Suzuki 1994 RF600R Manuals

Manuals and User Guides for Suzuki 1994 RF600R. We have 1 Suzuki 1994 RF600R manual available for free PDF download: Service Manual

Suzuki 1994 RF600R Service Manual (434 pages)

Brand: Suzuki | Category: Motorcycle | Size: 18.24 MB

Group Index
3
General Information
5
Serial Number Location
6
Fuel, Oil and Engine Coolant Recommendations
6
Fuel
6
Engine Oil
7
Brake Fluid
7
Front Fork Oil
7
Liquid Amount of Water/Engine Coolant
7
Break-In Procedures
8
Cylinder Identification
8
Special Materials
9
Precautions and General Instructions
12
Replacement Parts
12
Information Labels
13
Specifications
15
Dimensions and Dry Mass
15
Country or Area
17
Periodic Maintenance and Tune-Up Procedures
18
Periodic Maintenance Schedule
19
Periodic Maintenance Chart
19
Lubrication Points
20
Maintenance and Tune-Up Procedures
21
Exhaust Pipe Bolts
21
Air Cleaner
21
Tappet Clearance
22
Tappet Clearance Adjustment
23
Tappet Shim Selection Table
24
Spark Plug
26
Carbon Deposit
26
Spark Plug Gap
26
Electrode's Condition
26
Engine Oil and Oil Filter
27
Necessary Amount of Engine Oil
27
Fuel Line
28
Fuel Filter
28
Carburetor
28
Throttle Cable Play
28
Clutch
29
Drive Chain
29
Checking
30
Adjusting
30
Cleaning and Lubricating
30
Cooling System
31
Engine Coolant Level
31
Engine Coolant Change
31
Brake
32
Brake Fluid Level
32
Brake Pads
32
Brake Pedal Height
33
Brake Light Switch
33
Air Bleeding the Brake Fluid Circuit
33
Tire
34
Tire Tread Condition
35
Steering
35
Front Fork
36
Rear Suspension
36
Chassis Bolts and Nuts
37
Compression Pressure Check
39
Compression Test Procedure
39
Compression Pressure Specification
39
Oil Pressure Check
40
Oil Pressure Test Procedure
40
Low Oil Pressure
40
High Oil Pressure
40
Engine
42
Engine Components Removable with Engine in Place
43
Engine Center
43
Engine Left Side
43
Engine Right Side
43
Engine Removal
44
Engine Reinstallation
49
Engine Disassembly
52
Engine Components Inspection and Service
63
Cylinder Head Service
63
Cylinder Head Distortion
64
Valve Stem Runout
64
Valve Head Radial Runout
64
Valve Face Wear
64
Valve Stem Wear
65
Valve Guide Servicing
65
Valve Seat Width
66
Valve Seat Servicing
66
Valve Spring
68
Reassembly
68
Camshaft
69
Cam Wear
70
Camshaft Journal Wear
70
Camshaft Runout
71
Cam Sprocket
71
Cam Chain Tensioner
72
Cam Chain Guide
72
Cylinder Block Distortion
72
Cylinder Bore
73
Piston Diameter
73
Piston-Cylinder Clearance
73
Piston Ring-Groove Clearance
73
Piston Ring Free End Gap and Piston Ring End Gap
74
Oversize Piston Ring
74
Oversize Oil Ring
74
Oversize Side Rail
74
Piston Pin and Pin Bore
75
Conrod Big End Side Clearance
75
Conrod-Crank Pin Bearing Selection
76
Bearing Assembly
77
Crankcase-Crankshaft Bearing Selection
78
Bearing Selection Table
79
Crankcase I.D. Specification
79
Crankshaft Journal O.D. Specification
79
Crankshaft Thrust Clearance
80
Bearing Thickness Specification
80
Crankshaft Runout
81
Thrust Bearing Selection Table
81
Clutch Drive and Driven Plates
82
Clutch Spring Free Length
82
Clutch Release Bearing
82
Clutch Release Pinion and Rack
82
Transmission Disassembly
83
Gearshift Fork-Groove Clearance
86
Starter Clutch Disassembly and Inspection
87
Starter Clutch Reassembly
88
Engine Reassembly
89
Fuel and Lubrication System
109
Fuel System
110
Fuel Pump Distortion
111
Starting Engine
111
After Start
111
Fuel Pump Removal
112
Fuel Pump Inspection
112
Fuel Cock Mechanism
113
Fuel Cock Removal
113
