploded View
Front Fork Removal and Disassembly
Front Fork Inspection
Front Fork Reassembly and Remounting
Inner Tube Metal
Damper Rod
Outer Tube Metal, Oil Seal and Dust Seal
Fork Oil
Fork Spring
Front Fork Remounting
Steering Exploded View
Steering Removal and Disassembly
Steering Inspection and Disassembly
Steering Reassembly and Remounting
Outer Races
Handlebar Holder
Steering Stem Head Unit
Steering Tension Adjustment
Handlebars
Front Fork Lower Clamp Bolt
Rear Wheel and Brake Exploded View
Rear Wheel and Brake Removal
Rear Wheel and Brake Disassembly
Rear Wheel and Brake Inspection
Brake Shoe
Brake Panel
Brake Drum
Wheel Damper
Rear Wheel and Brake Reassembly and Remounting
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Table of Contents
Troubleshooting
Charging system troubleshooting
218
Starter system troubleshooting
223
Ignition system troubleshooting
230
Troubleshooting - Engine
245
Troubleshooting - Shaft Drive
248
Troubleshooting - Radiator
249
Troubleshooting - Brakes
250
Troubleshooting - Electrical
251
Troubleshooting - Battery
252
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