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2004 GSX-R600
Suzuki 2004 GSX-R600 Manuals
Manuals and User Guides for Suzuki 2004 GSX-R600. We have
1
Suzuki 2004 GSX-R600 manual available for free PDF download: Service Manual
Suzuki 2004 GSX-R600 Service Manual (467 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 62 MB
Table of Contents
Group Index
3
How to Use this Manual
4
Symbols
5
Abbreviations Used in this Manual
6
Wire Color
8
General Information
9
General Precautions
10
Vehicle View
12
Serial Number Location
12
Fuel, Oil and Engine Coolant Recommendations
13
Brake Fluid
13
Break-In Procedures
15
Cylinder Identification
15
Information Labels
16
Specifications
17
Periodic Maintenance
19
Lubrication Points
21
Maintenance and Tune-Up Procedures
22
Air Cleaner
22
Spark Plug
23
Heat Range
23
Carbon Deposits
23
Spark Plug Gap
24
Electrode's Condition
24
Spark Plug and Ignition Coil/Plug Cap Installation
24
Valve Clearance
25
Valve Clearance Adjustment
27
Tappet Shim Selection Table
28
Engine Oil and Oil Filter
30
Engine Oil Replacement
30
Oil Filter Replacement
31
Necessary Amount of Engine Oil
31
Fuel Line
32
Engine Idle Speed
32
Throttle Valve Synchronization
33
Evaporative Emission Control System
33
Pair (Air Supply) System
33
Throttle Cable Play
34
Clutch
34
Cooling System
35
Engine Coolant Change
35
Air Bleeding the Cooling Circuit
36
Radiator Hoses
37
Drive Chain
38
Brake Inspection
41
Brake Fluid Level Check
41
Brake Pads
42
Brake Pedal Height
42
Brake Light Switch
43
Air Bleeding from Brake Fluid Circuit
43
Tire Tread Condition
45
Tire Pressure
45
Steering
46
Front Fork
46
Rear Suspension
46
Exhaust Pipe Bolt and Muffler Bolt and Nut
47
Chassis Bolts and Nuts
48
Compression Pressure Check
50
Compression Test Procedure
50
Oil Pressure Check
51
Oil Pressure Test Procedure
51
Engine
53
Engine Components Removable with Engine in Place
54
Engine Removal
55
Engine Installation
62
Engine Disassembly
68
Engine Components Inspection and Service
81
Cylinder Head Cover Check
81
CMP Sensor Check
81
Pair Reed Valve Check
81
PCV Hose Check
82
Camshaft Check
82
Cam Chain Tension Adjuster Check
84
Cam Chain Tensioner
85
Cam Chain Guide
85
Cylinder Head and Valve
85
Cylinder Head Distortion
87
Valve Stem Runout
87
Valve Head Radial Runout
87
Valve Stem and Valve Face Wear Condition
88
Valve Stem Deflection
88
Valve Stem Wear
88
Valve Guide Servicing
89
Valve Seat Width Inspection
90
Valve Seat Servicing
91
Initial Seat Cut
91
Top Narrowing Cut
92
Bottom Narrowing Cut
92
Final Seat Cut
93
Valve Spring
94
Valve and Valve Spring Reassembly
95
Intake Pipe
96
Clutch Drive Plates Inspection
97
Water Bypass Union
97
Oil Pump Inspection
98
Clutch Driven Plates Inspection
98
Clutch Bearing Inspection
98
Clutch Sleeve Hub/Primary Driven Gear Assembly
98
Starter Clutch Inspection
99
Generator Inspection
99
Gearshift System Inspection
100
Oil Pressure Regulator Inspection
101
Oil Strainer Check
101
Transmission Inspection
102
Transmission Parts Location
104
Cylinder Check
105
Piston and Piston Ring Check
106
Piston Diameter
106
Piston-To-Cylinder Clearance
106
Piston Pin and Pin Bore
106
Piston Ring-To-Groove Clearance
107
Piston Ring Free End Gap and Piston Ring End Gap
107
Crankcase Inspection
108
Gearshift Fork and Gearshift Cam
108
Gearshift Fork-To-Groove Clearance
108
Gearshift Fork Groove Width
108
Gearshift Fork Thickness
109
Gearshift Cam Bearing and Gearshift Shaft Bearing
109
Oil Jet Removal, Inspection and Cleaning
112
Oil Jet Installation
113
Plug Removal