Fuel Tank Removal
114
Fuel Filter Removal
114
Fuel Filter Inspection and Cleaning
114
Carburetor Construction
115
Carburettor Specifications
116
I.D. No. Location
116
Diaphragm and Piston Operation
117
Power Position of Piston Valve
117
Upper Position of Piston Valve
117
Slow System
118
Main System
119
Starter System
120
Float System
120
Inspection and Adjustment
124
Needle Valve Inspection
124
Float Height Adjustment
124
Reassembly and Remounting
124
Balance of Carburetors
125
Calibrating each Gauge
125
Lubrication System
127
Oil Sump Filter
127
Engine Lubrication System Chart
128
Engine Oil Cooling System
130
Cooling System Description
132
Cooling System Construction
133
Cooling Solution
135
Cooling System Removal and Disassembly
136
Water Hoses and Thermostat Case
136
Radiator
136
Cooling Fan
137
Engine Coolant Temperature Gauge and Cooling Fan Thermo-Switch
137
Thermostat
137
Water Pump
137
Radiator Inspection
139
Radiator Removal
139
Radiator Installation
139
Engine Coolant Temperature Gauge
140
Engine Coolant Temperature Gauge Inspection
140
Temperature Gauge Specifications
140
Engine Coolant Temperature Gauge Reassembly
141
Cooling Fan Removal
141
Cooling Fan Inspection
141
Cooling Fan Thermo-Switch
141
Cooling Fan Thermo-Switch Removal
142
Cooling Fan Thermo-Switch Inspection
142
Cooling Fan Thermo-Switch Reassembly
142
Cooling Fan Thermo-Switch Specification
142
Thermostat Removal
143
Thermostat Inspection
143
Thermostat Reassembly
143
Water Pump Removal and Disassembly
144
Water Pump Inspection
144
Water Pump Bearing
144
Water Pump Mechanical Seal
144
Electrical System
146
Charging System Description (Generator with IC Regulator)
147
Charging Output Check
148
Removal and Disassembly
148
Rotor Bearing
150
Stator Coil Continuity Check
150
Rotor Coil Continuity Check
150
Slip Ring
151
Carbon Brush
151
Rectifier
151
IC Regulator
152
Tester Knob Indication: DC25V
152
Electrical System Reassembly and Remounting
153
Reassembly Information
155
Ignition System (Digital Ignitor) Description
156
Ignition System (Digital Ignitor) Inspection
157
Electro Tester
157
Pocket Tester
157
Spark Plugs
158
Heat Range
158
Ignitor Unit (Checking with Digital Ignitor Checker)
159
Starter System Description
161
Starter System Removal and Disassembly
161
Starter System Inspection
162
Commutator
162
Starter System Reassembly
163
Armature Coil
163
Oil Seal
163
Starter Relay Inspection
164
Starter Relay Circuit Diagram
164
Side-Stand/Ignition Interlock System Description
165
Side-Stand/Ignition Interlock System Inspection
166
Neutral Switch
167
Side-Stand Switch
167
Side-Stand/Ignition Interlock Relay
167
Combination Meter Removal and Disassembly
168
Combination Meter Inspection
168
Engine Coolant Temperature Meter Inspection
170
Fuel Level Indicator Inspection
171
Lamps
173
Headlight
173
Tail/Brake Light
173
Turn Signal Light
174
Switches
174
Oil Pressure Switch
174
Starter Relay
175
Side-Stand Relay
175
Turn Signal Relay
175
Battery Specifications
176
Initial Charging
176
Battery Servicing
177
Battery Recharging Operation
178
Chassis
179
Cowling and Frame Cover
180
Cowling Removal
181
Cowling Assembly and Cowling Brace
181
Frame Cover Assembly
184
Cowling Remounting
185
Front Wheel Removal
186
Front Wheel Inspection and Disassembly
187
Speedometer Gearbox Dust Seal
187
Wheel Bearings
187
Axle Shaft
187
Front Wheel Reassembly and Remounting
188
Brake Disc
188
Speedometer Gearbox
189
Brake Caliper
189