113
Conrod Big End Side Clearance
114
Conrod Big End Bearing Inspection
114
Conrod Big End Bearing Selection
114
Crankshaft and Conrod
115
Crankshaft Runout
115
Conrod Small End ID
115
Crankshaft Journal Bearing Inspection
119
Crankshaft Thrust Bearing
122
Crankshaft Thrust Clearance Adjustment
122
Thrust Bearing Selection Table
123
Engine Reassembly
124
FI System Diagnosis
158
Electrical Parts
160
Connector/Coupler
160
Fuse
161
Ecm/Various Sensors
161
Electrical Circuit Inspection
163
Open Circuit Check
163
Continuity Check
164
Voltage Check
164
Short Circuit Check (Wire Harness to Ground)
165
Using the Multi-Circuit Tester
166
FI System Technical Features
167
Injection Time (Injection Volume)
167
Compensation of Injection Time (Volume)
168
Injection Stop Control
168
Injection Timing
169
FI System Parts Location
170
FI System Wiring Diagram
172
Self-Diagnosis Function
173
User Mode
173
Dealer Mode
174
TPS Adjustment
176
Fail-Safe Function
177
FI System Troubleshooting
179
Customer Complaint Analysis
179
Self-Diagnostic Procedures
181
Self-Diagnosis Reset Procedure
181
Malfunction Code and Defective Condition
182
"C11" CMP Sensor Circuit Malfunction
184
"C12" CKP Sensor Circuit Malfunction
186
"C13" IAP Sensor Circuit Malfunction
188
"C14" TP Sensor Circuit Malfunction
191
"C15" ECT Sensor Circuit Malfunction
192
"C21" IAT Sensor Circuit Malfunction
196
"C22" AP Sensor Circuit Malfunction
198
"C23" to Sensor Circuit Malfunction
201
"C28" STV Actuator Circuit Malfunction
203
"C29" STP Sensor Circuit Malfunction
205
"C31" GP Switch Circuit Malfunction
208
"C32","C33", "C34" or "C35" Fuel Injector Circuit Malfunction
209
"C41" FP Relay Circuit Malfunction
211
"C42" IG Switch Circuit Malfunction
211
"C49" Pair Control Solenoid Valve Circuit Malfunction
212
Sensors
214
Fuel System and Throttle Body
217
Fuel Delivery System
218
Fuel System
219
Fuel Tank Lift-Up
219
Fuel Tank Removal
219
Fuel Tank Installation
219
Fuel Pressure Inspection
220
Fuel Pump Inspection
221
Fuel Discharge Amount Inspection
221
Fuel Pump Relay Inspection
222
Fuel Pump and Fuel Filter Removal
223
Fuel Mesh Filter Inspection and Cleaning
225
Fuel Pump and Fuel Mesh Filter Installation
225
Throttle Body Construction
229
Air Cleaner Box Removal
230
Throttle Body Removal
231
Throttle Body Disassembly
232
Throttle Body Cleaning
234
Throttle Body Inspection
234
Throttle Body Reassembly
235
Throttle Body Installation
237
Air Cleaner Box Installation
238
STP Sensor Adjustment
238
Fuel Injector Removal
239
Fuel Injector Inspection
239
Fuel Injector Installation
239
Fast Idle
240
Fast Idle Adjustment
240
Throttle Position Sensor (TPS) Setting
245
Exhaust System
247
Precautions for Exhaust System
248
Exhaust System Components
248
Exhaust Pipe and Muffler Removal
249
Exhaust Pipe and Muffler Installation
250
Exhaust Pipe and Muffler Inspection
250
Cooling and Lubrication System
251
Engine Coolant
252
Cooling Circuit
253
Cooling Circuit Inspection
253
Radiator and Water Hoses
254
Radiator Removal
254
Radiator Cap Inspection
254
Radiator Inspection and Cleaning
254
Radiator Installation
255
Water Hose Inspection
255
Cooling Fan Removal
256
Cooling Fan Inspection
256
Cooling Fan Installation
256
Cooling Fan Thermo-Switch Removal
257
Cooling Fan Thermo-Switch Inspection
257
Cooling Fan Thermo-Switch Installation
257
ECT Sensor Removal and Inspection
258
ECT Sensor Installation
259
Thermostat Removal
259
Thermostat Inspection
260
Thermostat Installation
260
Water Pump Removal and Disassembly
261
Water Pump Inspection
264
Water Pump Reassembly and Installation
264
Lubrication System
268
Oil Cooler Inspection, Removal and Installation
268
Engine Lubrication System Chart
270
Engine Lubrication System Diagram
271
Chassis
274
Exterior Parts
276
Fastener Removal and Reinstallation
276
Screen Removal and Installation
277
Body Cowling Cover and Lower Bracket Cover
277
Right and Left under Cowlings
277
Body Cowling
279
Right and Left Air Intake Pipes
280
Cowling Brace
280
Front Seat Removal and Installation
280
Rear Seat and Seat Tail Cover
281
Frame Cover
281
Front Wheel Construction
282
Front Wheel Removal
283
Front Wheel Inspection and Disassembly
283
Axle Shaft
284
Wheel Bearing
284
Reassembly and Installation
285
Brake Disc
286
Spacer Nut
287
Brake Caliper
287
Front Axle
287
Front Fork Construction
288
Front Fork Removal
289
Front Fork Disassembly
290
Front Fork Inspection
292
Front Fork Reassembly
293
Damper Rod Bolt
294
Fork Oil
294
Fork Spring
295
Front Fork Cap Bolt
296
Front Fork Installation
298
Suspension Setting
299
Spring Pre-Load Adjustment
299
Damping Force Adjustment
299
Steering Damper Construction
300
Steering Damper Removal
300
Steering Damper Inspection
300
Steering Damper Installation
301
Steering Construction
302
Steering Removal
303
Steering Inspection
304
Steering Disassembly
304
Steering Reassembly
304
Steering Installation
305
Stem Nut
305
Front Fork and Steering Stem Upper Bracket
306
Steering Tension Adjustment
307
Handlebars Construction
308
Handlebars Removal
308
Handlebars Installation
309
Rear Wheel Construction
312
Rear Wheel Removal
313
Rear Wheel Inspection and Disassembly
314
Rear Wheel Reassembly and Installation
316
Rear Shock Absorber Construction
320
Rear Shock Absorber Removal
321
Rear Shock Absorber Inspection
321
Rear Shock Absorber Scrapping
322
Rear Shock Absorber Installation
322
Rear Suspension Construction
324
Rear Suspension Removal
325
Rear Suspension Inspection and Disassembly
327
Rear Suspension Reassembly
329
Rear Suspension Installation
331
Rear Suspension Final Inspection and Adjustment
332
Front Brake Construction
333
Brake Pad Replacement
334
Brake Fluid Replacement
335
Caliper Removal
336
Caliper Disassembly
336
Caliper Inspection
338
Caliper Reassembly
338
Caliper Installation
339
Brake Disc Inspection
340
Master Cylinder Removal
341
Master Cylinder Disassembly
342
Master Cylinder Inspection
342
Master Cylinder Reassembly
343
Master Cylinder Installation
343
Rear Brake Construction
345
Master Cylinder Inspection and Reassembly
352
Tire Removal
354
Tire Inspection
354
Valve Inspection
355
Tire Installation
356
Balancer Weight Installation
357
Drive Chain Cutting
358
Drive Chain Connecting
359
Electrical System
362
Cautions in Servicing the Electrical System
364
Location of Electrical Components
367
Charging System Troubleshooting
369
Charging System Inspection
370
Battery Current Leakage
370
Regulated Voltage
371
Generator Coil Resistance
371
Generator No-Load Performance
372
Regulator/Rectifier
372
Starter System and Side-Stand/Ignition Interlock System Diagram
373
Starter System Troubleshooting
373
Starter Motor Removal
374
Starter Motor Disassembly
375
Starter Motor Inspection
376
Starter Motor Reassembly
376
Commutator Check
376
Armature Coil Inspection
376
Starter Motor Installation
377
Starter Relay Inspection
377
Side Stand/Ignition Interlock System Parts Inspection
378
Side-Stand Switch Check
378
GP Switch Check
379
Turn Signal/Side-Stand Relay
380
Side-Stand Relay Inspection
380
Diode Inspection
380