Tire and Wheel
191
Tire Removal
191
Wheel Inspection
193
Tire Inspection
193
Valve Inspection
193
Tire Depth Gauge
193
Tire Mounting
194
Valve Installation
194
Tire Pressure
195
Front Brake
196
Brake Pad Replacement
196
Caliper Removal and Disassembly
198
Caliper Inspection
199
Caliper Reassembly and Remounting
199
Rubber Parts
199
Caliper Bolts
199
Disc Servicing
200
Disc Inspection
200
Master Cylinder Removal and Disassembly
200
Master Cylinder Inspection
201
Master Cylinder Reassembly and Remounting
202
Front Fork Removal and Disassembly
203
Fork Spring Inspection
205
Inner and Outer Tube Inspection
205
Damper Rod Ring Inspection
206
Tube Metals and Seals
206
Damper Rod Bolt
206
Fork Oil
207
Suspension Setting
208
Spring Pre-Load Adjustment
208
Front Suspension Setting (STD)
208
Steering Removal and Disassembly
209
Steering Inspection
210
Steering Disassembly
210
Steering Reassembly and Remounting
211
Outer Races
211
Bearing
211
Stem Nut
211
Steering Tension Adjustment
212
Ignition Switch
213
Rear Brake
214
Rear Wheel Removal and Disassembly
220
Rear Wheel Inspection and Disassembly
222
Wheel
222
Rear Wheel Reassembly and Remounting
223
Cushion
223
Sprocket
223
Mounting Drum Bearing
224
Rear Sprocket
225
Rear Axle Shaft
225
Swingarm, Shock Absorber, and Cushion Lever
226
Swingarm Inspection and Disassembly
229
Cushion Lever
229
Shock Absorber
229
Swingarm Pivot Shaft
230
Chain Buffer
230
Swingarm Bearing
230
Reassembly Onto Frame
231
Final Inspection and Adjustment
232
Rebound Damping Force Adjustment
232
Rear Suspension Setting
232
Servicing Information
233
Engine Troubleshooting
234
Radiator Troubleshooting
237
Carburetor Troubleshooting
237
Electrical Troubleshooting
238
Battery Troubleshooting
239
Chassis Troubleshooting
240
Brakes Troubleshooting
241
Wiring Diagram
242
Wire Harness, Cable and Hose Routing
245
Wire Harness Routing
245
High-Tension Cord Routing
247
Cable Routing
248
Fuel System Hose Routing
249
Oil Hose Routing
250
Cooling System Hose Routing
251
Front Brake Hose Routing
253
Rear Brake Hose Routing
254
Pair (Air Supply) System Hose Routing
255
Cowling and Frame Cover Set up
256
Cowling Set up
256
Frame Cover Set up
258
Lower Cowling Cushion
258
Special Tools
259
Tightening Torque
262
Service Data
265
Emission Control Information
273
Emission Control Carburetor Components
274
Evaporative Emission Control System
275
Canister Hose Routing
276
Pair (Air Supply) System Diagram
277
RF600RS (95 Model)
279
RF600RT (96 Model)
296
RF600RV (97 Model)
308
Cylinder Head Cover Parts
321
Cylinder Head Parts
322
Cylinder Parts
323
Crankcase Parts
324
Crankcase Cover Parts
326
Pan - Oil Pump Parts
327
Crankshaft Parts
328
Starter Clutch Parts
329
Cam Shaft - Valve Parts
330
Cam Chain Parts
332
Carburetor Parts
333
Carburetor Fittings Parts
336
Air Cleaner Parts
338
Muffler Parts
339
Fuel Pump Parts
341
Oil Cooler - Oil Filter Parts
342
Water Pump Parts
343
Radiator Parts
344
Radiator Hose Parts
345
Second Air Parts
347
Clutch Parts
348
Transmission Parts
349
Rear Shifting Parts
351
Starting Motor Parts
353
Alternator Parts
354
Battery Parts
359
Electrical Parts
360
Speedometer Parts
361
Headlamp Parts
363
Tail Lamp Parts
365
Wiring Harness Parts
366
Handle Switch Parts
367
Frame Parts
368
Stand Parts
369
Footrest Parts
370

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Suzuki 1994 RF600R Service Manual (434 pages)

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