Ignition System Troubleshooting
381
Ignition System Inspection
383
Ignition Coil/Plug Cap Resistance
384
CKP Sensor Peak Voltage
385
CKP Sensor Resistance
386
Combination Meter Description
387
Combination Meter Removal and Disassembly
388
Combination Meter Inspection
389
LED (Light Emitting Diode) Check
389
Stepping Motor Check
389
Engine Coolant Temperature Meter and Indicator Check
390
Fuel Level Indicator Switch Inspection
391
Fuel Level Indicator Light Inspection
391
Speedometer
392
Speed Sensor Check
392
Oil Pressure Indicator Check
392
Lamps
393
Headlight Beam Adjustment
394
Relays
395
Ignition Switch Removal
396
Ignition Switch Installation
396
Switches Inspection
397
Battery Specifications
398
Battery Initial Charging
398
Battery Servicing
400
Battery Recharging
400
Servicing Information
401
Troubleshooting
402
FI System Malfunction Code and Defective Condition
402
Engine will Not Start or Is Hard to Start
404
Engine Idles Poorly
405
Engine Stalls Often
405
Noisy Engine
406
Engine Runs Poorly in High Speed Range
407
Engine Lacks Power
408
Engine Overheats
409
Dirty or Heavy Exhaust Smoke
409
Slipping Clutch/Dragging Clutch
409
Transmission will Not Shift
409
Radiator (Cooling System) Troubleshooting
410
Transmission will Not Shift Back
410
Transmission Jumps out of Gear
410
Engine Oveheats/Overcools
410
Chassis Troubleshooting
411
Heavy Steering
411
Wobbly Handlebars/Wobbly Front Wheel
411
Front Suspension too Soft/Stiff
411
Brakes Troubleshooting
412
Wobbly Rear Wheel
412
Rear Suspension too Soft/Stiff
412
Noisy Rear Suspension
412
Electrical Troubleshooting
413
Excessive Brake Lever Stroke
413
No Sparking or Poor Sparking
413
Spark Plug Become Fouled too Soon
413
Generator Does Not Charge
414
Generator Does Charge, but Charging Rate Is below the Specicifation
414
Generator Overcharges
414
Unstable Charging/Starter Button Is Not Effective
414
Battery Troubleshooting
415
Battery Runs down Quickly
415
Battery "Sulfation"
415
Wiring Harness Routing
416
Cable Routing
419
Throttle Body Hose Routing
420
Fuel Tank Drain Hose Routing
421
Cooling System Hose Routing
422
Front Brake Hose Routing
423
Rear Brake Hose Routing
424
Pair (Air Supply) System Hose Routing
425
Fuel Tank Installation Diagram
426
Fuel Tank Lower Side Cover
427
Cowling Installation
428
Frame Cover Installation
429
Under Cowling Heat Shield Installation
430
Side-Stand Installation
431
Gearshift Pedal Installation
431
Seat Lock Cable Routing
432
Handlebar Balancer
433
Combination Meter Installation
433
Rear Combination Light Installation
434
Special Tools
435
Tightening Torque
439
Service Data
443
Valve + Valve Guide Data
443
Camshaft + Cylinder Head Data
444
Cylinder + Piston + Piston Ring
444
Conrod + Crankshaft Data
445
Oil Pump Data
446
Clutch Data
446
Transmission + Drive Chain
446
Thermostat + Radiator + Fan + Coolant Data
447
Injector + Fuel Pump + Fuel Pressure Regulator Data
447
FI Sensors + Seconcary Throttle Valve Actuator Data
448
Throttle Body Data
449
Electrical Data
449
Wattage
450
Brake + Wheel Data
450
Tire Data
451
Suspension Data
452
Fuel + Oil Data
453
Emission Control Information
455
Fuel Injection System
456
Crankcase Emission Control System
457
Exhaust Emission Control System (Pair System)
458
Noise Emission Control System
459
Pair (Air Supply) System and Emission Control System Inspection
460
Pair Hoses
460
Pair Reed Valve
460
PCV Hose
460
Pair Control Solenoid Valve
461
Pair (Air Supply) System Diagram
462
Wiring Diagram
465
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